7/31, 7/41, 7/51, 7/71, 12/56 OPERATION AND MAINTENANCE MANUAL This manual contains important safety information and must be made available to personnel who operate and maintain this machine. [Tat SERIAL No : 320001 > | mat SERIAL No : 360001 ->, 751 SERIAL No | 7771, 12156 SERIAL No : 520006 —> C.C.N. : 54626486 GB DATE : FEBRUARY 2002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 EC 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 partis absolutely prohibited and would result in the CE Certification and marking being rendered invalid. A declaration of that conformity follows: DECLARATION OF CONFORMITY WITH EC DIRECTIVES 98/37/EC, 93/68/EEC, 89/336/EEC, 2000/14/EC We Ingersoll-Rand Company i Ingersoll-Rand Company Limited Portable Compressor Division Represented in EC by: Standard Products Division P.O. Box 868 ‘Swan Lane 501 Sanford Avenue Hindley Green Mocksville, North Carolina 27028 Wigan WN2 4EZ United Kingdom Declare that, under our sole responsibility for manufacture and supply, the product(s) 7134, 7/41, 7/54, 7/74, 12/56 ion relates, is (are) in conformity with the provisic directives using the following principal standards EN29001 : EN292, EN60204-1, EN1012-1, PN8SNTC2, EN50081 EN50082 Issued at Mocksville on Issued at Hindley Green on 4-1-2002 4-1-2002 Ze Hose Ric Lunsford Harry Seddon Manager of quality control Quality assurance manager CONFORMITY WITH NOISE DIRECTIVE 2000/14/EC Ingersoll-Rand Company Limited declare that the following Portable Compressors have been manufactured in conformity with the directive as shown Machine Serial number {Mean measured | Guaranteed Directive | ape KW fange ‘meas arante Notified body Tist_| 25.3 | 320000- 329999 99 Lwa 700 Lwa aooorrarec [741 | 343] 360000 - 369999 99 La 100Lwa | ay Technology ‘Annex VI [7/51 _| 46.9 | 440000 - 449999 99 La 100 La Stockport U Part! 7774 Nr 1087 S| 58.7 | 520000 - 529009 99 La 100 La 1256 =| Issued at « Hindley Green 4st Declaration’... August 2001 Quality assurance manager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.10 16 2 24 a7 49 66 CONTENTS & ABBREVIATIONS CONTENTS. FOREWORD WARRANTY DECALS NOISE EMISSION MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY SAFETY GENERAL INFORMATION Dimensions Data OPERATING INSTRUCTIONS Commissioning Prior to starting Starting Stopping Emergency stopping Re-starting Monitoring during operation Decommissioning MAINTENANCE Routine maintenance Lubrication Speed & pressure regulation Torque settings table Compressor lubrication MACHINE SYSTEMS Electrical system Piping & instrumentation system FAULT FINDING OPTIONS Lubricator. Safety. General information Operating Instructions. Maintenance Fault Finding Generator. Operating instructions. Maintenance. Fault Finding ENGINE INSTRUCTION MANUAL AR BR cN DE DK ES Fl FR cB HA NL No PT SE us FHR.G. VR. ABBREVIATIONS & SYMBOLS Contact Ingersoll-Rand for serial number Up to Serial No, From Serial No, Not illustrated Option As required Brazil China Germany Denmark Spain Finland France Great Britain (English) High ambient machine Italy Holland Norway Portugal Sweden United States Fixed height running gear Variable height running gearFOREWORD 2 Tho contents ofthis manual ae considered te be propritary and confidential to Ingersol-Rand end should not be reproduced wanout {he prior wien permission of Ingersoll-Rand Nothing contained in this document is intended to extend any promise, wartany or prasentation, expressed or mpled regarding {he Ingersol-Rand products described heron, Ary such warranties oF ‘ther terms ang conditions of sale of products shall ben eccordance ‘with tie standard teems and condlions of sale for such preducts, wien {are avalabie upon request ‘This manual contains instructons and technical data to cover al routine operation and scheduled maintenance tasks by operaton and ‘maintenance sail Major overhauls ste outside the scope of this ‘manuel are shouldbe rela to an euforeed Ingersol- Rand service department ‘The design specincation of this machine has been cerned es complying with EC directives. AS a result, (@)Any machine modifications ae sti prohibited, and wil ivalidata EC cetiication (014 unique specification for USA/Canada is adapted and taioed to Ihe tertory. ‘All components, accessories, pipas and connectors added to the compressed er system should be ‘ol good dually, procured fom a repuable manufacturer and, ‘wherever possible, be ofa type approved by Ingersoll-Rand ‘Cleaiy rated for a pressure atleast equa othe machine maximum alowable working pressure. ‘compatible wih the compressor ubricant/cookant ‘accompaniadvwih instructions for safe instalation, operation and ‘mainionance. Details of approved equipment are available from Ingersol-Rand Sonuce departments “The use ofepar pars / lubricants ids otner than those included sth the IngerSol-Rand approved parts list may create hazardous Conditions over which Ingersoll-Rand has_no control. Thorofore Ingersoll-Rand cannot be heid responsible for equipment in which non-approvedrepar pars are installed Ingersol-Rand reserves the right to make changes and Improvements io products without notce and without incutting any ‘bigation fo. make such changes or add such improvements 10 products sold previously The infeed uses ofthis machine are utined below and examples cof unapproved usage ae also gen, however Ingersol Rand cannot ‘ante pata every appbcation or Work stuabon ht may arse IF IN DOUBT CONSULT SUPERVISION. ‘This machine has been designed and supplied for use only in the {allowing specified conditions and applications Compression of norma ambient air containing no known or ‘etectable additonal gases, vapours. or particles ‘Operation wihin the ambient temperature range specified inthe