Ingersoll-Rand 7/31E Operation And Maintenance Manual
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Ingersoll-Rand 7/31E Operation And Maintenance Manual

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7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41
This manual contains
important safety information
and must be made available to
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.
OPERATION AND MAINTENANCE MANUAL
7/26E
P90 CWIR
P90 CWIR−UTM
7/31E
7/41
C.C.N. : 22221949 en
REV
DATE
Original Instruction
SERIAL No :
107000 −>
SERIAL No :
107000 −>
SERIAL No :
107000 −>
SERIAL No :
318000 −>
SERIAL No :
421500 −>
: G
: MARCH 2010
Revised (10-12)

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  • Page 1 SERIAL No : 421500 −> Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, C.C.N. : 22221949 en service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative...
  • Page 2 Machine models represented in this manual may be used in various locations world−wide. Machines sold and shipped into European Union Territories require that the machine display the CE Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid.
  • Page 4 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 5: Table Of Contents

    Routine maintenance Polish Lubrication Portuguese Speed & pressure regulation Romanian Torque settings table Russian Compressor lubrication Slovak Slovenian MACHINE SYSTEMS Swedish Electrical system Chinese Piping & instrumentation system FAULT FINDING OPTIONS ENGINE INSTRUCTION MANUAL 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 6: Foreword

    The use of the machine in any of the situation types listed in table 1:− a) Is not approved, b) May impair the safety of users and other persons, and c) May prejudice any claims made. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 7 WARRANTIES Ingersoll−Rand Engines − The earlier of twenty−four (24) MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR months from shipment to or the accumulation of 4,000 hours of PURPOSE. operation by the initial user. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 8 EXTENDED WARRANTY ON MAJOR COMPONENTS PROVIDED VIA ENGINE SUPPLIER’S OWN APPROVED NETWORK AT TIME OF PURCHASE. INGERSOLL−RAND 4,000 EXTENDED WARRANTY OF 60 MONTHS / 10,000 HRS. WHEN USING GENUINE INGERSOLL−RAND FLUIDS AND PARTS ON MAJOR COMPONENTS. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 9: Warranty

    OPTIONAL 36 MONTHS EXTENDED WARRANTY CONSTRUCTION TOOLS AVAILABLE FROM IR. ALL WARRANTY COVERS PARTS ONLY REPLACEMENT. NOTE: Actual warranty times may change. Consult the Manufacturer’s warranty policy as shipped with each new product. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 10 For units operating within the USA & Canada, call the Statesville Product Support Department on 1−800−633−5206 XHP650/900/1070/1170 will continue to use XHP505 and will have the extended warranty when above conditions are met. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 11 Caterpillar, Cummins and Perkins do not require a separate registration form but they stipulate that any new engine should be registered with their local dealer to initiate warranty. You MUST provide proof of the “in−service” date when requesting engine warranty repairs. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 12 Separate engine registration material is included with this literature package for John Deere powered machines. All other engine manufacturers do not require a separate engine registration. You MUST present proof of in−service date at time of requesting engine warranty service. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 13 Engine Serial Number : Engine Model Number : Post / Zip Code : Airend Serial Number : Country : Alternator Serial Number : Phone Number : Date of start up : Fax Number : e−mail : 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 14 WARNING − Before connecting the tow bar WARNING − For operating temperature (Refer to the GENERAL INFORMATION or commencing to tow consult the below 0_C, consult the operation and section of this manual). operation and maintenance manual. maintenance manual. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 15: Decals

