Ingersoll-Rand 7/26E Operation & Maintenance Manual
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Ingersoll-Rand 7/26E Operation & Maintenance Manual

Ingersoll-Rand 7/26E Operation & Maintenance Manual

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Operation & Maintenance Manual
7/26E Serial No.: 107000 ->
7/31E Serial No.: 318000 ->
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.
Utility Equipment
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
Book: 22221949 (12-15-06) Rev. A
Revised (10-12)
7/26E, 7/31E, 7/41, 7/51
7/41 Serial No.: 421500 ->
7/51 Serial No.: 442000 ->

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Summary of Contents for Ingersoll-Rand 7/26E

  • Page 1 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...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE FOREWORD ............9 WARRANTY .
  • Page 3 Starting the Machine ............. 60 Push After Warm Up - When Fitted 7/26E, 7/31E, 7/41, 7/51 - Optional ....61 Dual Pressure When Fitted .
  • Page 4 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Reassembly ..............76 Ventilation .
  • Page 5 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE Safety ..............107 General Information .
  • Page 6 Draining of the Fuel Tank (NOT 7/26E, 7/31E) ....... . .
  • Page 7 **Always use Ingersoll Rand Replacement parts!**...
  • Page 8 Foreword 22221949...
  • Page 9 Operation & Maintenance Manual Foreword Foreword The contents of this manual are considered to be proprietary and confidential to Ingersoll Rand and should not be reproduced without the prior written permission of Ingersoll Rand. Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll Rand products described herein.

  • Page 10: Foreword

    Foreword Operation & Maintenance Manual This machine has been designed and supplied for use only in the following specified conditions and applications: • Compression of normal ambient air containing no known or detectable additional gases, vapours. or particles • Operation within the ambient temperature range specified in the “General Information”...
  • Page 11 **Always use Ingersoll Rand Replacement parts!** 22221949...
  • Page 12 Warranty 22221949...
  • Page 13 Operation & Maintenance Manual Warranty 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 14: Warranty

    Warranty Operation & Maintenance Manual E. Portable Light Tower Alternator - The earlier of twelve (12) months from shipment to or the accumulation of 2,000 hours of operation by the initial user. Light Source model only, the earlier of twenty-four (24) months from shipment to or the accumulation of 4,000 hours of operation by the initial user.
  • Page 15 Operation & Maintenance Manual Warranty The above warranties do not apply to failures occurring as a result of abuse; misuse, negligent repairs, corrosion, erosion and normal wear and tear, alterations 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.

  • Page 16: General Warranty Information - Esa

    Warranty Operation & Maintenance Manual General Warranty Information - ESA Comments Portable Compressor Package 12 Months/2,000 hours Covers Controls, Switches, Sheet Metal, Radiator, Oil Cooler, Receiver, Pipework, Electrical Circuit Etc. Airend 24 Months/4,000 hours 60 Months/10,000 hours. Extended Limited Warranty available on major components.
  • Page 17 Operation & Maintenance Manual Warranty Mitsubishi 2,000 2 years/4,000 hours using IR fluids and filters Volvo 2,000 2 years/4,000 hours using IR fluids and filters PARTS Ingersoll Rand Months Hours Comments Unlimited Parts only available from IR Network. AIREND EXCHANGE Airend Months Hours...

  • Page 18: Extended Limited Airend Warranty

    Warranty Operation & Maintenance Manual 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 Pro-Tec™ Compressor Fluid. Pro-Tec™ Compressor Fluid is an amber coloured fluid specially formulated for Portable Compressors and is being provided as the factory filled fluid for all machines except XHP650/900/1070...

  • Page 19: Warranty Registration

    Operation & Maintenance Manual Warranty Warranty Registration FOR UNITS SOURCED FROM HORWICH, UK Complete Machine Registration To initiate the machine warranty, fill out the “Warranty Registration” form 85040285 supplied as part of the machine documentation, keep a copy for your records and mail the original to: Ingersoll Rand European Sales Ltd.

  • Page 20: Engine Registration

    Warranty Operation & Maintenance Manual FOR UNITS SOURCED FROM MOCKSVILLE, USA 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 21: Complete Machine Registration

    Operation & Maintenance Manual Warranty Portable Power Extended Warranty Registration Form Customer Details Service Provider Details Company Name : ______________________ Service Provider/Distributor : ______________ Contact Name : _______________________ Branch Office : _________________________ Signature : ___________________________ Company Address : ____________________ Machine Details ____________________________________ Product Type :__________________________ ____________________________________...
  • Page 22 Decals 22221949...
  • Page 23 Operation & Maintenance Manual Decals Decals 22221949...

  • Page 24: Decals

    Decals Operation & Maintenance Manual 22221949...
  • Page 25 Operation & Maintenance Manual Decals 22221949...
  • Page 26 Decals Operation & Maintenance Manual 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 your supervisor.
  • Page 27 Operation & Maintenance Manual Decals 22221949...
  • Page 28 Decals Operation & Maintenance Manual 22221949...
  • Page 29 **Always use Ingersoll Rand Replacement parts!** 22221949...
  • Page 30 Noise Emission 22221949...
  • Page 31 Operation & Maintenance Manual Noise Emission Noise Emission This section pertains only to machines distributed within 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 replacement, 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 32: Noise Emission

    Noise Emission Operation & Maintenance Manual Noise Emission Control Maintenance Log COMPRESSOR MODEL_____________________________ SERIAL NO. ______________________________________ USER UNIT NO. ___________________________________ DEALER OR DISTRIBUTOR FROM WHOM UNIT IDENTIFICATION PURCHASED: Engine Make & Model: ___________________ _____________________________________ Serial No.: _____________________________ _____________________________________ Purchaser or Owner:_____________________ _____________________________________ Address: ______________________________ Date Purchased: _______________________...

