Ingersoll-Rand CSAXHP1070WCAT Operating & Maintenance Manual
Operating & Maintenance Manual
Compressor Models
CSA XHP1070WCAT
Code: B
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: 23012958 (2-16-07) Rev. A
TABLE OF CONTENTS
Operating & Maintenance Manual
TITLE PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operating Controls and Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Lifting Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Setting Up (All Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Before Starting Unit - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Trouble Shooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Prior to attempting any maintenance work, ensure that:-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Prior to opening or removing panels or covers to work inside a machine, ensure that:- . . . . . . . . . 45
Prior to attempting any maintenance work on a running machine, ensure that:- . . . . . . . . . . . . . . .45
Protective Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Low engine fuel level switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3
TABLE OF CONTENTS
Operating & Maintenance Manual
TITLE PAGE
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Compressor Oil Cooler and Engine Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Running Gear/wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Engine Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Compressor Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4
TABLE OF CONTENTS
Operating & Maintenance Manual
TITLE PAGE
5
**Always use Ingersoll-Rand Replacement parts!**
6
Foreword
Book: 23012958 (2-16-07) Rev. A 7
Operating & Maintenance Manual Foreword
Foreword
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, IngersollRand 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 forese eable risk of hazardou s levels of fla mmable gases or
vapors exists.
D. With other than Ingersoll-Rand approved components.
E. With guards, or controls or switches missing or disabled.
8 Book: 23012958 (2-16-07) Rev. A
Foreword Operating & Maintenance Manual
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 will 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.
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. 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.
Book: 23012958 (2-16-07) Rev. A 9
**Always use Ingersoll-Rand Replacement parts!**
10 Book: 23012958 (2-16-07) Rev. A
Safety
Book: 23012958 (2-16-07) Rev. A 11
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.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenancce Manuals.
Make sure that all protective covers are in place and that the canopy/do ors are closed during
operation.
The specification of this machine is such that the machine is not suitable fo r 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.
A weekly visual check must be made on all fasteners/fixing screws securing mechanical parts.
In particular, safety-related parts such as coupling hitch, drawbar components, road-wheels,
and lifting bail should be checked for total security.
All components which are loose, damaged or unserviceable, must be rectified without delay.
Air discharged from this machine may contain carbon monoxide or other contaminants which
will cause serious injury or death. Do not breathe this air.
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 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).
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 inflammable gas. When it is specified as a starting aid,
use sparingly. DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUGS OR INLET
HEATER STARTING AIDS OR ENGINE DAMAGE WILL RESULT.
12 Book: 23012958 (2-16-07) Rev. A
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.
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 setting.
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 direct feed to any form of breathing appar atus or mask.
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.
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.
The safety valve located in the separator tank must be checked periodically for correct
operation.
Whenever the machine is stopped, air will flow back into the compressor system f rom 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 vent of an unexpected shutdown
when the service valve is open.
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).
Never allow the unit to sit stopped with pressure in the receiver-separator system.
Book: 23012958 (2-16-07) Rev. A 13
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.
The following substances are used in the manufacture of this machine and may be hazardous
to health if used incorrectly:
•anti-freeze
• compressor lubricant
• engine lubricant
• preservative grease
• rust preventative
• diesel fuel
• battery electrolyte
!
WARNING
Avoid ingestion, skin contact and inhalation of fumes
Should compressor lubricant come into contact with the eyes, then irrigate with water for at
least 5 minutes.
Should compressor lubricant come into contact with the skin, then wash off immediately.
Consult a physician if large amounts of compressor lubricant are ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious or having convulsions.
Safety data sheets for compressor and engine lubricants should be obtained from the lubricant
supplier.
Do NOT start or operate this machine in a confined area. Avoid breathing exhaust fumes when
working on or near the machine.
14 Book: 23012958 (2-16-07) Rev. A
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. Avoid contact with skin, eyes and clothing. In case of contact, flush area
immediately with water.
!
WARNING
Do not attempt to slave start a frozen battery since this may cause it to
explode.
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.
Radiator
Hot engine coolant and steam can cause injury. Ensure that the radiator filler cap is removed
with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before
removing pressure cap.
Book: 23012958 (2-16-07) Rev. A 15
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.
Do not exceed gross vehicle weight rating.
Before towing the machine, ensure that:-
• the tires and towing hitch are in a serviceable condition.
• the canopy is secure.
• all ancillary equipment is stored in a safe and secure manner.
• the brakes and lights are functioning correctly and meet necessary road traffic
requirements.
• break-away cables/safety chains are connected to the towing vehicle.
The machine must be towed in a level attitude in order to maintain correct handling, braking
and lighting functions. This can be achieved by correct selection and adjustment of the vehicle
towing hitch and, on variable height running gear, adjustment of the drawbar.
1. Make sure wheels, tires and tow bar connectors are in safe operating condition
and tow bar is properly connected before towing.
2. When parking always use the handbrake and, if necessary, suitable wheel
chocks.
16 Book: 23012958 (2-16-07) Rev. A
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,
death or property damage, if ignored.
!
WARNING
(Orange Background)
Indicates the presence of a hazard which CAN cause serious injury, death
or property damage, if ignored.
!
CAUTION
(Yellow Background)
Indicates the presence of a hazard which WILL or can cause injury or
property damage, if ignored.
NOTICE
(Blue Background)
Indicates important set-up, operating or maintenance information.
Book: 23012958 (2-16-07) Rev. A 17
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. Submit orders
for Safety Decals to the Mocksville Parts Service
Department. The no charge order should contain only
Safety Decals. Help promote product safety! Replace
decals that are not readable.
18 Book: 23012958 (2-16-07) Rev. A
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