This document is an Operating, Maintenance, and Parts Manual for the Ingersoll-Rand VHP600WCU Compressor Model. It provides comprehensive information for the safe and efficient operation, maintenance, and repair of the machine.
Function Description:
The Ingersoll-Rand VHP600WCU is a portable air compressor designed for various industrial applications. Its primary function is to compress ambient air, delivering it at a specified pressure and flow rate for powering pneumatic tools and equipment. The machine is equipped with a diesel engine to drive the compressor and a receiver-separator system to ensure clean, lubricated compressed air. It is designed for above-ground operation, compressing normal ambient air without additional gases, vapors, or particles within the specified temperature range.
Important Technical Specifications:
The manual provides detailed technical specifications for the VHP600WCU and related models (XP750WCU, HP750WCU, XP825WCU).
For the VHP600WCU:
- Air Delivery: 600 cfm (285 litres/sec)
- Engine Speed (Full Load): 2100 RPM
- Engine Speed (No Load): 1400 RPM
- Rated Operating Pressure: 200 psi (1400 kPa)
- Safety Valve Setting: 250 psi (1750 kPa)
- Engine: Cummins 6CTA.8.3, 24 VDC electrical system
- Fluid Capacities:
- Compressor Lubricant: 16 gal.
- Engine Lube (including filter): 5.9 gal.
- Engine Coolant: 7.0 gallons
- Fuel Tank: 86.5 gallons
- Units Measurements/Weights:
- Overall Length: 191 inches
- Overall Height: 88.6 inches
- Overall Width: 85.2 inches
- Net Weight (less fuel): 6900 pounds
- Gross Weight (all fluids): 7500 pounds
- Running Gear:
- Tire Size: 8.00 - 16.5
- Inflation Pressure (Cold): 60 psi
- Towing Speed (Maximum): 50 mph
Usage Features:
The compressor is designed for ease of operation and safety.
- Setting Up: The unit should be placed in an open, well-ventilated area, as level as possible, with a sidewise limit of 15 degrees for out-of-level operation. Proper engine crankcase oil level and compressor oil level (mid-scale when running at full load) are crucial for out-of-level operation.
- Starting: The starting procedure involves flipping the POWER switch to "ON," pressing and holding the BYPASS button for 10-15 seconds to pressurize the inlet valve air cylinder, and then pressing both START and BYPASS buttons to crank the engine. Ether injection is available for cold weather starting.
- Regulation: The unit's regulation system allows adjustment of full load engine speed and discharge pressure. The manual provides detailed steps for adjusting the throttle arm, jam nuts, and pressure regulator to achieve desired operating pressures and idle speeds.
- Safety Features: The machine incorporates five shutdown sensors/switches: high engine coolant temperature, low engine oil pressure, low fuel level (with a warning light), high discharge air temperature at the airend outlet, and a sensor in the separator tank side cover. These automatically shut down the unit and latch the primary signal lamp for diagnostics.
- Air Discharge: Compressed air can be dangerous if mishandled. Users are warned not to breathe the air, as it may contain carbon monoxide or other contaminants. Appropriate personal protective equipment should always be used.
- Noise Emission Control: The manual emphasizes compliance with U.S. EPA Regulations for Noise Emissions, prohibiting tampering with noise control devices such as the engine exhaust system, air intake system, enclosure, fan shroud, vibration mounts, and sound absorption material. Operation with enclosure doors open is also prohibited.
- Mounting: For portable compressors modified to remove running gear and mounted directly to trailers or truck beds, a flexible mounting system is necessary to isolate the compressor package from the carrier base and prevent detachment.
Maintenance Features:
The manual outlines a comprehensive maintenance schedule and procedures to ensure maximum output, performance, and longevity of the unit.
- General Maintenance: Routine operation and scheduled maintenance tasks are covered, with major overhauls referred to authorized Ingersoll-Rand service departments. Preventive maintenance is highlighted as crucial for preventing failures.
- Maintenance Schedule: A detailed schedule includes daily, weekly, monthly, 3-month/250-hour, 6-month/500-hour, and 12-month/1000-hour checks and replacements. Key items include:
- Compressed Air Leaks: Corrected as detected.
- Safety and Control Systems: Repaired/replaced as malfunctions occur.
- Acoustic Materials: Daily inspection, repair, or replacement of damaged sections.
- Fasteners: Inspected for looseness every 100 hours.
- Enclosure Panels: Inspected every 100 hours for warping, punctures, or deformation.
- Air Intake & Engine Exhaust: Inspected every 100 hours for loose, damaged, or deteriorated components.
- Cooling Systems: All components inspected every 250 hours. Unrestricted airflow over radiator and oil cooler is critical.
- Isolation Mounts: Inspected every 250 hours for cracks or bent bolts.
- Engine Operation: Maintained as per engine manufacturer's manual.
- Fuels & Lubricants: Use only recommended types and grades.
