Ingersoll-Rand 7/51 User Manual

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

Ingersoll-Rand 7/51 Specifications

General

Model	7/51
Free Air Delivery	5.0 m³/min
Air Delivery	5 m³/min (177 cfm)
Operating Pressure	125 psi
Max Pressure	8.6 bar (125 psi)
Engine Model	D1105
Horsepower	51 hp
Length	3320 mm
Width	1400 mm
Height	1380 mm

Summary

Foreword

Proprietary and Confidential Information

Manual contents are proprietary and confidential; reproduction requires permission.

EC Directives Compliance

Machine specifications comply with EC directives, prohibiting modifications.

Component and Accessory Guidelines

Guidelines for quality, rating, and compatibility of system components.

Use of Approved Parts and Fluids

Recommends genuine parts; non-approved parts may create hazards.

Specified Conditions and Applications

Defines intended use conditions and applications for the machine.

Prohibited Usage Scenarios

Lists situations where machine use is not approved or may be unsafe.

Warranty Information

Standard Warranty Terms

Details the general warranty period for defects in material and workmanship.

Extended Limited Airend Warranty

Details the optional extended warranty for the airend and its components.

Warranty Registration (USA Units)

Instructions for warranty registration for units sourced from Mocksville, USA.

Extended Warranty Registration Form

Form for registering for extended warranty coverage.

Decals and Safety Symbols

ISO Symbols and Meanings

Explains the graphic form and meaning of standard ISO symbols.

Hazard Identification Signs

Defines Danger, Warning, Caution, and Notice signs used for safety.

Machine Operation Decals

Illustrates various decals related to machine operation and safety.

Specific Hazard Warnings

Provides specific warnings for hazards like trapped air pressure and hot surfaces.

Noise Emission Information

Noise Control System Tampering Prohibition

Warns against tampering with noise control systems as per Federal law.

Noise Emission Control Maintenance Log

Provides a log for recording maintenance related to noise emission control.

Maintenance Schedule for Noise Emission Controls

Details the schedule for inspecting and maintaining noise emission controls.

Safety Precautions

Safety Sign Definitions

Explains the meaning of Danger, Warning, Caution, and Notice safety signs.

General Operating Safety Precautions

Provides essential safety guidelines for operating the machine.

Compressed Air Safety Precautions

Details safety measures for handling compressed air.

Battery Safety Precautions

Outlines safety measures related to battery handling and potential hazards.

Generator Operation Safety

Provides safety guidelines for operating the generator set.

Transport and Lifting Safety

Covers safety aspects related to transporting and lifting the machine.

Safety Chains and Connections Adjustment

Provides instructions for adjusting safety chains and connections for towing.

General Information

7/26E, 7/31E Variable Height Running Gear Dimensions

Provides dimensional data for the 7/26E and 7/31E with variable height running gear.

7/26E, 7/31E Fixed Height Running Gear Dimensions

Provides dimensional data for the 7/26E and 7/31E with fixed height running gear.

7/41 Fixed and Variable Height Running Gear Dimensions

Provides dimensional data for the 7/41 with fixed and variable height running gear.

7/51 Fixed and Variable Height Running Gear Dimensions

Provides dimensional data for the 7/51 with fixed and variable height running gear.

Compressor Specifications

Details technical specifications for the compressor models.

Lubricating Oil Specifications

Specifies the required lubricating oils for the engine and compressor.

Engine 7/26E Specifications

Provides technical data and specifications for the 7/26E engine.

Engine 7/31E Specifications

Provides technical data and specifications for the 7/31E engine.

Engine 7/41 Specifications

Provides technical data and specifications for the 7/41 engine.

Engine 7/51 Specifications

Provides technical data and specifications for the 7/51 engine.

Sound Level Data

Presents sound level measurements for the 'W' Model.

7/26E, 7/31E Running Gear Specifications

Details specifications for 7/26E and 7/31E running gear types.

7/41, 7/51 Running Gear Specifications

Details specifications for 7/41 and 7/51 running gear types.

Wheels and Tyres Specifications

Provides specifications for wheels and tyres, including pressure.

Operating Instructions

Commissioning Procedures

Steps to follow upon receipt of the unit before putting it into service.

Running Gear Drawbar Installation

Instructions for fitting the drawbar to the machine.

Starting Safety Warnings

Critical warnings regarding the use of volatile liquids for starting.

Prior to Starting Checklist

Key checks to perform before starting the engine and compressor.

Pre-Start System Checks

Checks for fuel system, radiator coolant, and canopy/door status.

Starting the Machine Procedure

Step-by-step guide for starting the machine using the key switch.

Cold Weather Starting

Procedure for starting the machine in temperatures below 0° C.

Optional Load Start Feature

Information on the feature allowing start at reduced load.

Stopping the Machine Procedure

Steps for properly stopping the machine, including cool-down.