  • Page 33: Compressor Noise Emission Control Information

    Operation & Maintenance Manual Noise Emission 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...

  • Page 34: Noise Emission Control Maintenance Log

    Noise Emission Operation & Maintenance Manual E. Enclosure Panels Enclosure panels should also be inspected at 100 hour operational intervals. All panels that are warped, punctured, torn, or otherwise deformed, such that their noise containment function is reduced, should be repaired 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 seating between gasket or acoustic material and the mating frame.
  • Page 35 Operation & Maintenance Manual Noise Emission MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY DESCRIPTION OF WORK OR HOURMETER MAINTENANCE/ LOCATION WORK DONE ITEM NO. READING INSPECT DATE CITY/STATE BY (NAME) COMMENTS 22221949...
  • Page 36 Safety 22221949...

  • Page 37: General Information

    Operation & Maintenance Manual Safety Safety Indicates the presence of a hazard which WILL DANGER cause serious injury, death or property damage, if ignored. (Red Background) Indicates the presence of a hazard which CAN WARNING cause serious injury, death or property damage, if ignored.

  • Page 38: Safety

    Safety Operation & Maintenance Manual 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.

  • Page 39: Materials

    Operation & Maintenance Manual Safety 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.

  • Page 40: Battery

    Safety Operation & Maintenance Manual 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.

  • Page 41: Emergency Stop Controls

    Operation & Maintenance Manual Safety Emergency Stop Controls NOTE: In addition to the key operated emergency stop control on the main control panel, a second control is provided at the socket control panel in the event of electrical hazards associated with generator operation.

  • Page 42: Transport

    Safety Operation & Maintenance Manual Keep all parts of the body and any hand-held tools or other conductive objects, away from exposed live parts of the generator set engine electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the generator set when making adjustments or repairs to exposed live parts of the generator set engine electrical system.

  • Page 43: Safety Chains/Connections And Their Adjustment

    Operation & Maintenance Manual Safety Before towing the machine, ensure that:- • the tires and towing hitch are in a serviceable condition. • the canopy is secure. • all ancillary equipment is stored in a safe and secure manner. • the brakes and lights are functioning correctly and meet necessary road traffic requirements.
  • Page 44 Safety Operation & Maintenance Manual Where safety chains only are fitted: a. Loop the chains onto the towing vehicle using the towing vehicle hitch as an anchorage point, or any other point of similar strength. b. When adjusting the safety chains there should be sufficient free length in the chains to allow normal articulation, whilst also being short enough to prevent the towbar from touching the ground in the event of an accidental separation of the towing vehicle from the trailer.
  • Page 45 Operation & Maintenance Manual Safety 22221949...

  • Page 46: General Information

    General Information 22221949...
  • Page 47 Operation & Maintenance Manual General Information General Information 22221949...
  • Page 48 General Information Operation & Maintenance Manual 22221949...
  • Page 49 Operation & Maintenance Manual General Information 22221949...
  • Page 50 General Information Operation & Maintenance Manual 22221949...

  • Page 51: Compressor

    Operation & Maintenance Manual General Information Compressor Actual free air delivery (7/26E) 2.5 m³ min (90 CFM) Actual free air delivery (7/31E) 3.0 m³ min (105 CFM) Actual free air delivery (7/41) 4.0 m³ min (140 CFM) Actual free air delivery (7/51) 5.0 m³...

  • Page 52: Lubricating Oil Specification

    -23° C (-9° F), IR Performance 500 only. Safety data sheets can be obtained on request from the lubricant supplier. For temperatures outside the specified ambient range, consult Ingersoll Rand. Engine 7/26E Type/model. Ingersoll Rand 3IRH2N Number of cylinders.

  • Page 53: Engine 7/31E

    Operation & Maintenance Manual General Information Engine 7/31E Type/model. Ingersoll Rand 3IRH8N Number of cylinders. Oil capacity. 6.7 litres (1.8 US GAL) Speed at full load. 2800 revs min Speed at idle. 1800 revs min Electrical system. 12V negative earth 26kW (34.8 HP) Power available at 2800 revs min Fuel tank capacity.

  • Page 54: Sound Level Data ('W' Model)

    B. In compliance with 86/188/EEC. Average sound pressure level at 10m to 79/113/EEC.* - 70 dB(A) (*Machine only :- at maximum load in open site conditions) Fixed Height Running Gear - 7/26E, 7/31E Unbraked version (Knott) 7/26E, 7/31E Shipping weight. 620 kg (1370 lbs) Maximum weight.

  • Page 55: Fixed Height Running Gear - 7/41, 7/51

    1233 kgf (2720 lbs) Maximum vertical coupling load (nose weight). 100 kgf (220 lbs) Wheels and Tyres (Knott) Number of wheels 7/26E, 7/31E, 7/41, 7/51 2 x 4½ J Tyre size 7/26E, 7/31E, 7/41, 7/51 155 R13 Tyre pressure 7/26E, 7/31E 2.4 bar (35 PSI)

  • Page 56: Operating Instructions

    Operating Instructions 22221949...

