Ingersoll-Rand CSA XHP900WCAT Operating & Maintenance Manual

Operating & Maintenance Manual

Compressor Model

CSA XHP900WCAT

Code: A

This manual contains important safety information.
Do not destroy this manual. This manual must be available to the personnel wh o

operate and maintain this machine.

Utility Equipment
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028

Book: 23010598 (2-16-07) Rev. A

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.

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

Before Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Towing (Steerable Axle Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

In cold weather: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Pressure Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Prior to attempting any maintenance work, ensure that:-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Prior to opening or removing panels or covers to work inside a machine, ensure that:- . . . . . . . . . 41

Prior to attempting any maintenance work on a running machine, ensure that:- . . . . . . . . . . . . . . .41

Protective Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Low engine fuel level switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Scavenge Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Compressor Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Compressor Oil Cooler and Engine Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Air Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

3

TABLE OF CONTENTS

Operating & Maintenance Manual

TITLE PAGE

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Fuel Filter Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Pressure System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Running Gear/wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Engine Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Compressor Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Running Gear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Portable Compressor Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ACTION PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

A. Think Before Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

B. Do The Simplest Things First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

C. Double Check Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

D. Find And Correct Basic Cause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Electrical/Electronic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4

**Always use Ingersoll-Rand Replacement parts!**

5

TABLE OF CONTENTS

Operating & Maintenance Manual

TITLE PAGE

6

Foreword

Book: 23010598 (2-16-07) Rev. A 7

Operating & Maintenance Manual 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.
F. For storage or transportation of materials inside or on the enclosure.

8 Book: 23010598 (2-16-07) Rev. A

Foreword Operating & Maintenance Manual

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: 23010598 (2-16-07) Rev. A 9

**Always use Ingersoll-Rand Replacement parts!**

10 Book: 23010598 (2-16-07) Rev. A

Safety

Book: 23010598 (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: 23010598 (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: 23010598 (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: 23010598 (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: 23010598 (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: 23010598 (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: 23010598 (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: 23010598 (2-16-07) Rev. A

General Data

Book: 23010598 (2-16-07) Rev. A 19

Operating & Maintenance Manual General Data

General Data

MODELS

Air Delivery - cfm (litres/sec) 900 (425)

COMPRESSOR

Rated Operating Pressure - psi (kPa) 350 (2400)

ENGINE (Diesel)

Manufacturer Caterpillar
Model 3406TA
Electrical System 24VDC
Full Load Speed - rpm 1800
No Load Speed - rpm 1200
FLUID CAPACITIES - U.S. Gallons (litres)
Compressor Lubricant, Initial (dry) Fill 55 (208)
Compressor Lubricant, Initial (dry) Service Refill 44 (167)
Engine Coolant (radiator) 17.04 (64)

XHP900CWCAT

Engine Crankcase Lubricant 9.0 (34.1)
Fuel Tank (Clean DIESEL fuel) 180 (680)

UNITS MEASUREMENTS - Feet (Meters)

Overall Length with drawbar up 15.9 (4.84)
Overall Height 8.46 (2.58)
Overall Width 7.38 (2.25)

RUNNING GEAR

Tire Size 8.25 x 15TR
Towing Speed (maximum) - MPH (km/hr) 20 (32)
Inflation Pressure (cold) - PSI (kPa) 105 (720)
Load Range “F”

20 Book: 23010598 (2-16-07) Rev. A

General Data Operating & Maintenance Manual

SERVICE PARTS
Part Number Description

36860336 .......................Compressor Oil Filter Element

22402242........................Compressor Oil Separator Element

36864361 .......................Air Cleaner Element (Outer)

36864379 .......................Air Cleaner Element (Inner)

36864361........................Engine Cleaner Element (Outer)

36864379 .......................Engine Cleaner Element (Inner)

!

CAUTION

Any departure from the specifications may make this equipment unsafe.

Book: 23010598 (2-16-07) Rev. A 21

**Always use Ingersoll-Rand Replacement parts!**

22

Operating Instructions

Book: 23010598 (2-16-07) Rev. A 23

Operating & Maintenance Manual Operating Instructions

Operating Instructions

Operating Controls and Instruments

The operating controls and instruments are arranged on the control panel as shown above. A
description of each panel device is as follows:

1. Compressor Discharge Pressure Gauge: Indicates pressure in receiver
tank, normally from 0 psi (kPa) to the rated pressure of the machine.

2. Lamp: Controlled by Switch 11.

3. Engine Tachometer: Indicates engine speed in RPM from 0 when stopped to
full speed.

4. Discharge Air Temperature Gauge: Indicates in °F and °C. Normal operating
range: 185°F/85°C to 230°F/110°C.

5. Fuel Level Gauge: Indicates amount of fuel in tanks.

6. Engine Oil Pressure Gauge: See Engine Operation Manual for normal range.

24 Book: 23010598 (2-16-07) Rev. A

Operating Instructions Operating & Maintenance Manual

7. Hourmeter: Records running time for maintenance purposes.

8. Voltmeter: Indicates battery condition.

9. Engine Water Temperature Gauge: Indicates coolant temperature, with

normal operating range from 180°F/82°C to 210°F/99°C.

10. Power Switch: Flip ““ON” to operate, “OFF” to stop.

11. Lights Switch: Operates Lamp 2 and those within gauges.

12. Heaters Switch: Activates control system heaters for operation below

32°F(°C).

13. Service Air Button: After warm up, provides full air pressure at the service

outlet.

14. Bypass Button: Bypasses automatic shutdown circuit.

15. Start Button: Activates the engine starter.

16. Ether Inject Button: Injects a measured shot. Use Sparingly.

17. High Compressor Temperature: 248°F(120°C) or more.

18. Low Engine Oil Pressure: 12 psi or less.

19. High Engine Temperature: Coolant above 215°F(102°C).

20. Low Fuel Level: Comes on first as a warning and eventually triggers a

shutdown.