GENERAL INFORMATION section of hs manual «Generation of electricity at 110v (ph) wth centre tap earth, 230v “rpm, 280 pi and 400v (3ph) 230 (Ap) nominal at 90 Hertz (wins) ‘The use of the machine in any ofthe situation types listed in table 1 2) Is not approved by Ingersoll-Rand, 'b) May impair the safety of users and other persons, and {¢} May prejudice any claims made against Ingersoll-Rand. TABLE? Use ofthe machine fo produce compressed a for 2) diect human consumption ») indrecthuman consumption, without sutable titration and purty checks Use of the machine outside the embient Temperature range specifisdin tne GENERAL INFORMATION SECTION of his manual Use ofthe machine whore theres any actual or foreseeable isk of hazardous leve's of ammable gases or vapours Use of the machine fied with non Ingersol-Rand approved components Iudecants/Tuxds Use of he machine win safety or contol components missing or asabled Use ofthe machine for stowage ot ransportaion of malevals nse cron the enclosure except when contained wihin te toalbox. (GENERATOR Use ofthe generator o supply loads) greater than those speciied Use of unsale or unserviceable alecical aqupment connected to the generator Use of ecincal equpment (@)Having incorrect valiage andlor requency ratings (©) Containing computor equipment andor similar electronics. ‘The company accepts no responsiilty for errs in ransiaton of this manval rom the original Engish version. ‘©COPYRIGHT 2002 INGERSOLL-RAND COMPANY3 WARRANTY IngorsollRand. through its distributor, warrants that each item of ‘equipment manufactured by and delivered hereunder tothe intial {seri be fea of defts i material and werkmanshyp fot a parod of three 3) months from inital operation or six (0) montis from the date (of shpment othe iia use, whichever occurs frst. with respect to the fllowing types of equipment, the warranty pesed «enumerated below wll apply i leu ofthe foregoing warranty period A. Ahtercoolers ~ The earlier of nine (9) months from dato of shipmentto or six (6) manths from start up by intel user B. Portable Compressors, Portable Generator Sets — 8 Kva through te 0 Ka, Portable Liat Towers and Air Dryers ~ The eerie of twelve (12) months from shipment to oF the accumulation of 2,000 hours of senvce by the inal user. 25 Kva Through to 8 Kva— The earlier of twelve (12) months ‘fromshipment o othe accumulation of 2000 hours of eperaion by the intal user Ingorsol-Randwil provide a now pat or repaited part tits sole iscreton, n place ofan pat wien is found fo be detective in material or workmanship during the period described above. Labor cost to replace the parts the responsibilty of the ints ©. Portable Compressor Air Ends - The earier of twenty-four (24) months from shipment to othe accumuiaton of 4 000 ours of service by the intial user For Ar Ends, the warranty aganst Gofocts will include replacement of tne complete Air End, Provided the original Air End is returned assembled and ali Driginal seals are intact C1 Portable Compressor Airend Limited Extended Warranty — The earlier of sixty (60) months ftom shipment to or the accumulationaf 10,000 hours of cperaton by the inal usr Tis texlended warranty i limited to defecis in design or defective matorialor workmanship ots, housings, baarings and gears {nd provided all the folowing conditions are met: ‘Tho orignal ar end is retumed assembled and al original seals sre ntact Continued use of genuine Ingersoll-Rand parts, ids, ots and fiers. Maintenance is performed at prescribed intervals by authorized ‘and propery ianed service engineers D. Generator Alternator -@ Kva through to 850 Kva, Tho carior Cf haenty-four (24) months from shipment oor the accumulation (4000 hours of operation by the inal user 2.5 Kva Through to 8 Kva — The earior of tuolve (12) months from shipment or ne accumulation 02,000 nous of operation by the intial user E_ Portable Light Tower Alternator ~ The earier of hele (12) manins from shigment to or the accumulation of 2000 nous of ‘perationby the nal user. Light Source model only the eater (of henty-four (24) months rom shipment oor the accumulation (04,000 hours of operation by the inital user F Ingersoll-Rand Engines — The oatlor of twenty-four (24) mantis ftom shigment to or the accumulation of 4,000 hours of| ‘operation by he intial user G__ Ingersoll-Rand Platinum Drive Train Limited Extended Warranty Platnum drive tran refers fo the Ingersol- Rand Engine and Arend combination The earrof sy (60) marin fiom shipment to, or tie accumulation of 10.000 hours of ‘paraianby te ital usar The stale alterna, ue injection systom and all elactical components are excluded from tis extended warranty. The airend seal and drive coupling are Includdin he watranty but end dive bets are excluded. Ths limited extended warranty is automatically avaiable when ‘meeting the Tolovang conditions are met 1. The orginal rend ts returned assembled and unopened. 