  • Page 57: Commissioning

    Operation & Maintenance Manual Operating Instructions Operating Instructions Commissioning Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in “Prior to Starting”. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
  • Page 58 Operating Instructions Operation & Maintenance Manual WARNING All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure, and materials compatible with the compressor lubricant (refer to the “General Information” section). WARNING If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be...

  • Page 59: Prior To Starting

    Operation & Maintenance Manual Operating Instructions Prior to Starting 1. Place the unit in a position that is as level as possible. The design of the unit permits a 15 degree lengthways and sideways limit on out of level operation. It is the engine, not the compressor, that is the limiting factor.
  • Page 60 Operating Instructions Operation & Maintenance Manual CAUTION When refueling:- • switch off the engine. • do not smoke. • extinguish all naked lights. • do not allow the fuel to come into contact with hot surfaces. • wear personal protective equipment. 5.

  • Page 61: Starting The Machine

    Operation & Maintenance Manual Operating Instructions Starting the Machine WARNING Under no circumstances should volatile liquids such as Ether be used for starting this machine. All normal starting functions are incorporated in the key operated switch. • Turn the key switch to position 2 and hold for max 15 seconds to allow the air inlet heater to reach working temperature.

  • Page 62: Push After Warm Up - When Fitted 7/26E, 7/31E, 7/41, 7/51 - Optional

    Push After Warm Up - When Fitted 7/26E, 7/31E, 7/41, 7/51 - Optional NOTE: In order to allow the machine to start at a reduced load, a valve, which is operated by a button located on the instrument panel, is incorporated in the regulation system.

  • Page 63: Stopping The Machine

    Operation & Maintenance Manual Operating Instructions Stopping the Machine • Close the service valve. • Allow the machine to run unloaded for a short period of time to reduce the engine temperature. • Turn the start switch to the 0 (OFF) position. NOTE: As soon as the engine stops, the automatic blowdown valve will relieve all pressure from the system.

  • Page 64: Monitoring During Operation

    Operating Instructions Operation & Maintenance Manual Monitoring During Operation Should any of the safety shut-down conditions occur, the unit will stop. These are: • Low engine oil pressure • High air discharge temperature • High engine water temperature CAUTION To ensure an adequate flow of oil to the compressor at low temperature, never allow the discharge pressure to fall below 3.5 bar.
  • Page 65 **Always use Ingersoll Rand Replacement parts!** 22221949...

  • Page 66: Maintenance

    Maintenance 22221949...

  • Page 67: Maintenance Schedule

    Operation & Maintenance Manual Maintenance Maintenance Maintenance Schedule Initial 500 miles Daily Weekly Monthly Monthly/ Monthly/ Monthly/ /850 kms 250 hrs 500 hrs 1000 hrs Compressor Oil Level Engine Oil Level *Radiator Coolant Level Gauges/Lamps *Air Cleaner Service Indicators Fuel Tank (Fill at end of day) *Fuel/Water Separator Drain Oil Leaks Fuel Leaks...
  • Page 68 Maintenance Operation & Maintenance Manual Initial 500 miles/ Daily Weekly Monthly Monthly/ Monthly/ Monthly/ Monthly/ 850 kms 250 hrs 500 hrs 1000 hrs 1500 hrs *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease.
  • Page 69 Operation & Maintenance Manual Maintenance Initial Daily Weekly Monthly Monthly/ Monthly/ Monthly/ 500 miles 250 hrs 500 hrs 1000 hrs Scavenge line Pressure system Engine breather element Pressure gauge Pressure regulator Separator tank (2) exterior Lubricator (Fill) 2 Yrs 4 Yrs 6 Yrs Safety valve Hoses...

  • Page 70: Routine Maintenance

    Maintenance Operation & Maintenance Manual Routine Maintenance This section refers to the various components which require periodic maintenance and replacement. The “Maintenance Schedule” indicates the various components’ descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the “General Information”...

  • Page 71: Protective Shutdown System

    Operation & Maintenance Manual Maintenance Prior to opening or removing panels or covers to work inside a machine, ensure that:- • anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts. •...

  • Page 72: Low Engine Oil Pressure Switch

    Maintenance Operation & Maintenance Manual Low Engine Oil Pressure Switch. At three month intervals, test the engine oil pressure switch circuit as follows: • Start the machine. NOTE: Do not press the load button. • Remove a wire from one terminal of the switch. The machine should shutdown. At twelve month intervals, test the engine oil pressure switch as follows: •...

  • Page 73: Alternator/Drive Belt Failure Circuit

    Operation & Maintenance Manual Maintenance Alternator/Drive Belt Failure Circuit. At twelve month intervals test the alternator drive belt failure circuit as follows: • Remove the drive belt from the machine. • Turn the key switch to position 1, the alternator charge light will illuminate. •...

  • Page 74: Compressor Oil Filter

    Maintenance Operation & Maintenance Manual Compressor Oil Filter Refer to the “Maintenance Schedule” in this section for the recommended servicing intervals. Removal WARNING Do not remove the filter(s) without first making sure that the machine is stopped and the system has been completely relieved of all air pressure.

  • Page 75: Compressor Oil Separator Element

    Thoroughly clean the orifice/drop tube and filter gasket contact area before reassembly. Install the new element. For 7/26E and 7/31E models replace element O-ring in every reassembly. WARNING Do not remove the staple from the anti-static gasket on the separator element since it serves to ground any possible static build-up.