21. Alternator Not Charging: Needs attention.

22. Low Coolant Level: Dangerously low; needs attention.

23. Air Filters Restricted: Needs servicing.

!

WARNING

Do not climb on top of unit. The lifting eye can be reached through the
roof door ONLY from inside of the unit.

Before Towing

When lifting or lowering drawbar, always grasp drawbar firmly and stand to one side.
Ensure that the tires, wheels and running gear are in good condition and secure.

Towing (Steerable Axle Units)

Do not tow this unit in excess of 20 mph (32km/hr). Use a tow vehicle whose towing capacity
is greater than the gross weight of this unit.

Book: 23010598 (2-16-07) Rev. A 25

Operating & Maintenance Manual Operating Instructions

Set-Up

Place the unit in an open, well-ventilated area. Position as level as possible. The design of
these units permits a maximum 15 degree limit on out-of-level operation.

When the unit is to be operated out-of-level, it is important: (1) to keep the engine crankcase
oil level near the high level mark (with the unit level), and (2) to have the compressor oil level
gauge show no more than mid-scale (with the unit running at full load). Do not overfill either
the engine crankcase or the compressor lubricating oil system.

Chock wheels or set parking brake.

Compressor Mounting

Portable compressors, which are modified to remove the running gear and mount the machine
direct to trailers, truck beds or frames, etc. may experience failure of the enclosure, frame,
and/or other components. It is necessary to isolate the compressor package from the carrier
base with a flexible mounting system. Such a system must also prevent detachment of the
package from the carrier base in the event the isolators fail. Contact Ingersoll-Rand
representative for flexible mounting kits.

Warranty does not cover failures attributable to mounting of the compressor package to the
carrier base unless it is an Ingersoll-Rand provided system.

26 Book: 23010598 (2-16-07) Rev. A

Operating Instructions Operating & Maintenance Manual

Disconnect

Engage parking brakes and chock wheels of both tow vehicle and compressor.
Stand aside while:

• Withdraw pin, swing jack down and fully insert pin to lock in down position.

• Disconnect safety chains from tow vehicle.

• Disconnect brake actuator chain from tow vehicle.

• If so equipped, disconnect running light plug from the tow vehicle.

• Operate drawbar jack to raise pintle eye from hitch of tow vehicle.

!

WARNING

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 servic e valve
to prevent reverse flow in the event of an unexpected shutdown when the
service valve is open.

!

WARNING

Unrestricted air flow from a hose will result in a whipping motion of the
hose which can cause serious injury or death. A safety device must be
attached to the hose at the source of supply to reduce pressure in case
of hose failure or other sudden pressure release. Reference: OSHA
regulation 29 CFR Section 1926.302 (b).

Air hose restraining cable installation:
Secure hose restraining cable at each end to prevent accidental hose whipping. At the

machine-side of the air hose, install and secure one end of the hose restraining cable on the
3” nipple on the inlet side of the 3” service valve. Install the other end of the hose restraining
cable over the main hose connector.

Install suitable 3” air hose between service valve on unit and point of air use. The air hose must
be rated for outdoor use and for pressurized air service. Minimum rating is 250°F (121°C) a nd
200 psig (HP) or 425 psig (XHP).

Book: 23010598 (2-16-07) Rev. A 27

Operating & Maintenance Manual Operating Instructions

Before Starting

All checks should be made while unit is level.

• Open service valve(s) to ensure pressure is relieved in receiver-separator system.

• Close valve(s) in order to build up full air pressure and ensure proper oil circulation.

• Check battery for proper connections and condition.

Inspect the complete installation including remote fuel lines (if any) and air hose routing and
connections.

Check battery for proper connections and condition.

!

WARNING

Combustible gas can cause severe burns, blindness or death. Keep
sparks and open flame away from battery.

• Check the compressor fluid level. Maintain the fluid level between bottom and
midway of the sight glass on the separator tank.

• Check engine oil level. The proper level is labeled on the engine dipstick. Add oil
when required. Do not overfill.

• To jump-start, connect the positive booster/charger cable to the 24VDC positive (+)
terminal of the battery. Then connect the negative booster/charger cable to the
engine block...Not to the negative (-) terminal of the weak battery. After starting,
disconnect the negative (-) cable from engine block; then from the booster battery/
charger. Disconnect positive (+) cable from both batteries.

!

WARNING

Do not remove the cap from a HOT engine radiator. The sudden release
of pressure from a heated cooling system can result in a loss of coolant
and possible severe personal injury.

!

WARNING

Hot pressurized fluid can cause serious burns. Do not open radiator while
hot.

28 Book: 23010598 (2-16-07) Rev. A

Operating Instructions Operating & Maintenance Manual

Check coolant to assure coolant level by removing the radiator top cap and looking for coolant
in the filler neck of the radiator. Add coolant as required. Insure that radiator cap is installed
properly and tightened.

Check engine coolant level on coolant recovery bottle on inside of rear door. Add coolant as
required.

Insure that radiator cap is installed properly and tightened.

NOTE: This machine will not allow engine starting if engine coolant is low.

NOTICE

If the appropriate mixture of antifreeze is not used during freezing
temperatures, failure to drain the engine may cause costly engine
damage. Never use water only, as corrosion inhibitors are required in
engine coolant fluid.

!

CAUTION

No smoking, sparks, or open flame near fuel.

Check the fuel level. Add only CLEAN DIESEL fuel for maximum service from the engine.
Refer to the Engine Operator’s Section for fuel specifications.

NOTICE

To minimize condensation (water) in the fuel tank, it is recommended to
fill the tank at the end of each day.

NOTE: This machine will not allow engine starting if the fuel level is below
the minimum fuel shut off level.

