Csa Xhp900wcat PDF

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 who
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
Downloaded from www.Manualslib.com manuals search engine
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
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
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
TITLE
6
PAGE
Foreword
Book: 23010598 (2-16-07) Rev. A

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 foreseeable risk of hazardous levels of flammable 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
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

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

11
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/doors are closed during
operation.
The specification of this machine is such that the machine is not suitable for 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
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 apparatus 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 from 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
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
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
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
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
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 compressors 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
General Data
General Data
MODELS
Air Delivery - cfm (litres/sec)
XHP900CWCAT
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)
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
20
Book: 23010598 (2-16-07) Rev. A
General Data
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
22
Operating Instructions
Book: 23010598 (2-16-07) Rev. A

23
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: 185F/85C to 230F/110C.
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
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 180F/82C to 210F/99C.
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
32F(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: 248F(120C) or more.
18. Low Engine Oil Pressure: 12 psi or less.
19. High Engine Temperature: Coolant above 215F(102C).
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
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
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 service 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 250F (121C) and
200 psig (HP) or 425 psig (XHP).
Book: 23010598 (2-16-07) Rev. A

27
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
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 Operators 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
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
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 Operators 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 140F (60C).
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 speed.
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
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
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 remain 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
Pressure Regulation
Adjustment Instructions
Normally, regulation requires no adjusting; but if proper adjustment is lost, proceed as follows:
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
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
36
Book: 23010598 (2-16-07) Rev. A
Maintenance
Book: 23010598 (2-16-07) Rev. A

37
Maintenance
Maintenance
Initial
500 miles
/850 km
Daily
Compressor Oil Level
Engine Oil Level
*Radiator Coolant Level
Gauges/Lamps
*Air Cleaner Service Indicators
Fuel Tank (Fill at end of day)
*Fuel/Water Separator Drain
Oil Leaks
Fuel Leaks
Drain Water From Fuel Filters
Coolant Leaks
Radiator Filler Cap
Weekly
Monthly
3 Months 6 Months
500 hrs. 1000 hrs.
12
Months
2000 hrs.
Air Cleaner Precleaner Dumps
Fan/Alternator Belts
Battery Connections/Electrolyte
Tire Pressure and Surface
*Wheel Lug Nuts
Hoses (Oil, Air, Intake, etc.)
Automatic Shutdown System
Air Cleaner System
Compressor Oil Cooler Exterior
*Engine Rad/Oil Cooler Exterior
Fasteners, Guards
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
Initial
500 miles
/850 km
Daily
Weekly
Monthly
3 Months 6 Months
500 hrs. 1000 hrs
*Fue/Water Separator Element
Compressor Oil Filter Element
Compressor Oil
18
12
Months Months
2000 hrs 3000 hrs
Engine Oil Change
Engine Oil Filter
*Water Pump Grease.
*Wheels (Bearings, Seals, etc.)
*Engine Coolant
Fuel Filter Element
*Injection Nozzle Check
Shutdown Switch Settings
Scavenger Orifice & Related Parts
Oil Separator Element
*Feed Pump Strainer Cleaning.
*Valve Clearance Check
Lights (running, brake, & turn)
CBT
Pintle Eye Bolts
CBT
* Brakes
* Brake linkage
* Emergency stop
Running gear linkage
Safety valve
Running gear bolts(1)
D = Drain
G = Grease
(2) or as defined by local or national legislation
R = Replace
T = Test

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

39
Maintenance
Initial
500 miles
/850 km
Daily
Weekly
Monthly
3 Months 6 Months
500 hrs. 1000 hrs
12
Months
2000 hrs
Scavenge line
* Engine breather element
Separator tank (2) exterior
CR
*Lubricator (Fill)
2 Yrs
Safety valve
4 Yrs
6 Yrs
Hoses
Separator tank (2) interior
R
C
D = Drain
G = Grease
(2) or as defined by local or national legislation
R = Replace
T = Test