    Do not open the service valve before the Do not exceed the trailer speed limit. No naked lights. airhose is attached. Use fork lift truck from this side only. Emergency stop. Tie down point 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 16 Compressor oil filling before operation or maintenance of this wheel chocks. machine is undertaken. Diesel fuel Rough Service Designation. Parking brake. No open flame. Wet Location Operation. Replace any cracked protective shield. Oil drain. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 17 Do not breathe this air. WARNING WARNING Rotating Fan Blade. Hot pressurized fluid. CAN cause serious injury. Can cause serious burns. Do NOT operate with guard Do not open radiator while removed. hot. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 18 High pressure air. Can cause serious injury or death. Relieve pressure before removing filler plugs/ Door under pressure CAN cause serious caps, fittings or covers. injury. Use both hands to open door when machine is running. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 19 Safety Decals to the Doosan Portable Power EMEA Aftermarket 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. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 20 The company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 21 Federal Standards are covered by this warranty for the life of the air compressor. (40FR204.58−1). 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 22: Noise Emission

    FASTENERS 100 HOURS ENCLOSURE PANELS 100 HOURS AIR INTAKE & ENGINE EXHAUST 100 HOURS COOLING SYSTEMS 250 HOURS ISOLATION MOUNTS 250 HOURS ENGINE OPERATION SEE OPERATOR’S MANUAL FUELS & LUBRICANTS SEE OPERATOR’S MANUAL 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 23 Doors, access panels, and hatch closures especially, should be checked and adjusted at this time to insure continuous sealing between gasket or acoustic material and the mating frame. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 24: Maintenance Record For Noise Ha Emission Control And Extended Warranty

    MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY − USA ONLY MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY ITEM NO. DESCRIPTION OF WORK OR HOURMETER MAINT/INSPECT LOCATION WORK DONE BY COMMENTS READING DATE CITY/STATE (NAME) 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 25: Safety

    Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.). 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 26 Avoid contact with skin, eyes and generator set and/or interconnecting cables or conductors with any clothing. In case of contact, flush area immediately with water. part of the body or with any non−insulated conductive object. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 27 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 28 GENERAL INFORMATION 7/26E, 7/31E, P90 CWIR FIXED HEIGHT RUNNING GEAR 7/26E, 7/31E VARIABLE HEIGHT RUNNING GEAR 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 29: General Information

    GENERAL INFORMATION 7/41 FIXED HEIGHT RUNNING GEAR 7/41 VARIABLE HEIGHT RUNNING GEAR 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 30 GENERAL INFORMATION 7/26E, 7/31E SHIPPING SKID, P90 CWIR−UTM 7/41 PERMANENT SKID 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 31 1425 1470 1220 1138 1138 1390 1205 750 kg BB 1996 MAX 3050 MAX 741 fixed height extended 2360 MIN 3449 MIN 1650 1235 1369 1220 1072 1390 1205 2380 MAX 3502 MAX 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 32 Power available at 2800 revs min 35kW (47,0 HP) For temperatures outside the specified ambient range, consult the Fuel tank capacity 40 litres(10,6 US GAL) company. Oil specification Refer engine section Coolant capacity 7,8 litres (2 US GAL) 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 33 Shipping weight. 630 kg (1389 lbs) Maximum weight. 650 kg (1433 lbs) Maximum horizontal towing force. 7,12 kN (1600 lbs) Maximum vertical coupling load (nose weight). 75 kg (165 lbs) 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 34 WARNING: If flexible discharge hoses are to carry more than 7 bar pressure then it is recommended that safety retaining wires are Ensure that all transport and packing materials are discarded. used on the hoses. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 35: Operating Instructions

    45 and a sulphur content not greater than 0,5%. 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. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 36 Open the service valve fully, with no hose connected. incorporated in the regulation system. (The valve automatically returns to the start position when the machine is switched off and air pressure Complete starting sequence above. relieved from the system). 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 37: Emergency Stopping

    In the event that the unit has to be stopped in an emergency, TURN Do not dispose of a complete machine without documentation THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO relating to instructions for its use. THE 0 (OFF) POSITION. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 38 = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 39 = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 40 = Check (adjust, clean or replace as necessary) = Test =check before towing. =or when indicated if earlier. = Check and report Refer to specific sections of the operator’s manual for more information. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 41: Maintenance

