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Book 22091102 (12/01)

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MAINTENANCE RECOMMENDATION:

Some Ingersoll--Rand Company non--road engines

are certified by the United States Environmental

Protection Agency and California Air Resource Board

to comply with smoke and gaseous emission stan-

dards prescribed by Federal laws at the time of

manufacture.

The engine is certified if it has a special certification

label. An INGERSOLL--RAND Dealer can also inform

you if the engine is certified.

Efficiency of emission control and engine perfor-

mance depends on adherence to proper operation

and maintenance recommendations and use of rec-

ommended fuels and lubrication oils. It is recom-

mended that major adjustments and repair be made

by your authorized INGERSOLL--RAND Dealer.

Various chemical fuel additives, which claim to reduce

visible smoke, are available commercially. Although

additives have been used by individuals to solve

some isolated smoke problems in the field, they are

not recommended for general use.

Federal smoke regulations require that engines be

certified without smoke depressants.

The corrective steps taken immediately on discovery

of worn parts, which may affect emission levels, will

help assure proper operation of emission control sys-

tems. The use of genuine INGERSOLL--RAND parts

is recommended. Suppliers of non--INGERSOLL--

RAND parts must assure the owner that the use of

such parts will not adversely affect emission levels.

Regular maintenance intervals, along with special

emphasis on the following items, are necessary to

keep exhaust emissions within acceptable limits for

the useful life of the engine. Refer to the Maintenance

Section of this manual. If the engine is operating un-

der severe conditions, adjust the maintenance sched-

ule accordingly. See your authorized INGERSOLL--

RAND Dealer to help analyze your specific

application, operating environment and maintenance

schedule adjustments.

The following is an explanation of maintenance for

emission--related components.

See the Maintenance Schedule for the specific inter-

val for the following items.

FUEL INJECTION PUMPS OR NOZZLES – Fuel in-

jection pumps or nozzles are subject to tip wear as a

result to fuel contamination. This damage can cause

an increase in fuel consumption, the engine to emit

black smoke, misfire or run rough. Inspect, test and

replace if necessary. Fuel injection pumps can be

tested by an authorized INGERSOLL--RAND Dealer.

TURBOCHARGER – Check for any unusual sound or

vibration in the turbocharger. Inspect inlet and ex-

haust piping and connections. Check bearing condi-

tion and perform maintenance as described in the

Maintenance Schedule.

Slow engine response and low power may indicate a

need for adjustment or repair. Your INGERSOLL--

RAND Dealer is equipped with the necessary tools,

personnel, and procedures to perform this service.

Owner is encouraged to keep adequate maintenance

records, but the absence of such, in and of itself, will

not invalidate the warranty.

The machine or equipment owner may perform rou-

tine maintenance, repairs and other non--warranty

work or have it done at any repair facility. Such non--

warranty work need not e performed at a designated

warranty station in order for the warranty to remain in

force.

CUSTOMER ASSISTANCE – EMISSION CON-
TROL SYSTEM WARRANTY:

Ingersoll--Rand Company aims to ensure that the

Emission Control Systems Warranty is properly

administered. In the event that you do not receive the

warranty service to which you believe you are entitled

under the Emission Control Systems Warranty, call or

write:

Ingersoll--Rand Company

P.O. Box 868

Mocksville, NC 27028

Tel.: 336--751--3561

Authorized Dealers are recommended for major

maintenance and repair work as they are staffed with

trained personnel, proper tools and are aware of the

latest maintenance methods and procedures. Own-

ers and others who desire to perform their own work

should purchase a Service Manual and obtain current

service information from their INGERSOLL--RAND

Dealer.

Содержание VHP600WCU

Страница 1: ...CE PARTS MANUAL COMPRESSOR MODEL VHP600WCU www portablepower irco com 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 a...

Страница 2: ...nd 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 ...

Страница 3: ...501 Sanford Avenue Mocksville North Carolina 27028 Declare that under our sole responsibility for manufacture and supply the product s To which this declaration relates is are in conformity with the provisions of the above directives using the following principal standards ________________________________ Represented In EC By Ingersoll Rand Company Limited Standard Products Division Swan Lane Hind...

Страница 4: ...ed parts list may create hazardous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand 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 prev...

Страница 5: ...TION 2 WARRANTY REGISTRATION SECTION 3 NOISE EMISSION SECTION 4 GENERAL DATA SECTION 5 OPERATION SECTION 6 MAINTENANCE SECTION 7 LUBRICATION SECTION 8 TROUBLESHOOTING SECTION 9 PARTS ORDERING SECTION 10 PARTS LIST SECTION 11 OPTIONS PARTS LIST SECTION 12 ENGINE ...

Страница 6: ...nstalled in or connected to the machine must have safe working pressure ratings of at least the machine safety valve rating If more than one compressor is connected to one com mon 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 ...