!

WARNING

This machine produces loud noise with doors open. Extended exposure
to loud noise can cause hearing loss. Wear hearing protection when
doors or valve(s) are open.

Book: 23010598 (2-16-07) Rev. A 29

Operating & Maintenance Manual Operating Instructions

• Close the side doors to maintain a cooling air path and to avoid recirculation of hot
air. This will maximize the life of the engine and compressor and protect the hearing
of surrounding personnel.

• Make sure no one is IN or ON the compressor unit.

Starting

!

CAUTION

Exercise caution when using a booster battery charger to start.

To jump-start, connect the positive booster/charger cable to the 24VDC positive (+) terminal
of the battery. Then connect the negative booster/charger cable to the engine block...Not to
the negative (-) terminal of the weak battery. After starting, disconnect the negative (-) cable
from engine block; then from the booster battery/charger. Disconnect positive (+) cable from
both batteries.

• Flip the POWER switch to “ON”. All diagnostics lamps will light (glow) for two (2)
seconds. Then all lamps should go off except for ALTERNATOR NOT CHARGING
and LOW ENGINE OIL PRESSURE.

• In freezing weather, flip HEATERS switch “ON” and wait sixty (60) seconds. This
applies heat to the control system components for easier starting. Leave this switch
“ON” while operating at these temperatures.

If equipped with 24 volt compressor (Cold Start Option)

• Press and hold the BYPASS button for ten (10) to fifteen (15) seconds. This operates
the 24 volt compressor which pressurizes the inlet valve and holds it closed for easier
starting.

• Press both the START and the BYPASS buttons to crank the engine. DO NOT
OPERATE THE STARTER MOTOR FOR MORE THAN TEN (10) SECONDS
WITHOUT ALLOWING AT LEAST ONE MINUTE COOLING TIME BETWEEN
START ATTEMPTS.

30 Book: 23010598 (2-16-07) Rev. A

Operating Instructions Operating & Maintenance Manual

!

CAUTION

Ether is an extremely volatile, high flammable gas. Use Sparingly! If too
much is injected, the uncontrolled explosion may result in costly damage
to the engine.

In cold weather:

In cold weather, as required, press the ETHER INJECT button once or twice only while the
engine is cranking. This injects a measured amount of ETHER to the engine.

Release the START button when the engine starts and sustains running. If the engine does
not start after a couple of attempts, refer to Trouble Shooting Section.

Delivered air volume at set point pressure is accomplished by two methods:
Release BYPASS button when the engine speed reaches 1000 rpm. The engine oil pressure

should be above 20 psi. If the engine oil pressure does not rise within five (5) seconds, stop
the unit and refer to Engine Operator’s Manual.

Once running, All DIAGNOSTIC lamps should be off. If not, stop the machine and investigate.
Observe the gauges while the unit warms up for five (5) to ten (10) minutes or until the coolant

temperature reaches 140°F (60°C).
Push the SERVICE AIR button. The engine should go to full speed and the discharge pressure

rise to slightly over rated pressure. If there is no air being consumed, the compressor will
unload (intake should be throttled or closed) and the engine speed drop to the no load spee d.

Compressor is now ready to furnish air when the service valve is opened.

Stopping

• Close air service valve(s).

• Allow the unit to run at “no load” for 3 to 5 minutes to reduce the engine temperatures.

• Flip all toggle switches to “OFF” position.

Note: Once the engine stops, the automatic blowdown valve will begin to relieve all pressure
from the receiver-separator system.

Book: 23010598 (2-16-07) Rev. A 31

Operating & Maintenance Manual Operating Instructions

!

CAUTION

Never allow the unit to sit stopped with pressure in the receiver-separator
system. As a precaution, open the service valve.

!

WARNING

Even after pressure is relieved from the piping system, any air supply line
from the compressor to a tool or machine could remain under pressure
and cause serious personal injury or death. After the compressor stops,
carefully open a valve at any tool or machine to exhaust the pressure in
any line prior to removal or servicing.

!

CAUTION

When the machine is connected for operation, its system will become
pressurized and/or contaminated if it is stopped with the service valve
open. Any volume of air downstream of the compressor will flow back
into the compressor through the open service valve. A check valve is
required as close to the service valve as possible to prevent reverse flow.

Equipment Protection

NOTICE

Do NOT wire around or bypass a shutdown sensor or switch.

All units in this family of machines are protected by five (5) sensors or switches at the following
locations:

1. High engine coolant temperature in the engine.

2. Low engine oil pressure, in the engine.

3. Low fuel level. (First the light on the control panel will come on as a warning).

High Discharge AIR Temperature

4. At the airend outlet.

5. In the safety valve connection on the side of the separator tank.

All sensors will automatically reset when the problem condition is corrected.

32 Book: 23010598 (2-16-07) Rev. A

Operating Instructions Operating & Maintenance Manual

Automatic Shutdown/Diagnostics

Should any of these problem situations occur, the unit will automatically shutdown and stop.
BEFORE restarting the unit or flipping the POWER switch to “OFF”, check the DIAGNOSTICS
area on the instrument panel.

In a shutdown situation, the function of the panel lamps is to indicate what specific failure
caused the unit to shutdown. These lamps will remain illuminated until the Power Switch is
turned “OFF”.

Note: None of the panel lamps should be glowing when the machine is operating. If they are,
shut unit down and investigate.

The upper four (4) lamps are electronically “latched” to only respond to the first or primary
signal for a shutdown. In other words, if the automatic shutdown is the result of one of these
four problems, only that particular problem lamp will be lit. And the lamp will remai n lit as long
as the batteries provide power.

Refer to OPERATING CONTROLS and INSTRUMENTS for the various problem signal criteria
(°F, psi, etc). The indicated problem area should be inspected for a physical cause (low fluid,
broken fan belt, evidence of excessive heat, etc.) and corrections made.