  • Page 76: Compressor Oil Cooler And Engine Radiator

    Maintenance Operation & Maintenance Manual CAUTION Start the machine (refer to “Prior to Starting” and “Starting the Machine” in the “Operating Instructions” section of this manual) and check for leakage before the machine is put back into service. Compressor Oil Cooler and Engine Radiator When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler and radiator, the efficiency is impaired.

  • Page 77: Air Filter Elements

    Operation & Maintenance Manual Maintenance Air Filter Elements The air filter should be inspected regularly (refer to the “Maintenance Schedule”) and the element replaced when the restriction indicator shows red or every 6 Months (500 hours), whichever comes first. The dust collector box(es) should be cleaned daily (more frequently in dusty operating conditions) and not allowed to become more than half full.

  • Page 78: Cooling Fan Drive

    Maintenance Operation & Maintenance Manual Cooling Fan Drive Periodically check that the fan mounting bolts in the fan hub have not loosened. If, for any reason, it becomes necessary to remove the fan or re-tighten the fan mounting bolts, apply a good grade of commercially available thread locking compound to the bolt threads and tighten to the torque value shown in the “Torque Values”...

  • Page 79: Battery

    Operation & Maintenance Manual Maintenance Battery Keep the battery terminals and cable clamps clean and lightly coated with petroleum jelly to prevent corrosion. The retaining clamp should be kept tight enough to prevent the battery from moving. Pressure System At 500 hour intervals it is necessary to inspect the external surfaces of the system (from the airend through to the discharge valve(s)) including hoses, tubes, tube fittings and the separator tank, for visible signs of impact damage, excessive corrosion, abrasion, tightness and chafing.

  • Page 80: Brakes

    Maintenance Operation & Maintenance Manual Brakes Check and adjust the brake linkage at 500 miles (850 Km) then every 3000 miles (5000 Km) or 3 months (whichever is the sooner) to compensate for any stretch of the adjustable cables. Check and adjust the wheel brakes to compensate for wear. Adjusting the Overrun Braking System (Knott Running Gear) Preparation Jack up the machine...

  • Page 81: Brake Shoe Adjustment

    Operation & Maintenance Manual Maintenance CAUTION The compression spring [9] must only be lightly pre-tensioned and when operating must never touch the axle tube. Never adjust the brakes at the brake linkage [7]. Brake Shoe Adjustment Width across flats of adjusting screw [12] Brake size Key width 160 X 35 / 200 X 50...

  • Page 82: Compensator Assembly Adjustment

    Maintenance Operation & Maintenance Manual Tighten adjusting screw [12] clockwise until the wheel locks. Loosen adjusting screw [12] anti-clockwise (approx. ½ turn) until the wheel can be moved freely. Slight dragging noises that do not impede the free movement of the wheel are permissible. This adjustment procedure must be carried out as described on both wheel brakes.

  • Page 83: Re-Adjusting The Overrun Braking System (Knott Running Gear)

    Operation & Maintenance Manual Maintenance Final Test Check the fastenings on the transmission system (cables, brake equalisation system and linkage). Check the handbrake cable [5] for a small amount of play and adjust if necessary (Variable height only). Check the compression spring [9] for pre-tensioning. Test Run If necessary carry out 2-3 test brake actions.

  • Page 84: Final Test

    Maintenance Operation & Maintenance Manual Final test Check the fastenings on the transmission system (cables, brake equalisation system and linkage). Apply the handbrake while rolling the machine forward, travel of the handbrake lever up to 2/3 of maximum is allowed. Check the handbrake cable [5] for a small amount of play and adjust if necessary (Variable height only).

  • Page 85: Compressor Lubricating Oil

    Operation & Maintenance Manual Maintenance Compressor Lubricating Oil Refer to the “Maintenance Schedule” in this section for service intervals. NOTE: If the machine has been operating under adverse conditions, or has suffered long shutdown periods, then more frequent service intervals will be required. WARNING DO NOT, under any circumstances, remove any drain plugs or the oil filler plug from the compressor lubricating and cooling system without...

  • Page 86: Running Gear Wheel Bearings

    Maintenance Operation & Maintenance Manual Running Gear Wheel Bearings Wheel bearings should be packed with grease every 6 months. The type of grease used should conform to specification MIL-G-10924. Speed and Pressure Regulation Adjustment Normally, regulation requires no adjusting, but if correct adjustment is lost, proceed as follows: Refer to the diagram above.

  • Page 87: Torque Values

    Operation & Maintenance Manual Maintenance Close the service valve. The engine will slow to idle speed. CAUTION Never allow the idle pressure to exceed 8.6 bar on the pressure gauge, otherwise the safety valve will operate. Torque Values ft. lbf. Airend to engine 29 - 35 39 - 47...

  • Page 88: Compressor Lubrication

    Maintenance Operation & Maintenance Manual Compressor Lubrication Portable Compressor Fluid Chart Refer to these charts for correct compressor fluid required. Note that the selection of fluid is dependent on the design operating pressure of the machine and the ambient temperature expected to be encountered before the next oil change. Design Operating Pressure Ambient Temperature Specification...
  • Page 89 Operation & Maintenance Manual Maintenance Recommended Ingersoll Rand Fluids - Use of these fluids with original IR filters can extend airend warranty. Refer to operator’s manual “Warranty” section for details or contact your IR representative. Recommended Fluid 3.8 Litres 19.0 Litres 208.2 Litres IR Pro-Tec™...