Страница 7: ...he skin and result in serious illness wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye s 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 Hot pressurized fluid can cause serious burns D...

Страница 8: ...RNING Flammable liquid Air gas flow or Air discharge 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 handbrake and wheel chocks Diesel Fuel No open flame Do not breathe the compr...

Страница 9: ...anual Rough Service Designation Wet Location Operation WARNING Consult the operation and maintenance manual before performing any maintenance WARNING Before connecting the tow bar or when preparing to tow consult the operation and maintenance manual Replace any cracked protective shield On power Off power Emergency stop Do not use fork lift truck from this side Do not stack Do not operate with the...

Страница 10: ... and Maintenance manual before operation or maintenance of this machine is undertaken XX km h Pressurized component or system Do not exceed the speed limit Pressurized vessel Do not remove the Operating and Maintenance manual and manual holder from this machine Use fork lift truck from this side only 0_C WARNING For operating temperature below 0_C consult the operation and maintenance manual ...

Страница 11: ...rth 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 Air discharged from this machine can contain carbon monoxide or other contaminants which will cause serious injury or death Do not breathe this air DANGER Hot pressurized fluid Can cause serious burns Do no...

Страница 12: ...ion or alteration of this machine CAN cause serious injury or death Do NOT alter or modify this machine without the express written consent of the manufacturer WARNING WARNING WARNING WARNING Falling off machine CAN cause serious injury or death Access Lifting Bail from inside machine Rotating Fan Blade CAN cause serious injury Do NOT operate with guard removed Excessive Towing Speed CAN cause ser...

Страница 13: ... in the compressor s 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 Assure that decals are present on the machines Replace decals that are not readable FREE SAFETY DECALS Disconnected Air Hoses Whip CAN cause serious injury or death When using air tools attach safety device OS...

Страница 14: ...re met The original airend is returned assembled and unopened Continued use of genuine Ingersoll Rand parts fluids oils and filters Maintenance is performed at prescribed inter vals D Genset Generators The earlier of twenty four 24 months from shipment to or the accumula tion of 4 000 hours of service by the initial user E Portable Light Tower Generators The earlier of twelve 12 months from shipme...

Страница 15: ...lt of abuse misuse negligent repairs corrosion erosion and normal wear and tear alter ations or modifications made to the product without express written consent of Ingersoll Rand or failure to follow the recommended operating practices and maintenance procedures as provided in the product s operating and maintenance publications Accessories or equipment furnished by Ingersoll Rand but manufacture...

Страница 16: ...or other estab lishment authorized by Ingersoll Rand Company This warranty covers the following emission related parts and components Charge Air Cooling System If Equipped Fuel Injection System Intake Manifold Exhaust Manifold Turbocharger System Miscellaneous hoses clamps connectors and sealing devices used in the above systems If failure of one of these components results in failure of another p...

Страница 17: ...ists an authorized INGERSOLL RAND Dealer will repair the heavy duty off road engine at no cost to the owner including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 1996 and later heavy duty off road engines are warranted for a period of five 5 years or 3000 hours of operation which ever occurs first If any emission related part on your engine is defective thepart willbe repaired o...

Страница 18: ...justments The following is an explanation of maintenance for emission related components See the Maintenance Schedule for the specific inter val for the following items FUEL INJECTION PUMPS OR NOZZLES Fuel in jection pumps or nozzles are subject to tip wear as a result to fuel contamination This damage can cause an increase in fuel consumption the engine to emit black smoke misfire or run rough In...

Страница 19: ... Extended Coverage 12 No Limit Available at dealer Cummins 24 2000 Major components 3 yrs 10 000 hours avail able at dealer John Deere 24 2000 Available at dealer Deutz 24 2000 Available at dealer Kubota 24 2000 Major components 36 months 3000 hours parts only Ingersoll Rand 24 4000 5 years 10 000 hours when using genuine In gersoll Rand fluids and parts Refer to operator s manual PARTS Months Hou...

Страница 20: ...arranty is limited to defects in major components rotors housings gears bearings and is automatically available when the following three conditions are met 1 The original airend is returned assembled and unopened 2 Submissions of proof that Ingersoll Rand fluid filters and separators have been used Refer to the Operation and Parts manual for the correct fluids filters and separator elements requir...

Страница 21: ...y for your records and mail form to Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attn Warranty Department Note Completion of this form validates the warranty Engine Registration John Deere requires a separate engine registration be completed and mailed direct to John Deere Separate engine registration material is included with this literature pack...

Страница 22: ...ectric water etc Utility Contractor SERVICING DISTRIBUTOR USER ACKNOWLEDGEMENT 1 The Purchaser has been instructed and or has read the manual and understands proper preventative maintenance general operation and safety precautions 2 The warranty and limitation of liability has been reviewed and understood by the owner user 3 In the event that this unit is to be used within a nuclear facility the o...

