Ingersoll-Rand HP600WJD Operating, Maintenance & Parts Manual

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Portable Air Compressor Division

P.O. Box 868 - - 501 Sanford Ave

Mocksville, N.C. 27028

Book 35389923 (04/02)

OPERATING, MAINTENANCE,

PARTS MANUAL

COMPRESSOR MODEL

HP600WJD

XP750WJD

HP750WJD

XP825WJD

( )

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Summary of Contents for Ingersoll-Rand HP600WJD

Page 1 OPERATING, MAINTENANCE, PARTS MANUAL COMPRESSOR MODEL HP600WJD XP750WJD HP750WJD XP825WJD Code: 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.
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 Compressed air must not be used for a feed to any form of breathing apparatus or mask. General Information The discharged air contains a very small percentage Ensure that the operator reads and understands the of compressor lubricating oil and care should be taken decals and consults the manuals before maintenance to ensure that downstream equipment is compatible.
Page 7 This machine may include such materials as oil, diesel Use care to avoid contacting hot surfaces (engine fuel, antifreeze, brake fluid, oil/air filters and batteries exhaust manifold and piping, air receiver and air which may require proper disposal when performing discharge piping, etc.).
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 serious injury or death. Combustible Gas. CAN cause serious burns, blindness or death. When using air tools attach safety device (OSHA Valve) at source of air supply for Keep sparks and open flames away each tool.
Page 14 SECTION 2 - - Warranty Ingersoll--Rand, through its distributor, warrants that each item of equipment manufactured by it and delivered hereunder to the initial user will be free of defects in material and workmanship for a period of three (3) months from initial operation or six (6) months from the date of shipment to the initial user, whichever occurs first.
Page 15 Ingersoll- -Rand Platinum Drive Train Warranty (Optional) – Platinum drive train pertains to the Ingersoll-- Rand Engine and Airend combination. The earlier of sixty (60) months from shipment to, or the accumulation of 10,000 hours of service. The starter, alternator, fuel injection system and all electrical components are excluded from the extended warranty.
Page 16 GENERAL WARRANTY INFORMATION GENERAL WARRANTY Extended Coverage Portable Compressor Package 1 year/2000 hrs Airend 2 yrs/4000 hrs 5 yrs/10,000 hrs Limited warranty, major components (refer to operator’s manual). Portable Genset 8kW, 11KW, Package 1 yr/2000 hrs None 20KVA thru 575KVA Generator 2 yrs/4000 hrs None...
Page 17 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 18 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 19 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 20 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Book 35389923 (04/02)
Page 21 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 22 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 23 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 24 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 35389923 (04/02)
Page 25 SECTION 4 - - GENERAL DATA UNIT MODEL HP600WJD XP750WJD HP750WJD XP825WJD Air Delivery -- cfm (litres/sec) 750 (355) 600 (285) 750 (355) 825 (390) Engine Speed -- RPM (Full Load) 2100 2100 2000 2000 -- RPM (No Load) 1400...
Page 26 SECTION 5 - - OPERATION WARNING Do not climb on top of unit. The lifting eye can be WARNING reached through the roof door ONLY from INSIDE of the unit. Hot pressurized fluid can cause severe burns. TOWING Do not open radiator while hot. Steerable Axle Units •...
Page 27 STARTING - - Flip the POWER switch to “ON”. All diagnostics • Push the SERVICE AIR button. The engine should lamps will light (glow for two (2) seconds. Then all go to full speed and the discharge pressure rise to lamps should go off except for ALTERNATOR NOT slightly over rated pressure.
Page 28 (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 side cover of the separator tank. All sensors and additional low oil pressure switch (mentioned above) will automatically reset when the problem condition is corrected.
Page 29 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 30 SECTION 6 - - MAINTENANCE GENERAL To service the air cleaners on all units proceed as fol- lows: In addition to periodic inspections, many of the compo- nents in these units require periodic servicing to pro- Loosen outer wing nut and remove with outer vide maximum output and performance.
Page 31 NOTICE To prevent damage to the element, never exceed a maximum air pressure of 100 psi (700 kPa). When filling the fuel tank on this unit, by methods other than a pump and hose, use a CLEAN non--metallic In the event the element is contaminated with dry dirt, funnel.
Page 32 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 33 COMPRESSOR OIL FILTERS The compressor lubrication and cooling oil system The flexible hoses used in the fuel, oil and air lines on includes dual spin--on, throw away type oil filters, each these units are primarily used for their ability to with an internal bypass valve.
Page 34 Place a spoonful of grease in the palm of one hand and NOTICE take the bearing in the other hand. Push a segment of If there is any indication of formation of varnishes, the wider end of the bearing down into the outer edge shellacs or lacquers on the oil filter element, it is a of the grease pile closest to the thumb.
Page 35 Disconnect the hose from the scavenge tube. RECEIVER- -SEPARATOR SYSTEMS Remove scavenge tube from tank cover. WARNING d. Disconnect service line from cover. Remove (8) cover mounting screws. High pressure air can cause severe injury or death from hot oil and flying parts. Always relieve Remove cover, element and inner shell.
Page 36 cut line if necessary NOTICE SCAVENGE LINE Excessive oil carry- -over may be caused by an oil- - WARNING logged separator element. Do not replace ele- ment without first performing the following main- High pressure air can cause severe injury or death tenance procedure: from hot oil and flying parts.
Page 37 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 38 MAINTENANCE SCHEDULE These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet). Daily Weekly Monthly 3 MOS . 6 MOS. 12 MOS. SMALL UNITS (P100- - P600) 250 hours 500 hours 1000 hours LARGE UNITS (HP600- - P1600) 500 hours 1000 hours...
Page 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 Always specify the number of the parts list pub- MARKINGS AND DECALS 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 48 Warranty: The Company warrants that parts man- Limitation of Liability: ufactured by it will be as specified and will be free from The remedies of the Purchaser set forth herein are ex- defects in materials and workmanship. The Compa- clusive, and the total liability of the Company with re- ny’s liability under this warranty shall be limited to the spect to this order whether based on contract, warran- repair or replacement of any part which was defective...
Page 49 AIREND EXCHANGE PROGRAM NOTICE Your Ingersoll--Rand Company Construction Equip- Airends being returned to the factory in ment Group Sales Offices and authorized distributors connection with a WARRANTY CLAIM must as well as Ingersoll--Rand International autonomous be processed through the Customer Ser- companies and authorized distributors now vice Department.

This manual is also suitable for:

Xp750wjd Hp750wjd Xp825wjd