Ingersoll-Rand 4IRQ2N Operation & Maintenance Manual
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Ingersoll-Rand 4IRQ2N Operation & Maintenance Manual

Ingersoll-Rand 4IRQ2N Operation & Maintenance Manual

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Operation & Maintenance Manual
4IRQ2N & 4IRS2N DIESEL ENGINE
This m an u al contains im p o rtant safety inform ation.
D o n ot destroy th is m anual.
This m an u al m u st be availab le to the personn el w ho operate and m aintain th is m ach ine.
P.O . Box 868 - 501 Sanford Ave
M ocksville, N.C. 27028
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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Summary of Contents for Ingersoll-Rand 4IRQ2N

  • Page 1 This m an u al m u st be availab le to the personn el w ho operate and m aintain th is m ach ine. 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...
  • Page 2 C A L IFO R N IA P ro p o sitio n 65 Warning D iesel engin e exh au st an d som e o f its con stituents are kno w n to th e State o f C alifo rn ia to cause cancer, birth d efects, an d o ther reprodu ctive harm .

  • Page 3: Introduction

    In g erso ll-R an d E q u ip m en t E n g in e O w n er: Don’t wait until you need warranty or other service to m eet your local Ingersoll-Rand Distributor or Service Dealer.

  • Page 4: Engine Details

    Engine Details S4Q2 Water Thermostat Oil Drain Plug Lifting Eye Dipstick Charge Alternator Crankcase Pulley Oil Filler Neck V-belt Fuel Pump Oil sump Water Pump Flywheel Oil Filler Neck Starter Motor Governor Exhaust manifold Fuel Feed Pump Injector Engine Serial Number Air Inlet Housing Fuel Filter Water Drain Plug...

  • Page 5: Table Of Contents

    Table of Contents Introduction..............................3 Forward ..............................3 Engine Owner............................3 Engine Details ............................... 4 Safety Symbols ............................. 7 Safety ................................11 Fuels, Lubricants, and Coolant ........................15 Fuel specifications ........................15 Recommended oil Specifications........................ 15 Quality ..............................15 Viscosity .............................
  • Page 6 Check the pipes for leaks ......................27 Retighten mountings........................27 #These operations require specialist knowledge and must be carried out by a factory trained Ingersoll-Rand technician with special tools.Maintenance Record..........27 Maintenance Record ........................28 Engine Maintenance......................... 29 Checking the Oil Level........................29 Checking the Coolant level ......................

  • Page 7: Safety Symbols

    Safety Symbols Sym bols below point out potential safety hazards and provide im portant inform ation about this m achine. Read and understand. Heed warnings and follow instructions. If you do not understand, inform your supervisor. Prohibition/ M andatory Inform ation/Instructions WARNING WARNING - Read the WARNING - Do not open...
  • Page 8 WARNING - Battery WARNING - Do not perform WARNING - Diesel fuel is contains acid. Gases are m aintenance until all electrical flam m able. No open flam es or flam m able. No open flam es or power has been sparks.
  • Page 9 Safety Symbols Look fo r th ese sig ns on m achin es m an u factu red in N o rth A m erica, w hich poin t out poten tial hazard s to the safety of yo u an d o thers. R ead an d und erstand tho ro ug h ly.

  • Page 11: Safety

    Safety T his m achine is not designed for operatin g life-su stain in g eq uip m ent. It is equ ipped w ith a safety shutdow n system that w ill cause th e m ach in e to stop o p erating w henever a shutdow n cond ition is p resen t.
  • Page 12 E xercise extrem e caution w hen usin g bo oster battery. T o jum p battery, conn ect end s of one booster cable to the po sitive (+) term inal of each battery. C o nnect one en d of other cable to the negative (-) term in al of the b ooster battery an d other end to a ground connection aw ay from dead battery (to avoid a sp ark occu rring n ear any explosive gases that m ay b e p resent).
  • Page 13 D isable Start Control - Before performing any service or maintenanceoperation , alw ays discon nect b attery cab les to p reven t accid en tal start- u ps. U se extreme care to avoid contacting hot surfaces (engine exhaust m anifold and pipin g).
  • Page 14 H A ZA R D O U S S U B STA N C E P R E C A U TIO N Ensure that adequate ventilation of the cooling system and exhaust gases is m aintained at all tim es. The following substances are used in the m anufacture of this machine and m ay be hazardous to health if used incorrectly.

