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Ingersoll-Rand VHP600WCU Operating, Maintenance & Parts Manual
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Ingersoll-Rand VHP600WCU Operating, Maintenance & Parts Manual

Ingersoll-Rand VHP600WCU Operating, Maintenance & Parts Manual

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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.
Portable Air Compressor Division
P.O. Box 868 - - 501 Sanford Ave
Mocksville, N.C. 27028
www.portablepower.irco.com
Book 22091102 (12/01)
OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODEL
VHP600WCU
Revised (10-12)
( )
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
1

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Summary of Contents for Ingersoll-Rand VHP600WCU

  • Page 1 This manual must be available to the personnel who operate and maintain this machine. Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging...
  • Page 2 QUALITY POLICY We will supply products and services that consistently meet the requirements of our customers and each other. 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.
  • Page 3 Foreword Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European common market countries requires that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives.
  • Page 4 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.
  • Page 5 TABLE OF CONTENTS SECTION 1 ....SAFETY SECTION 2 ....WARRANTY/REGISTRATION SECTION 3 .
  • Page 6 SECTION 1- - SAFETY SAFETY PRECAUTIONS If more than one compressor is connected to one com- mon downstream plant, effective check valves and General Information isolation valves must be fitted and controlled by work Ensure that the operator reads and understands the procedures, so that one machine cannot accidentally decals and consults the manuals before maintenance be pressurized or over pressurized by another.
  • Page 7 accordance with OSHA Regulation 29CFR Section 1926.302(b). Exercise extreme caution when using booster battery. Hot pressurized fluid can cause serious burns. Do not To jump battery, connect ends of one booster cable to open radiator while hot. the positive (+) terminal of each battery. Connect one end of other cable to the negative (--) terminal of the Rotating fan blade can cause serious injury.
  • Page 8 SAFETY LABELS Look for these signs on machines shipped to international markets outside North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor. Hot Surface Corrosion risk Lifting point...
  • Page 9 Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. WARNING - - Maintain correct tire pressure. (Refer to the GENERAL INFORMATION section of this manual). WARNING: Consult the operation and maintenance manual before performing any maintenance. Rough Service Designation Wet Location Operation Do not stack...
  • Page 10 Oil Drain km/h WARNING undertake Do not exceed the speed limit. maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken remove Operating...
  • Page 11 Look for these signs on machines shipped to markets in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform you supervisor. Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.
  • Page 12 WARNING WARNING Improper operation of this equipment. Modification or alteration of this machine. CAN cause serious injury or death. CAN cause serious injury or death. Read Operator’s Manual supplied with this Do NOT alter or modify this machine without the machine before operation or servicing.
  • Page 13 WARNING WARNING Disconnected Air Hoses Whip. CAN cause Combustible Gas. CAN cause serious serious injury or death. burns, blindness or death. When using air tools attach safety device (OSHA Valve) at source of air supply for each tool. Keep sparks and open flames away from batteries.
  • Page 14 SECTION 2 - - Warranty Ingersoll--Rand, through its distributor, warrants that Genset Generators - - The earlier of twenty--four each item of equipment manufactured by it and deliv- (24) months from shipment to or the accumula- ered hereunder to the initial user will be free of defects tion of 4,000 hours of service by the initial user.
  • Page 15 Ingersoll--Rand will provide a new part or repaired part, at its election, in place of any part which is found upon its inspection to be defective in material and workman- ship during the period prescribed above. Such part will be repaired or replaced without charge to the initial user during normal working hours at the place of busi- ness of an Ingersoll--Rand distributor authorized to sell the type of equipment involved or other establishment...
  • Page 16 CALIFORNIA EMISSION CONTROL WARRANTY Exhaust Manifold • STATEMENT Turbocharger System • Miscellaneous hoses, clamps, connectors and • sealing devices used in the above systems. EMISSION RELATED SYSTEM DEFECT WAR- If failure of one of these components results in failure RANTY of another part, both will be covered by this warranty.
  • Page 17 Your emission control system may include parts such as the fuel injection system, air induction system. LIMITATIONS Also included may be hoses, belts, connectors and other emission--related assemblies. Ingersoll--Rand Company is not responsible for re- Where a warrantable condition exists, an authorized sultant damages to an emission related part or com- INGERSOLL--RAND Dealer will repair the heavy-- ponent resulting from:...
  • Page 18 FUEL INJECTION PUMPS OR NOZZLES – Fuel in- MAINTENANCE RECOMMENDATION: jection pumps or nozzles are subject to tip wear as a Some Ingersoll--Rand Company non--road engines result to fuel contamination. This damage can cause are certified by the United States Environmental an increase in fuel consumption, the engine to emit Protection Agency and California Air Resource Board black smoke, misfire or run rough.
