Ingersoll-Rand 3IRL2N User manual

Book: 23076011 (4/07) Rev. B
3IRL2N
4IRQ2N
For Engine Models
Engine Operation Manual
4IRS2N
4IRS2T
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.
Revised (10-12)

3
Engine Information

Operating & Maintenance Manual Engine Information
4
Engine Safety Instructions
If you do not understand or have any doubts about any point in this instruction manual, please contact
your agent who can explain or give you a demonstration.
• Please also refer to the local and national regulations applicable to your region or country.
• Read the manuals supplied with the generating set carefully.
• Do not modify the engine.
• Do not smoke when refuelling the tank.
• Always wipe off spillage and store impregnated cloths in a safe place.
• Avoid refuelling when the engine is running.
• Never clean, lubricate or adjust a running engine (unless you are qualified to do so, in which
case great care should be taken to avoid injury).
• Do not attempt to make any adjustments unfamiliar to you.
• Ensure that the engine is placed in such a way so as to avoid toxic gas accumulation.
• Warn the people around to keep their distance during the operation.
• Do not wear loose-fitting clothing and do not go near operating machines. Note that fan
blades are not clearly visible when the engine is running.
• Do not run the engine without reinstalling the protective covers.
• Do not remove the radiator cap when the engine is hot or when the coolant is under pressure.
• Do not touch hot parts such as the exhaust pipe and do not put combustible materials on
them.
• Never use sea water or any other electrolytic or corrosive product in the cooling system.
• Never allow sparks or naked flames near the batteries because the electrolyte gases are
flammable. Battery acid can cause serious injury.
• Always operate the generating set from the control panel.
• If your skin is exposed to high pressure fuel (injector), consult a doctor immediately.
• Diesel fuel can, in some people, cause a skin reaction. Use protective gloves or a hand
cream.
• Disconnect the battery before undertaking any repair works to prevent accidental start-up of
the engine. Place a notice forbidding any starting attempts on the controls.
• ONLY use the correct engine barring techniques for manually rotating the crankshaft. Do not
attempt to rotate the crankshaft by pulling or levering the fan. This method can cause serious
personal injury, property damage or damage to the fan blade(s) leading to a premature fan
failure.
• Relieve all pressure in the air, oil and cooling systems before removing or disconnecting any
lines, fittings, hoses or connected items. Beware of possible pressure when disconnecting a

Engine Information Operating & Maintenance Manual
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device from a system under pressure. Do not check for pressure leaks with your hand. High
pressure oil or fuel can cause personal injury.
• The corrosion inhibitor contains alkali. Avoid any prolonged or repeated contact with the skin,
or eyes. Do not Swallow, In case of contact with the skin, thoroughly wash with water and
soap. In case of contact with the eyes, immediately and thoroughly rinse with water for at least
15 minutes. IMMEDIATELY CALL A DOCTOR. KEEP THE PRODUCT OUT OF REACH OF
CHILDREN.
• Always use tools that are in good condition. Make sure that you understand instructions
before taking any action.
• Never use petrol or other inflammable substances to clean the parts.
• Only install original parts.
• Any action on the equipment should be performed with the installation or equipment switched
off.
• Electrical connections must be carried out according to the standards and regulations in force
in your country.
• Do not use frayed or faulty cables.
• Engines with a turbocharger: Never start the engine without fitting the air filter. The rotating
compressor blades in the turbo charger can lead to serious personal injury. Foreign bodies
in the inlet pipe can lead to mechanical damage.
• Engines with an air heater (starting element) : Never use starting aerosol or other similar
product as a starting aid. Contact with the starting element can cause an explosion in the
intake manifold and lead to personal injury.
• Lubricating oil is toxic and dangerous if swallowed. Avoid prolonged or repeated contact with
the skin. Avoid inhaling these oil vapors. Read the instructions on the packaging.
• Anti-corrosion agents are toxic and dangerous if swallowed. Avoid contact with the skin and
eyes. Read the instructions on the packaging.
• Glycol is toxic and dangerous if swallowed. Avoid contact with the skin and eyes. Read the
instructions on the package.
• Some inhibiting oils are inflammable. Also, some are dangerous if inhaled. Ensure good
ventilation. Use a protective mask for the injection.
• Avoid contact of hot oil with the skin. Before any action, ensure that the system is no longer
under pressure. Never start or run the engine with the oil filler cap removed to avoid oil
splashing.
• Do not reverse the positive and negative battery terminals when fitting them. Reversing can
lead to serious damage to the electrical system. Refer to the electrical diagram.
• Use correct lifting points to lift the generating set. Always check that the lifting equipment is
in good condition and has a sufficient lifting capacity.
• If other equipment fitted on to the generating set changes its center of gravity, special lifting
devices may be necessary to maintain correct balance and safe working conditions.