  • Page 15: Fuels, Lubricants, And Coolant

    Fuels, Lubricants, and Coolant Fuel 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 ...

  • Page 16: Viscosity

    In new or reconditioned engines, 3 series API CD or MIL-L2104C/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.

  • Page 17: Limiting Requirements For Engine Oils

    Limiting Requirements For Engine Oils If a used oil analysis program is conducted in order to determine the condition of the oil, consult the char 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.

  • Page 18: Coolant Specifications

    /or corrosion. Coolant Quality To contact the quality of your coolant, contact you local Ingersoll-Rand dealer. Coolant Specifications Note: Basically, harmful chemical properties and substances contained water (as coolant) must not exceed the limits specified by the manufacturer;...

  • Page 19: How To Use Non-Amine Type Llc

    Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environm ental or recycling center, or from your Ingersoll-Rand distributor or servicing dealer. Capacity of Cooling and Lubricating Systems...

  • Page 20: Engine Operating Guidelines

    Engine Operating Guidelines Follow the instructions below in order to avoid problems during the first operation of the unit. Any failure to comply with these instructions could lead to injury or serious damage. The various capacities of the systems that contain fluids are listed above. Engine Check the oil level in the engine sump and top off or fill as necessary.

  • Page 21: Coolant

    Coolant Check the coolant level and top off with water or fill with the specified coolant (listed above) if necessary. Check hoses and pipes for leaks. IMPORTANT: Filling the cooling system Particular care should be taken during this operation. Note, during filling, the escaping air trapped in the system can indicate that the system is full.

  • Page 22: Fuel

    Fuel Use only clean and filtered fuel complying the specifications listed above. Fill tanks and check lines and fittings for leaks. Crank the engine using the starter motor. Do not crank the engine using the start motor for more than 30 seconds. Bleed the fuel pump by disconnecting the outlet fuel line until air free fuel flows out.

  • Page 23: Starting The Engine

    Additionally, your Engine m ay be fitted with a block heater, and increased capacity battery and/or lower viscosity oil m ay also be used. See your local Ingersoll-Rand distributor or servicing dealer for recom m endations.

  • Page 24: Using A Booster Battery Or Charger

    Using a Booster Battery or Charger A 12-volt booster battery can be connected in parallel with battery (ies) on the unit to aid in cold weather starting. ALW AYS use heavy-duty jum per cables. C A U T IO N : G as g iven o ff b y b attery is exp lo sive.

  • Page 25: Checks, Adjustments And Maintenance Procedures To Be Carried Out After The First 50 Running Hours

    Carried Out After The First 50 Running Hours NOTE: This the first compulsory maintenance call (other than daily and monthly inspections) to be carried out by your Ingersoll-Rand dealer. Before performing any operation on the generating set, ensure that cannot be started.

  • Page 26: Preventive Maintnenace

    Use the following schedule to establish your own schedule and adapt it to your particular operating conditions. If you are unsure of the need to shorten the recommended maintenance periods, contact your local Ingersoll-Rand dealer. Before any maintenance operations occur on the engine, disconnect the battery to prevent inadvertent starting.

  • Page 27: General Maintenance Schedule

    General Maintenance Schedule The operations indicated below must be carried out at the earliest service period reached, in hours or in months. To be performed every MAINTENANCE TO BE PERFORMED 1000 Required Engine Check the degree of clogging of the air filter ●...

  • Page 28: Maintenance Record

    Maintenance Record This summary will help you keep a record of the maintenance performed on you engine. It must be filled in by the individual undertaking the service work in accordance with general maintenance guide. Running Date Maintenance Technician Running Date Maintenance Technician...

  • Page 29: Engine Maintenance

    Engine Maintenance Checking the Oil Level  Remove the engine oil sump dipstick (1), and then wipe it with a clean cloth.  Fully reinsert the dipstick and then remove it to visually check the oil level.  The correct oil level is situated between the max and min marks on the dipstick.