Sensors 1 thru 5 will automatically reset when the problem condition is corrected.
Other possible causes for an unexpected shutdown are listed on the Trouble Shooting Chart.

Book: 23010598 (2-16-07) Rev. A 33

Operating & Maintenance Manual Operating Instructions

Pressure Regulation

Adjustment Instructions

Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follo ws:
The operating pressure of this unit was set at the factory to the maximum rating (at full speed).

See General Data. However, this pressure may be reset down to 150 psi (1050 kPa).

1. WITH UNIT STOPPED, disconnect rod end bearing on governor cable (GC) at
engine governor lever.

2. At bracket (A) near butterfly valve (BV) run nut (B) back on governor cable
housing. Push governor cable housing toward lever (C). Tighten nut (D).

3. Loosen nut (E) to relax spring (G).

4. With locking pliers, clamp onto butterfly valve shaft and rotate and hold it so
butterfly valve is fully shut. Place a wrench on lever screw (K) and rotate
butterfly valve lever (C) so air cylinder rod (L) fully bottoms out in air cylinder.
While holding the butterfly valve closed AND holding air cylinder shaft fully in,
tighten lever screw (J). Then release hold on butterfly valve and lever.

5. Loosen nut (H). Turn rod (L) in Air Cylinder (AC) until approximately 3/4 inch
(20 mm) between nut (H) and flats of rod (L).

6. Turn rod (L) one round into rod end bearing. Tighten nut (H). Rotate butterfly
shaft/lever (C), open and close, several times to assure that linkage is not
binding.

7. With engine governor lever in full speed position, reconnect rod end bearing.

8. Take slack out of spring (G) by moving nuts (E) and (F). Tighten nuts.

9. Start unit and allow to warm up for 3 to 5 minutes.

10. Push “Service Air” button on control panel.

34 Book: 23010598 (2-16-07) Rev. A

Operating Instructions Operating & Maintenance Manual

11. With service air valve closed, adjust pressure regulator (PR) to rated pressure

(*) plus 10 psi (70 kPa) as follows:

12. Loosen locknut (M) counterclockwise. Turn adjustment cap (N) clockwise to

increase pressure, counterclockwise to decrease pressure.

13. Set no load speed (*) by adjusting position of rod end bearing on governor

cable at engine. Tighten lock nut.

14. Open service air valve and observe full load engine speed (*). Adjust regulator

to give rated operating pressure (*). Tighten locknut (M).

15. Close and slowly open service air valve. If engine speed surges, increase

tension on spring (G) by moving nuts (E) and (F). XHP900 Units ONLY: Should
not be adjusted by moving nuts (E) and (F). See Step 7. If set speeds are not
correct, repeat steps 12, 13 and 14 as required.

16. To regulate to any pressure between 150 psi (1050 kPa) and maximum rating

(*), make adjustments at the pressure regulator.

Book: 23010598 (2-16-07) Rev. A 35

**Always use Ingersoll-Rand Replacement parts!**

36 Book: 23010598 (2-16-07) Rev. A

Maintenance

Book: 23010598 (2-16-07) Rev. A 37

Operating & Maintenance Manual Maintenance

Maintenance

Initial

500 miles

/850 km

Compressor Oil Level C
Engine Oil Level C
*Radiator Coolant Level C
Gauges/Lamps C
*Air Cleaner Service Indicators C
Fuel Tank (Fill at end of day) C D
*Fuel/Water Separator Drain C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters D
Coolant Leaks C
Radiator Filler Cap C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C

Daily Weekly Monthly

3 Months

500 hrs.

6 Months
1000 hrs.

12

Months

2000 hrs.

Battery Connections/Electrolyte C
Tire Pressure and Surface C
*Wheel Lug Nuts C
Hoses (Oil, Air, Intake, etc.) C
Automatic Shutdown System C
Air Cleaner System C
Compressor Oil Cooler Exterior C
*Engine Rad/Oil Cooler Exterior C
Fasteners, Guards C
Air Cleaner Elements R/WI

*Disregard if not appropriate for this particular machine. D = Drain
(1) or 3000 miles/5000km whichever is the sooner G = Grease

C = Check (adjust, clean or replace as necessary) R = Replace
CBT = Check before towing. T = Test
CR = Check and report W I = or when indicated if earlier.

Refer to specific sections of the operator's manual for
more information.

38 Book: 23010598 (2-16-07) Rev. A

Maintenance Operating & Maintenance Manual

Initial

500 miles

/850 km

*Fue/Water Separator Element R
Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change R
Engine Oil Filter R
*Water Pump Grease. R
*Wheels (Bearings, Seals, etc.) C G
*Engine Coolant CR
Fuel Filter Element R
*Injection Nozzle Check C
Shutdown Switch Settings T
Scavenger Orifice & Related Parts C
Oil Separator Element R
*Feed Pump Strainer Cleaning. C

Daily Weekly Monthly

3 Months

500 hrs.

6 Months

1000 hrs

12

Months

2000 hrs

Months

3000 hrs

18

*Valve Clearance Check C
Lights (running, brake, & turn) CBT
Pintle Eye Bolts CBT
* Brakes C C
* Brake linkage C
* Emergency stop T
Running gear linkage G
Safety valve C
Running gear bolts(1) C

*Disregard if not appropriate for this particular machine. D = Drain
(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R = Replace

C = Check (adjust, clean or replace as necessary) T = Test
CBT = Check before towing. W I = or when indicated if earlier.
CR = Check and report Refer to specific sections of the operator's manual for

more information.