  • Page 90: Electrical System

    Electrical System 22221949...
  • Page 91 Operation & Maintenance Manual Electrical System Electrical System 22221949...
  • Page 92 Electrical System Operation & Maintenance Manual 22221949...
  • Page 93 Operation & Maintenance Manual Electrical System Battery 12V Connector, minicontroller (Option) Fuse 25A LED 1 High air temperature, airend Fuse 5A LED 2 High water temperature, engine Alternator 12V LED 3 Low oil pressure, engine Air heater LED 4 Low fuel Hourmeter LED 5 No charge...
  • Page 94 Electrical System Operation & Maintenance Manual 22221949...
  • Page 95 Operation & Maintenance Manual Electrical System Battery 12V High air temperature switch (airend) CF1 Control fuse 5A High air temperature switch (discharge) (Option) D1-7 Diode, blocking High water temperature switch (engine) Alternator 12V WLK Link GEN Generator (Option) Timer Air heater Safety unit Hourmeter Fuel pump...
  • Page 96 Electrical System Operation & Maintenance Manual 22221949...
  • Page 97 Operation & Maintenance Manual Electrical System Battery 12V Solenoid, load/unload (Option) Control fuse 5A High air temperature switch (airend) D1-8 Diode, blocking High air temperature switch (discharge) (Option) Alternator 12V High water temperature switch (engine) GEN Generator (Option) WLK Link Air heater Timer Hourmeter...
  • Page 98 Electrical System Operation & Maintenance Manual Schematic Diagram for European CE Lighting System Plug Orange Light (right hand) Purple Fog light Light (left hand) Grey Black Blue Green White Pink Yellow Brown 22221949...
  • Page 99 Operation & Maintenance Manual Electrical System Schematic Diagram for American SAE Lighting System Stop/turn (left hand) Pink Tail (left hand) Brown Stop/turn (right hand) Orange Tail (right hand) Purple Front side marker (left hand) Front side marker (right hand) Grey Ground/earth Blue Black...

  • Page 100: Piping And Instrumentation System

    Piping and Instrumentation System 22221949...
  • Page 101 Operation & Maintenance Manual Piping and Instrumentation System Piping and Instrumentation System Air discharge Compressor Sonic orifice (restricts flow) Engine Pressure gauge Oil cooler Separator tank Oil filter Safety valve Thermostatic valve (Where fitted) Air/Oil 22221949...

  • Page 102: Fault Finding

    Fault Finding 22221949...
  • Page 103 Operation & Maintenance Manual Fault Finding Fault Finding Fault Cause Remedy Engine fails to Low battery charge. Check the fan belt tension, battery and cable start. connections. Bad earth connection. Check the earth cables, clean as required. Loose connection. Locate and make the connection good. Fuel starvation.
  • Page 104 Fault Finding Operation & Maintenance Manual Fault Cause Remedy Engine speed too Incorrect throttle arm Check the engine speed setting. high. setting. Faulty regulator valve. Check the regulation system. Engine speed too Incorrect throttle arm Check the throttle setting. low. setting.
  • Page 105 Operation & Maintenance Manual Fault Finding Fault Cause Remedy Excessive oil Blocked scavenge line. Check the scavenge line, drop tube and orifice. present in the Clean and replace. discharge air. Perforated separator Replace the separator element. element. Pressure in the system Check the minimum pressure valve or sonic is too low.

  • Page 106: Options

    Options 22221949...

  • Page 107: Lubricator

    Operation & Maintenance Manual Options Options Lubricator Safety WARNING Ensure that the lubricator filler cap is re-tightened correctly after replenishing with oil. Do not replenish the lubricator oil, or service the lubricator without first making sure that the machine is stopped and the system has been completely relieved of all air pressure (Refer to “Stopping the Machine”...

  • Page 108: Generator (Wdg)

    Options Operation & Maintenance Manual Generator (WDG) Safety Refer to the “Safety” section in this manual. General Information Rated output: 4.8 kW @ 0.8 Power factor (PF) lagging Rated voltage: 110V 1ph or 230V 1ph or 230V 3ph or 400V 3ph + 230V 1ph @ 3000 revs min Voltage regulation: ±...

  • Page 109: Operating Instructions

    Operation & Maintenance Manual Options Operating Instructions A mode selector switch is provided to switch the machine between compressor and generator mode. CAUTION Do not start or stop the machine with the compressor/generator mode switch in the Generator position. When the switch is in the Generator position the normally-open solenoid valve switches to the closed position and air in the line to the engine speed control cylinder vents to the atmosphere via the solenoid exhaust port.

  • Page 110: Starting The Machine

    Options Operation & Maintenance Manual Starting the Machine WARNING Under no circumstances should volatile liquids such as Ether be used for starting this machine. CAUTION Do not start or stop the machine with the compressor/generator mode switch in the Generator position. All normal starting functions are incorporated in the key operated switch.

  • Page 111: Stopping The Machine

    Operation & Maintenance Manual Options Stopping the Machine 1. Close the service valve. 2. Allow the machine to run unloaded for a short period of time to reduce the engine temperature. 3. Turn the start switch to the 0 (off) position. NOTE: As soon as the engine stops, the automatic blowdown valve will relieve all pressure from the system.

  • Page 112: Decommissioning

    Options Operation & Maintenance Manual CAUTION To ensure an adequate flow of oil to the compressor at low temperature, never allow the discharge pressure to fall below 3.5 bar. Decommissioning When the machine is to be permanently decommissioned or dismantled, it is important to ensure that all hazard risks are either eliminated or notified to the recipient of the machine.