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• Never carry out any work on the generating set when only supported by a lifting device.
•WARNING! The engine must not be operated in areas containing explosive products.
• The fuel filter must be replaced on a cold engine to avoid any risk of fire due to spillage of the
fuel onto the exhaust manifold. Always cover the alternator if it is placed under the fuel filters.
Fuel spillage can damage the alternator.
• Always protect your hands when checking for leaks. High pressure liquids can penetrate body
tissues and cause severe injury. They can contaminate blood.
• Always use recommended fuels. Using poor quality fuels can damage the engine. On a diesel
engine, incorrect fuel can lead to seizure of the control rod and engine over-speed with risks
of personal injuries and mechanical damage. Poor quality fuels can also lead to higher
maintenance costs.
• Engine exhaust gases are toxic. Do not operate the generating set in rooms which are not
ventilated.
• The electrical equipment (including connecting wires and plugs) must be defect free.

Engine Information Operating & Maintenance Manual
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Fuel, Oil and Coolant Specifications
When set to factory standards, these engines operate properly with a diesel fuel complying with one of
the following specifications :
.BS 2869: 1988, class A2
.BS EN590 : 1995, class 1
.ASTM D-975-77 : quality 2D
Use commercially available diesel fuel with a sulphur content lower than 0.5 %.
Gaseous emissions, measured during standard checks, always refer to a standard diesel fuel
recommended by the authorities in charge of these standards.
The fuel must be a distillate, and not a residual oil or a blend. The user is warned that, although engines
can operate with fuels not complying with the specifications mentioned above, this could lead to
excessive wear and damage.
CAUTION
!
Fuel injection equipment is manufactured in accordance within very precise
limits and the smallest foreign body will affect its efficiency.
It is essential to use fuel free from water and other impurities.
Note: To operate the genset at temperatures below 0°C (32°F), use an anti-parafining additive or use a
fuel preheater.
Example: ACCEL additive for cold weather. Recommended mixture ration: 1 litre for 1000 liters ofdiesel
fuel. Average operation of diesel engines guaranteed down to -18°C.
Features:
• Appearance: clear, dark red
• Flash point: above 55°C
• Viscosity at 20°C : around 10 cSt
• Non corrosive
• Does not color fuels
• Specific gravity at 15°C : 0.9
• Flow point: -20°C
• Ash content: nil
• Non toxic

Operating & Maintenance Manual Engine Information
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Recommended Oil Specifications
Quality
The oil must be suitable for oil changes as specified in the general maintenance schedule. The
temperatures mentioned in the Oil Viscosity Table below are ambient temperatures during engine start-
up. However, if operating ambient temperatures are much higher than the starting temperatures, a
compromise must be found and higher viscosity oil must be used providing the engine starts
satisfactorily.
Multi-grade oils can solve this problem provided that they have an appropriate specification. These
diesel engines must be used with heavy duty lubricating oil in compliance with the requirements of the
standards API CC, DEF2101D, Mil-I-2104C or Mil-L-46152A/B for L.E. + S.L + S.Q engines and API
CD for S.S engines. Straight mineral oils are not suitable, neither are oils of less detergency than
specified.
In new or reconditioned engines, 3rd series API CD or Mil-l-2104C/D oils can inhibit the running-in
process and are not suitable for engines used in light service cycles. These oils can be recommended
for engines operating with a high load factor, particularly with high ambient temperatures after the last
oil change. Note, they must be used when the fuel sulphur content exceeds 0.5%.
Viscosity
The following chart shows the correct oil viscosities for various ambient temperatures from cold start to
maximum operating levels.
CAUTION
!
Avoid mixing oils of different brands. In most cases, the various oil brands are
not compatible with each other, and when mixed, can seize parts such as piston
rings, cylinders, etc. or abnormally wear moving parts. It is preferable to stick
with one and the same brand of oil at successive service intervals.
Oil Viscosities Ambient Temperature Range
SAE 30 -5°C to 40°C (23°F to 104°F)
SAE 5W-20 -30°C to -5°C (-22°F to 23°F)
SAE 10W-30 -25°C to 40°C (-13°F to 104°F)
SAE 15W-40 -20°C to 50°C (-4°F to 122°F)