74, Go nveduse of genune nersl-Rane pas, tis, and tere 3. Maintenance is performed at_ prescribed intervals. by ‘autnoized and propery trained service enginaors Ingersoll-Rand shal be provided with such information as it requires to confirm that these conditions have been camped ‘th, Hi Construction Tools, (Portable Power range oniy) ~ Twelve (12) months ftom shipment to mital user. Ingersol-Rand wall provide. new pat or repaired pat at its sole discretion place Of any part which is found 10 be defective i matonal or ‘workmanship duting the pried described above. Labor cost to replace the pat he responsibilty ofthe inital user. H2. Construction Tools Limited Extended Warranty, (Portable ower range only) ~Thity=six (20) montis from shipment to inital user This extendod warranty is automaticaly avaiable ‘nly when the tool is registered wih Ingersol-Rand by completing and submiting the Warranty Registration form Ingersol-Randwill provide a new part or repaired part atits sole screton, in olace of any part which s found fo be defective in ‘material or workmanship during the period descrited above Labor cost to raplace te part the responsibilty ofthe intial | Spare Parts —Six(@) months fom dato of shipment fo the initia Ingetsol-Rand will provide a new part oF repsited pat. at ts sole [E WARNING - Pressurised component or ‘system a. A WARNING ~ Hot surface Ay WARNING — Pressure control > WARNING ~ Corrosion risk. WARNING ~ Alrigas flow or Air discharge. Ay WARNING - Pressurised vessel [> WARNING — Het and harmful exhaust gas. LO. WARNING — Maintain correct tyre pressure. ‘Refer to tho GENERAL INFORMATION section of ts manual) WARNING ~ Flammable liquid ia) WARNING — Before connecting the tow bar commencing to tow consult the operation and maintenance manual ©-@-> ds oc « EE) WARNING - For operating temperature below 0°C, consult the operation and maintenance manualWARNING - Do not undertake any maintenance on this machine unt the electrical supply is disconnected and the air ‘pressure fe totally relieve 7 Bia) WARNING ~ Consult the operation and maintenance manual before commencing any maintenanee. © Do not breathe the compressed ai from tis ® jt remove the Operating and Maintenance marval and manual holder from ths machine. Do not stack © Do nat aparate the machine without the guard being fied. (3) ot stand on any sorvice valve or ather @®@ Do not operate withthe doors or enclosure ® Do nat use frk it tuck from this side Do nol exceed the trailer speed limit ® No naked bos, © Do not open the service valve before the ‘ainose i alacned © Use fork if ruck from tis side only Emergen e Tie down pointeo Ling point n (power DECALS 12 Of (power). Tmachne undertaken ‘s \When parking use prop stand, handrake and wheel chocks Compressor ol itng [-0| Diasel fuel No open flame. (P) Parking brake 1.5m. 2 T 1P54 @y Rough Service Dé ‘Wet Location @ Roplace any cracked protective shila aha U Oil drain13 DECALS 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. Ifyou do not understand, inform your supervisor. EPY NNT UNF NU Ten Red background Yellow background Indicates the presence of 2 hazard which WILL cause Indicates the presence of a hazard which WILL or can serious injury, death or property damage, if ignored. cause injury or property damage, if ignored /\WARNING NOTICE Orange background Blue background Indicates the presence of a hazard which CAN cause Indicates important set-up, operating or maintenance serious injury, death or property damage, if ignored. information. A\DANGER Z\ WARNING Trapped air pressure. Can cause serious injury or death. Close service valve and operate tool to vent trapped air Air discharged from this machine can contain before performing any service carbon monoxide or other contaminants which will cause serious injury or death. Do not breathe this air Ingerot-Aand Ca, Mock, NC. 27008 Ingetst-Aand Co, Mocks, NC. 27028, A\ WARNING Z\ WARNING Hot pressurized fluid. Rotating Fan Blade. Can cause serious burns. CAN cause serious injury. Do not open radiator while . Do NOT operate with guard hot ‘ removed. Ingortot-Aand Co, Mocavilo, NC. 27088Ge pecaLs 14 Z\WARNING A\ WARNING Improper operation of this equipment. CAN cause serious injury or death. Read Operator's Manual supplied with this machine before operation or servicing, Modi Nn oF alteration of this machine. CAN cause serious injury or death. Do NOT alter or modify this machine without the ‘express written consent of the manufacturer, ingersol-Aand Co, Modkavte, NC 27028 Trapped air pressure. Can cause serious injury or death. Close service valve and operate tool to vent trapped air before performing any service, IngersoAend Co, Mockaile, NC. 27028 Disconnected Air Hoses Whip. CAN cause serious injury or death. When using air tools attach safety device (OSHA Valve) at source of air supply for each tool. Ingerot-Rand Ca, Mocks, NO. 27028 Falling off machine. CAN cause serious injury or death, ‘Access Lifting Bail from inside machine. AA WARNING High pressure air. Can cause serious injury or death. Relieve pressure before removing filler plugs/ caps, fitings or covers, Ingorot-Rand Co, Mockavle, NC. 27028, Door under pressure CAN cause serious injury. Use both hands to open door when machine is running15 DECALS WARNING oe ZAWARNING Collapsing propstand. Can cause serious injury. Excessive Towing Speed. CAN cause serious injury or death. Do NOT Tow on Highway. Excessive towing speed. Do NOT exceed 20 mph (32 km/h) Can cause serious injury or death. Do NOT exceed 65 mph (105 km/hr) Clamp propstand securely ingersol-Aand Co, Mookavile, NC 27028 For Highway Towable Units For Non—Highway Towable Machines FREE SAFETY DECALS! To promote communication of Safety Warnings on products manufactured by the Portable Compressor Division in Mocksville, N.C., Safety Decals are available free of charge. Safety decals are identified by the decal heading: DANGER, WARNING or CAUTION. Decal part numbers are on the bottom of each decal and are also listed in the compressor’s parts manual. Submit orders for Safety Decals to the Mocksville Parts Service 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NOISEEMISSION 16 This section pertains only to machines distributed within the United States. ‘TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federallaw prohibits the folowing acts or the causing thereof (1) The removal or rendering inoperative by any parsons, cer than for purposes of maintenance, ropa, or replacement, of any device or element of design incorporated into any new compressor for