  • Page 113: Fault Finding

    Operation & Maintenance Manual Options An earth leakage circuit breaker provides additional protection in the event of a leakage to earth in excess of 30 milliamperes on the connected appliance or in the connections to the generator. For alternator maintenance refer to Mecc Alte operation and maintenance manual. Fault Finding Fault Cause...
  • Page 114 Options Operation & Maintenance Manual Fault Cause Remedy The output voltage Overload condition. Check and reset each circuit breaker. If the collapses when a condition persists then investigate the load is connected cause and rectify the fault as necessary. (see also ’Circuit breaker trips’) Short circuit.

  • Page 115: A.c. Electrical Power Schematic Diagram, 115V 1 - Phase

    Operation & Maintenance Manual Options A.C. Electrical Power Schematic Diagram, 115V 1 - Phase Circuit breaker 63A Switch, start Circuit breaker 32A Socket outlet 32A Circuit breaker 16A Socket outlet 16A Circuit breaker 16A Socket outlet 16A Alternator Valve, solenoid Contactor Voltmeter Pushbutton...

  • Page 116: A.c. Electrical Power Schematic Diagram, 230V 1 - Phase

    Options Operation & Maintenance Manual A.C. Electrical Power Schematic Diagram, 230V 1 - Phase. Circuit breaker 32A Switch, start Circuit breaker 16A Socket outlet 32A Circuit breaker 16A Socket outlet 16A Alternator Socket outlet 16A Contactor Valve, solenoid Pushbutton Voltmeter Resistor Fuse Voltmeter Fuse Voltmeter...

  • Page 117: A.c. Electrical Power Schematic Diagram, 400/230V 3 - Phase

    Operation & Maintenance Manual Options A.C. Electrical Power Schematic Diagram, 400/230V 3 - Phase Circuit breaker 16A Switch, start Circuit breaker 10A Socket outlet 16A Circuit breaker 10A Socket outlet 16A Alternator Socket outlet 16A Contactor Valve, solenoid Pushbutton Voltmeter Resistor Fuse Voltmeter Resistor...

  • Page 118: Engine

    Engine 22221949...

  • Page 119: Foreword

    Operation & Maintenance Manual Engine Engine - 3IRH2N, 3IRH8N, 4IRH8N & 4IRI8N Foreword The INGERSOLL RAND industrial diesel engines are a product of long years of experience, advanced technology, and up-to date production facilities.INGERSOLL RAND takes great pride in the superior durability and operating economy of these engines. In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly.

  • Page 120: Diesel Engine

    Engine Operation & Maintenance Manual Diesel Engine Engine External View - Model Lifting eye Fuel filter Cooling water pump Fuel oil inlet Cooling fan Fuel filter mounting with fuel priming pump Crank shaft V-pulley Fuel priming pump V-belt Engine name plate Filler port (engine oil) Air intake port Drain plug (engine oil)

  • Page 121: General Information

    Operation & Maintenance Manual Engine General Information EPA Certified Engine Data and Specifications - 3IRH2N Model: 3IRH2N Engine model name 3IRH2N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders - bore X stroke mm 3 - 82 X 84 Engine displacement L 1.331...

  • Page 122: Engine Identification

    Engine Operation & Maintenance Manual Engine Identification Serial No. Location The engine serial number is stamped on engine name plate on top of rocker cover. See illustration on Page - 119. Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the Ingersoll Rand branch or distributor for repair, service or parts ordering.

  • Page 123: Epa Certified Engine Data And Specifications - 3Irh8N

    Operation & Maintenance Manual Engine EPA Certified Engine Data and Specifications - 3IRH8N Model: 3IRH8N Engine model name 3IRH8N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders - bore X stroke mm 3 - 88 X 90 Engine displacement L 1.642 Compression ratio...

  • Page 124: Engine Identification

    Engine Operation & Maintenance Manual Engine Identification Serial No. Location The engine serial number is stamped on engine name plate on top of rocker cover. See illustration on Page - 119. Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the Ingersoll Rand branch or distributor for repair, service or parts ordering.

  • Page 125: Epa Certified Engine Data And Specifications - 4Irh8N

    Operation & Maintenance Manual Engine EPA Certified Engine Data and Specifications - 4IRH8N Model: 4IRH8N Engine model name 4IRH8N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders - bore X stroke mm 88 X 90 Engine displacement L 2.19 Compression ratio...

  • Page 126: Engine Identification

    Engine Operation & Maintenance Manual Engine Identification Serial No. Location The engine serial number is stamped on engine name plate on top of rocker cover. See illustration on Page - 119. Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the Ingersoll Rand branch or distributor for repair, service or parts ordering.

  • Page 127: Epa Certified Engine Data And Specifications - 4Iri8N

    Operation & Maintenance Manual Engine EPA Certified Engine Data and Specifications - 4IRI8N Model: 4IRI8N Engine model name 4IRI8N Engine type Vertical inline water cooled diesel engine Combustion type Direct injection No. of cylinders - bore X stroke mm 4 - 98 X 110 Engine displacement L 3.319 Compression ratio...

  • Page 128: Engine Identification

    Engine Operation & Maintenance Manual Engine Identification Serial No. Location The engine serial number is stamped on engine name plate on top of rocker cover. See illustration on Page - 119. Confirmation of Engine Number It is advisable to quote the engine serial number together with the machine serial number, as it is required when you contact the Ingersoll Rand branch or distributor for repair, service or parts ordering.

  • Page 129: Emission Control Label

    Operation & Maintenance Manual Engine Emission Control Label Engine Label (for EPA) Emission control label is attached on the “top of rocker arm cover”. The location of emission control label attached on the engine may vary depending on the engine specification. The following is the sample of a label required for engine emission control information, along with location.