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
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
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
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.
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43
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
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
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
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
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
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
50
Book: 23010598 (2-16-07) Rev. A
Lubrication
Book: 23010598 (2-16-07) Rev. A

51
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 the use of alternative
fluids.
Design Operating
Ambient
Pressure
Temperature
Specification
100 psi to 300 psi
-10F to 125F Preferred:

(-23C to 52C) IR Pro-Tec
Alternate:
ISO Viscosity Grade 46
with rust and oxidation
inhibitors, designed for
air compressor service.
350 psi
-10Fto 125F Preferred:

(-23C to 52C) IR XHP 605
Alternate:
IR XHP405
ISO Viscosity Grade 68
Group 3 or 5 with rust and
oxidation inhibitors
65Fto125F designed for air
(18C to 52C) 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 operators manual warranty section for details or contact your I-R
representative.
Ingersoll-Rand
1 gal. (3.8 Litre) 5 gal. (19.0 Litre) 55 gal. (208.2 Litre) 220 gal. (836 Llitre)
Preferred Fluids
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
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 does 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
C. Double Check Before Disassembly

The source of most compressor troubles can be traced not to one component 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
Trouble Shooting
TROUBLE SHOOTING CHART

Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE
NOTE: Subheadings suggest sequence to follow troubleshooting.
1. Unit Shutdown:
Out of Fuel
Compressor Oil Temp. Too High
Engine Water Temp. Too High
Engine Oil Pressure Too Low
Broken Engine Fan Belt
Loose Wire Connection
Low Fuel Level Shutdown
Defective Sensor
Malfunctioning Relay
Blown Fuse
Engine Malfunctioning
* Airend Malfunctioning
Corrective Action
Add CLEAN diesel Fuel
See Complaint 10
Check coolant level. If necessary, Add.
See Complaint 3 and Complaint 4.
Replace fan belt.
Wiggle wires at switches & connector blocks. Make
repairs.
Replace fuel sender.
Replace sensor.
Replace relay.
Replace fuse.
See Trouble Shooting in Engine Manual.
See Complaint 10.
2. Wont Start/Run:
Low Battery Voltage
Blown Fuse
Malfunctioning Start Switch
Clogged Fuel Filters
Out of Fuel
Compressor Oil Temp. Too High
Engine Water Temp. Too High
Engine Oil Pressure Too Low
Defective Sensor
Malfunctioning Relay
Airend Malfunctioning
Check electrolyte level. Check connections.

Replace fuse.
Replace switch.
Service filters. See Engine Operators Manual.
Add CLEAN fuel.
See Complaint 10.
Check fluid level. If necessary, Add.
See Complaint 3 and Complaint 4.
Repair or replace connection.
Replace sensor.
Replace relay.
See Complaint 10.
3. High Engine Temperature

Broken Engine Fan Belt
*Ambient Temp. >115F
Dirty Operating Conditions
Dirty Cooler
*Out of Level >15 degrees
Operating Pressure Too High
Recirculation of Cooling Air
Replace fan belt set.

Above spec limit.
Move unit to cleaner environment.
Clean exterior of cooler.
Relocate or reposition unit.
Reduce pressure to spec.
Close side doors.
Repair or replace.
* : > = greater than, < = less than

4. Low Engine Oil Pressure
Corrective Action
56
Book: 23010598 (2-16-07) Rev. A
Trouble Shooting
Low Oil Level
Out of Level >15 degrees
Wrong Lube Oil
Clogged Oil Filter Element(s)
Loose Wire Connection.
5. Alternator Low Voltage
Loose or Broken Belts
Low Battery Voltage
Malfunctioning Alternator

Add oil.
Relocate or reposition.
See Engine Oil Spec. Change oil.
Replace element(s).
Repair or replace.
Tighten or replace belt set.