fe purpose of nose contal pir ta is alo or delivery tothe ultimate purchaser or whl isin use (02) the use ofthe compressor aftr such device or element of design has bean removed of rendered inoperative by any parson ‘Among those atts included in the prohibition against tampering are these: 1. Removal or renderng noperatve any ofthe following «a. the engine exhaust system or parts thereof ' the airintake system or parts thereof enclosure or pars thereof 2 Removal of any ofthe folowing 2 fan shroud © bation moun's Sound absorption material 2. Operation of the compressor with any of the enclosure doors open, Compressor Noise Emission Control Information ‘A. The removal or rendering inoperative, cine han fore purpose of maintenance, repay, or replacement of any noise contol device of element of design incorporated into this compressor in compliance with the nose control act, B. The use ofthis compressor afer such device or element of design has been removed or rendered inoperative. ‘Note: the above information applies only to units that are builtin compliance with the U.S. Environmental Protection Agency. Ingersoll-Rand Compeny reserves the nghtto make changes or edd improvements without notice and without incurring any obligation to make such changes or add such improvements o products sold previously “The Purchaser is urged fo include the above provisions in any agreement for any resale f this compressor.17 NOISE EMISSION NOISE EMISSION CONTROL MAINTENANCE LOG COMPRESSOR MODEL SERIAL NO. USER UNIT NO. UNIT IDENTIFICATION DEALER OR DISTRIBUTOR ENGINE MAKE & MODEL FROM WHOM PURCHASED: SERIAL NO PURCHASER OR OWNER ADDRESS DATE PURCHASED: “The Noise Conttol Act of 1972 (80 Stat 1234) profits tampering withthe noise contel system of eny compressor manufactured and sold under the above regulations, specifically the folowing acts or the causing thereof. (1) The removal or rendering inoperative by any parsons, cher than for purposes of maintenance, repair, or replacement, of any devic or element of ‘design incorporated into any now compressor for the purpose a aise conto prorat sala or devary tothe utbmate purchaser or whila isin uso (0 (2) the use ofthe compressor afte such a device or element of design has been removed or rendered inoperative by any person NOISE EMISSION WARRANTY “The manufacturer warrants tothe ulimate purchaser and each subsequent purchaser thal tis ai compressor was designed, bull and equipped {o conform atthe time of sae tothe fist retail purchaser, wth all applicable U.S. EPA Noise Control Regulations “This waranty i not lmited to any particuler par, component, or system ofthe air compressor Defects inthe design, assembly, o in any par, component or systom ofthe compressor which, et the time of sale tothe frst real purchaser, caused nose emissons fo exceed Federal Standards ‘are covered by tis waranty forthe Iie ofthe ale compressor. (40FR204 58-1)NOISE EMISSION 18 INTRODUCTION ‘The unit for whieh this Maintenance Log is provided conforms to U.S. EPA Regulations for Noise Emissions, applicable to Portable A Comoressors ‘The purpose ofthis book i fo provide (1) the Maintenance Performance Schedule below for al quired noise emission contro and (2) space so thatthe purchaser or owner can record what maintenance was done, by whom, where and when. Detaled instructions on the maintenance items ‘below are gwen on the folowing page MAINTENANCE SCHEDULE TEM [AREA PERIOD A | COMPRESSED AIR LEAKS ‘AS DETECTED 5 __ | SAFETY AND CONTROL SYSTENS 'AS DETECTED ©__ | ACOUSTICMATERIALS DALY 0 __ [FASTENERS 700 HOURS: E__ [ENCLOSURE PANELS 00 HOURS: F___ | AIRINTAKE & ENGINE EXHAUST 100 HOURS: | COOLING SYSTEMS 260 HOURS: F.___ [ISOLATION MOUNTS: 250 HOURS: T ENGINE OPERATION ‘SEE OPERATOR'S MANUAL J [FUELS @ LUBRICANTS ‘SEE OPERATOR'S MANUAL19 NOISE EMISSION A. COMPRESSED AIR LEAKS FAIR INTAKE AND ENGINE EXHAUST ‘Correct all compressed air leaks during the fst shuldown ponicd| after ciscover. If severe enough to cause serious noise problems and ficiency loss, shut own mmediaaly and cortect the leaks) B. SAFETY AND CONTROL SYSTEMS Repair of replace al safety and control systems or ercults es ‘maifuncton occu's. No compressor shouid be operated wih either system bypassed, disabled, or nonfunctional, ©, ACOUSTIC MATERIALS. In dally inspections, observe these materials. Maintain all ‘couste material as nearly as possbie in is oxginal condition. Repai ‘replace all sections that have. 1) sustained damage, 2) have partly ‘Separated om pares o which they ware alached, 4) are missing, oF have otherwse detenorated due to severe operating or storage condtions, D. FASTENERS. ‘All fastene's such aS hinges, nus, ols, clamps, screws, vets ‘and laches should bo inspocted for looseness aftr ach 100 hours of, ‘operation. They should be reightened, repaired, of — if missing — replaced immediately to prevent subsequent damage and noise emission increase E. ENCLOSURE PANELS Enclosure panels should abo be inspected at 100 hour ‘operatonal ntorvals. All panels that are warped, puncture, torn, oF ‘therwise doformed, such that thelr noise containment function is ‘educed, should be repaired oF replaced betore the nex! operation Intorval. Doors, accoss panels, and hatcn closures especially, shoud ‘be checked and adjusted at nis ime fo Insure continuous sealing ‘between gasket or acoustic materiel and the meting tame, Engine and compressor a nlake and engine exhaust ystems should be inspected afer each 100 hours of operation for loose, damaged, or deteriorated components. Repalls or replacements should be made before the next period of use. . COOLING SYSTEMS. ‘All components of tho cooling systoms for engine water and compressor oll should be Inspected every 250 hours