    NOTE: Do not press the load button. the work carried out is limited to only those tasks which require the Disconnect each switch in turn. The machine should shutdown. machine to run. Re−connect the switch. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 42 Thoroughly clean the orifice/drop tube and filter gasket contact area discharge air. before reassembly. Install the new element. COMPRESSOR OIL FILTER For 7/26E, 7/31E, P90 CWIR and P90 CWIR−UTM models replace element O−ring in every reassembly. Refer to the MAINTENANCE CHART in this section for the recommended servicing intervals.
  • Page 43 Check for cracks, holes or any other damage to the element by holding it up to a light source, or by passing a lamp inside. Check the seal at the end of the element and replace if any sign of damage is evident. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 44 Disengage the handbrake lever [1]. Never adjust the brakes at the brake linkage [7]. Fully extend the draw bar [2] on the overrun braking system. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 45 If necessary adjust the brake linkage [7] again without play and without period of operation (for more information, consult the Engine section of pre−tensioning this manual). There must still be a little play in cable [5] (Variable Height Only) 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 46 Refer to the SERVICE / MAINTENANCE CHART in this section for service intervals. 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. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 47 Inspect the throttle arm on the engine governor to see that it is extended in the full speed position when the engine is running at full−load speed and the service valve is fully open. (Refer to the GENERAL INFORMATION section of this manual). 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 48 54−68 Euro−Loc adaptor to separator tank 58−67 78−91 Separator tank to frame 18−22 24−30 Exhaust flange to manifold 17−21 23−28 Service pipe (−20jic) 106−133 143−180 Sight glass 40−50 54−68 Wheel nuts 62−70 85−95 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 49: Compressor Lubrication

    Recommended Fluid 3.8 Litre 19.0 Litre 208.2 Litre IR Pro−Tect 36899698 36899706 36899714 IR XHP 505 35365188 35365170 IR Performance 500 35382928 35382936 35382944 IR XHP1001 35612738 35300516 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 50 ELECTRICAL SYSTEM 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 51: Electrical System

    Engine heater relay 7/26E 108475−> 7/31E 319789−> Relay, crank Key−switch Switch, generator (Option) Solenoid, fuel Solenoid, load / unload (Option) Solenoid, generator (Option) High air temperature switch (airend) High water temperature switch (engine) 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 52 ELECTRICAL SYSTEM 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 53 Engine heater relay 7/26E 108475−> 7/31E 319789−> Relay, crank Key−switch Switch, generator (Option) Solenoid, fuel Solenoid, load / unload (Option) Solenoid, generator (Option) High air temperature switch (airend) High water temperature switch (engine) 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 54 ELECTRICAL SYSTEM 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 55 Relay, fuel solenoid Key−switch Solenoid, fuel Solenoid, load / unload (Option) High air temperature switch (airend) High air temperature switch (discharge) (Option) High water temperature switch (engine) Link Timer Safety unit Fuel pump 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 56 Stop light − left hand Brown SL RH Stop light − right hand Orange TL LH Tail light − left hand Purple TL RH Tail light − right hand Plug Grey Blue White Yellow 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 57 Stop light − left hand Orange SL RH Stop light − right hand Purple TL LH Tail light − left hand TL RH Tail light − right hand Grey Plug Blue White Yellow 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 58 Orange SL RH Stop light − right hand Purple TL LH Tail light − left hand TL RH Tail light − right hand Grey Plug Blue Rear view of the connector White Yellow 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 59 Tail (left hand) Green Stop / turn (right hand) Pink Tail (right hand) Brown Front side marker (left hand) Orange Front side marker (right hand) Purple Ground / earth Grey Blue White Yellow 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 60 PIPING AND INSTRUMENTATION SYSTEM Air discharge Oil cooler Sonic orifice (restricts flow) Oil filter Pressure gauge Thermostatic valve (Where fitted) Separator tank Safety valve Compressor Engine Air/oil 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 61: Fault Finding