  • Page 30: Replacing The Lube Oil And Oil Filter

    Replacing the Lube Oil and Oil Filter Start and run the engine to operating temperature. Remove the oil filler cap. Two drain methods are available: Drain tap:  Place the fee end of the flexible pipe into a drain pan with a capacity equivalent to the oil sup, and make secure.

  • Page 31: Replacing The Fuel Filter

     After replacing, prime the fuel system. Adjusting the Valve Clearnance This operation requires special knowledge and use of special tools, contact your local Ingersoll-Rand dealer for this service. Checking and Cleaning the Injectors A faulty injector will be indicated by engine misfire.

  • Page 32: How To Replace An Injector

    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. ...

  • Page 33: Checking The Condition And The Tension Of The V-Belt, Replacing The V-Belt

    Checking the Condition and the Tension of the V-belt, Replacing the V-Belt To check, retighten or replace V-belts, then engine must not be running. Visually check the V-belt along its entire surface looking for cracks and wear and change it if it is excessively worn or damaged In the case of new belts, check the tension after 15 running minutes and 50 running hours.

  • Page 34: Checking The Preheating Glow Plugs

    O , is to rn , o r visib ly d irty. NOTE: Refer to m anufacturers’ instructions for servicing air cleaners not supplied by Ingersoll-Rand. If engine is NOT equipped with an air restriction indicator, replace air filter elem ent every 500 hours of operation or every 12 m onths, whichever occurs first.

  • Page 35: Cleaning The Radiator And The Fan Blades

    Clean the fan blades with a clean cloth. Change the fan if the axial and radial play is excessive or if the blades are cracked. Refit the fan guard. Checking the injectors This operation requires special knowledge and use of special tools, contact your local Ingersoll-Rand dealer for this service.

  • Page 36: Lubricating The Water Pump

    Lubricating the water pump Lubricate with 20 grams (0.7 oz) of grease. Retightening Fasteners Check for loose fasteners and retighten as necessary. Draining the Cooling System The cooling system is pressurized and great care must be taken when removing the radiator cap on a hot engine.

  • Page 37: Filling The Cooling System

     Fill the cooling system with a cleaning solution that does not chemically attack rubber and metal surfaces. Operate the engine for 15 minutes, then stop it and drain the cleaning solution.  Fill the system with clean water and rinse with water. Filling the cooling system: In some cases, an air bubble can form during filling of the system, giving a wrong indication of the level.

  • Page 38: Troubleshooting

    Troubleshooting Engine Fault Cause Action Blown Fuse Replace Start switch faulty Repair or replace Recharge battery. Check and Starting speed too slow replace starter motor Oil of incorrect viscosity Change oil to correct grade Mobile parts seized Repair Air in the fuel delivery system Prime Engine will not start Fuel tank empty...

  • Page 39: Fault

    Fault Cause Action Air filter element clogged Clean or replace Adjust Valve clearance incorrect Too much black or gray Engine overloaded Reduce load smoke Poor compression (cylinders, Repair or replace piston rings, etc, worn) Fuel of incorrect quality Change the fuel Fuel injection pump faulty Repair or replace Fuel injectors faulty...

  • Page 40: Specifications

    Specifications General Engine Specifications—S4Q2 Bore x Stroke 88 X 103 m m Num ber of Cylinders Displacem ent 2.505 L Com bustion System Swirl Cham ber – IDI Dry W eight kg / lbs. 195 / 430 Start System Electric start with cell starter Fuel Oil Diesel fuel oil (ASTM No.

  • Page 41: General Engine Specifications-S4S

    General Engine Specifications—S4S Bore x Stroke 94 x 120 Num ber of Cylinders Displacem ent 3.331 L Com bustion System Swirl Cham ber – IDI Dry W eight kg / lbs. 245 / 540 Start System Electric start with cell starter Fuel Oil Diesel fuel oil (ASTM No.

  • Page 42: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS Manual American Petroleum Institute ASTM American Society of Testing and Materials ºC Celsius Depression ºF Fahrenheit ft-lb Foot – Pound Water Kilograms Kilowatts Liter per hour Liter per second Meter Millimeter Cubic Meter per second mm H Millimeters of water Newton-meter Pound per square inch...

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