of use Any ‘dscrepancies found should be corocted before placing fo Unt back. in operation. Unrestricted aow ove the radiator and ol cooler must be maintained et all imes during operation, H. ISOLATION MOUNTS. Enginelairendisolation mounts should be inspected ater each 250 how's of operation. Those mounts with cracks or spits ithe ‘Tiokdedrubber,o* wrth bent or broker bots due {o operation or storage in sovero envirmonts, all shouldbe replaced with equivalent parts. LENGINE OPERATION Inspect and maintain engine conditon and operation as recommendedin the manuals supplied by the engine manufacturer J. FUELS AND LUBRICANTS Use only the types. and grades of fuels and lubncants recommended inthe ingersoll-Rend Company end Engine Manufacturo’s Operator and Maintenance Manual.MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY 20 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY TTEMNO. DESCRIPTION OF WORK OR ‘COMMENTS HOURMETER READING MAINTINSPECT DATE LOCATION CITYISTATE, WORK DONE BY (NAME)21 SAFETY WARNINGS ‘Warnings call attenton to instructions which must be folowed precisely 0 avoid iniury or death CAUTIONS: Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or fs surroundings. NoTes Notes aro used for supplementary information, General Information ‘Nover epeate uni without fst observing allsalely warnings and careful reading te operation and maintenance manual shipped fom the factory with this machine. Ensure thatthe operator reads and understands te decals and consults the manuals before maintenance or operation Ensure that the Operation and Maintenance manus, and the ‘manuel holst, ae not remaved permanently from the machine. Ensure that maintenance personnel are adequately trained competent and have read the Mantenance Manuals. Make sure that sl protective covers are in place and thatthe ccanopyldoors ara closes ung eperaton. ‘The specification ofthis machine is such thatthe machine is not suitable fr uso inflammable gas tsk arees Il such an application Fequiredtnn al local ragulatons, codes of practice ana so rules MUSt bbe observed. To ensure thal the machine can operate in a safe and ‘oliablemanner addtional equipment such as gas detection, exnaust Spark artestors, and intake (shut-off valves may be require, ‘dependant on local reguatons or he degree oF risk involved ‘A weekly visual check must be made on all fastenersfieng screws ‘securing mechanical pars In particular, safety~eleted parts such as Coupling hitch, drawbar components, road-aneels, and lifing ball Shouldbe checked for foal secu ‘Allcomponents which are loose, damaged o: unserviceabla, must be recifed witout delay ‘Ar dscharged trom this machine may contan carbon monoxte or ‘thar contaminants which wil cause Sencus injury or death. DO nat breathe ts a This machine produces loud nase with the doors open or service valve vented, Extended exposure fo loud nose can cause heating iss ‘Always weer hearng protecion when doors ate open or service vane 's vented NNover inspect of service unt without frst disconnecting battery cable(s) to prevent accidental stating (Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious ilness \wear eye prtecton whl cleaning unt win compressed ai to prevent, bis rom injuring eyets) Rotating fan blade can cause serious injury Do not eparate wihout guard n place Use care fo avoid contacting hot surfaces (engine exhaust manifold ‘and piping, air ecawer and arraisenarge piping. et) Ether is an extremely volatile, highly inflammable gas. When it is specified as a sizing ad use spaxny DO NOT USE ETHER IF THE MACHINE HAS GLOW PLUG STARTING AD OR ENGINE DAMAGE ‘WILL RESULT [Never operate unt with guards, covers or screens removed. Keep hands, hai, ciofing, tools, blow gun tps, ete. well away rom moving parts Compressed air ‘Compressed ar can be dangerous H incorrectly handled, Botore ‘doing any work on be und ensure Tha al pressure fs vented fom te system and that fhe machine cannot be started accidentally Ensure thatthe machine s operating at tho ratod pressure and that the rated pressure is known to al elevant personnel Alla prossure equipment istallod in or connected tothe machine must have safe workng pressure ratings of at least the machine reted pressure If more than ono compressor is connected to one common ‘downstream pan, effective cieck vaves and Solaton valves must be {ited and contralioc by work procedures, so that ene machine cannot aceidenly be pressurised / over pressurised by another. Compressed air must nol be used fora direct feed to ary form of breathing apparatus or mask High Pressure Arr can cause serious inzy or death, Relieve pressure before removing filer plugslcaps,fiings oF covers. Ar pressure can remain trappedtin at supply ina wnich can resut in senus iyury or death Aways carefully vent ai suppY line a ool cx vent valve before performing any serwce ‘The discharged ai contains a very smal percentage of compressor lubricating ail and care should be taken to ensure that downstream equipmentis compatible Ifthe discharged airis to be utimately released into a confined space, adequata ventiation must be provided whan using compressed air alvays use appropriate personal protective equipment Al pressure containing pers, especialy exible noses and ther couplings, must be requarly nspacted, be ree lrom detects and be replaced according tothe Manual instructions ‘Avoid bodily contact wih compressed ait “The safety valve located in the separator tank must be checked periedeally for correct operation Whenever the machine is stopped, air wil flow back ito the compressor system fam devices or systems downstieam of the machineuniess the serve valves closed Install a check valve athe machine servica valve to prevent reverse