Emergency Stopping

Instructions for stopping the unit immediately in an emergency.

Decommissioning Procedures

Guidance on safely decommissioning or dismantling the machine.

Maintenance Procedures

Maintenance Schedule Overview

Presents a comprehensive schedule of maintenance tasks and intervals.

Routine Maintenance Introduction

Introduces components requiring periodic maintenance and replacement.

Protective Shutdown System Components

Lists the components that comprise the protective shutdown system.

Low Engine Oil Pressure Switch Test

Details testing procedures for the low engine oil pressure switch.

Alternator/Drive Belt Failure Circuit Test

Explains how to test the alternator/drive belt failure detection circuit.

Compressor Oil Filter Replacement

Provides steps for removing, inspecting, and replacing the compressor oil filter.

Compressor Oil Separator Element Replacement

Details the procedure for replacing the compressor oil separator element.

Oil Cooler and Radiator Cleaning

Instructions for cleaning the oil cooler and engine radiator for optimal performance.

Air Filter Element Service

Guide for servicing air filter elements, including replacement and ventilation.

Fuel System Maintenance

Covers maintenance of the fuel system, including filter and separator.

Brake System Checks and Adjustments

Procedures for checking and adjusting the brake system.

Engine Oil and Filter Maintenance

Guidance on changing engine oil and replacing the oil filter element.

Compressor Lubricating Oil Management

Information on compressor oil, its replacement, and filter element service.

Speed and Pressure Regulation Adjustment

Instructions for adjusting the engine speed and pressure regulation.

Torque Values Table

A table listing torque specifications for various components.

Compressor Lubrication Fluid Chart

Chart detailing recommended compressor fluids based on operating pressure and temperature.

Electrical System

7/26E, 7/31E Electrical Schematic

Schematic diagram illustrating the electrical system for 7/26E and 7/31E models.

Electrical System Key and Indicators

Key for electrical symbols, LEDs, and component identification.

7/41 Electrical Schematic

Schematic diagram illustrating the electrical system for the 7/41 model.

7/51 Electrical Schematic

Schematic diagram illustrating the electrical system for the 7/51 model.

European CE Lighting System Schematic

Schematic diagram for the European CE lighting system.

American SAE Lighting System Schematic

Schematic diagram for the American SAE lighting system.

Piping and Instrumentation System

Piping and Instrumentation Diagram

Diagram illustrating the piping and instrumentation of the system.

Piping and Instrumentation Diagram Key

Key explaining the components and lines in the P&ID diagram.

Fault Finding

Troubleshooting Engine Start and Running Issues

Diagnoses common engine start, stall, and running problems.

Troubleshooting Engine Speed and Performance Issues

Addresses issues related to engine speed, vibration, and discharge capacity.

Troubleshooting Oil and Pressure Issues

Diagnoses problems with oil in discharge, safety valve operation, and pressure.

Options

Lubricator System

Information on the lubricator system, including safety and maintenance.

Generator (WDG) Information

Details on the generator's specifications, de-rating factors, and sockets.

Generator Operating Instructions

Instructions for operating the generator set in compressor or generator mode.

Starting the Generator

Procedure for starting the generator, including safety warnings.

Generator Stopping and Restarting

Guidelines for stopping, emergency stopping, and restarting the generator.

Generator Electrical Maintenance

Covers general electrical maintenance and ELCB testing for generators.

Generator Fault Finding - Output Issues

Troubleshooting steps for generator output problems.

Generator Fault Finding - Electrical Issues

Troubleshooting steps for generator electrical faults and circuit breakers.

115V 1-Phase Electrical Schematic

Schematic diagram for the 115V single-phase AC power system.

230V 1-Phase Electrical Schematic

Schematic diagram for the 230V single-phase AC power system.

400/230V 3-Phase Electrical Schematic

Schematic diagram for the 400/230V three-phase AC power system.

Engine Information

Engine Foreword

Introduction to Ingersoll Rand industrial diesel engines and manual usage.

Diesel Engine External View

Diagram showing the external view of the diesel engine with labeled parts.

Engine Data and Specifications - 3IRH2N

EPA certified data and specifications for the 3IRH2N engine model.

Engine Identification and Serial Number

Information on locating and confirming the engine serial number.

Engine Data and Specifications - 3IRH8N

EPA certified data and specifications for the 3IRH8N engine model.

Engine Data and Specifications - 4IRH8N

EPA certified data and specifications for the 4IRH8N engine model.

Engine Data and Specifications - 4IRI8N

EPA certified data and specifications for the 4IRI8N engine model.

Emission Control Label (EPA)

Details about the emission control label attached to the engine.

Engine Label (4IRL5N)

Information regarding the engine label for the 4IRL5N model.