  • Page 130: Engine Label (For 4Irl5N)

    Engine Operation & Maintenance Manual Engine Label (for 4IRL5N) EC EMISSION CONTROL LABEL: ENGINE LABEL Emission control label is attached on the “top of the rocker arm cover”. The following is the detail of a label required for engine emission control information, along with location.

  • Page 131: Fuel, Lubricants And Coolant

    Operation & Maintenance Manual Engine Fuel, Lubricants and Coolant Fuel Fuel Selection The following properties are required of the diesel fuel: • Must be free from minute dust particles. • Must have adequate viscosity. • Must have high cetane value. •...

  • Page 132: Handling Of The Fuel

    Engine Operation & Maintenance Manual To help avoid fuel system or engine damage, please read the following: Do not use diesel fuel which has been contaminated with engine oil. Besides causing engine damage, such fuel can also affect emission control. Before using any diesel fuel, check with the fuel supplier to see if the fuel has been mixed with engine oil.

  • Page 133: Water In Fuel

    Operation & Maintenance Manual Engine Water in Fuel During refueling, it is possible for water (and other contaminants) to be pumped into your fuel tank along with the diesel fuel. This can happen if a fuel provider does not regularly inspect and clean its fuel tanks, or receives contaminated fuel from its supplier(s).

  • Page 134: Lubricant

    Engine Operation & Maintenance Manual Lubricant The quality of engine oil can affect engine performance, start ability and engine life. Use of unsuitable engine oil will result in piston ring, piston and cylinder seizure and accelerate surface wear causing increased oil consumption, lowered output and, finally engine failure.

  • Page 135: Coolant

    Operation & Maintenance Manual Engine Coolant All Ingersoll- Rand portable compressor engines are factory filled with a 50/50 Ethylene glycol base antifreeze/water mix. which provides protection to -33° C (-27° F). NOTICE Be sure to add Long Life Coolant Antifreeze (LLC) to soft water. In cold season, the LLC is especially important.

  • Page 136: Engine Operation

    Engine Operation & Maintenance Manual Engine Operation Engine Exhaust Gas Caution (Carbon Monoxide) CAUTION Do not breathe exhaust gas because it contains carbon monoxide, which by itself has no color or odor. Carbon monoxide is a dangerous gas. It can cause unconsciousness and can be lethal. Do not run the engine in confined areas (such as garages or next to a building).

  • Page 137: Fan Belt Check

    Operation & Maintenance Manual Engine Remove filler cap (yellow coloured) on the rocker arm cover side of engine. Fill with engine oil up to the upper limit on the dipstick. Manually tighten the filler cap. Do not use a tool such as pliers to tighten it. Table of oil pan capacities.

  • Page 138: Coolant Level Check

    Engine Operation & Maintenance Manual Coolant Level Check The coolant level must be between “MAX COLD” and “MIN” marks on the reserve tank depending on the temperature of the engine. Check and ensure that the level is correct. CAUTION When removing the radiator filler cap, while the engine is still hot, cover the cap with cloth, then turn it slowly to gradually release the internal steam pressure.

  • Page 139: Battery Electrolyte Level

    Operation & Maintenance Manual Engine Battery Electrolyte Level The amount of electrolyte in the batteries will be reduced after repeated discharge and recharge. Check the electrolyte level in the batteries, replenish with a commercially available electrolyte such as distilled water, if necessary. The battery electrolyte level checking procedure will vary with battery type.

  • Page 140: Checks And Operation After Start-Up

    Engine Operation & Maintenance Manual Checks and Operation after Start-Up Check After the Engine Start-Up Check the following items in the engine warming-up operation. Engine noise and exhaust smoke color Listen to the engine and, if any abnormal noise is heard, check to determine the cause. Check the fuel combustion condition by observing the exhaust smoke color.

  • Page 141: Operation And Care Of A New Engine

    Operation & Maintenance Manual Engine Operation and Care of a New Engine Your Ingersoll Rand engine is carefully tested and adjusted in the factory, however, further run-in is necessary. Avoid any harsh engine operation within the initial 100 operating hours. Do not operate the unit at full load until the engine is warmed-up.

  • Page 142: Overcooling

    Engine Operation & Maintenance Manual If no steam or engine coolant can be seen or heard, open the canopy or door. If the engine coolant is boiling, wait until it stops before proceeding. The engine coolant level should be between the “MAX COLD” and “MIN” marks on the reserve tank. Make sure the fan belt is not broken, or off the pulley, and that the fan turns when the engine is started.

  • Page 143: Engine Stopping

    Operation & Maintenance Manual Engine Engine Stopping 1. Close service valves. 2. Before stopping the engine, cool down the engine by operating it at reduced load about three minutes. In this period, check the engine noise for abnormalities. Long Term Storage If the equipment is to be out of operation for an extended period, it should be started at least once per week and run on load for about 15 minutes after it has reached normal operating temperature.

  • Page 144: Engine Maintenance Schedule

    Engine Operation & Maintenance Manual Engine Maintenance Schedule When performing the following items, the daily inspection items should also be carried out. NOTE: Establish a periodic check plan according to the operating conditions and make sure to conduct checks at specified intervals. Otherwise, malfunctioning may occur to shorten the engine life.