Book: 23010598 (2-16-07) Rev. A 39

Operating & Maintenance Manual Maintenance

Initial

500 miles

/850 km

Scavenge line C
* Engine breather element C
Separator tank (2) exterior CR
*Lubricator (Fill) C

2 Yrs4 Yrs6 Yrs

Safety valve C
Hoses R
Separator tank (2) interior C

*Disregard if not appropriate for this particular machine. D = Drain
(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R = Replace

C = Check (adjust, clean or replace as necessary) T = Test

Daily Weekly Monthly

3 Months

500 hrs.

6 Months

1000 hrs

12

Months

2000 hrs

CBT = Check before towing. W I = or when indicated if earlier.
CR = Check and report Refer to specific sections of the operator's manual for

more information.

Routine Maintenance

This section refers to the various components which require periodic maintenance and
replacement.

The MAINTENANCE CHART indicates the various components' descriptions and the
intervals when maintenance has to take place. Oil capacities, etc., can be found in the
GENERAL DATA SECTION of this manual.

For any specification or specific requirement on service or preventative maintenance for
the engine, refer to the Engine Section.

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.

If the automatic blowdown fails to operate, then pressure must be gradually relieved by
operating the manual blowdown valve. Suitable personal protective equipment should be
worn.

Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.

40 Book: 23010598 (2-16-07) Rev. A

Maintenance Operating & Maintenance Manual

Prior to attempting any maintenance work, ensure that:-

• all air pressure is fully discharged and isolated from the system. If the automatic
blowdown valve is used for this purpose, then allow enough time for it to complete
the operation.

• the discharge pipe / manifold area is depressurized by opening the discharge valve,
while keeping clear of any airflow from it.

!

WARNING

Pressure will remain in the system between the minimum pressure
valve and the service valve after shutdown and operation of the auto
blowdown valve.

This pressure must be relieved by :

(a) Disconnecting any downstream equipment.

(b) Opening the discharge valve to atmosphere.

• the machine cannot be started. Post warning signs and/or fit anti-start devices.

• Disconnect battery cables.

Prior to opening or removing panels or covers to work inside a machine,
ensure that:-

• anyone entering the machine is aware of the reduced level of protection and the
additional hazards, including hot surfaces and intermittently moving parts.

• The machine cannot be started.

Prior to attempting any maintenance work on a running machine, ensure
that:-

• the work carried out is limited to only those tasks which require the machine to
run.

• the work carried out with safety protection devices disabled or removed is limited
to only those tasks which require the machine to be running with safety protection
devices disabled or removed.

• all hazards present are known (e.g. pressurised components, electrically live
components, removed panels, covers and guards, extreme temperatures, inflow
and outflow of air, intermittently moving parts, safety valve discharge etc.).

• appropriate personal protective equipment is worn.

• loose clothing, jewelry, long hair etc. is made safe.

Book: 23010598 (2-16-07) Rev. A 41

Operating & Maintenance Manual Maintenance

• warning signs indicating that Maintenance Work is in Progress are posted in a
position that can be clearly seen.

Upon completion of maintenance tasks and prior to returning the machine into
service, ensure that:-

• the machine is suitably tested.

• all guards and safety protection devices are refitted.

• all panels are replaced, canopy and doors closed.

• hazardous materials are effectively contained and disposed of.

Protective Shutdown System

Refer to the diagnostic display codes table for a listing of shutdown conditions.

Low engine fuel level switch.

Test the low engine fuel level switch circuit as follows:

• Start the machine.

NOTE: Do not press the load button.

• Disconnect the switch, the machine should shutdown.

• Re-connect the switch.

Test the low engine fuel level switch by removing and operating the float manually.

!

WARNING

Never remove or replace switches when the machine is running.

Scavenge Line

The scavenge line runs from the combined orifice/drop tube in the separator tank, to the
orifice fitting located in the airend.

Check that the scavenge line and tube are clear of any obstruction each time the
compressor lubricant is changed as any blockage will result in oil carryover into the
discharge air.

42 Book: 23010598 (2-16-07) Rev. A

Maintenance Operating & Maintenance Manual

Compressor Oil Filter

Refer to the MAINTENANCE CHART in this section for the recommended servicing
intervals.

Removal

!

WARNING

Do not remove the filter(s) without first making sure that the machine
is stopped and the system has been completely relieved of all air
pressure. (Refer to STOPPING THE MACHINE in the OPERATING
INSTRUCTIONS section of this manual)

Clean the exterior of the filter housing and remove the spin-on element.

lnspection

Inspect the oil filter head to be sure the gasket was removed with the oil filter element.
Clean the gasket seal area on the oil filter head.

!

CAUTION

If there is any indication of the formation of varnishes, shellacs or
lacquers on the filter element, it is a warning that the compressor
lubricating and cooling oil has deteriorated and that it should be
changed immediately. Refer to LUBRICATION later in this section.

NOTICE

Installing a new oil filter element when the old gasket remains on the
filter head, will cause an oil leak and can cause property damage.

Book: 23010598 (2-16-07) Rev. A 43

Operating & Maintenance Manual Maintenance

Reassembly

Clean the filter gasket contact area and install the new element.Tighten until the gasket
makes contact with the filter housing. Tighten an additional 1/2 to 3/4 of a revolution.

!

CAUTION

Start the machine (refer to PRIOR TO STARTING and STARTING THE
MACHINE in the OPERATING INSTRUCTIONS section of this manual)
and check for leakage before the machine is put back into service.

Compressor Oil Separator Element

Refer to the MAINTENANCE CHART in this section for the recommended servicing
intervals.

If, however, the element has to be replaced, then proceed as follows:

Removal

!

WARNING

Do not remove the filter(s) without first making sure that the machine
is stopped and the system has been completely relieved of all air
pressure. (Refer to STOPPING THE MACHINE in the OPERATING
INSTRUCTIONS section of this manual).

