Ingersoll-Rand IR Series Gebrauchsanweisung

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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