flow inthe event of an unexpected shutdown when the service valve is openSAFETY 22 Disconnected hosas whip and can cause serous injury or death ‘Aways atlach a safety flow restcior fo each hose atthe source of ‘supply or branch line accordance with OSHA Regulation 2SCFR ‘Section 1026 202(0), Nover allow the unit to sit stopped with pressure in the receiver-separalorsystem Materia “The folowing substances may be produced during the operation of this machine bake lining dust ‘engine exhaust fumes AVOID INHALATION Ensure mat adequate vention ofthe cooing system and exhaust ‘gases s mania at al imes The following substances are used in the msnufacture of ths machine and may be hazardous to heain fused incoroctiy ‘compressor lubricant ‘engine lubricant Dreservalive grease fst preventalve diesel fuel batlry elecwoiyte AVOID INGESTION, SKIN CONTACT AND INHALATION OF Fumes. ‘Shouls compressor lubricant come info contect with the eyes, then lrngate wih water for at least 5 minutos. ‘Should compressor brant come ito contact wth the ski, then wash lf mediately Consulta physician iflarge amounts of compressor lubricant are ingested CConsutta physician if compressor lubricants nao ‘Naver ave fds or induce vomiting ithe patents unconscious or having convulsions, Solely dota sheets for compressor and engine lubicants should be ‘biained rom tha lneant supplier Never operate the engine ofthis machine inside a bulking without ‘adequate ventlaton Avoid breathing exhaust umes whan working on ‘ornear the machine Ths machine may include such materials as ol, diesel fue antfieeze, brake Tui, cir fiers and batteries which may require rape" disposal when performing mainlenance and service tasks ‘Contact iocal eutorites for proper disposal ofthese materials Battery “A bation contains aulphure atid and can give off gases which are corrosive and potently exolesive. Avoid contact wth skin, eyes and clothing, In ease of conact, fush area mimedatey with water DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY SINCE THIS MAY CAUSE IT TO EXPLODE. Exercise extreme caution when using booster battery. To jump battery connect ands of ana booster cade tothe postive (+) terminal of each battery. Connect one end of other cadle to the negatve (-) terminal of the booster battery end other end io a ground connection ‘aay fom dead battery (lo void a spark occuring near eny explosive ‘gases thal may be present) Afi staring unt, always dsconnect fables in raverse order Radiator ot engine coolant and steam can cause injury. Eneure tat the radio ler cap is removed with due cave and atenton. Do not remove the pressure cap ftom a HOT radiator Alow radiator to cool down before removing pressure cap. Generator sets The gereraior sets Gesioned for safely m use However the responsibly for safe operation rests wit those who instal, use and maitan i The following safely precautions are offered as a guide, whieh, if conscientiously flowed, wil mnimse the possibilty of faccidents throughout the useful life of tis equipment Emergency Stop Controle Important Note — In adiibon to the Key operated emergency stop controton the main contal panel, a second contol is proved at the socket contol panel n the event of electrical hazards assocsted with ‘generator operation, Use this second carl to immediately alata al Seectical power to all sockets, than use the key conto 10 stop the engine Operation the generator must bein accordance with recognised elecifcal codes and ical neath and salety codes. ‘The generator set should be operated by those who havo been ‘rained in ifs use and delegated to do $0, and who Nave read and Understand he operator's manual. Falure fo folw the instructors, procedures and safety precautions in the manuel may increase the possibly of accidents and nuns Do not start the gonerator set unloss its safe to do so. Do not attempt operate the generator set wih a known unsae condiion Fit 2 danger notice to the gonerator sat and render it inoperative by ‘dscomecting the batiery and. disconnecting all ungrounded Conductors so cher who may not now ofthe unsafe conditon wil not fattemptto operate untl the conditon is comected ‘An earth points provided beneath the sockst oul ‘The ganeraler set should only be used with tne earth point connactd drat tothe general eafhvground mass An earth spike ki is avaiable as an optional extra for this purpose (refer tothe parts Catalogue) WARNING: DO NOT OPERATE THE MACHINE UNLESS IT HAS BEEN SUITABLY EARTHI Generator sets must be connected to hs load ony by tained and ‘quale electricians wha nave been delagatad to 09 £0, and waen Fequiredby appicable regulations, their work sould be inspected, and accepted by tha ispecton agency having authorty,pricrio attempting to operate the generator set Do not make contact with electicaly energised parts of the _generetor set andlor inferconnecting cables or conductors wth any ar ofthe body or wih any non-nsuated conductive object23 SAFETY Make sure the generator sets efactivaly grounded in accordance uth all appieatle Reguabons pro oatampting to make or break load Connectons ad pir fostering operston, DDo no temp to make or oak olgetncal connections to generator sets standing in water or on wel ground Prior to attempting to make or break electrical connections atthe ‘generators stop the engine, disconnect the batlery and disconnect {and lock out the ungrounded conductors a the load end Keep all pats of the body and any hand-held to0' or other conductive obec, away fom exposed Ive parts ofthe generator set fengine alectnicl system. Maintain dry footing, stand cn insulating surfaces and do not contact any oer porion ofthe generator set en ‘Making agustments or repairs to exposed live parts ofthe generator