Engine Information Operating & Maintenance Manual
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Limiting requirements for engine oils
If a used oil analysis program is conducted in order to determine the condition of the oil, consult the
chart below. Change the oil if any of these requirements is not met.
Note:
• Oil change intervals depend to a great extent on fuel properties. Be sure to use only
recommended fuels.
• The limit of total base number is half of that of a new oil in case of a perchloricacid analysis
method.
Property Test
Method Limit
Viscosity cSt@100°C
(212°F) JIS K 2283 + 30% maximum of new oil
Total Base Number (Hcl) mgKOH/g JIS K
2501 2.0 minimum
Total Acid Number mgKOH/g +3,0%, maximum of new oil
Water Content Vol % JIS K
2275 0.2, maximum
Flash Point (coc) °C (°F) JIS K
2265 180 (356), minimum
Pentane Insolubles Wt% ASTM
D893 0.5, maximum
Pentane Insolubles
Coagulated Wt% 3.0, maximum

Operating & Maintenance Manual Engine Information
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Coolant Specifications
The coolant quality has a significant effect on the efficiency and life of the cooling system. The
recommendations below will help users to keep their cooling system in good condition with protection
against frost and/or corrosion.
Note: Basically, harmful chemical properties and substances contained in water (as coolant) must not
exceed the limits specificed; however they are tolerable up to the limits shown in the table below.
Item Chemical
Symbol Unit Limit Recommended Corrosion & Rust Scale Formation
pH, 25°C (77°F) - - 6.5 a 8.5 (6.5 a 8.0) 0 0
Electrical
conductivity, pH,
25°C (77°F)
-<400 (<250) 0 0
Total hardness Ca CO3PPM <100 (<95) - 0
M alkalinity PPM <150 (<70) - 0
Chlorine ion CI” PPM <100 (<100) -
Sulphuric acid ion SO PPM <100 (<50) 0 -
Total Iron Fe PPM <1.0 (<1.0) - 0
Sillica SiO2PPM <50 (-) - 0
Residue from
evaporation -PPM <400 (<250) - 0
2
4
2
4
/cm

Engine Information Operating & Maintenance Manual
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Recommended Types of Long Life Coolants (LLC)
All-season, non-amine LLC or equivalent are recommended.
Features of Recommended Brands
• None of amines (methyl amines, ethyl amines, n-propyl amines, etc., all being derivatives of
ammonia, NH3) are contained).
• Silicate and borate are not contained.
• Close to neutral on the pH scale, and hence, slightly basic (alkaline).
• Balanced additive ingredients, some being substitutes for amines.
• Long life. The coolant with 30% concentration.
WARNING
!
LLC is toxic and can cause personal injury if in contact with the skin or eyes. If
LLC enters the eyes, immediately and thoroughly rinse with water and seek
medical attention at once.
How to use non-amine Type LLC
(1) Engine coolant containing any of the recommended additives should be changed every two years.
Note: If any other LLC is used, refer to the coolant mixture chart displayed on the container.
(2) Proper concentration of LLC is from 30% to 60% year-round. Aim at a temperature level lower by
5°C (9°F) than the expected lowest temperature. An LLC with a concentration below 30% does not
provide sufficient corrosion protection. However, concentrations above 60% affect freeze protection
and heat transfer rates. When adding coolant, use LLC of the same concentration.
RECOMMENDED LLC CONCENTRATIONS (Reference)
Ambient temperature °C (°F) -10 (14) -20 (-4) -30 (-22) -45 (-49)
LLC concentration % 30 40 50 60

