Ingersoll-Rand HP600WJD, Operating, Maintenance & Parts Manual

Page 1: ...o 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 OPERATING MAINTENANCE PARTS MANUAL COMPRESSOR MODEL HP600WJD XP750WJD HP750WJD XP825WJD ...

Page 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 ...

Page 3: ...01 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 Swan Lane Hindley Green Wigan WN2 4EZ Unit...

Page 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...

Page 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 ...

Page 6: ...o that one machine cannot accidentally be pressurized or over pressurized by another Compressed air must not be used for a feed to any form of breathing apparatus or mask 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...

Page 7: ...e in accordance with OSHA Regulation 29CFR Section 1926 302 b Hot pressurized fluid can cause serious burns Do not open radiator while hot 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 flammable gas USE SPAR...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 14: ...of twenty four 24 months from shipment to or the accumulation of 4 000 hours of service by the initial user For Air Ends the warranty against defects will include replace ment of the complete Air End provided the original Air End is returned assembled and unopened C 1 Portable Compressor Airend Limited Optional Warranty The earlier of sixty 60 months from shipment to or the accumulation of 10 000 ...

Page 15: ... workmanship 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 business of an Ingersoll Rand distributor authorized to sell the type of equipment involved or other establishment au thorized by Ingersoll Rand User must present proof of purchase at the time of exercising warranty The above warrante...

Page 16: ...in compressors in generators as of 1 1 01 24 24 2000 2000 5 yrs 5000 hrs using OEM fluids and filters with 250 deductible 2 yrs 4000 hrs using IR fluids and filters DEUTZ 24 2000 Available at dealer INGERSOLL RAND 24 4000 5 yrs 10 000 hrs when using genuine Ingersoll Rand fluids and parts Refer to operator s manual KUBOTA North America only Western Europe Oceania Central South America Asia Middle ...

Page 17: ...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...

Page 18: ... i e change of ownership Machines shipped outside the United States require notification be made to initiate the machine warranty Fill out the Warranty Registration Form in this section keep a copy 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 warr...

Page 19: ...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...

Page 20: ...Book 35389923 04 02 20 Ingersoll Rand Company Portable Compressor Division P O Box 868 Mocksville North Carolina 27028 Attention Warranty Department fold ...

Page 21: ... 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 ...

Page 22: ...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...

Page 23: ...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...

Page 24: ...Book 35389923 04 02 24 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 ...

Page 25: ... John Deere Model 6076A 6076A 6081A 6081A Electrical System 24 VDC FLUID CAPACITIES Compressor Lubricant 16 gal Engine Lube including filter 5 9 5 9 8 4 8 4 gal Engine Coolant 7 0 7 0 9 5 9 5 gal Fuel Tank 86 5 86 5 99 5 99 5 gal UNITS MEASUREMENTS WEIGHTS Overall Length 191 inches Overall Height 88 6 inches Overall Width 85 2 inches Net Weight less fuel pounds 6900 6900 7050 7050 Gross Weight all...

Page 26: ...e is used between the header and the unit If this unit is connected in parallel with anotherunit ofhigher discharge pressure and capacity a safety hazard could occur in a back flow condition WARNING Hot pressurized fluid can cause severe burns Do not open radiator while hot Check engine coolant level by removing the radiator top cap and looking for coolant in the filler neck of the radiator Add co...

Page 27: ... 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 pressure rise to slightly over rated pressure If there is no air being consumed the compressor will unload intake...

Page 28: ...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 signal for a shut down In other words if the automatic shutdown is the result of one of these four problems only t...

Page 29: ... 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 ...

Page 30: ... 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 after the main power switch is flipped to OFF To service the air cleaners on all units proceed as fol lows 1 Loosen outer w...

Page 31: ...ith 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 pump and hose use a CLEAN non metallic funnel Every six months the drain plugs should be removed from the tanks so that ...

Page 32: ...efore 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 ethylene glycol This permanent type antifreeze contains rust inhibitors and provides protect...

Page 33: ...RS 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 differential is created in the filter housing between the oil inlet and outlet ports As this diff...

Page 34: ... 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...

Page 35: ...or 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 shell g Re...

Page 36: ... 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...

Page 37: ...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...

Page 38: ...e C Wheel Lug Nuts C Hoses oil air intake etc C Automatic Shutdown System Test C Air Cleaner System Visual C Compressor Oil Cooler Exterior C CLEAN Engine Radiator Exterior C CLEAN Fasteners Guards C Air Cleaner Elements WI Fuel Water Separator Element R Compressor Oil Filter Element B A Compressor Oil R Wheels bearings seals etc C C Engine Coolant Test C R Shutdown Switch Settings Test C Scavenge...

Page 39: ...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...

Page 40: ...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...

Page 41: ...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...

Page 42: ...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...

Page 43: ...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...

Page 44: ...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 ...

Page 45: ... Unloader 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...

Page 46: ...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...

Page 47: ...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...

Page 48: ... or failure in the estimated delivery or shipment of ma terial and equipment or for any damages suffered by reason thereof The company makes no other warranty or representa tion of any kind whatsoever expressed or implied ex cept that of title and all implied warranties including any warranty of merchantability and fitness for a par ticular purpose are hereby disclaimed Limitation of Liability The...

Page 49: ... old and returned with two or more reusable major castings Category C The airend must be over five years old Your nearest sales office autonomous company or authorized distributor must first contact the Parts Ser vice Department at the factory at which your portable air compressor was manufactured for an airend ex change number The airend must be tagged with this preassigned number and returned to...

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