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Ingersoll-Rand XP900WCU User Manual

Ingersoll-Rand XP900WCU
434 pages
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Book 35393560 (12/02)
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This manual contains important safety information.
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OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODELS
Portable Power
P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
Code: D
VHP825WCU
HP935WCU
XP1050WCU
HP825WCU
XP900WCU
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Ingersoll-Rand XP900WCU Specifications

General IconGeneral
BrandIngersoll-Rand
ModelXP900WCU
CategoryAir Compressor
LanguageEnglish

Summary

OPERATING, MAINTENANCE, PARTS MANUAL

SECTION 1 - SAFETY

SAFETY PRECAUTIONS

Outlines critical safety measures and general information for operation and maintenance.

SECTION 2 - Warranty

GENERAL WARRANTY INFORMATION

Details warranty coverage for various compressor and engine components.

SECTION 5 - OPERATION

DISCONNECT and SET -- UP

Instructions for properly positioning and preparing the unit before operation.

SECTION 6 - MAINTENANCE

GENERAL

Discusses the importance of maintenance for unit performance and longevity.

COMPRESSOR OIL LEVEL

COMPRESSOR OIL

MAINTENANCE SCHEDULE

SMALL UNITS (P100--P600)

Provides daily, weekly, monthly, and interval maintenance schedules for small units.

SECTION 7 - LUBRICATION

GENERAL INFORMATION

Explains the importance of lubrication and lists items requiring regular service.

COMPRESSOR LUBRICATION

SECTION 8 - Trouble Shooting

ACTION PLAN

Outlines a systematic approach to troubleshooting problems, starting with basic checks.

TROUBLE SHOOTING CHART

1. Unit Shutdown:

Lists common unit shutdown symptoms, their causes, and corrective actions.

SYMPTOM: Air Compressor Pressure Rises Slowly

Intake Air Restriction to Air Compressor Excessive (Naturally Aspirated Air Compressors Only)

Identifies intake air restriction as a cause for slow pressure rise and suggests checking air cleaner.

SYMPTOM: Air Compressor Noise Excessive

SYMPTOM: Air Compressor Pumping Excessive Lubricating Oil Into Air System

Intake Air Restriction to Air Compressor Excessive (Naturally Aspirated Air Compressor Only)

Links intake air restriction to excessive oil pumping and suggests checking air cleaner.

SYMPTOM: Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)

SYMPTOM: Air Compressor Will Not Stop Pumping

Air System Leaks

Identifies air system leaks as a cause for the compressor not stopping pumping.

SYMPTOM: Alternator Not Charging or Insufficient Charging

SYMPTOM: Coolant Loss -- External

Coolant Leaks

Identifies coolant leaks as a cause for coolant loss and suggests visual inspection.

SYMPTOM: Coolant Temperature Above Normal -- Gradual Overheat

SYMPTOM: Coolant Temperature Above Normal -- Gradual Overheat (Continued)

SYMPTOM: Coolant Temperature Above Normal -- Sudden Overheat

Coolant Level Low

Identifies low coolant level as a cause for sudden overheat and suggests adding coolant.

SYMPTOM: Coolant Temperature Below Normal

SYMPTOM: Crankcase Gases (Blowby) -- Excessive

SYMPTOM: Engine Acceleration and Response Poor

SYMPTOM: Engine Cranks But Will Not Start (No Smoke From Exhaust)

Fuel in Tank Too Low

Identifies low fuel level as a cause for the engine not starting and suggests adding fuel.

SYMPTOM: Engine Decelerates Slowly

SYMPTOM: Engine Difficult to Start or Will Not Start -- Exhaust Smoke Present

Battery Does Not Have at Least 7 Volts

Checks battery voltage, suggesting recharge if below 7 volts, as a cause for starting issues.

SYMPTOM: Engine Noise Excessive

Engine Oil Supply Insufficient or Engine Oil Pressure Low

Links insufficient oil supply or low pressure to excessive engine noise.

SYMPTOM: Engine Noise Excessive -- Combustion Knocks

SYMPTOM: Engine Power Output Low

SYMPTOM: Engine Power Output Low (Continued)

Fuel Drain Line Restricted or Fuel Tank Vents Plugged

Identifies restricted fuel drain lines or plugged vents as causes for low engine power.

SYMPTOM: Engine Runs Rough or Misfires

SYMPTOM: Engine Shuts Off Unexpectedly or Dies During Deceleration

Engine Will Not Restart

Refers to symptom chart for engine not starting issues.

SYMPTOM: Engine Speed Surges at Low Idle

SYMPTOM: Engine Speed Surges (Other Than Low Idle)

Fuel Level Low in the Tank

Identifies low fuel level as a cause for speed surges.

SYMPTOM: Engine Starts But Will Not Keep Running

Fuel Level in Tank Too Low

Suggests adding fuel if the engine starts but does not keep running.

SYMPTOM: Engine Vibration Excessive

SYMPTOM: Engine Will Not Crank or Cranks Slowly (Air Starting Motor)

Air Pressure Insufficient in Air Tank

Identifies insufficient air pressure in the tank as a cause for the engine not cranking.

SYMPTOM: Engine Will Not Crank or Cranks Slowly (Electric Starting Motor)

SYMPTOM: Engine Will Not Reach Rated Speed When Loaded

Excessive Load for Engine Horsepower Rating

Suggests reducing load or using lower gear if engine power is insufficient.

SYMPTOM: Engine Will Not Shut Off

Fuel Pump Manual Override Open

Identifies an open fuel pump manual override as a cause for the engine not shutting off.

SYMPTOM: Fuel Consumption -- Excessive

SYMPTOM: Fuel in Coolant

SYMPTOM: Lubricating Oil Contaminated

SYMPTOM: Lubricating Oil Consumption Excessive

SYMPTOM: Lubricating Oil Pressure High

SYMPTOM: Lubricating Oil Pressure Low

Incorrect Oil Level

Identifies incorrect oil level as a cause for low oil pressure.

SYMPTOM: Lubricating Oil Sludge in the Engine Crankcase Excessive

SYMPTOM: Lubricating Oil Temperature Above Specification

Oil Level Incorrect

Identifies incorrect oil level as a cause for high lubricating oil temperature.

SYMPTOM: Smoke, Black -- Excessive

Intake Air System Restricted

Identifies restricted intake air system as a cause for black smoke.

SYMPTOM: Smoke, White -- Excessive

SYMPTOM: Turbocharger Boost Pressure Low

Turbocharger Incorrect

Suggests checking turbocharger part number and replacing if necessary for low boost.

SYMPTOM: Turbocharger Leaks -- Engine Oil or Fuel

Section V - Maintenance Specifications

Specifications

Cummins/Fleetguard® Filter Specifications

Fuel Recommendations and Specifications

Lubricating Oil Recommendations and Specifications

General Information

Oil Drain Intervals

Coolant Recommendations and Specifications

Engine Component Torque Values

Capscrew Markings and Torque Values

Capscrew Markings and Torque Values -- Metric

Capscrew Markings and Torque Values -- U.S. Customary

Section W - Warranty

Cummins Warranty - International Industrial

Cummins Warranty - United States and Canada Industrial

Owner's Warranty Responsibilities

Section TS - Troubleshooting Symptoms

Procedures and Techniques

Troubleshooting Symptoms Charts

Explains how to use troubleshooting charts to diagnose specific engine symptoms.

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