Disconnect all hoses and tubes from the separator tank cover plate. Remove the drop-tube
from the separator tank cover plate and then remove the cover plate. Remove the
separator element.

lnspection

Examine the filter element. Examine all hoses and tubes, and replace if necessary.

44 Book: 23010598 (2-16-07) Rev. A

Maintenance Operating & Maintenance Manual

Reassembly

Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly.
Install the new element.

!

WARNING

DO not remove the staple from the anti-static gasket on the separator
element since it serves to ground any possible static build-up. Do not
use gasket sealant since this will affect electrical conductance.

Reposition the cover plate, taking care not to damage the gasket, and replace the cover
plate screws tightening in a criss-cross pattern to the recommended torque (refer to the
TORQUE SETTING TABLE later in this section).

Reconnect all hoses and tubes to the separator tank cover plate.
Replace the compressor oil (refer to LUBRICATION later in this section).

!

CAUTION

Start the machine (refer to PRIOR TO STARTING and STARTING THE
MACHINE in the OPERATING INSTRUCTIONS section of this manual)
and check for leakage before the machine is put back into service.

Compressor Oil Cooler and Engine Radiator

When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator,
the efficiency is impaired. It is recommended that each month the oil cooler and radiator
be cleaned by directing a jet of compressed air, (carrying if possible a non-flammable
cleaning solvent) over the exterior core of the cooler/radiator. This should remove any
accumulation of oil, grease and dirt from the exterior core of the cooler so that the entire
cooling area can radiate the heat of the lubricating and cooling oil/water into the air stream.

!

WARNING

Hot engine coolant and steam can cause injury. When adding coolant
or antifreeze solution to the engine radiator, stop the engine at least
one minute prior to releasing the radiator filler cap. Using a cloth to
protect the hand, slowly release the filler cap, absorbing any released
fluid with the cloth. Do not remove the filler cap until all excess fluid is
released and the engine cooling system fully depressurised.

Book: 23010598 (2-16-07) Rev. A 45

Operating & Maintenance Manual Maintenance

!

WARNING

Follow the instructions provided by the antifreeze supplier when
adding or draining the antifreeze solution. It is advisable to wear
personal protective equipment to prevent skin and eye contact with
the antifreeze solution.

Air Filter Elements

The air filter element should be replaced regularly (refer to the MAINTENANCE CHART)
or when the restriction indicator shows red, whichever comes first. The aircleaner
precleaner dumps should be cleaned as indicated in the MAINTENANCE CHART (more
frequently in dusty operating conditions).

Removal

!

CAUTION

Never remove and replace element(s) when the machine is running.

Clean the exterior of the filter housing and remove the filter element by releasing the nut.

Reassembly

Assemble the new element into the filter housing ensuring that the seal seats properly.
Secure element by tightening nut.

Before restarting the machine, check that all clamps are tight.

Ventilation

Always check that the air inlets and outlets are clear of debris etc.

Cooling Fan Drive

Periodically check that the fan mounting bolts in the fan hub have not loosened. If, for any
reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolts, apply
a good grade of commercially available thread locking compound to the bolt threads and
tighten to the torque value shown in the TORQUE SETTING TABLE later in this section.

The fan belt(s) should be checked regularly for wear and correct tensioning.

46 Book: 23010598 (2-16-07) Rev. A

Maintenance Operating & Maintenance Manual

Fuel System

The fuel tank should be filled daily or every eight hours. To minimise condensation in the
fuel tank(s), it is advisable to top up after the machine is shut down or at the end of each
working day. Drain any sediment or condensate that may have accumulated in the tank(s).
Refer to MAINTENANCE CHART.

Fuel Filter Water Separator

The fuel filter water separator contains a filter element which should be replaced at regular
intervals (see the SERVICE/MAINTENANCE CHART).

Hoses

All components of the engine cooling air intake system should be checked periodically to
keep the engine at peak efficiency.

At the recommended intervals, (see the MAINTENANCE CHART), inspect all of the intake
lines to the air filter, and all flexible hoses used for air lines, oil lines and fuel lines.

Periodically inspect all pipework for cracks, leaks, etc. and replace immediately if
damaged.

Electrical System

!

WARNING

Disconnect the battery cables before performing any maintenance or
service.

Check the security of electrical terminals on the switches and relays i.e. nuts or screws
loose, which may cause local hot spot oxidation.

Inspect the components and wiring for signs of overheating i.e. discolouration, charring of
cables, deformation of parts, acrid smells and blistered paint.

Battery

Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly
to prevent corrosion.

The battery restraint should be kept tight enough to prevent the battery from moving.

Book: 23010598 (2-16-07) Rev. A 47

Operating & Maintenance Manual Maintenance

Pressure System

Regularly, it is necessary to inspect the external surfaces of the system (from the airend
through to the discharge valve(s)) including hoses, tubes, tube fittings and the separator
tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and
chafing. Any suspect parts should be replaced before the machine is put back into service.

Tire Pressure

See the GENERAL DATA SECTION of this manual.

Running Gear/wheels

Check the wheel nut torque 20 miles (30 kilometres) after refitting the wheels. Refer to the
TORQUE SETTING TABLE later in this section.

Lifting jacks should only be used under the axle
The bolts securing the running gear to the chassis should be checked periodically for

tightness (refer to the MAINTENANCE CHART for frequency) and re-tighten where
necessary. Refer to the TORQUE SETTING TABLE later in this section.

Lubrication

!

CAUTION

Always check the oil levels before a new machine is put into service.

If, for any reason, the unit has been drained, it must be re-filled with new oil before it is put
into operation.

Engine Lubricating Oil

The engine oil and oil filter element should be changed at the engine manufacturer's
recommended intervals. Refer to the Engine operator manual/section.

Refer to the Engine operators' manual/section for engine oil specifications.