- Compressor Oil Level: Checked when the unit is running at full load, aiming for midway on the sight tube.
- Air Cleaner: Equipped with a "AIR FILTERS RESTRICTED" lamp. If the lamp glows red at full speed, the element needs servicing. Weekly squeezing of the rubber valve (precleaner dirt dump) is recommended. Cleaning involves compressed air from the inside out, or washing if heavily contaminated. New elements are highly recommended.
- Fuel Tank: Dual tanks. Use clean diesel fuel. Drain plugs should be removed every six months to drain sediment/condensate.
- Battery: Weekly inspection of posts-to-cable connections, cleanliness, and electrolyte level.
- Tires: Weekly inspection for cuts, cracks, or tread wear. Monthly check of wheel lug nuts.
- Compressor Oil Cooler: Monthly cleaning by directing compressed air with a nonflammable safety solvent through the core. Internal clogging requires cleaning with a suitable compound and flushing.
- Radiator: Monthly inspection for obstructions. Clean with water or compressed air. The cooling system is filled with a 50/50 mixture of water and ethylene glycol, providing protection to -35°F (-37°C). Freezing protection should be tested every six months.
- Hoses: Monthly inspection of all intake, engine cooling, and flexible air, oil, and fuel hoses for wear and deterioration. Clamps must be tight.
- Compressor Oil Filters: Dual spin-on, throw-away type. Replaced every 500 hours (first 50 and 150 hours for new/overhauled units). Pressure must be relieved before removal.
- Compressor Oil Change: Every 1000 hours or six months. Complete draining of receiver-separator, piping, and oil cooler is recommended when hot.
- Running Gear: Wheel lug nuts tightened monthly (85-95 lbs.-ft.). Wheel bearings, grease seals, and axle spindles inspected every six months or 500 miles. Bearings should be repacked with MIL-G-10924 grease.
- Receiver-Separator Systems: Oil separator element replaced every 12 months or 2000 hours. Scavenge line, orifice, filter, and check valve should be cleaned annually or every 2000 hours.
- Exterior Finish Care: The unit has a thermoset polyester powder coating. Cleaning with water and soap, or alcohol for grease, is recommended. Field repair instructions for texture paint are provided, including sanding, priming, and texture application techniques.
Ingersoll-Rand provides a warranty against defects in material and workmanship.
- Standard Warranty:
- Portable Compressor Package: 1 year/2000 hours
- Airend: 2 years/4000 hours
- Extended Coverage:
- Portable Compressor Package: 5 years/10,000 hours (limited warranty on major components).
- Airend: 5 years/10,000 hours when using genuine Ingersoll-Rand fluids and parts, and following prescribed maintenance intervals. The original airend must be returned assembled and unopened.
- Parts Warranty: 6 months from date of shipment.
- Airend Exchange Program: Allows for exchange of airends with warranty based on age and condition (Category "A" under 2 years, "B" 2-5 years, "C" over 5 years).
- California Emission Control Warranty: Covers emission-related parts for five years or 3,000 hours of operation, whichever comes first, for certified non-road diesel engines. This includes components like the charge air cooling system, fuel injection system, intake manifold, exhaust manifold, turbocharger system, and associated hoses, clamps, connectors, and sealing devices. The owner is responsible for performing required maintenance.
Safety:
The manual includes extensive safety precautions and warning labels.
- General Safety: Emphasizes reading manuals, ensuring protective covers are in place, and proper training for maintenance personnel. Warns against breathing compressed air, incorrect handling of compressed air, and operating the engine in confined spaces.
- Hazardous Substances: Lists antifreeze, compressor oil, engine lubricating oil, grease, rust preventative, diesel fuel, and battery electrolyte as hazardous. Warns against engine exhaust fumes and brake lining dust.
- Specific Warnings:
- Corrosion risk, hot surface, lifting point, electrical shock risk, parking brake, no open flame (diesel fuel), flammable liquid, hot and harmful exhaust gas, tie-down point, do not breathe compressed air.
- Read manual before operation/maintenance.
- Maintain correct tire pressure.
- Do not stack.
- Do not use forklift from the side.
- Replace cracked protective shields.
- On/Off/Emergency stop indicators.
- Oil drain, speed limit.
- Warning for operating temperature below 0°C.
- Do not undertake maintenance until electrical supply is disconnected and air pressure relieved.
- Pressurized vessel/component warnings.
- DANGER/WARNING/CAUTION labels for North American markets, indicating severity of hazard.
- Warnings for improper operation, modification, collapsing jack stand, excessive towing speed, rotating fan blade, falling off machine, and door under pressure.
- Warnings for disconnected air hoses and combustible gas (batteries).
The manual stresses that any unauthorized modification or failure to maintain the equipment may make it unsafe and void the factory warranty. It also notes that both SAE/inch and ISO/metric hardware are used, and proper fasteners must be used for replacement.
To Next Page
Need help?
General