    Clean and replace. valve. Perforated Replace the separator element. discharge separator air. element. Pressure in Check the minimum pressure valve the system is or sonic orifice. too low. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 62 Replace the solenoid. Check the valve. Replace the safety valve if faulty. to load when solenoid. electrical circuit by feeling for DO NOT ATTEMPT A REPAIR. the load movement whilst depressing the button is load button. pressed. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 63: Options

    A drain for the rear space of the unit is located at the rear left side Do not use high pressure water jet cleaning directly at the decals behind the left hand fender. area. It may cause damage or removal of the decals. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 64 Any warnings necessary have been suitably displayed (where applicable). CAUTION: Do not start or stop the machine with the compressor/generator mode switch in the Generator position. Ensure compressor / generator mode switch is set to compressor. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 65 CAUTION: To ensure an adequate flow of oil to the compressor at low Turn the start switch to the 0 (off) position. temperature, never allow the discharge pressure to fall below 3,5 bar. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 66 30 milliamperes on the controlled. connected appliance or in the connections to the generator. Ensure all earth connections are secure and regularly maintained. For alternator maintenance refer to Mecc Alte operation and maintenance manual. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...

  • Page 67: As Required

    (Refer to section 4 output. General Information). Drive belt is Re−tension the drive belt. not tensioned correctly. Drive pulley is Check the drive pulley and tighten loose on the as required. drive shaft. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 68 Valid for units with socket box located outside, on the front panel. Circuit breaker Switch, start Socket outlet 32A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Valve, solenoid Circuit breaker Voltmeter Fuse Voltmeter Alternator Contactor Fuse Voltmeter Pushbutton Resistor 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 69 Circuit breaker Alternator − 1 phase Earth stud Circuit breaker Contactor Connector − voltmeter Circuit breaker Connector − generator enable switch Circuit breaker Socket outlet 32A/110V Fuse Socket outlet 16A/110V Fuse Socket outlet 16A/110V 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 70 Valid for units with socket box located outside, on the front panel. Circuit breaker Switch, start Socket outlet 32A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Valve, solenoid Alternator Voltmeter Contactor Fuse Voltmeter Pushbutton Fuse Resistor Voltmeter 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 71 CB1/ Circuit breaker Earth stud Contactor Circuit breaker Connector − voltmeter Connector − generator enable switch Circuit breaker Socket outlet 32A/230V Fuse Socket outlet 16A/230V Fuse Socket outlet 16A/230V Alternator − 1 phase 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 72 Valid for units with socket box located outside, on the front panel. Circuit breaker Switch, start Socket outlet 16A Circuit breaker Socket outlet 16A Socket outlet 16A Circuit breaker Valve, solenoid Alternator Voltmeter Contactor Fuse Voltmeter Pushbutton Fuse Resistor Voltmeter Resistor 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 73 CB1/ Circuit breaker Earth stud Contactor Circuit breaker Connector − voltmeter Connector − generator enable switch Circuit breaker Socket outlet 16A/400V Fuse Socket outlet 16A/230V Fuse Socket outlet 16A/230V Alternator − 3 phase 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 74 The heater must not −20_C til −30_C (−4_F til −22_F) be restarted until the unit has been checked by trained personnel. Required: EN 590: 1996 Grade 2 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 75 S Do not allow machine to run for long period with service valve open. Warm up before loading engine (For ambient temperature −10_C to −30_C (14_F to −22_F)) S Switch of the coolant heater. Do not allow the coolant heater to run together with the engine. 7/26E, P90 CWIR, P90 CWIR−UTM, 7/31E, 7/41...
  • Page 76 Coolant OPERATION Check before operation Check and operation after start− up Operation and care of a new engine MAINTENANCE SCHEDULE PERIODICAL INSPECTION AND MAINTENANCE Lubricating system Cooling system Fuel system Air intake system Routine maintenance TROUBLESHOOTING 7/26E, 7/31E, 7/41, 7/51...

