Ingersoll-Rand IR Series Instruction manual

1
Ingersoll-Rand Engine
Workshop Manual
Model Series
3IRH2N 3IRH8N
4IRH8N 4IRI8N
4IRI8T
Ingersoll-Rand
Portable Power
P.O. Box 868 – 501 Sanford Ave
Mocksville, N.C. 27028 P/N 22333660 (8/03)
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.

2
PREFACE
This manual describes the service procedures for the IR series engines of direct injection system that have
been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use.
Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in
this manual assumes the standard type engine, the specifications and components may partially be
different from the engine installed on individual work equipment (power generator, pump, compressor, etc.).
Please also refer to the service manual for each work equipment for details.
The specifications and components may be subject to change for improvement of the engine quality
without notice. If any modification of the contents described herein becomes necessary, it will be notified in
the form of correction information each time.

3
SAFETY LABELS
Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it
is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully
understand safety precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected
accident.
It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient
consideration for safety is required in addition to the matters marked . Especially for safety
precautions in a repair or maintenance job not described in this manual, receive instructions from a
knowledgeable leader.
Safety marks used in this manual and their meanings are as follows:
DANGER-indicates an imminently hazardous situation which,
If not avoided, WILL result in death or serious injury.
WARNING-indicates a potentially hazardous situation which, if not
avoided, COULD result in death or serious injury.
CAUTION-indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE-indicates that if not observed, the product performance or quality may not be guaranteed.

4
Safety Precautions
1. SERVICE AREA
Sufficient Ventilation
Inhalation of exhaust fumes and dust particles may be hazardous to ones
health. Running engines welding, sanding, painting, and polishing tasks
should be only done in well-ventilated areas.
Safe / Adequate Work Area
The service area should be clean, spacious, level and free from holes in
the floor, to prevent “slip” or “trip and fall” type accidents.
Bright, Safely Illuminated Area
The work area should be well lit or illuminated in a safe manner. For work
in enclosed or dark areas, a “drop cord” should be utilized. The drop cord
must have a wire cage to prevent bulb breakage and possible ignition of
flammable substances.
Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.

5
2. WORK – WEAR (GARMENTS
Safe Work Clothing
Appropriate safety wear (gloves, special shoes/boots, eye/ear protection,
head gear, harness’, clothing, etc.) should be used/worn to match the task
at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting
clothes around moving machinery. A serious accident may occur if caught
in moving/rotating machinery.
3. TOOLS
Appropriate Lifting / Holding
When lifting an engine, use only a lifting device (crane, jack, etc.) with
sufficient lifting capacity. Do not overload the device. Use only a chain,
cable, or lifting strap as an attaching device. Do not use rope, serious
injury may result.
To hold or support an engine, secure the engine to a support stand, test
bed or test cart designed to carry the weight of the engine. Do not
overload this device, serious injury may result
Never run an engine without being properly secured to an engine support
stand, test bed or test cart, serious injury may result.
Appropriate Tools
Always use tools that are designed for the task at hand. Incorrect usage of
tools may result in damage to the engine and or serious personal injury.
4. GENUINE PARTS and MATERIALS
Genuine Parts
Always use genuine INGERSOLL-RAND parts or INGERSOLL-RAND
recommended parts and goods. Damage to the engine, shortened engine
life and or personal injury may result.

6
5. FASTENER TORQUE
Torqueing Fasteners
Always follow the torque values and procedures as designated in the
service manual. Incorrect values, procedures and or tools may cause
damage to the engine and or personal injury.
6. Electrical
Short Circuits
Always disconnect the (-) Negative battery cable before working on the
electrical system. An accidental “short circuit” may cause damage, fire and
or personal injury. Remember to connect the (-) Negative battery cable
(back onto the battery) LAST
Charging Batteries
Charging wet celled batteries produces hydrogen gas. Hydrogen gas is
extremely explosive. Keep sparks, open flame and any other form of
ignition away. Explosion may occur causing severe personal injury.
Battery Electrolyte
Batteries contain sulfuric acid. Do NOT allow it to come in contact with
clothing, skin and or eyes, severe burns will result.
7. WASTE MANAGEMENT
Observe the following instructions with regard to hazardous waste
disposal. Negligence of these will have a serious impact on environmental
pollution concerns.
Waste fluids such as lube oil, fuel and coolant shall be carefully put
into separate sealed containers and disposed of properly.
Do NOT dispose of waste materials irresponsibly by dumping them
into the sewer, overland or into natural waterways.
Waste materials such as oil, fuel, coolant, solvents, filter elements
and batteries, must be disposed of properly according to local ordinances.
Consult the local authorities or reclamation facility.

7
8. FURTHER PRECAUTIONS
Fueling / Refueling
Keep sparks, open flames or any other form of ignition (match, cigarette,
etc.) away when fueling/refueling the unit. Fire and or an explosion may
result.
Hot Surfaces.
Do NOT touch the engine (or any of its components) during running or
shortly after shutting it down. Scalding / serious burns may result. Allow
the engine to cool down before attempting to approach the unit.
Rotating Parts
Be careful around moving/rotating parts. Loose clothing, jewelry, ties or
tools may become entangled causing damage to the engine and or severe
personal injury.

8
Precautions for Service Work
1.Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
2.Preparation for Service Work
Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history
of the engine.
Preceding service date
Period/operation hours after preceding service
Problems and actions in preceding service
Replacement parts expected to be required for service
Recording form/check sheet required for service
3.Preparation before Disassembly
Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts, and
parts expected to be required for replacement.
When disassembling complicated portions, put match marks and other marks at places not adversely
affecting the function for easy reassembly.
4.Precautions in Disassembly
Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface
defect, etc.
Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
Parts to be used again shall be washed and cleaned sufficiently.
Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel
injection pump.
5.Precautions for Inspection and Measurement
Inspect and measure parts to be used again as required to determine whether they are reusable or not.
6.Precautions for Reassembly
Reassemble correct parts in correct order according to the specified standards (tightening torques, and
adjustment standards). Apply oil important bolts and nuts before tightening when specified.
Always use genuine parts for replacement.
Always use new oil seals, O-rings, packing and cotter pins.
Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact
portions, and apply grease to oil seal lips.
7.Precautions for Adjustment and Check
Use measuring instruments for adjustment to the specified service standards.

9
How to Read this Manual
(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly,
inspection, adjustment and adjusting operation procedures for the IR series engines with direct injection
system.
Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and
alternator except for their installation.

10
2.How to Read the Explanations
An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section as
required for easy understanding of the mounted states of the components.
For the removal/installation of each part, the procedure is shown with the procedural step No. in the
illustration.
Precautions and key points for disassembly and reassembly of parts are described as points. In the
explanation for each point, detailed operation method, information, standard and precautions are
described. Description Example
The job contents are described in the disassembly procedure for Nos. not shown in the illustration.
•Disassembly procedure
1) Follow steps (1) to (15) of the cylinder head disassembly procedure.
2) Remove the cooling water pump.
3) Remove the crankshaft pulley. (Point 1) ←Operation point to be explained on a later page.
•Operation points
Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble: Service point required in both removal and installation.