Ingersoll-Rand 3IRL2N Instruction manual

1
Ingersoll-Rand
3IRL2N, 3IRL4N & 4IRL5N
Diesel Engines
WORKSHOP MANUAL
© Ingersoll-Rand Co. 2001
54579925 March.2001
Revised (10-12)
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.

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FOREWORD
This Workshop Manual is designed to help you perform necessary
maintenance, service, and repair procedures on applicable Ingersoll-
Rand industrial engines.
Information contained in this Workshop Manual is the latest
available at the time of publication.
Ingersoll-Rand reserves the right to make changes at any time without
prior notice.

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TABLE OF CONTENTS
SECTION 1. GENERAL INFORMATION ................................................................................... 4
SECTION 2. ENGINE .............................................................................................................. 31
SECTION 3. LUBRICATING SYSTEM ..................................................................................... 94
SECTION 4. COOLING SYSTEM ............................................................................................ 97
SECTION 5. FUEL SYSTEM ..................................................................................................102
SECTION 6. TROUBLESHOOTING ......................................................................................... 115
SECTION 7. CONVERSION TABLE ........................................................................................120

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SECTION 1
GENERAL INFORMATION
TABLE OF CONTENTS
CONTENTS PAGE
GENERAL REPAIR INSTRUCTIONS .................................................................................... 5
NOTES ON THE FORMAT OF THIS MANUAL ..................................................................... 5
APPEARANCE .................................................................................................................... 8
MAIN DATAAND SPECIFICATIONS ..................................................................................... 9
TIGHTENING TORQUE SPECIFICATIONS .......................................................................... 10
ANGULAR NUTAND BOLT TIGHTENING METHOD ............................................................ 12
TIGHTENING TORQUE ON MAJOR COMPONENTS .......................................................... 14
GASKET LOCATION ........................................................................................................... 21
MAINTENANCE .................................................................................................................. 25
RECOMMENDED LUBRICATING OIL ................................................................................. 30
GENERAL INFORMATION

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GENERAL REPAIR INSTRUCTIONS
1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine INGERSOLL-RAND parts.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are
completely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses. To not do so is extremely dangerous.
11. Always check and recheck your work. No service operation is complete until you have done this.
NOTES ON THE FORMAT OF THIS MANUAL
This workshop manual is applicable to the Ingersoll Rand L series 3 and 4 cylinder industrial engines, namely
the 3IRL2N, 3IRL4N & 4IRL5N models.
A large majority of components, parts and data specifications are common within the L series, and for
simplicity, the illustrations are based on the 4IRL5N engine. Where there are differences or exceptions for
individual models, the relevant illustrations and / or data tables are clearly identified with the appropriate engine
model to which they apply.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications, and tightening
torques are included in the General Information section.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and
reassembly.
4. When the same servicing operation is applicable to several different units, the manual will direct you to the
appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.
GENERAL INFORMATION

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6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable
area.
(Example)
Major components
Figures in parentheses ( ) show the order of disassembling or reassembling.
7. Measurement criteria are defined by the terms standard and limit.
A measurement falling within the standard range indicates that the applicable part or
parts are serviceable.
Limit should be thought of as an absolute value.
A measurement which is outside the limit indicates that the applicable part or parts
must be either repaired or replaced.
8. Components and parts are listed in the singular form throughout the Manual.
GENERAL INFORMATION

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GENERAL INFORMATION
9. The following symbols appear throughout this Worshop Manual. They tell you the type of
service operation or step to perform.
10. Direction used in this Manual are as follows:
Front
The cooling fan side of the engine viewed from the flywheel.
Right
The injection pump side of the engine.
Left
The exhaust manifold side of the engine.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is No.4.
The engines direction of rotation is counterclockwise viewed from the flywheel.

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APPEARANCE
1. MODEL 4IRL5N
(1) Left side view
GENERAL INFORMATION
(2) Right side view

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MAIN DATA AND SPECIFICATIONS
GENERAL INFORMATION
1.
(Note) These specifications may be subject to change without notice.
Figures in the column with an asterisk (*) are different for each machine. Refer to the specifications
in compressor operators manual.
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)dic(LtnemecalpsiD)96(21.1)29(5.1)331(971.2
oitarnoisserpmoC1:221:8.81
noitsubmocfoepyTnoitcejnitceridnInoitcejnitceriD
*mmthgiehxhtdiwxhtgnelllarevO355x574x735906x574x275616x944x196
*)bl(gkthgiewyrD)352(511)092(231)243(551
*)potstanehw()CDTB(gnimitnoitcejnileuF°91°41
redrogniriF 2-4-3-1
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-1
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)ni(mm
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tsuahxE)800.0(2.0)7510.0(4.0
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evlavekatnI )CDTB(nepO°51
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evlavtsuahxE )CDBB(nepO°04
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*)stq(LlatotnI:yticapactnacirbuL)4.5(1.5)2.7(8.6)2.9(7.8tuobA
*)A-U(tuptuorotareneG 53-21
*)WK-U(tuptuoretratS 0.2-21

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GENERAL INFORMATION
TIGHTENING TORQUE SPECIFICATIONS
The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

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GENERAL INFORMATION
TIGHTENING TORQUE SPECIFICATIONS
The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

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GENERAL INFORMATION
ANGULAR NUT AND BOLT TIGHTENING METHOD
1. Carefully wash the nuts and bolts to remove all oil
and grease.
2. Apply a coat of molybdenum disulfide grease to the
threads and setting faces of the nuts and bolts.
3.Tighten the nuts and bolts to the specified torque
(snug torque) with a torque wrench.
4. Draw a line [A-B] across the center of each bolt.

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GENERAL INFORMATION
5. Draw another line [C-D] on the face of each of the
parts to be clamped. This line should be an exten-
sion of the line [A-B].
6. Draw another line [F-G] on the face of each of the
parts to be clamped. This line will be in the direction
of the specified angle [Q] across the center [E]
of the nut or bolt.
7. Use a socket wrench to tighten each nut or bolt to
the point where the line [A-B] is aligned with the line
[F-G].

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GENERAL INFORMATION
TIGHTENING TORQUE ON MAJOR COMPONENTS
1. COOLING FAN AND WATER PUMP

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GENERAL INFORMATION
2. CYLINDER HEAD AND CYLINDER HEAD COVER

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GENERAL INFORMATION
3. CYLINDER BLOCK AND OTHER COMPONENTS (1)
N-m (kgf-m/ft. lb)

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GENERAL INFORMATION
4. CYLINDER BLOCK AND OTHER COMPONENTS (2)
Kg.m (ft..lbs.)
3IRL2N

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GENERAL INFORMATION
4. CYLINDER BLOCK AND OTHER COMPONENTS (2)
3IRL4N & 4IRL5N

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GENERAL INFORMATION
5. CYLINDER BLOCK AND OTHER COMPONENTS (3)

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GENERAL INFORMATION
6. EXHAUST MANIFOLD AND GASKET