  • Page 77: Foreword

    The company reserves the right to make changes in this Manual at any time without prior notice. This manual covers both 3 and 4 cylinder naturally aspirated engines. The pictures contained within are for guidance only and might not reflect the physical characteristics of each individual engine covered 7/26E, 7/31E, 7/41, 7/51...

  • Page 78: External View

    7. Drain plug (engine oil) 20.Flywheel 8. Fuel injection pump 21.Flywheel housing 9. Engine oil cooler (4IRH8N−2) 22.Starter motor 10.Engine oil filter 23.Exhaust manifold 11.Dipstick (engine oil) 24.Alternator 12.Governor lever 25.Rocker arm cover 13.Intake manifold 26.Filler port (engine oil) 7/26E, 7/31E, 7/41, 7/51...

  • Page 79: General Information

    Please ensure that only genuine Ingersoll−Rand parts, lubricants and CAUTION: Conduct confirmation of engine serial number with the fluids are used for service and/or repair. engine stopped. To avoid being injured, do not check it, while the engine is still hot. 7/26E, 7/31E, 7/41, 7/51...
  • Page 80 Please ensure that only genuine Ingersoll−Rand parts, lubricants and CAUTION: Conduct confirmation of engine serial number with the fluids are used for service and/or repair. engine stopped. To avoid being injured, do not check it, while the engine is still hot. 7/26E, 7/31E, 7/41, 7/51...
  • Page 81 Please ensure that only genuine Ingersoll−Rand parts, lubricants and CAUTION: Conduct confirmation of engine serial number with the fluids are used for service and/or repair. engine stopped. To avoid being injured, do not check it, while the engine is still hot. 7/26E, 7/31E, 7/41, 7/51...
  • Page 82 Please ensure that only genuine Ingersoll−Rand parts, lubricants and CAUTION: Conduct confirmation of engine serial number with the fluids are used for service and/or repair. engine stopped. To avoid being injured, do not check it, while the engine is still hot. 7/26E, 7/31E, 7/41, 7/51...

  • Page 83: Emission Control Label

    * Engine family name as assigned by EPA and ARB identifying engine family group 3YDXL1.33M3N and this identifies 3 YDX L 1.33 M 3 N Method of air aspiration Number of cylinders Engine speed specifications3*:2003 Displacement (liter)4:2004 Non road / Off−road engine5:2005 Yanmar Diesel *2003 Model year 7/26E, 7/31E, 7/41, 7/51...
  • Page 84 EMISSION CONTROL LABEL 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. (97/68/EC Directive label) S Label location: A.

  • Page 85: Fuel, Lubricant, And Coolant

    Any fuel containing dust particles or water might cause engine failure . Therefore, the following must be observed. Take care to protect the fuel from ingress of dust particles or water when filling the fuel tank. 7/26E, 7/31E, 7/41, 7/51...

  • Page 86: Lubricant

    • Replace the cooling water every once a year CAUTION: When handling Long Life Coolant Antifreeze, wear protective rubber gloves not to contact with it. If contact with the eyes or skin should occur, wash with clean water 7/26E, 7/31E, 7/41, 7/51...

  • Page 87: Operation

    Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water. C. Dipstick D. Upper limit Radiator Cap Condition E. Lower limit After the replenishment of the coolant, install the radiator filler cap. Make sure the cap is securely installed. F. Dipstick 7/26E, 7/31E, 7/41, 7/51...

  • Page 88: Check And Operation After Start− Up

    When disconnecting the terminals, start with “−” terminal. When connecting them, connect the “−” terminal last. Fuel level Check the remaining fuel oil level in the fuel tank and re−fuel if necessary. 7/26E, 7/31E, 7/41, 7/51...