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PREVENTIVE MAINTENANCE
Although specific regular maintenance operations have been given in the maintenance schedule, you
are reminded that it is the environment in which the engine operates which defines the maintenance
schedule.
You must therefore realize that, if the engine operates under extreme conditions, intervals between
operations should be shortened. Use the maintenance schedule to establish your own schedule and
adapt it to your particular operating conditions.
DAILY MAINTENANCE CHECKS
These checks must be carried out every day or before every start-up (except repeat starts on the same
day).
• Check the oil level in the engine oil sump and top up if necessary.
• Check the fuel level and fill up if necessary.**
• Check the coolant level and top up if necessary.
• Check the pipe work** for leaks and deterioration.
• Check for unusual noises or vibration. **
• Check the oil level in the oil bath air cleaner (optional).
• Check for unrestricted air flow on the parts to be ventilated.
• Check that the control panel safety indicators and systems are operational.**
AFTER THE ENGINE HAS BEEN STARTED
• Check the colour of the exhaust gases (the emission of black gas indicates that the engine is
malfunctioning).
• Check for oil, fuel or coolant leaks.
• Check for unusual noises corning from the generating set.
• During repeat engine start-ups, checks can still be carried out: see texts followed by (**).

Engine Information Operating & Maintenance Manual
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Maintenance Schedule Every
Operations to be performed 50
hrs 100 hrs 250 hrs 400/ 500
hrs
800/
1000
hrs
2 yrs if
req’d
MOTOR
Check the degree of clogging of air filter x
Replace the lube oil and oil filter x x
Lubricate all the couplings x
Replace the fuel filter x
Adjust the valve clearance #
Clean and check the injectors #
Check condition/tension of v-belt x
Check the Preheating Glow Plugs #
Clean or change the air filter x
Check the starter and charge alternator #
Clean the radiator x
Check the injection pump (L.E. engines) #
Clean the generator set #
Retighten the nuts and bolts #
Drain the cooling system x
ALTERNATOR
Check the nameplate before carrying out any
maintenance or repair work or 3 mths or 12 mths or 12 mths
Check for unrestricted air flow x x
Check the insulation of the windings #
Check the bearings x #
Check the electrical connections x
Remove dust from the inside of the machine x
CONTROL PANEL
Operate genset on load for 15 minutes and check the safety indicators every 2 weeks
Check the tightness of electrical connections x
Remove dust if operating in dusty conditions x
Remove dust from inside and out and lightly
lubricate hinges and locks x
# = Operations require specialist knowledge and must be carried out by an engineer with special tools.

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This summary will help you keep a record of the maintenance performed on your generating
set. It must be filled in by the engineer undertaking the service work in accordance with the
general maintenance schedule
Spare Parts Changed (except Maintenance Parts)
Running
hours Date Maintenance performed Engineer Running hours Date Maintenance performed Engineer Running hours Date Maintenance performed Engineer
100 200 300
400 500 600
700 800 900
1 000 1 100 1 200
1 300 1 400 1 500
1 600 1 700 1 800
1 900 2 000 2 100
2 200 2 300 2 400
2 500 2 600 2 700
2 800 2 900 3 000
3 100 3 200 3 300
3 400 3 500 3 600
3 700 3 800 3 900
4 000 4 100 4 200
4 300 4 400 4 500
4 600 4 700 4 800
4 900 5 000 5 100
5 200 5 300 5 400
5 500 5 600 5 700
5 800 5 900 6 000
6 100 6 200 6 300
6 400 6 500 6 600
6 700 6 800 6 900
7 000 7 100 7 200
7 300 7 400 7 500
7 600 7 700 7 800
7 900 8 000 8 100
8 200 8 300 8 400
8 500 8 600 8 700
8 800 8 900 9 000
9 100 9 200 9 300
9 400 9 500 9 600
9 700 9 800 9 900
10 000 Start a new table from
10 100 running hours
Running
Hours Parts Running Hours Parts Running Hours Parts