Страница 23: ...Book 22091102 12 01 23 Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attention Warranty Department fold ...

Страница 24: ... the air intake system or parts thereof c enclosure or parts thereof 5 Removal of any of the following a fan shroud b vibration mounts c sound absorption material 6 Operation of the compressor with any of the enclosure doors open Compressor Noise Emission Control Information A The removal or rendering inoperative other than for the purpose of maintenance repair or replacement of any noise control ...

Страница 25: ...NTY The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser with all applicable U S EPA Noise Control Regulations This warranty is not limited to any particular part component or system of the air compressor Defects in the de sign assembly or in any part c...

Страница 26: ...se E Enclosure Panels Enclosure panels should also be inspectedat 100hour operational intervals All panels that are warped punc tured torn or otherwise deformed such that their noise containment function is reduced should be re paired or replaced before the next operation interval Doors access panels and hatch closures especially should be checked and adjusted at this time to insure continuous sea...

Страница 27: ...Book 22091102 12 01 27 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO DESCRIPTION OF WORK HOURMETER READING MAINT INSPECT DATE LOCATION CITY STATE WORK DONE BY NAME ...

Страница 28: ...anufacturer Cummins Model 6CTA 8 3 Electrical System 24 VDC FLUID CAPACITIES Compressor Lubricant 16 gal Engine Lube including filter 5 9 gal UNITS MEASUREMENTS WEIGHTS Overall Length 191 inches Overall Height 88 6 inches Overall Width 85 2 inches RUNNING GEAR Tire Size 8 00 16 5 Inflation Pressure Cold 60 psi Towing Speed Maximum 50 mph CAUTION Any departure from the specifications may make this ...

Страница 29: ...or 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 isnot 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 N...

Страница 30: ...he engine oil pressure does not rise within five 5 seconds stop the unit and refer to Engine Operator s Manual WARNING All DIAGNOSTIC lamps should be off If not stop the machine and investigate Watch the gauges while the unit warms up for five 5 to ten 10 minutes or until the coolant temperature reaches 140 F 60 C Push the SERVICE AIR button The engine should go to full speed and the discharge pre...

Страница 31: ...l low oil pressure switch in the supply line to the airend bearings AUTOMATIC SHUTDOWN DIAGNOSTICS Should any of these problem situations occur the unit will automatically shutdown and stop BEFORE re starting the unit or flipping the POWER switch to Off check the DIAGNOSTICS area on the instrument pan el The upper four 4 lamps are electronically latched to only respond to the first or primary sign...

Страница 32: ... will slow to no load or idle speed Loosen jam nut L at air cylinder AC shaft Rotate air cylinder shaft M to adjust speed to no load rpm If unable to obtain no load rpm loosen nut C and rotate throttle arm A as required Moving throttle arm A clockwise in creases idle speed Tighten nut C and if necessary finely adjust idle speed by rotat ing air cylinder shaft M Then tighten jam nut L 2 Adjust jam ...

Страница 33: ...the lamp glows red with the unit operating at full speed servicing of the cleaner element is necessary Also weekly squeeze the rubber valve precleaner dirt dump on each air cleaner housing to ensure that they are not clogged NOTE Holes or cracks downstream of the air cleaner housing will cause the restriction indicators to be ineffective The air filters restricted sensor will automatically reset a...

Страница 34: ...nd any lamps for proper functioning Refer to Operating Controls for the normal readings FUEL TANK This unit is equipped with dual tanks that can be filled from either side Using clean fuel in the fuel tanks is vitally important and every precaution should be taken to ensure that only clean fuel is either poured or pumped into the tank When filling the fuel tank on this unit by methods other than a...

Страница 35: ...chemical composition After completing the cleaning procedure the oil cooler must be flushed before returning to service RADIATOR WARNING Do not remove the cap from a HOT engine radia tor The sudden release of pressure from a heated cooling system can result in a loss of cool ant and possible severe personal injury The engine cooling system is filled at the factory with a 50 50 mixture of water and...

Страница 36: ...is will ensure that the tubing is fully engaged in the sealing mechanism COMPRESSOR OIL FILTERS The compressor lubrication and cooling oil system includes dual spin on throw away type oil filters each with an internal bypass valve With a clean new filter element all of the oil flows through the full element area from the outside inside As each element becomes contaminated with dirt a pressure diff...

Страница 37: ... bearing cups which are pressed in the hub Place a spoonful of grease in the palm of one hand and take the bearing in the other hand Push a segment of the wider end of the bearing down into the outer edge of the grease pile closest to the thumb Keep lifting and pushing the bearing down into the edge of the grease pile until grease oozes out both from the top and from between the rollers Then rotat...

