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Ingersoll-Rand VHP400CMH User manual

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Book 43212455 (11/03) 1
OPERATING, MAINTENANCE,
PARTS MANUAL
COMPRESSOR MODELS
VHP400CMH
VHP500CMH
VHP550CMH
HP600CMH
XP650CMH
P
ortable Powe
r
P
.O. Box 868
501 Sanford Ave
M
ocksville, N.C. 27028
www.portablepower.irco.com
Manual 43212455 (11/03)
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.
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.
Revised (10-12)
Book 43212455 (11/03)
2
Quality Policy
We will supply products and services that consistently meet the
requirements of our customers and each other.
Book 43212455 (11/03)
3
TABLE OF CONTENTS
SECTION 1 . . . . . SAFETY
SECTION 2 . . . . . WARRANTY
SECTION 3 . . . . . WARRANTY REGISTRATION
SECTION 4 . . . . . SYSTEM DESCRIPTION
SECTION 5 . . . . . INSTALLATION
SECTION 6 . . . . . OPERATION
SECTION 7 . . . . . GENERAL DATA
SECTION 8 . . . . . MAINTENANCE/LUBRICATION
SECTION 9 . . . . . PARTS ORDERING
SECTION 10 . . . . PARTS LIST
SECTION 11 . . . . COMMON FASTENERS
Book 43212455 (11/03)
4
SECTION 1 – SAFETY
General Information
Never operate unit without first observing all safety warnings and carefully reading the operation and
maintenance manual shipped from the factory with this machine.
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance
Manuals.
Make sure that all protective covers are in place and that the canopy/doors are closed during operation.
The specification of this machine is such that the machine is not suitable for use in flammable gas risk
areas. If such an application is required then all local regulations, codes of practice and site rules must be
observed. To ensure that the machine can operate in a safe and reliable manner, additional equipment
such as gas detection, exhaust spark arrestors, and intake (shut-off) valves may be required, dependant
on local regulations or the degree of risk involved.
A weekly visual check must be made on all fasteners/fixing screws securing mechanical parts. In
particular, safety-related parts such as coupling hitch, drawbar components, road-wheels, and lifting bail
should be checked for total security.
All components which are loose, damaged or unserviceable, must be rectified without delay.
Air discharged from this machine may contain carbon monoxide or other contaminants which will cause
serious injury or death. Do not breathe this air.
This machine produces loud noise with the doors open or service valve vented. Extended exposure to
loud noise can cause hearing loss. Always wear hearing protection when doors are open or service valve
is vented.
Never inspect or service unit without first disconnecting battery cable(s) to prevent accidental starting.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and
result in serious illness. wear eye protection while cleaning unit with compressed
air to prevent debris from injuring eye(s).
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 inflammable gas. When it is specified as a starting aid, use sparingly.
DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUGS OR INLET HEATER STARTING AIDS OR
ENGINE DAMAGE WILL RESULT.
Book 43212455 (11/03)
5
Compressed Air
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that
all pressure is vented from the system and that the machine cannot be started accidentally.
Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all
relevant personnel.
All air pressure equipment installed in or connected to the machine must have safe working pressure
ratings of at least the machines safety valve setting.
If more than one compressor is connected to one common downstream plant, effective check valves and
isolation valves must be fitted and controlled by work procedures, so that one machine cannot
accidentally be pressurized/over pressurized by another.
Compressed air must not be used for a direct feed to any form of breathing apparatus or mask.
High Pressure Air can cause serious injury or death. Relieve pressure before removing filler plugs/caps,
fittings or covers.
Air pressure can remain trapped in air supply line which can result in serious injury or death. Always
carefully vent air supply line at tool or vent valve before performing any service.
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, adequate ventilation must be
provided.
When using compressed air always use appropriate personal protective equipment.
All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected,
be free from defects and be replaced according to the Manual instructions.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be checked periodically for correct operation.
Whenever the machine is stopped, air will flow back into the compressor system from devices or systems
downstream of the machine unless the service valve is closed. Install a check valve at the machine
service valve to prevent reverse flow in the event of an unexpected shutdown when the service valve is
open.
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).
Never allow the unit to sit stopped with pressure in the receiver-separator system.
Book 43212455 (11/03)
6
Materials
The following substances may be produced during the operation of this machine:
brake lining dust
engine exhaust fumes
AVOID INHALATION
Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times.
The following substances are used in the manufacture of this machine and may be hazardous to health if
used incorrectly:
• anti-freeze
• compressor lubricant engine lubricant
• preservative grease rust preventative diesel fuel
• battery electrolyte
AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.
Should compressor lubricant come into contact with the eyes, then irrigate with water for at least 5
minutes.
Should compressor lubricant come into contact with the skin, then wash off immediately.
Consult a physician if large amounts of compressor lubricant are ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious or having convulsions.
Safety data sheets for compressor and engine lubricants should be obtained from the lubricant supplier.
Do NOT start or operate this machine in a confined area. Avoid breathing exhaust fumes when working
on or near the machine.
This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and
batteries which may require proper disposal when performing maintenance and service tasks. Contact
local authorities for proper disposal of these materials.
Battery
A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive.
Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water.
DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY SINCE THIS MAY CAUSE IT TO
EXPLODE.
Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster
cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative ( -)
terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a
spark occurring near any explosive gases that may be present). After starting unit, always disconnect
cables in reverse order.
Book 43212455 (11/03)
7
Radiator
Hot engine coolant and steam can cause injury. Ensure that the radiator filler cap is removed with due
care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing
pressure cap.
Transport
When Loading or transporting machines, ensure that the specified lifting and tie down points are used.
When loading or transporting machines, ensure that the towing vehicle, its size, weight, towing hitch and
electrical supply are all suitable to provide safe and stable towing at speeds either, up to the legal
maximum for the country in which it is being towed or, as specified for the machine model if lower than
the legal maximum. Do not exceed gross vehicle weight rating.
Before towing the machine, ensure that:
• Tires and towing hitch are in a serviceable condition. the canopy is secure.
• All ancillary equipment is stored in a safe and secure manner.
• Brakes and lights are functioning correctly and meet necessary road traffic requirements.
• Break-away cables/safety chains are connected to the towing vehicle.
The machine must be towed in a level attitude in order to maintain correct handling, braking and lighting
functions. This can be achieved by correct selection and adjustment of the vehicle towing hitch and, on
variable height running gear, adjustment of the drawbar.
1. Make sure wheels, tires and tow bar connectors are in safe operating condition and tow bar is
properly connected before towing.
2. When parking always use the handbrake and, if necessary, suitable wheel chocks.
Safety chains/connections and their adjustment where fitted:
Ensure that the breakaway cable is securely coupled to the
trailer and also to a substantial point on the towing vehicle.
Ensure that the cable length is as short as possible, while still allowing enough slackness for the trailer to
articulate without the handbrake being applied.
Loop the chains onto the towing vehicle using the towing vehicle hitch as an anchorage point, or any
other point of similar strength. Ensure that the effective chain length is as short as possible while still
allowing normal articulation of the trailer and effective operation of the breakaway cable.
Book 43212455 (11/03)
8
IMPORTANT SAFETY INSTRUCTIONS
Book 43212455 (11/03)
9
Book 43212455 (11/03)
10