Ingersoll-Rand CSAXHP1070WCAT, Operating & Maintenance Manual

Page 1: ...nt P O Box 868 501 Sanford Ave Mocksville N C 27028 Book 23012958 2 16 07 Rev A 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 ...

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Page 3: ...ore 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 runni...

Page 4: ...ts 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 Fl...

Page 5: ...5 TABLE OF CONTENTS Operating Maintenance Manual TITLE PAGE ...

Page 6: ...6 Always use Ingersoll Rand Replacement parts ...

Page 7: ...Book 23012958 2 16 07 Rev A 7 Foreword ...

Page 8: ...gersoll Rand Service departments The use of repair parts other than those included within the Ingersoll Rand approved parts list may create hazardous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand cannot be held responsible for equipment in which non approved repair parts are installed Ingersoll Rand reserves the right to make changes and improvements to products with...

Page 9: ...nctions 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 ...

Page 10: ...10 Book 23012958 2 16 07 Rev A Always use Ingersoll Rand Replacement parts ...

Page 11: ...Book 23012958 2 16 07 Rev A 11 Safety ...

Page 12: ...anical 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 mac...

Page 13: ...hich 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...

Page 14: ...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 lubri...

Page 15: ...G 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 an...

Page 16: ...e 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...

Page 17: ... 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 Bl...

Page 18: ...ety 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...

Page 19: ...Book 23012958 2 16 07 Rev A 19 General Data ...

Page 20: ...LUID CAPACITIES U S Gallons litres Compressor Lubricant initial dry fill 55 208 Compressor Lubricant service refill 44 167 Engine Crankcase Lubricant 9 0 34 1 Engine Coolant radiator 16 5 62 5 Fuel Tank Clean DIESEL fuel 180 680 Note Above 15 F 9 C use No 2 Diesel Fuel with sulfur content not greater than 0 5 and minimum cetane number of 42 UNITS MEASUREMENTS WEIGHTS Feet Meters Low Speed Overall ...

Page 21: ...23012958 2 16 07 Rev A 21 CAUTION Any departure from the specifications may make this equipment unsafe RUNNING GEAR Low Speed Tire Size Load Range 8 25 x 15TR Load Range F Inflation Pressure cold psi kPa 105 720 Towing Speed Maximum mph km hr 20 32 ...

Page 22: ...22 Always use Ingersoll Rand Replacement parts ...

Page 23: ...Book 23012958 2 16 07 Rev A 23 Operating Instructions ...

Page 24: ...sor Disch 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 about of fuel in tanks 6 Engin...

Page 25: ...utomatic shutdown circuit 15 Start Button Activates the engine starter 16 Ether Inject Button Injects a measured shot CAUTION Use Sparingly 17 High Compressor Temperature 248 F 120 C 18 Low Engine Oil Pressure 12 psi 80kPa or less 19 High Engine Temperature Coolant above 220 F 104 C 20 Low Fuel Level Comes on first as a warning and eventually triggers a shutdown 21 Alternator Not Charging Needs at...

Page 26: ...or 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 WARNING Do not connect the air discharge on this unit onto a common header with any other unit of any description or any other source of compressed air without first making sure a check valve is used between the header a...

Page 27: ...vented of all pressure Close the valve before starting 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 ...

Page 28: ...r 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 CAUT...

Page 29: ... near the battery This switch must be turned ON to provide power to the control panel for starting this unit Close the air service valve to isolate the compressor from the compressed air tool until the engine is warmed up 1 Turn the keyswitch to the ON position first position All diagnostic lamps and the LED display will light for two 2 seconds All lamps should then go off and ALTERNATOR NOT CHARG...

Page 30: ...the unit will shutdown In the event the machine controller detects a parameter at a dangerously high or low level the machine will be automatically stopped with the cause of the SHUTDOWN shown on the diagnostic lights and display Delivered air volume at set point pressure is accomplished by two methods 1 The compressor is loaded inlet valve fully open or modulated partially open or unloaded inlet ...

Page 31: ...normal machine stopping Button must be reset before starting can be accomplished NOTICE Once the engine stops the automatic blowdown valve will relieve pressure from the separator tank 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...

Page 32: ...g 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 shaft and lever 7 Turn rod L One comple...

Page 33: ...r 2 0 minutes repeat steps 13 and or 14 as needed Start unit and allow to warm up for 3 to 5 minutes 16 Push Service Air Button on control panel 17 With service air valve closed adjust pressure regulator PR to rated pressure plus 30 psi 70 kPa as follows 18 Loosen locknut M counterclockwise Turn adjustment cap N clockwise to increase pressure counterclockwise to decrease pressure 19 Set idle speed...

Page 34: ...34 Book 23012958 2 16 07 Rev A Always use Ingersoll Rand Replacement parts ...

Page 35: ...Book 23012958 2 16 07 Rev A 35 Trouble Shooting ...

Page 36: ...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 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 compresso...

Page 37: ...un Low Battery Voltage 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 6 Engine Water Temp too High Check fluid level If necessary Add Engine Oil Pressure too Low See Complaint 3 and Complaint 4 Loose Wi...

Page 38: ... Oil Check spec in this manual 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 by...

Page 39: ... 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 6 Ice in Regulation Lines Orifice Appl...

Page 40: ...40 Book 23012958 2 16 07 Rev A Always use Ingersoll Rand Replacement parts ...

Page 41: ...Book 23012958 2 16 07 Rev A 41 Maintenance ...

Page 42: ...C Air Cleaner Precleaner Dumps C Fan Alternator Belts C 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 mil...

Page 43: ...T Scavenger Orifice Related Parts C Oil Separator Element R Feed Pump Strainer Cleaning C 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 d...

Page 44: ...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 Initial 500miles 850 km Daily Weekly Monthly 3 Months 500 hrs 6 Months 1000 hrs 12 Months 2000 hrs Scavenge line C Engine bre...

Page 45: ... 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 ...

Page 46: ...ay 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 machi...

Page 47: ...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 deterio...

Page 48: ...r 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 ...

Page 49: ...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 solve...

Page 50: ... 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...

Page 51: ...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 elec...

Page 52: ...heels 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 ...

Page 53: ... 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 ...

Page 54: ...54 Book 23012958 2 16 07 Rev A Always use Ingersoll Rand Replacement parts ...

Page 55: ...Book 23012958 2 16 07 Rev A 55 Lubrication ...

Page 56: ...r are in Maintenance Section All filters and filter elements for air and compressor lubricant must be obtained through Ingersoll Rand to assure the proper size and filtration for the compressor Compressor Oil Change These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 6 months or 1000 hours whichever comes first If a unit has ...

Page 57: ...voir piping and cooler If the oil is drained immediately after the unit has been run for some time most of the sediment will be in suspension and therefore will drain more readily However the fluid will be hot and care must be taken to avoid contact with the skin or eyes After the unit has been completely drained of all old fluid close the drain valve install new oil filter elements Add oil in the...

Page 58: ...Refer to operator s manual warranty section for details or contact your I R representative DesignOperating Pressure Ambient Temperature Specification 100 psi to 300 psi 10 F to 125 F 23 C to 52 C Preferred IR Pro Tec Alternate ISO Viscosity Grade 46 with rust and oxidation inhibitors designed for air compressor service 350 psi 10 Fto125 F 23 C to 52 C 65 Fto125 F 18 C to 52 C Preferred IR XHP 605 ...

Page 59: ... 2004 Ingersoll Rand Company Printed in the USA ...