Страница 38: ...separator element is dependent upon the operating environment soot dust etc and should be replaced every twelve months or 2000 hours To replace the element proceed as follows a Ensure the tank pressure is zero b Disconnect the hose from the scavenge tube c Remove scavenge tube from tank cover d Disconnect service line from cover e Remove 8 cover mounting screws f Remove cover element and inner she...

Страница 39: ... year or every 2000 hours of operation which ever comes first remove this line thoroughly clean then reassemble NOTICE Excessive oil carry over may be caused by an oil logged separator element Do not replace ele ment without first performing the following main tenance procedure 1 Check oil level Maintain as indicated earlier in this section 2 Thoroughly clean scavenge line any orifice and check va...

Страница 40: ...medium wet coats of Duponts 222S Adhesion Promoter over the entire area to be painted with a 5 minute flash in between coats 9 To apply the texture coat use Duponts 1854S Tuffcoat Primer The proper technique to do this is to spray the Tuffcoat Primer using a pressure pot and use about 2 5 pounds of air pressure This will allow the primer to splatter causing the textured look Note you must be caref...

Страница 41: ...pressor Oil Cooler Exterior C CLEAN Engine Rad Oil Cooler Exterior C CLEAN Fasteners Guards C Air Cleaner Elements WI Fuel Water Separator Element R Compressor Oil Filter Element R Compressor Oil R Wheels bearings seals etc C Engine Coolant Test C R Shutdown Switch Settings Test C Scavenger Orifice Related Parts CLEAN Oil Separator Element R Lights running brake turn CBT Pintle Eye Bolts CBT Engin...

Страница 42: ...r lacquers which may be insoluble Such deposits can cause se rious troubles including clogging of the filters Where possible do NOT mix oils of different types and avoid mixing different brands A type or brand change is best made at the time of a complete oil drain and refill If the unit has been operated for the time hours men tioned above it should be completely drained of oil If the unit has be...

Страница 43: ...ory Portable Compressor Fluid Chart SECTION 7 COMPRESSOR LUBRICATION 23_C to 52_C 10_F to 125_F 40_F to 125_F 40_C to 52_C Mil PRF 2104G SAE 10W IR Pro Tect IR Performance 500 Mil L 46167 IR XHP 505 10_F to 125_F 23_C to 52_C 65_F to 125_F 18_C to 52_C IR XHP1001 40_F to 65_F 40_C to 18_C IR Performance 500 Mil L 46167 10_C to 52_C 10_F to 65_F 12_C to 18_C below 10_F 12_C IR XHP1001 IR XHP 505 Co...

Страница 44: ...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...

Страница 45: ...n of Cooling Air Loose Wire Connection Malfunctioning circuit board TROUBLE SHOOTING CHART Bold Headings depict the COMPLAINT Subheadings suggest the CAUSE Note Subheadings suggest sequence to follow troubleshooting 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 Repl...

Страница 46: ...enoid Malfunctioning Relay Defective Safety Bypass Switch Add oil Relocate or reposition See Engine Oil Spec Change oil Replace element s See Trouble Shooting in Engine Manual Repair or replace Replace circuit Replace circuit board Replace circuit board Replace circuit board Replace circuit board Tighten or replace belt set Repair or replace connection Check electrolyte level Add if necessary Chec...

Страница 47: ...efective Minimum Pressure Valve Defective Separator Element Wrong Air Filter Element Above spec limit Relocate or reposition unit Add oil Look for any leaks Check spec in this manual Clean exterior surfaces Move unit to cleaner environment Replace elements Change oil Tighten or replace belt set Reduce pressure to spec Close side doors Replace belly pan Replace thermostat in bypass valve Check fan ...

Страница 48: ...loader Butterfly Valve Defective Safety Valve Defective Separator Element Ice in Regulation Lines Orifice Move unit to cleaner environment Install new element Read procedure in this manual Install proper element Inspect coupling If necessary replace coupling Read procedure in this manual Relocate or reposition unit Remove scavenge orifice Clean and Replace Remove scavenge tube Clean and Replace Re...

Страница 49: ...and in location relative to the other parts in the assembly The part number the description of the part and the quantity of parts required are shown on each illustration or on adjacent page The quantities specified are the number of parts used per one assembly and are not necessarily the total number of parts used in the machine Where no quantity is specified the quantity is assumed to be one Each...

Страница 50: ...so permanently stamped in the metal of the frame side rail c Always specify the number of the parts list pub lication d Always specify the quantity of parts required e Always specify the part number as well as the description of the part or parts exactly as it is given on the parts list illustration In the event parts are being returned to your nearest sales office autonomous company or authorized...

Страница 51: ...o event be liable to the Purchaser any successors in in terest or any beneficiary of this order for any conse quential incidental indirect special or punitive dam ages arising out of this order or any breach thereof or any defect in or failure of or malfunction of the parts hereunder whether based upon loss of use lost prof its or revenue interest lost goodwill work stoppage impairment of other go...

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