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Description of Engine
1 Water Thermostat 13 Oil Filter
2 Lifting Eye 14 Oil Drain Plug
3 Charging Alternator 15 Dipstick
4 Fan 16 Crankcase Pulley
5 V-Belt 17 Oil Filler Neck
6 Oil Sump 18 Fuel Pump
7 Flywheel 19 Water Pump
8 Starter Motor 20 Oil Filler Neck
9 Exhaust Manifold 21 Governor
10 Injector 22 Fuel Feed Pump
11 Air Inlet Housing 23 Engine Serial No.
12 Water Drain Plug 24 Fuel Filter
25 Oil Pressure Plug

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Replacing the lube oil and oil filter
Only change the oil when the engine Is at operating temperature but stationary (lubricating oil
temperature of around 80 °C).
This operation is carried out when the engine is warm and stationary (around 80 °C).
- Remove the oil filler cap.
Two drain methods are available :
1st method: drain tap
- Place the free end of the flexible into a drain pan with a capacity equivalent to the oil sump,
and make secure.
- Open the drain tap and let the used oil drain out completely.
2nd method: drain tap
- Place the free end of the flexible pipe into a drain pan with a capacity equivalent to the oil
sump, and make secure.
- Open the drain tap if necessary with a spanner, then pump the used oil out with the hand
pump until the engine oil sump is completely empty.
CAUTION
!
Great care must be taken when draining hot oil. Risk of scalding. Collect
the used oil and avoid spillage. Used oil must be disposed in accordance
with pollution recommendations.
- Slacken the oil filter cartridge with a commercially available tool and unscrew it.
- Collect any leaking oil.
- Clean the seal surface of the filter holder.
- Lightly coat the rubber seal of the new lubricating oil filter cartridge with oil.
- Retighten the cartridge by hand until the seal is in place.
- Tighten the oil filter cartridge an extra 1 turn.
- Start the engine and wait for a few moments, then check that the oil pressure is correct and
that the oil filter does not leak.
- Stop the engine and check the oil level and top off with oil, if necessary.
Lubricate the couplings and grease all the mechanical couplings.
Replacing the fuel filter (Plastic see-through filter which cannot be dismantled)
- Remove the fuel inlet and outlet flexible pipes from the filter.
- Unclip the used filter then replace with a new one.
- Reinstall the flexible pipes and tighten the 2 clamps.

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- Start the engine to fill the fuel filter and bleed the air if necessary at the injection pump.
- Check for any fuel leaks. The operation is then complete.
Cartridge fuel filter
- Remove the cartridge with a filter wrench and apply a small amout of fuel to the o-ring of new
cartridge.
- Install new cartridge by hand. CAUTION: Do not add fuel to new cartridge.
- After replacing the cartridge, prime the fuel system.
Adjusting the valve clearance
-These operations require specialist knowledge and the use of special tools.
Checking and cleaning the injectors
- Checking the operation of an injector
A faulty injector will be indicated by engine misfire.
- To locate the faulty injector, run the engine at fast idle speed.
- Slacken then retighten in turn the high pressure pipe fitting on each injector.
- When the nut connecting the faulty injector is slackened, there will be no or little effect on
engine speed.
WARNING: Keep away from fuel sprays.
How to replace an injector
- Remove the fuel leak off pipe.
- Remove the nuts connecting the high pressure pipe from the injector to the injector pump
then remove the pipe. If necessary, remove the pipe clamps.
- Remove the injector assembly.
- Install a new injector assembly taking care not to block the injector.
- Reinstall the fuel leak off pipe and clamps if necessary.
- Operate the engine and check for combustion air and fuel leaks.
Checking the condition and the tension of the V-belt. Replacing the V-belt
- To check, retighten or replace V-belts, the engine must be stationary.
- Visually check the V-belt along all its surface and change it if damaged.
- In the case of new belts, check the tension after 15 running minutes and 50 running hours.
-To check the tension, remove the fan and belt guards.
- Measure the distortion obtained by pressing your finger on the longest straight part of the belt
when stationary.