Repair or replace connection.
Check electrolyte level. Add if necessary.
Check connectors. Clean & tighten.
Recharge battery.
Repair or replace alternator.
6. High Compressor Discharge Temperature:

Ambient Temp. > 115F
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 manual.
Dirty Cooler
Clean exterior surfaces.
Clogged Oil Filter Elements
Replace elements. Change oil.
Loose or Broken Belts
Tighten or replace belt set.
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.
See Complaint 11, 12
7. Engine RPM Down:
Clogged Fuel Filter (primary)
Dirty Air Filter
Wrong Air Filter Element
8. Excessive Vibration:
Rubber Mounts, Loose or Damaged
Defective Fan
Drive Coupling Defective
Engine idle speed too low.
9. Low CFM:
Dirty Air Filter
Book: 23010598 (2-16-07) Rev. A

Replace primary filter. Replace final filter. Drain

tanks. Add CLEAN fuel.
Reduce pressure to spec limit.
Clean or replace elements.
Install correct element.
Refer to Factory.
Tighten or replace.
Replace fan.
Replace coupling.
See Complaint 11 and 12.
See Engine Manual.
Clean or replace elements.
57
Trouble Shooting
Incorrect Linkage Adjustment

Malfunctioning Inlet Unloader/Butterfly Valve
Make adjustment per Section 4.

Inspect valve. Make adjustment per Section 4.
Install correct element.
10. Short Air Cleaner Life:

Inadequate Element Cleaning
Incorrect Stopping Procedure

Install new element.
Read procedure in this manual.
Install proper element.
11. Will Not Unload:

Malfunctioning Inlet Butterfly Valve
Ice in Regulation Lines/Orifice
Load Solenoid Leak
Plugged Vent Leak
Inspect valve fit. Re-adjust per Section 4.

Apply heat to line(s) and or orifice.
Replace load solenoid.
Clean and/or replace.
12. Safety Valve Relieves:

Malfunctioning Inlet Unloader/Butterfly Valve
Defective Safety Valve
Unit Will Not Unload Fast Enough
Reduce pressure to spec limit.

Inspect valve fit. Readjust per Section 4.
Replace safety valve.
Apply heat to lines and/or orifice.
58
Book: 23010598 (2-16-07) Rev. A
2004 Ingersoll-Rand Company, Printed in the USA


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Operating & Maintenance Manual

This manual contains important safety information.

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

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

Operating & Maintenance Manual

Nothing contained in this document is intended to extend any promise, warranty or

of good quality, procured from a reputable manufacturer and, wherever possible, be

compatible with the compressor lubricant/coolant.

accompanied with instructions for safe installation, operation and maintenance.

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

Operating & Maintenance Manual

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

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

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

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

Operating & Maintenance Manual

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

Operating & Maintenance Manual

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

Operating & Maintenance Manual

brake lining dust

engine exhaust fumes

Avoid ingestion, skin contact and inhalation of fumes

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

Operating & Maintenance Manual

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

Operating & Maintenance Manual

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.

break-away cables/safety chains are connected to the towing vehicle.

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

Operating & Maintenance Manual

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

Operating & Maintenance Manual

FREE SAFETY DECALS

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

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

Operating & Maintenance Manual

Full Load Speed - rpm

No Load Speed - rpm

FLUID CAPACITIES - U.S. Gallons (litres)

Compressor Lubricant, Initial (dry) Service Refill

Engine Coolant (radiator)

Engine Crankcase Lubricant

Fuel Tank (Clean DIESEL fuel)

UNITS MEASUREMENTS - Feet (Meters)

Towing Speed (maximum) - MPH (km/hr)

Inflation Pressure (cold) - PSI (kPa)

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

Operating & Maintenance Manual

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

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

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

Operating & Maintenance Manual

Operating Controls and Instruments

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

Operating & Maintenance Manual

7. Hourmeter: Records running time for maintenance purposes.

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

Operating & Maintenance Manual

Always use Ingersoll-Rand Replacement parts!

Always use Ingersoll-Rand Replacement parts!

Always use Ingersoll-Rand Replacement parts!

Always use Ingersoll-Rand Replacement parts!