  • Page 145: Periodical Inspection And Maintenance

    Operation & Maintenance Manual Engine Periodical Inspection and Maintenance Inspection after Initial 50 Hours Operation Replacing the Engine Oil and Engine Oil Filter (1 time) When the engine oil is still hot, be careful with a splash of engine oil which may cause burns.
  • Page 146 Engine Operation & Maintenance Manual 9. Stop the engine after warming up and leave it stopping for about 10 minute to recheck the engine oil level with dipstick and replenish the engine oil. If any oil is spilled, wipe it away with a clean cloth. The location depends on the engine installed on the machine unit.

  • Page 147: Checking And Adjusting Cooling Fan V-Belt

    Operation & Maintenance Manual Engine Checking and Adjusting Cooling Fan V-Belt When there is not enough tension in the V-belt, the V-belt will slip making it impossible for the alternator to generate power and cooling water pump and cooling fan will not work causing the engine to overheat.

  • Page 148: Use Of Genuine Ingersoll Rand Fan Belt

    Engine Operation & Maintenance Manual • Install the new V-belt adjusting the deflection to the value in the table below according to the above manner. After adjusting, run the engine for 5 minutes and readjust the deflection to the value in the table above. 8~12mm 5~8mm 7~11mm...

  • Page 149: Inspection Every 50 Hours Operation

    Operation & Maintenance Manual Engine Inspection Every 50 Hours Operation Draining of the Fuel Tank (NOT 7/26E, 7/31E) 1. Prepare a waste oil container. 2. Remove the drain plug of the fuel tank to drain (water, dust, etc.) from the fuel tank bottom.

  • Page 150: Inspection Of Battery

    Engine Operation & Maintenance Manual Air bleeding method: When the “starter switch” is set to the “ON” position to activate the electromagnetic pump, fuel is forced to the fuel valve of each injection pump and then to the leak-off pipe of each injector nozzle, so that any air in the fuel system bleeds off automatically to the fuel tank.
  • Page 151 Operation & Maintenance Manual Engine Do not come in Contact with Battery Electrolyte Pay sufficient attention to avoid your eyes or skin from being in contact with the fluid. The battery electrolyte is dilute sulphuric acid and causes burns. Wash it off immediately with a large amount of fresh water if you get any on you.

  • Page 152: Inspection Every 250 Hours Operation

    Engine Operation & Maintenance Manual Inspection Every 250 Hours Operation Replacing the Engine Oil and Engine Oil Filter (2nd time and after) Replace the engine oil every 250 hours operation from 2nd time and on. Replace the engine oil filter at the same time. Refer to “Inspection Every 50 Hours Operation”. Checking and Cleaning Radiator Fins.

  • Page 153: Replacing Fuel Filter

    Operation & Maintenance Manual Engine Governor Control Seals As the governor is precisely adjusted, most of the controls are sealed, please do not break them. Should any adjustment be necessary, contact your local Ingersoll Rand branch or distributor. NOTE: Ingersoll Rand will not accept any warranty claim on an engine with broken governor seals.

  • Page 154: Air Intake System

    Engine Operation & Maintenance Manual Remove the old ‘O’ ring from the bowl ‘D’ and install the new one supplied with the element. Apply a light coat of clean engine oil to the 'O' ring and screw the bowl ‘D’ onto the new element ‘C’.

  • Page 155: Air Cleaner With Dust Indicator

    Operation & Maintenance Manual Engine Air Cleaner with Dust Indicator This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake resistance becomes greater and the dust indicator signal turns to red indicating the element needs to be changed.

  • Page 156: Adjusting Intake/Exhaust Valve Clearance

    Engine Operation & Maintenance Manual Adjusting Intake/Exhaust Valve Clearance As this adjustment requires specialized knowledge and skill, consult your Ingersoll Rand dealer. The adjustment is necessary to maintain the correct timing for the opening and closing of valves. Neglecting the adjustment will cause the engine to run noisily and result in poor engine performance and other damage.

  • Page 157: Engine Maintenance Schedule

    Operation & Maintenance Manual Engine Engine Maintenance Schedule NOTE: * This is a recommended maintenance. The failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion engine useful life. Ingersoll Rand, however, urges that recommended maintenance service is performed at the indicated intervals.

  • Page 158: Engine Troubleshooting

    Engine Operation & Maintenance Manual Engine Troubleshooting This item contains a simple troubleshooting. When a failure takes place on your Ingersoll Rand engine, diagnose the cause referring this troubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest Ingersoll Rand engine service outlet.
  • Page 159 Operation & Maintenance Manual Engine Engine overheat Insufficient coolant volume. Fan belt slippage. Thermostat malfunction. Cooling system defect. Radiator filler cap malfunction. Cooling system interior fouled. Radiator clogged. Engine over-loaded. Air cleaner element clogged. Improper servicing. Insufficient airflow/restriction. Restricted coolant flow (high concentration of antifreeze, etc.). Low oil pressure Oil leakage.
  • Page 160 Engine Operation & Maintenance Manual Improper exhaust Clogged air cleaner. Damaged injector nozzle. Wrong injector nozzle. Excessive black smoke. Injection timing incorrect. Excessive injection volume. Incorrect fuel. Water mixing in fuel. Low compression pressure. Excessive white smoke. Injection timing incorrect. Low coolant temperature.
  • Page 161 **Always use Ingersoll Rand Replacement parts!** 22221949...
  • Page 162 Ingersoll Rand Company Utility Equipment P.O. Box 868 - 501 Sanford Ave Mocksville, N.C. 27028 © 2006 Ingersoll Rand Company, Printed in the USA...

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