setengine electrical system, Replace the generar set terminal compartment cover as soon a connections have been made or broken. De not apeete the generator ‘sel without the terminal cover secured firmly in place ose and lock all access doors whon the gonerator sot is lft unattended. Do not use extinguishers itanded for Cass A oF Cass B fies on lectrical res. Use only extinguishers sutable for class BC or class ABC tres keep the fowing vehicle or equpment carer, generator set connating cabias tools and all personnel at least 3 metres ftom ali ‘powerlines and buried power cables, otter than hose connected tothe ‘enerator set. ‘Attempt repairs only n clean, dry, weiligted and ventiated areas, Connect the generator set only to loads andlor electrical systems thal are compatle wih ts electrical charactonstes and thal are wihin tS rated capacity Transport Viner loading or Wansporing machines ensure thatthe speciied ling end te down points are used ‘Wen loading or transporing machines ensure thatthe towing vehicle, its size, weight, towing hich and sloctical supply are all Sullable fo provide safe and stable towing at speeds ether, Up to the legal maximum for the country in which tis boing towed of, a8 specied {er tne machine made ower than the legal maximum, Ensure that the maximum trailer weight does not exceed the ‘maximumgross weight ofthe mactine (oy imtng the equpment oad), limted bythe capacity of the runing gear Note: ‘Gioss mass (on data plate) sf tha basic machine and fuel only, ‘excluding any ftted options, teo's, equipment end foreign material. Bofore towing the machine, ensure that— {the tyres and towing hitch are in serviceable condition ‘the canopy is secure al ancilary equpments stored ina sale and secure manner the brakes and lights ae functoning correctly and meet nacessary Toad tafe requirements. break avay cablessately chains are connected to he towing vehicle “Toe machine must be towed in a lave! attude in order to maintain correct handing, braking and iotting functons. This ean be acheved by cortect selecton and adjustment ofthe vehicle towing hich and, on variableheight running gear, adjustment of the drawbar To ensure ful braking eficioney, tho front (owing eye) secon must sways be set level \wmen aduusing variable net running 98@r-— Ensure front towing eye) section is set level \whn casing towing eye, set rear joint fist, then front joint (when lowering towing eye, st front joint fist, then rea joint ‘Alter setting fuly tighten each joint by hand and then tighten furtnerto the next pin. Refi the pin, whan parking alvays use the handbrake and, necessary, suitable wheel hocks. Make sure wheels, tyres and tow bar connectors are in sare ‘operating conction and tow bar's properly connected before towing Safety chains / connections their adjustment The Tegal requrements Tor the ont operation of the breakaway cable and safty chains aro as yet unidentiiod by 71;320/EEC or UK reguiatons. Consequently we ofr the folowing advice / instructions. mere brakes only are tited 8) Ensure that the breakaway cable is securely coupled to the handbrake lever and aise toa substantia pair on the Towng vehicle Ensue thatthe effective cable length i as short as possible, whist sllallowng enough slackness forthe tral o articulate without the handbrake bang applied Ware brakes and sfely chains ae ited 28) Loop the chains onto the townng vehicle using the towing vehicle Inteh a an anchorage point, or ay cther post of simiar strength ) Ensure tat me erectve chan feng is as short as possible whist stil alowing normal articulation of the traler and oflecive eperation of the breakaway cable, mare safety chains only are fited 2) Loop ie chains onto te townng venice using he towing vehicle hitch as an anchorage point, or ay other point of similar strength. ) When adjusting the safely chains there should be suficient ree length in the chains to alow normal ariction, whist eso being short ‘2ncugh lo prevent the toner ram touching Bie ground nthe evant of ‘3 accidental separation of the towing vehicle ftom the Wale.GENERAL INFORMATION 24 7/91, 7/41 FIXED HEIGHT RUNNING GEAR Unbraked version (M&E) 1195 1380 | Ti008 ‘09100 7/81, 7/41 VARIABLE HEIGHT RUNNING GEAR Unbraked version (M&E) 40 OI 50 C= e608 QS 290-675, 1195 1390. 190725 GENERAL INFORMATION 7/91, 7/41 FIXED HEIGHT RUNNING GEAR Braked version (Knott) 7/81, 7i41 VARIABLE HEIGHT RUNNING GEAR BBraked version (Knett) 1072 f é E 2210-244 3973-3537 een 3413-3577GENERAL INFORMATION 26 7/91, 7/41 FIXED HEIGHT RUNNING GEAR Braked version (MBE) 9 —1 il ! 1208 1300 tar 00 pevten 1 00 7/81, Ti41 VARIABLE HEIGHT RUNNING GEAR Braked version (M&E) eao Ccmr oso G=mr 1208 "1390 1990-2037 1910-2117 sraoo . 1925-2132 0027 GENERAL INFORMATION 7/61 FIXED HEIGHT RUNNING GEAR Braked version (M&E) 1225 neve Fevision 02 1/61 FIXED HEIGHT RUNNING GEAR BBraked version (Knott) 228 | - waa 10 7850 1070 1 755 ast L 1938.GENERAL INFORMATION 28 7/61 VARIABLE HEIGHT RUNNING GEAR Braked version (Knott) 7171, 12186 FIXED HEIGHT RUNNING GEAR Braked version (M&E) oo T29 GENERAL INFORMATION 7/71, 12186 VARIABLE HEIGHT RUNNING GEAR Braked version (M&E) Normal operating charge pressure 12>bar (175 PSI) (1280) “Warum alonable pressure BG bar (125 PS) (rn 744.7151, 7771) ‘Maximum allowable pressure 13bar (190 PS) (1288) Salat valve seg Tarr — Pay (av 741-7881, 7171) ‘Safety valve setting 135 ber 200 PSI) (i286) ‘Maximum pressure rato absouta). 7B 1 (3, 184, 7151, 7771) ‘Maximum pressure rato absolute) 11,5. t (1256) ‘Operating ambient temperature Wihisparsed AD°C TO +48°C (14°F TO 115°) ‘Stendard “10°C TO +52°C (14°F TO 125°F) “Waxman dscharge temperature 120°C 48°F) (1286) ono O76 em a sees ser 0 ‘0 . 3 1 3 2000] ' = 3g 35) a l ——==() 0 Lesa es Actual free alr delivery. 