48 Book: 23010598 (2-16-07) Rev. A

Maintenance Operating & Maintenance Manual

Compressor Lubricating Oil

Refer to the MAINTENANCE CHART in this section for service intervals.

NOTE: If the machine has been operating under adverse conditions, or
has suffered long shutdown periods, then more frequent service
intervals will be required.

!

WARNING

DO NOT, under any circumstances, remove any drain plugs or the oil
filler-plug from the compressor lubricating and cooling system
without first making sure that the machine is stopped and the system
has been completely relieved of all air pressure (refer to STOPPING
THE MACHINE in the OPERATING INSTRUCTIONS section of this
manual).

Completely drain the receiver/separator system including the piping and oil cooler by
removing the drain plug(s) and collecting the used oil in a suitable container.

Replace the drain plug(s) ensuring that each one is secure.

NOTE: If the oil is drained immediately after the machine has been
running, then most of the sediment will be in suspension and will
therefore drain more readily.

!

CAUTION

Some oil mixtures are incompatible and result in the formation of
varnishes, shellacs or lacquers which may be insoluble. Refer to
Portable Compressor Fluid Chart.

Running Gear Wheel Bearings

Wheel bearings should be packed with grease every 12 months. The type of grease used
should conform to specification MIL-G-10924.

Book: 23010598 (2-16-07) Rev. A 49

**Always use Ingersoll-Rand Replacement parts!**

50 Book: 23010598 (2-16-07) Rev. A

Lubrication

Book: 23010598 (2-16-07) Rev. A 51

Operating & Maintenance Manual Lubrication

Portable Compressor Fluid Chart

Refer to these charts for correct compressor fluid required. Note that the selection of fluid is
dependent on the design operating pressure of the machine and the ambient temperature
expected to be encountered before the next oil change.

NOTE: Fluids listed as “preferred” are required for extended warranty.

Compressor oil carryover (oil consumption) may be greater with th e use of alternative
fluids.

Design Operating

Pressure

100 psi to 300 psi

350 psi

Ambient

Temperature

-10°F to 125°F

(-23°C to 52°C)

-10°F to 125°F

(-23°C to 52°C)

65°F to 125°F

(18°C to 52°C)

Specification

Preferred:

IR Pro-Tec™

Alternate:
ISO Viscosity Grade 46
with rust and oxidation
inhibitors, designed for
air compressor service.

Preferred:

IR XHP 605

Alternate:
IR XHP405
ISO Viscosity Grade 68
Group 3 or 5 with rust and
oxidation inhibitors
designed for air
compressor service.
Preferred:

XHP605
IR XHP1001

Preferred Ingersoll-Rand Fluids - Use of these fluids with original I-R filters can extend airend
warranty. Refer to operator’s manual warranty section for details or contact your I-R
representative.

Ingersoll-Rand

Preferred Fluids

1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Llitre)

IR Pro-Tec™ 36899698 36899706 36899714 36899722
IR XHP605 - 22252076 22252050 22252068
IR XHP1001 - 35612738 35300516 ­XHP405 - 22252126 22252100 22252118

52 Book: 23010598 (2-16-07) Rev. A

Trouble Shooting

Book: 23010598 (2-16-07) Rev. A 53

Operating & Maintenance Manual Trouble Shooting

Trouble Shooting

INTRODUCTION

Trouble shooting for a portable air compressor is an organized study of a particular problem
or series of problems and a planned method of procedure for investigation and correction. The
trouble shooting chart that follows includes some of the problems that an operator may
encounter during the operation of a portable compressor.

The chart does not attempt to list all of the troubles that may occur, nor d oes it attempt to give
all of the answers for correction of the problems. The chart does give those problems that are
most apt to occur. To use the trouble shooting chart:

A. Find the “complaint” depicted as a bold heading.
B. Follow down that column to find the potential cause or causes. The causes are

listed in order (1,2,3 etc.) to suggest an order to follow in trouble shooting.

ACTION PLAN

A. Think Before Acting

Study the problem thoroughly and ask yourself these questions:

1. What were the warning signals that preceded the trouble?

2. Has a similar trouble occurred before?

3. What previous maintenance work has been done?

4. If the compressor will still operate, is it safe to continue operating it to make
further checks?

B. Do The Simplest Things First

Most troubles are simple and easily corrected. For example, most complaints are “low
capacity” which may be caused by too low an engine speed or “compressor over- heats” which
may be caused by low oil level.

Always check the easiest and most obvious things first; following this simple rule will save time
and trouble.

NOTE: For trouble shooting electrical problems, refer to the Wiring
Diagram Schematic found in Parts List Section.

54 Book: 23010598 (2-16-07) Rev. A

Trouble Shooting Operating & Maintenance Manual

C. Double Check Before Disassembly

The source of most compressor troubles can be traced not to one componen t alone, but to the
relationship of one component with another. Too often, a compressor can be partially
disassembled in search of the cause of a certain trouble and all evidence is destroyed during
disassembly. Check again to be sure an easy solution to the problem has not been
overlooked.

D. Find And Correct Basic Cause

After a mechanical failure has been corrected, be sure to locate and correct the cause of the
trouble so the same failure will not be repeated. A complaint of “premature breakdown” may
be corrected by repairing any improper wiring connections, but something caused the
defective wiring. The cause may be excessive vibration.

Electrical/Electronic Troubleshooting

Refer to the Electrical/Electronic Service Manual for troubleshooting information and
diagnostic code descriptions.

Book: 23010598 (2-16-07) Rev. A 55

Operating & Maintenance Manual Trouble Shooting

TROUBLE SHOOTING CHART

Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE

NOTE: Subheadings suggest sequence to follow troubleshooting.