  • Page 19 GENERAL WARRANTY INFORMATION GENERAL WARRANTY Extended Coverage Portable Compressor Package 1 year/2000 hours Airend 2 years/4000 hours 5 years/10,000 hours Limited warranty, major components (refer to op- erator’s manual). Portable Genset Package 1 year/2000 hours Generator 2 years/4000 hours Light Tower Package 1 year/2000 hours Generator...
  • Page 20 Extended Limited Airend Warranty Ingersoll--Rand Portable Compressor Division is pleased to announce the availability of extended limited airend warranty. Announcement of the extended warranty coincides with the introduction of PROSTECt Compressor Fluid. PROSTECt Compressor Fluid is an amber colored fluid specially formulated for Portable Compressors and is being provided as the factory filled fluid for all machines except ! XHP650/900/1070 models.
  • Page 21 WARRANTY REGISTRATION Complete Machine Registration Machines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e. change of ownership). Machines shipped outside the United States require notification be made to initiate the machine warranty.
  • Page 22 WARRANTY REGISTRATION Selling Distributor Servicing Distributor Name Name Owner/User Name Address Address Address City City City County County County State State State Zip Code Zip Code Zip Code Telephone Telephone Telephone Complete the Applicable Blocks Owner/User Type of Business (check one only) Construction--Heavy Asphalt Contractor Coal Mining...
  • Page 23 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Book 22091102 (12/01)
  • Page 24 SECTION 3 - - NOISE EMISSION This section pertains only to machines distributed with- in the United States. WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or re- placement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 25 NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL SERIAL NO. USER UNIT NO. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR FROM WHOM PURCHASED: Engine Make & Model: Serial No.: Purchaser or Owner: Address: Date Purchased: The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under the above regulations, specifically the following acts or the causing thereof: (1) the removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or re- placement, of any device or element of design incorporated into new compressor for the purpose of noise control...
  • Page 26 MAINTENANCE SCHEDULE ITEM AREA PERIOD Compressed Air Leaks As Detected Safety and Control Systems As Detected Acoustic Materials Daily Fasteners 100 hours Enclosure Panels 100 hours Air Intake & Engine Exhaust 100 hours Cooling Systems 250 hours Isolation Mounts 250 hours Engine Operation See Operator’s Manual Fuels &...
  • Page 27 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK HOURMETER MAINT/ LOCATION CITY/ WORK DONE BY READING STATE (NAME) INSPECT DATE Book 22091102 (12/01)
  • Page 28 SECTION 4 - - GENERAL DATA UNIT MODEL VHP600WCU XP750WCU HP750WCU XP825WCU Air Delivery -- cfm (litres/sec) 600 (285) 750 (355) 750 (355) 825 (390) Engine Speed -- RPM (Full Load) 2100 2100 2000 2000 -- RPM (No Load) 1400...
  • Page 29 SECTION 5 - - OPERATION cap is installed properly and tightened. Note: this WARNING machine will not allow engine starting if engine coolant is low. Do not climb on top of unit. The lifting eye can be reached through the roof door ONLY from NOTICE: If the appropriate mixture of antifreeze is not INSIDE of the unit.
  • Page 30 STARTING - - • Watch the gauges while the unit warms up for five (5) Flip the POWER switch to “ON”. All diagnostics lamps will light (glow for two (2) seconds. Then all to ten (10) minutes or until the coolant temperature lamps should go off except for ALTERNATOR NOT reaches 140°...
  • Page 31 NOTICE AUTOMATIC SHUTDOWN / DIAGNOSTICS Do NOT wire around or bypass a shutdown sensor or switch. Should any of these problem situations occur, the unit will automatically shutdown and stop. BEFORE re- All units in this family of machines are protected by five starting the unit or flipping the POWER switch to “Off”, (5) sensors or switches at the following locations: check the DIAGNOSTICS area on the instrument pan-...
  • Page 32 Note: If the rated operating pressure cannot be maintained with engine at full load speed and rod (M) fully extended, turn regulator adjustment screw (H) clockwise until throttle arm (A) moves against governor stop. Insure that pressure is maintained at rated pressure, then turn regulator adjustment screw (H) counterclockwise until throttle arm (A) just begins to move.
  • Page 33 SECTION 6 - - MAINTENANCE The air filters restricted sensor will automatically reset GENERAL after the main power switch is flipped to “OFF.” In addition to periodic inspections, many of the compo- nents in these units require periodic servicing to pro- To service the air cleaners on all units proceed as fol- vide maximum output and performance.
  • Page 34 Direct compressed air through the element in the FUEL TANK direction opposite to the normal air flow through the This unit is equipped with dual tanks that can be filled element. from either side. Using clean fuel in the fuel tanks is Move the nozzle up and down while rotating the vitally important and every precaution should be taken element.
  • Page 35 RADIATOR WARNING As the pressure is slowly decreased to 8 psi (0.56 kgf per cm2) the contacts should open and the ohmmeter Do not remove the cap from a HOT engine radia- should show lack of continuity (infinite ohms) through tor.