4.0.m? min-* (140 CFM) Oil capacity. 65 les AN) (7/51) Les) igri argystempressure Ga tar (25PS (1031, 141, TDA, TTA) ‘Maximum oil system pressure. 43,0 bar (190 PSI)GENERAL INFORMATION 30 LUBRICATING OIL SPECIFICATION (forthe specified ambient iomporatures). ABOVE -23°C(-9"F) Recommended Pro-Tec ~ ‘Approved: SAE 10W, API CF-AiGG-4 BELOW-23°C)-9°F) Mandatory. TR Performance 500 Ingersol-RandPro-Tec™ compressor fu is factory-fited, for use at all ambien! temperatures above -22°C(-"F NOTE: Warranty may bo extended only by continuous use of Pro-Tec and Ingersoll-Rand o ltrs and separators No other ollfuids are compatible with Pro-Tec™ Nother olstids should be moxed with Pro-Tec™ because the resulting mature could cause damage tothe airond Inthe event that Pro-TecT™is nat availabe and / or the end user noedsto use an approved singe rad engine ol, tho compte system Including separator! recewver, cooler and pipework must be flushed Clear ofthe st Mud end new Ingersoi-Rand ol iter installed ‘When this has bean competed, the folowng ots are approved 2) for ambient temperatures ebove -23°C(-S°F), SAE 10W, API GF-4IGG-4 ') for ambient temperatures below -23°C(-8°F), ER Pertarmance 500 cay. Slety dala sheets can be obtained on request from the lubricant supplier For temperatures outside the specified ambient range, consult Ingersoi-Rand ENGINE 731 Typermodel Number of cylinders Oil capacity. Speed at full load Speed at ile Electrical systom Power avaliable at 3000 revs mia-* Fuel tenk capacity Oitspecitcaton Coolant capacity ENGINE mat Typermodel Number of cylinders Oil capacity. Speed at fll loa Speed at ida Electrical system Power avaliable at 2450 rovs min? Fuel tank cepacty Oitspecitcaton Coolant capacity ENGINE 7151 Typermodel Number of cylinders it capacity. ‘Speed at fl load Speed at idl Elecical system Power avaliable at 2525 rovs min-* Fuol tank capacity Oil specication Coolant capacity ENGINE 174, 12166 “Typeimedel Number of eyinders Oil capacity ‘Speed at fll loa, Speed at ido Elecincal systom Power avalible at 2300 revs min-* Fuel tenk cepacity Oil specication Coolant capacity Tngorso- Rand SIRLAN 3 8 res 3000 revs min 1800 evs mir 12 negative artn 25,60 4oltres Refer engine section Tngesol-Rand ARLEN a 80 tres 2450 revs min! 1500 evs mi! 12V negative earth 343K 4Oltes Refer engine section Tngersol-Rang aIRIIN 12 negative eartn kw lives Rear engine section Tngersol-Rand 4IRITT 4 o.sves 2300 revs min! 4700 rovs mier* 12V negative earth oKW ‘valtres Rete engine section31 GENERAL INFORMATION SOUND LEVEL DATA (W maul) ‘AV Te Preurop code PNENTCD Equivalent continuous sound pressure level* Rated load 84054) (Operator postion ~m ftom machine) ‘Sound powerlevel(@4'S3VEEC) 100 dB(A) B) In compliance with 86/188EEC ‘Average sound prossure level at 10m teTaTseEC 72454) (Machine only at maximum loadin open site conditions) FIXED HEIGHT RUNNING GEAR BBraked version (MAE) 7191, 7144 ‘Shipping weight 70kg (7009 Ts) ‘Maximum weight. 900Kg (1984 bs) Maximum horzontal towing force 1228 ko (2708 Ibs) ‘Maximum vertical couping load (nase weigh) 75 kof (165 Ibs) VARIABLE HEIGHT RUNNING GEAR Braked version (M&E) 7131, 7144 Shipping went 75 KG (164205) Maximum weight 200 kg (1884105) ‘Maximum horzontal towing force 1228 kof (2708 Ibs) ‘Maximum varieal coupling load (nose weigh), ‘75 kgf (*65ibs) FIXED HEIGHT RUNNING GEAR raked version (M&E) 7151 ‘Shipping weigh a By ‘Maximum weight ko( bs) [Maximum horzontal towing force, 1228 kgf (2708 Ibs) ‘Maximum vecical coupling load (nose weigh), ‘T5kgf (*65ibs) VARIABLE HEIGHT RUNNING GEAR raked version (MBE) 7181 ‘Shipping weight Maximum weigat Maximum horzontal towing free. Maximum vertical counting load (nose weit) FIXED HEIGHT RUNNING GEAR, raked version (MBE) 17, 12166 ‘Shipping weight Maximum weight Maximum horzootal towing fore Maximum vertical cougling load (nose wert VARIABLE HEIGHT RUNNING GEAR raked version (M&E) 174, 12186 ‘Shipping weight Maximam weight Maximum horizontal towing force Maximum vertical cougling load (nose weight) WHEELS AND TYRES (MBE) Namber ofwheas, 7134, 74, 7161 Number af whoo, 77, 12166 Tye se 7131, 7141 Tye size 751 Tye size 7174, 12166 Tyee pressure 7131, Tt Tyre pressure 781 Tyee prossure 1174, 12166 rat bs) ka( bs) 1228 ka (2706 tbs) 75 kaf (185 bs) rot Ba) ka( bs) 1492 kat (2208 tbs) 100 kat (220 bs) ¥520ig (2070 Tbs) *1500Kg (2207 ibs) 1492 kgf (2286 tbs) 100 kgf (220 bs) Dead 2eSTad 155 R13 465 R13 780140, 195 R14 27 bar (98 PSI) 2,9 bar (42 PSI) 4Sbar (85 PSI)GENERAL INFORMATION 32 FIXED HEIGHT RUNNING GEAR VARIABLE HEIGHT RUNNING GEAR Braked version (KNOTT) Braked version (KNOTT) 7131, 7144 7181 Shipping weight (50kg (1430 5) ‘Shipping weight ‘62k (TOOOS) ‘Maximum weight. 800Kg (1760 ns) Maximum weight *100kg (243005) Maximum horzontal towing force 1233 ko (2720 lbs) Maximum horizontal towing forea, 1288 af (2720 tbs) ‘Maximum vertical coupling load Maximum vertical counting load (nese wag) 20 kof (108 bs) (nose weight 100 kat (220 ibs) VARIABLE HEIGHT RUNNING GEAR raked version (KNOTT) 7131, 7181 ‘Shipping weight. ‘Maximum weight ‘Maximum horzortal towing force ‘Maximum verical couping load (nase weg) FIXED HEIGHT RUNNING GEAR raked version (KNOTT) 7151 ‘Shipping weigh. ‘Maximum weigt ‘Maximum horzortal towing force, ‘Maximum vacical couping load (nase weight) (85 kg (1500065) 800 Ka (176005) 1233 kgf (2720 os) 20 kat (198 bs) Brig (A7OOBS) *100kg (2490108) 1289 kgf 2720 bs) 100 kgf (220 bs) WHEELS AND TYRES (KNOTT) Number ofwheais, Dead 7131, 741, 781 Tye see 155 R13 7h, 71, 761 Tyre pressure 27 bar 3 PSI) 7131, 7144 Tyee pressure 29 bar (42 PSI) 781 Further information may bo obtained by request through Ingersoll-Randeustomer services department.