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Tension of the belt
If necessary, readjust the tension of the belt and measure again.
To retighten or tighten the belt :
- Undo the charge alternator screws 1.
- Pull on the alternator until the correct belt tension is achieved.
- Retighten the alternator screws.
- Reinstall the guards.
To replace the belt
- Remove the fan and belt guards.
- Undo the charge alternator screws 1.
- Push on the alternator and remove the worn belt.
- Install a new belt and pull on the alternator until the correct tension is achieved.
- Retighten the alternator screws and check the belt tension.
- Reinstall the guards.

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Checking the preheating glow plugs requires specialist knowledge and the use of special tools.
Checking the injectors requires specialist knowledge and the use of special tools.
Exhaust Muffler
- Check the pipe for leaks. Check that there are no gas leaks or deterioration of the pipe work.
- Retighten the Mountings. Check and retighten if necessary, all mountings (engine, exhaust
outlet, exhaust mounting, connections, etc.).

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- Check for leaks. Visually check that the tank does not leak.
Fault Cause Action Fault Cause Action
The engine will
not start Blown fuse Replace Not enough Power Oil of Incorrect viscosity Change the oil
Start switch faulty Repair or replace Air filter element clogged Clean or replace
Starting speed too slow Recharge battery.
Check and replace
the starter motor
Fuel filter clogged Clean or replace
Oil of incorrect viscosity Change the oil Fuel injection pump
clogged Clean or replace
Mobile parts seized Repair Fuel Injectors faulty Clean or replace
Air in the delivery system Prime Wrong injection timing Adjust
Fuel tank empty Fill the tank Fuel of Incorrect quality Change the fuel
Fuel of incorrect quality Change the fuel Overheat Rinse the cooling
system andreplace
parts
Fuel filter clogged Clean or replace Valve clearance incorrect Adjust
Fuel Injection pump faulty Repair or replace Poor
compression(cylinders,
piston rings, etc, worn)
Repair or replace
Ignition control unit faulty Replace
Air filter element clogged Clean or replace
Fault Cause Action Fault Cause Action
Overheating Not enough coolant in the
system Add more coolant Air filter element clogged Clean or replace
Leaks in the cooling
system Retighten or repair Valve clearance incorrect Adjust
Slack fan belt Adjust Engine overloaded Reduce load
Air flow obstructed in the
radiator Remove obstruction Poor compression (cylinders, piston rings,
etc, worn)
Replace or repair
Water pump faulty Replace Fuel
consumption
too high
Fuel of incorrect quality Change the fuel
Fan faulty Replace Fuel injection pump faulty Replace or repair
Thermostat faulty Replace Fuel injectors faulty Replace or repair
High concentration of LLC Adjust the LLC
concentration Wrong injection timing Adjust
Air filter element clogged Clean or replace
Too much
white or blue
smoke
Too much oil in the engine Do not fillabovelevel
indicated Poor compression (cylinders, piston rings,
etc, worn)
Replace or repair
Oil viscosity too low Change the oil Oil
consumption
too high
Too much oil in the engine Do not fill above level
indicated
Thermostat faulty (coolant
temperature too low) Replace Oil viscosity too low Change the oil
Fuel injector faulty Repair or replace Leaks in the lubrication
system Replace or repair
Wrong injection timing Adjust Cylinders and piston rings
worn Repair or replace
Wrong fuel cetane number Change the fuel Valve stem seals worn Replace
Poor compression
(cylinders, piston rings,
etc, worn)
Repair or replace Not enough oil in the
engine Add more oil
Too much
black or gray
smoke
Fuel of incorrect quality Change the fuel Oil viscosity too low Change the oil
Fuel injection pump faulty Repair or replace Oil filter clogged Replace
Fuel injectors faulty Repair or replace Oil pump faulty Repair or replace
Wrong injection timing Adjust Relief valve faulty Repair or replace
Pressure switch faulty Replace