Fuel, Lubricants, and Coolant

Fuel Selection Criteria

Properties required for diesel fuel and recommended standards.

Fuel Handling and Storage Precautions

Guidelines for safe handling of fuel to prevent contamination and damage.

Water in Fuel and Biocide Usage

Information on water contamination in fuel and the use of biocides.

Lubricant Selection and Viscosity

Guidance on selecting engine oil based on performance and operating temperature.

Coolant Information and Precautions

Details on coolant type, mixing, and safety precautions when handling.

Engine Operation and Care

Engine Exhaust Gas Safety

Warning about the hazards of carbon monoxide in exhaust gas.

Pre-Operation Checks

Essential checks to perform before starting the engine.

Engine Oil Level Check

Procedure for checking the engine oil level using the dipstick.

Fan Belt Tension Check

Instructions for checking and adjusting the fan belt tension.

Coolant Level and Radiator Cap Check

Procedures for checking coolant level and radiator cap condition.

Battery Cable Connection Inspection

Guidance on checking battery cable connections for looseness or corrosion.

Battery Electrolyte Level Check

Instructions for checking and maintaining the battery electrolyte level.

Post Start-Up Checks

Items to check during the engine warming-up operation.

Engine Noise and Smoke Color

Guidance on assessing engine noise and exhaust smoke color for combustion issues.

System Leakage Checks

Procedures for checking lubrication, fuel, and coolant system leakages.

New Engine Break-in and Operation

Recommendations for break-in period and general engine operation care.

Engine Monitoring Parameters

Key parameters to monitor during operation: oil pressure and coolant temperature.

Overheating Diagnosis and Actions

Steps to take if an overheating condition is suspected.

Overcooling Issues

Information on the consequences of overcooling and how to prevent it.

Operation Monitoring

Checks for hourmeter, leakages, engine noise, and exhaust smoke.

Engine Stopping Procedure

Steps for properly stopping the engine and cool-down period.

Long Term Storage Guidelines

Instructions for storing the equipment for extended periods.

Engine Maintenance Schedule

Maintenance Schedule Overview

Presents a comprehensive schedule of periodic engine maintenance tasks.

Initial 50-Hour Service: Oil and Filter Replacement

Procedure for the first engine oil and filter change after 50 hours.

Engine Oil and Filter Replacement Procedure

Detailed steps for changing engine oil and replacing the oil filter.

Cooling Fan V-Belt Check and Adjustment

Instructions for checking and adjusting the cooling fan V-belt tension.

50-Hour Service: Fuel System Draining

Procedure for draining fuel tank and oil/water separator.

Fuel System Air Bleeding

Steps to bleed air from the fuel system after service.

Battery Inspection and Safety

Guidance on battery inspection, short-circuit prevention, and ventilation.

Battery Electrolyte and Fluid Safety

Precautions for handling battery electrolyte and fluid levels.

250-Hour Service: Oil and Filter Replacement

Procedure for engine oil and filter change at 250-hour intervals.

Radiator Fin Cleaning

Instructions for cleaning radiator fins to maintain cooling efficiency.

Governor Lever and Linkage Check

Checking the governor lever and linkage for looseness or play.

Fuel Filter Replacement

Procedure for replacing the fuel filter element.

Oil/Water Separator Element Change

Procedure for changing the oil/water separator element.

Air Intake System: Air Cleaner

Information on the air cleaner, its indicator, and maintenance.

500-Hour Service: Air Cleaner Element Replacement

Procedure for replacing the air cleaner element at 500-hour intervals.

1000-Hour Service: Cooling Water Replacement

Procedure for replacing cooling water at 1000-hour intervals.

Fuel Injection Valve Adjustment

Guidance on checking and adjusting the fuel injection valve.

Valve Clearance Adjustment

Procedure for adjusting intake and exhaust valve clearance.

2000-Hour Service: Cooling System Flush

Procedure for flushing the cooling system and checking its parts.

Fuel and Cooling Hose Replacement

Instructions for checking and replacing fuel and cooling water hoses.

Intake and Exhaust Valve Lapping

Procedure for lapping intake and exhaust valves.

Fuel Injection Timing Adjustment

Guidance on checking and adjusting the fuel injection timing.

EPA Emission Related Parts Service

Information on servicing EPA emission related parts.

Explanation of Maintenance Schedule Items

Detailed explanation of each maintenance item listed in the schedule.

Engine Troubleshooting

Troubleshooting Engine Start and Running Issues

Diagnoses common engine start, stall, and running problems.

Troubleshooting Engine Overheat and Oil Issues

Diagnoses engine overheat, low oil pressure, and high oil consumption issues.

Troubleshooting Engine Output and Consumption Issues

Addresses low engine output, excessive oil/fuel consumption.

Troubleshooting Exhaust and Battery Issues

Diagnoses improper exhaust, black smoke, and battery over-discharge problems.