  • Page 36 COMPRESSOR OIL FILTERS Premature wear of both the engine and compressor is The compressor lubrication and cooling oil system ASSURED whenever dust--laden air is permitted to includes dual spin--on, throw away type oil filters, each enter the engine’s combustion chamber or the with an internal bypass valve.
  • Page 37 NOTICE Place a spoonful of grease in the palm of one hand and If there is any indication of formation of varnishes, take the bearing in the other hand. Push a segment of shellacs or lacquers on the oil filter element, it is a the wider end of the bearing down into the outer edge warning the compressor lubricating oil has im- of the grease pile closest to the thumb.
  • Page 38 RECEIVER- - SEPARATOR SYSTEMS Disconnect the hose from the scavenge tube. WARNING Remove scavenge tube from tank cover. d. Disconnect service line from cover. High pressure air can cause severe injury or death Remove (8) cover mounting screws. from hot oil and flying parts. Always relieve pressure before removing caps, plugs, covers or Remove cover, element and inner shell.
  • Page 39 cut line if necessary NOTICE Excessive oil carry- -over may be caused by an oil- - SCAVENGE LINE logged separator element. Do not replace ele- ment without first performing the following main- WARNING tenance procedure: Check oil level. Maintain as indicated earlier High pressure air can cause severe injury or death in this section.
  • Page 40 EXTERIOR FINISH CARE This unit was painted and heat cured at the factory with a high quality, thermoset polyester powder coating. The following care will ensure the longest possible life from this finish. If necessary to remove dust, pollen, etc. from Blow and tack the area to be painted.
  • Page 41 MAINTENANCE SCHEDULE Daily Weekly Monthly 3 MOS . 6 MOS. 12 MOS. 250 hrs. 500 hrs 1000 hrs Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps Fuel Tank (fill at end of day) DRAIN *Fuel/Water Separator Drain Air Cleaner Precleaner Dumps Fan/Alternator Belts Battery Connections/Electrolyte Tire Pressure and Surface...
  • Page 42 SECTION 7 - - LUBRICATION GENERAL INFORMATION Lubrication is an essential part of preventive mainte- If the unit has been operated for the time/ hours men- nance, affecting to a great extent the useful life of the tioned above, it should be completely drained of oil. If unit.
  • Page 43 RATED OPERATING PRESSURE SECTION 7 - - COMPRESSOR 350 PSI 100 - - 300 PSI 500 PSI 125_F LUBRICATION 50_C 40_C 104_F Portable Compressor Fluid Chart XHP505 XHP 1001 XHP1001 86_F 30_C Refer to these charts for correct compressor 65_F 20_C fluid required.
  • Page 44 SECTION 8 - - Trouble Shooting INTRODUCTION B. Do The Simplest Things First Trouble shooting for a portable air compressor Most troubles are simple and easily corrected. is an organized study of a particular problem or example, most complaints are “low capacity” which may series of problems and a planned method of be caused by too low an engine speed or “compressor procedure for investigation and correction.
  • Page 45 TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT - - Subheadings suggest the CAUSE Note: Subheadings suggest sequence to follow troubleshooting. Corrective Action Unit Shutdown: Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. Too High See Complaint 10 Engine Water Temp.
  • Page 46 Engine Oil Pressure Lamp Stays On: Corrective Action Low Oil Level Add oil. Out of Level >15 degrees Relocate or reposition. Wrong Lube Oil See Engine Oil Spec. Change oil. Clogged Oil Filter Element(s) Replace element(s). Engine Malfunctioning See Trouble Shooting in Engine Manual. Loose Wire Connection.
  • Page 47 Excessive Compressor Oil Temperature: Corrective Action Ambient Temp. > 125_F (52_C) 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.
  • Page 48 Short Air Cleaner Life: Corrective Action 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. Oil Pump Drive Coupling Inspect coupling. If necessary, replace coupling. Excessive Oil In Air: High Oil Level Read procedure in this manual.
  • Page 49 SECTION 9 - - PARTS ORDERING location relative to the other parts in the assembly. GENERAL The part number, the description of the part and the quantity of parts required are shown on each This publication, which contains an illustrated parts illustration or on adjacent page.
  • Page 50 MARKINGS AND DECALS Always specify the number of the parts list pub- lication. NOTICE Always specify the quantity of parts required. Do not paint over safety warnings or instructional decals. If safety warning decals become illegible, Always specify the part number, as well as the immediately order replacements from the factory.
  • Page 51 Warranty: The Company warrants that parts man- any defect in, or failure of, or malfunction of the parts ufactured by it will be as specified and will be free from hereunder, whether based upon loss of use, lost prof- its or revenue, interest, lost goodwill, work stoppage, defects in materials and workmanship.