1. Unit Shutdown: Corrective Action

Out of Fuel Add CLEAN diesel Fuel
Compressor Oil Temp. Too High See Complaint 10
Engine Water Temp. Too High Check coolant level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Broken Engine Fan Belt Replace fan belt.
Loose Wire Connection Wiggle wires at switches & connector blocks. Make

repairs.
Low Fuel Level Shutdown Replace fuel sender.
Defective Sensor Replace sensor.
Malfunctioning Relay Replace relay.
Blown Fuse Replace fuse.
Engine Malfunctioning See Trouble Shooting in Engine Ma nual.
* Airend Malfunctioning See Complaint 10.

2. Won’t Start/Run:

Low Battery Volt age Check electrolyte level. Check connections.
Blown Fuse Replace fuse.
Malfunctioning Start Switch Replace switch.
Clogged Fuel Filters Service filters. See Engine Operator’s Manual.
Out of Fuel Add CLEAN fuel.
Compressor Oil Temp. Too High See Complaint 10.
Engine Water Temp. Too High Check fluid level. If necessary, Add.
Engine Oil Pressure Too Low See Complaint 3 and Complaint 4.
Loose Wire Connection Repair or replace connection.
Defective Sensor Replace sensor.
Malfunctioning Relay Replace relay.
Engine Malfunctioning See Trouble Shooting in Engine Ma nual.
Airend Malfunctioning See Complaint 10.

3. High Engine Temperature

Broken Engine Fan Belt Replace fan belt set.
*Ambient Temp. >115°F Above spec limit.
Dirty Operating Conditions Move unit to cleaner environment.
Dirty Cooler Clean exterior of cooler.
*Out of Level >15 degrees Relocate or reposition unit.
Operating Pressure Too High Reduce pressure to spec.
Recirculation of Cooling Air Close side doors.
Loose Wire Connection Repair or replace.

* : > = greater than, < = less than

4. Low Engine Oil Pressure Corrective Action

56 Book: 23010598 (2-16-07) Rev. A

Trouble Shooting Operating & Maintenance Manual

Low Oil Level Add oil.
Out of Level >15 degrees Relocate or reposition.
Wrong Lube Oil See Engine Oil Spec. Change oil.
Clogged Oil Filter Element(s) Replace element(s).
Engine Malfunctioning See Trouble Shooting in Engine Ma nual.
Loose Wire Connection. Repair or replace.

5. Alternator Low Voltage

Loose or Broken Belts Tighten or replace belt set.
Loose Wire Connection Repair or replace connection.
Low Battery Voltage Check electrolyte level. Add if necessary.

Check connectors. Clean & tighten.
Recharge battery.

Malfunctioning Alternator Repair or replace alternator.

6. High Compressor Discharge Temperature:

Ambient Temp. > 115°F Above spec limit.
Out of Level > 15 degrees Relocate or reposition unit.
Low Oil Level Add oil. Look for any leaks.
Wrong Lube Oil Check spec in this manu al.
Dirty Cooler Clean exterior surfaces.
Dirty Operating Conditions Move unit to cleaner environment.
Clogged Oil Filter Elements Replace elements. Change oil.
Loose or Broken Belts Tighten or replace belt set.
Operating Pressure Too High Reduce pressure to spec.
Recirculation Of Cooling Air Close side doors. Replace belly pan.
Malfunctioning Thermostat Replace thermostat in bypass valve.
Malfunctioning Fan Check fan belt tension. Tighten or replace belt set.
Defective Oil Cooler Relief Valve Replace valve.
Defective Minimum Pressure Valve Repair or replace valve.
Blocked or Restricted Oil Lines Clean by flushing or replace.
Airend Malfunctioning See Complaint 11, 12

7. Engine RPM Down:

Clogged Fuel Filter (primary) Replace primary filter. Replace final filter. Drain

tanks. Add CLEAN fuel.
Operating Pressure Too High Reduce pressure to spec limit.
Dirty Air Filter Clean or replace elements.
Wrong Air Filter Element Install correct element.
Engine Malfunctioning See Trouble Shooting in Engine Ma nual.
Airend Malfunctioning Refer to Factory.

8. Excessive Vibration:

Rubber Mounts, Loose or Damaged Tighten or replace.
Defective Fan Replace fan.
Drive Coupling Defective Replace coupling.
Engine Malfunctioning See Trouble Shooting in Engine Ma nual.
Airend Malfunctioning See Complaint 11 and 12.
Engine idle speed too low. Se e Eng ine Ma nu a l.

9. Low CFM:

Dirty Air Filter Clean or replace elements.

Book: 23010598 (2-16-07) Rev. A 57

Operating & Maintenance Manual Trouble Shooting

Incorrect Linkage Adjustment Make adjustment per Section 4.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve. Make adjustment per Section 4.
Wrong Air Filter Element Install correct element.

10. Short Air Cleaner Life:

Dirty Operating Conditions Move unit to cleaner environment.
Inadequate Element Cleaning Install new element.
Incorrect Stopping Procedure Read procedure in this manual.
Wrong Air Filter Element Install proper element.

11. Will Not Unload:

Malfunctioning Inlet Butterfly Valve Inspect valve fit. Re-adjust per Section 4.
Ice in Regulation Lines/Orifice Apply heat to line(s) and or orifice.
Load Solenoid Leak Replace load solenoid.
Plugged Vent Leak Clean and/or replace.

12. Safety Valve Relieves:

Operating Pressure Too High Reduce pressure to spec limit.
Malfunctioning Inlet Unloader/Butterfly Valve Inspect valve fit. Readjust per Section 4.
Defective Safety Valve Replace safety valve.
Unit Will Not Unload Fast Enough Apply heat to lines and/or orifice.

58 Book: 23010598 (2-16-07) Rev. A

©2004 Ingersoll-Rand Company, Printed in the USA