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Ingersoll-Rand CSA XHP900WCAT User Manual

Ingersoll-Rand CSA XHP900WCAT
59 pages
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Operating & Maintenance Manual
Compressor Model
Utility Equipment
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book: 23010598 (2-16-07) Rev. A
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.
CSA XHP900WCAT
Code: A
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Ingersoll-Rand CSA XHP900WCAT Specifications

General IconGeneral
ModelXHP900WCAT
CategoryAir Compressor
TypeRotary Screw
Free Air Delivery900 cfm
EngineCaterpillar C9
Fuel Capacity150 gallons
Drive TypeDirect Drive
Cooling MethodAir Cooled
Control TypeElectronic
Rated Operating Pressure150 PSI
Noise Level76 dB(A)

Summary

Foreword

Safety

Safety Precautions

General safety warnings and instructions for operating the machine safely.

General Information

Information regarding safe operation, maintenance, and machine specifications.

Compressed Air Safety

Precautions and hazards associated with the handling and use of compressed air.

Hazardous Materials and Substances

Details on substances used in the machine and potential health hazards.

Battery Safety Precautions

Safety guidelines for handling and jump-starting the machine's battery.

Radiator Safety

Precautions for dealing with hot engine coolant and steam from the radiator.

Transport and Towing Safety

Guidelines for safely loading, transporting, and towing the compressor unit.

Understanding Safety Decals

Explanation of different safety decal types (Danger, Warning, Caution, Notice) and their meanings.

General Data

Machine Models and Specifications

Overview of compressor models and their key specifications.

Compressor Specifications

Technical data for the compressor unit.

Engine Specifications

Details on the diesel engine powering the compressor.

Fluid Capacities

Information on lubricant, coolant, and fuel capacities for the machine.

Machine Dimensions and Measurements

Physical dimensions and measurement units for the compressor.

Running Gear Specifications

Details related to the running gear, tires, and towing specifications.

Service Parts Identification

List of part numbers for essential service components like filters.

Operating Instructions

Control Panel Devices and Indicators

Detailed explanation of each gauge, switch, button, and indicator on the control panel.

Before Towing Procedures

Essential checks and actions to perform before towing the compressor unit.

Towing Specifications and Guidelines

Maximum towing speeds and requirements for steerable axle units.

Machine Set-Up Procedures

Instructions for positioning the unit, managing out-of-level operation, and securing it.

Compressor Mounting Guidelines

Information on mounting the compressor package directly to trailers or frames.

Disconnecting Procedures

Steps for safely disconnecting the compressor from the towing vehicle.

Before Starting Checks

Pre-start checks including fluid levels, battery, and system pressure relief.

Starting the Compressor

Procedures for starting the compressor, including cold weather and booster starting.

Cold Weather Starting Procedures

Specific steps for starting the compressor in cold weather conditions.

Stopping the Compressor

Steps for safely shutting down the compressor unit.

Equipment Protection Systems

Details on the machine's protective shutdown sensors and switches.

Automatic Shutdown and Diagnostics

Explanation of automatic shutdown features and diagnostic indicator lamps.

Pressure Regulation Adjustment

Step-by-step guide for adjusting the pressure regulation system.

Maintenance

Maintenance Schedule Chart

A comprehensive chart detailing maintenance tasks and their recommended intervals.

Routine Maintenance Procedures

Overview of routine maintenance tasks and where to find detailed information.

Maintenance Safety Precautions

Critical safety steps to follow before performing any maintenance on the machine.

Protective Shutdown System Testing

How to test the low engine fuel level switch and other protective systems.

Scavenge Line Maintenance

Checking the scavenge line for obstructions during oil changes.

Compressor Oil Filter Servicing

Instructions for removing, inspecting, and replacing the compressor oil filter element.

Compressor Oil Separator Element Replacement

Procedure for removing and replacing the compressor oil separator element.

Oil Cooler and Radiator Cleaning

Guidelines for cleaning the compressor oil cooler and engine radiator for optimal efficiency.

Air Filter Element Replacement

Instructions for replacing the air filter element and cleaning the air cleaner.

Ventilation System Check

Ensuring air inlets and outlets are clear of debris for proper ventilation.

Cooling Fan Drive Maintenance

Checking fan mounting bolts and fan belt tension and wear.

Fuel System Maintenance

Recommendations for fueling the tank and draining sediment or condensate.

Fuel Filter Water Separator Servicing

Information on replacing the filter element in the fuel filter water separator.

Hose and Pipework Inspection

Periodic inspection of hoses and pipework for cracks, leaks, and damage.

Electrical System Checks

Checking electrical terminals for security and signs of overheating.

Battery Maintenance

Keeping battery terminals clean and ensuring the battery restraint is tight.

Pressure System Inspection

Inspecting the pressure system for signs of damage, corrosion, or wear.

Tire Pressure Check

Referencing General Data section for correct tire pressure specifications.

Running Gear and Wheel Checks

Checking wheel nut torque and securing bolts for the running gear.

Lubrication Procedures

General guidelines for checking oil levels and refilling the machine.

Compressor Lubricating Oil Change

Procedure for draining and replacing compressor lubricating oil.

Wheel Bearing Greasing

Instructions for packing wheel bearings with grease every 12 months.

Lubrication Details

Portable Compressor Fluid Chart

Guide to selecting the correct compressor fluid based on operating pressure and ambient temperature.

Trouble Shooting

Trouble Shooting Introduction

Overview of the trouble shooting process and how to use the chart.

Trouble Shooting Action Plan

A systematic approach to diagnosing and resolving compressor problems.

Analyze the Problem Before Acting

Questions to consider before attempting to diagnose or fix a problem.

Prioritize Simple Solutions

Emphasizes checking the easiest and most obvious causes first for quick resolution.

Double Check Before Disassembly

Importance of verifying simple solutions and not disassembling unnecessarily.

Find and Correct Basic Cause

Ensuring the root cause of a failure is identified and corrected to prevent recurrence.

Electrical and Electronic Troubleshooting

Guidance for troubleshooting electrical and electronic issues, referring to a separate manual.

Trouble Shooting Chart Overview

A guide to identifying compressor complaints and their potential causes and corrective actions.

Unit Shutdown Problems

Common causes and corrective actions for unexpected unit shutdowns.

Starting and Running Problems

Troubleshooting issues related to the compressor failing to start or run properly.

High Engine Temperature Issues

Causes and solutions for the engine overheating during operation.

Low Engine Oil Pressure

Diagnosing and correcting low engine oil pressure conditions.

Alternator Low Voltage Issues

Causes and corrective actions for low voltage output from the alternator.

High Compressor Discharge Temperature

Addressing issues leading to excessive discharge air temperatures.

Engine RPM Drop or Low Speed

Troubleshooting causes for reduced engine speed or RPM.

Excessive Vibration Problems

Identifying and resolving causes of excessive vibration in the compressor.

Low Compressed Air Volume (CFM)

Diagnosing and fixing issues causing low output of compressed air.

Short Air Cleaner Life

Addressing causes of premature air cleaner element clogging or failure.

Compressor Will Not Unload

Troubleshooting why the compressor fails to transition to the unloaded state.

Safety Valve Relieving Issues

Identifying and correcting problems causing the safety valve to activate.

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