  • Page 89: Operation And Care Of A New Engine

    S Do not drain the cooling water S Clean dust or oil from the engine extension S Either fill completely or drain the fuel tank S Grease accelerator joints and electrical connections S Disconnect the negative battery terminal 7/26E, 7/31E, 7/41, 7/51...

  • Page 90: Maintenance Schedule

    Check Fuel Valve Nozzle and clean Adjust, cleaning and repair of fuel injection Pump and fuel valve nozzle 1500 hours of use and at 1500−hour intervals 3000 hours of use and at 3000−hour intervals kW x 130 thereafter thereafter 7/26E, 7/31E, 7/41, 7/51...

  • Page 91: Periodical Inspection And Maintenance

    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. A. Engine oil filter B. Loosen C. Tighten 7/26E, 7/31E, 7/41, 7/51...
  • Page 92 CAUTION: S “New, V−belt” refers to a V−belt which has been used less than 5 To help avoid being injured, check and adjust the fan belt tension with minutes on a running engine. engine stopped. 7/26E, 7/31E, 7/41, 7/51...
  • Page 93 PERIODICAL INSPECTION AND MAINTENANCE Inspection every 50 hours operation Start the engine and visually check the fuel system for leaks. (1) Draining of the fuel tank (NOT 7/26E, 7/31E, P90 CWIR, P90 CWIR−UTM) 1) Prepare a waste oil container. Governor Control Seals 2) Remove the drain plug of the fuel tank to drain (water, dust ,etc.)
  • Page 94 C. Upper limit A. Dust, dirt. B. Radiator fins C. Air blow IMPORTANT: Never use high pressure water or air from close by fins or never attempt to clean using a wire brush. Radiator fins can be damaged. 7/26E, 7/31E, 7/41, 7/51...

  • Page 95: Air Intake System

    Check and adjust the cooling fan V−belt tension every 250 hours Discard the old element into a suitable container. operation from 2nd time and on. See “inspection after initial 50 hours” section (2) Inspection every 500 hours operation (1) Replacing the air cleaner element 7/26E, 7/31E, 7/41, 7/51...
  • Page 96 Checking and adjusting the EPA emission related parts. The inspection and servicing require specialized knowledge and techniques. Consult your dealer or distributor. EPA allows to apply maintenance schedule for emission related parts as follow. 7/26E, 7/31E, 7/41, 7/51...
  • Page 97 Change element at 500 hrs or sooner if the restriction indicator shows red. replacement Cylinder compression Consult your dealer or distributor pressure Valve clearance check Check and adjust every 1000 hours. Consult your dealer or distributor 7/26E, 7/31E, 7/41, 7/51...
  • Page 98 Faulty air heater. Fuel is injected but engine does not Incorrect injection timing. fire. cylinder compression pressure. Engine stop solenoid not fully returned. Engine fires but stalls immediately. Air in the fuel system. Incorrect low idle speed adjustment. 7/26E, 7/31E, 7/41, 7/51...

  • Page 99: Troubleshooting

    Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure Lack of oil Oil leakage High oil consumption Wrong oil Wrong type and viscosity. High coolant temperature. Over heat. Clogged filter and strainer. Worn bearings and oil pump. Faulty relief valve. 7/26E, 7/31E, 7/41, 7/51...
  • Page 100 Damaged seal / Damaged turbocharger seal Oil leakage Loose joints/gaskets. Improper installation of filter and piping. Fuel leakage Damaged seals. Excessive fuel consumption Improper component installation or tightening. Excessive injection volume. Injection pump defective. Excessive mechanical loads 7/26E, 7/31E, 7/41, 7/51...
  • Page 101 Faulty turbocharger Battery over discharge Low electrolyte level Crack in battery body. Natural consumption. Charging failure Loose or damaged belt. Faulty alternator. Damaged wiring or contact failure. Excessive electrical loads Insufficient battery capacity for the application. 7/26E, 7/31E, 7/41, 7/51...

This manual is also suitable for:

P90 cwirP90 cwir-utm7/26e7/41

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