Page 1 Model Series 3IRH2N 3IRH8N 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 4IRH8N 4IRI8N to Ingersoll-Rand Company in this manual is historical or nominative...
Page 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.).
Page 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.
Page 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”...
Page 5 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.
Page 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.
Page 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.
Page 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.
Page 9 (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...
Page 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.
Page 11 Contents omitted in this manual Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual work: 1) Jacking up and lifting 2) Cleaning and washing of removed parts as required 3) Visual inspection 3.Definition of Terms [NOTICE]: Instruction whose negligence is very likely to cause an accident.
Page 12: Table Of Contents
CONTENTS 1. General ................................1.1 Engine Nomenclature..........................15 1.2 Specifications ............................15 1.3 Fuel Oil, Lubricating Oil and Cooling Water ................... 21 1.3.1 Fuel oil ............................. 21 1.3.2 Lubricating oil ..........................22 1.3.3 Cooling water........................... 22 1.4 Engine External Views ........................... 23 1.5 Structural Description ..........................
Page 13 4.3.2 Disassembly procedure:........................90 4.3.3 Reassembly procedure: ........................90 4.3.4 Servicing points ..........................91 4.3.5 Parts inspection and measurement....................94 4.3.6 Oil seal replacement........................96 4.3.7 Camshaft bushing replacement....................... 96 4.4 Cylinder Block ............................. 97 4.4.1 Components ............................ 97 4.4.2 Disassembly procedure:........................97 4.4.3 Reassembly procedure: ........................
Page 14 8.6.2 Reassembly........................... 141 8.7 Handling after Disassembly and Reassembly..................144 8.7.1 Instructions for turbocharger installation ..................144 8.8 Troubleshooting............................ 145 8.8.1 Excessively exhaust smoke ......................145 8.8.2 White smoke generation........................ 145 8.8.3 Sudden oil decrease........................146 8.8.4 Decrease in output ........................146 8.8.5 Poor (slow) response (starting) of turbocharger................
Page 15: General
Atmospheric condition: Room temp. 25 ° C, Atmospheric press. 100 kPa (750mm Hg), Relative humidity 30% Fuel temp: 25 ° C (Fuel injection pump inlet) With cooling fan, air cleaner, exhaust silencer (Ingersoll-Rand standard parts) After running-in hours. Output allowable deviation: ±3%...
Page 16 1.3IRH2N Engine name Unit 3IRH2N Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore x stroke mmxmm 82x84 Displacement 1.331 Revolving 1500 1800 speed Continuous rating 12.0 Output (hp) (13.5) (16.3) Revolving 1500...
Page 17 2.3IRH8N Engine name Unit 3IRH8N Engine specification class Type Vertical, in-line, 4-cylinder, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore x stroke mmxmm 88x90 Displacement 1.642 Revolving 1800 speed Continuous 12.3 rating 14.8 Output (16. (hp) (20.1) Revolving 1800...
Page 18 3.4IRH8N Engine name Unit 4IRH8N Engine specification class Type Vertical, in-line, 4-cylinder, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore x stroke mmxmm 88x90 Displacement 2.190 Revolving 1500 1800 speed Continuous rating 16.4 19.6 Output (hp) (22.3) (26.7) Revolving...
Page 19 4.4IRI8N Engine name Unit 4IRI8N Engine specification class Type Vertical, in-line, 4-cylinder, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore x stroke mmxmm 98x110 Displacement 3.318 Revolving 1500 1800 speed Continuous rating 30.9 36.8 Output (hp) (42.0) (50.0) Revolving...
Page 20 5.4IRI8T Engine name Unit 4IRI8T Engine specification class Type Vertical, in-line, 4-cylinder, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore x stroke mmxmm 88x110 Displacement 3.318 Revolving 1500 1800 speed Continuous rating 37.9 45.6 Output (hp) (51.5) (62.0) Revolving...
Page 21: Fuel Oil, Lubricating Oil And Cooling Water
1.3 Fuel Oil, Lubrica ting Oil and Cooling Water 1.3.1 Fuel oil IMPORTANT: Only use the recommended fuel to obtain the best engine performance and prevent damage of parts, also prevent air pollution. (1) Selection of fuel oil Use the following diesel fuels for best engine performance: BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard, JIS.
Page 22: Lubricating Oil
(1) Selection of engine lube oil Use the following engine oil: Ingersoll-Rand Pro-Tec (15W-40) Engine Oil for optional Extended Engine Warranty. API classification ---------- CI-4, CH-4, CG-4, CF-4, CF/SL, SH (Standards of America Petroleum Institute) SAE viscosity...
Page 23: Engine External Views
1.4 Engine External Views...
Page 24: Structural Description
1.5 Structural Descript ion...
Page 25: Exhaust Gas Emission Regulation
1.6 Exhaust gas emi ssion regulation The US EPA, CALIFORNIA ARB and/or the 97/68/EC Directive have certified the engines in this manual. California Proposition 65 Warning Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Page 26: Engine Identification
1.6.2 Engine identification (1) Emission control labels of US EPA EPA label for constant speed engines EPA label for variable speed engines (2) Emission control label for both EPA and ARB...
Page 27: Guarantee Conditions For The Epa Emission Standard
1.6.3 Guarantee Condition s for the EPA Emission Standard The following guarantee conditions are set down in the operation manual. In addition to making sure that these conditions are met, check for any deterioration that may occur before the required periodic maintenance times.
Page 28 (4) Perform maintenance without fail. Note: Inspections to be carried out by the user and by the maker are divided and set down in the “List of Periodic Inspections” and should be checked carefully. (5) Maintenance period and Quality guarantee period for exhaust emission related parts The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period as shown in the below table.
Page 29: Inspection And Adjustment
2. Inspection and Adjustment 2.1 Periodic Mainten ance Schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection...
Page 30: Periodic Inspection And Maintenance Procedure
2.2 Periodic Inspect ion and Maintenance Procedure 2.2.1 Check before Daily O peration Be sure to check the following points before starting an engine every day. Inspection Item Visual inspection of engine outside Fuel Inspection Oil Inspection Cooling Water Inspection Accelerator Alarm device and Panel (1) Visual check around engine.
Page 31 (Unit: liter) Model Total volume (L) Effective volume (L) 3IRH2N 3IRH8N 4IRH8N 4IRI8N 10.5 Engine oil capacity may differ from the above volume depending on an engine installed on a machine unit. (b) Replenishing oil pan with engine oil If the remaining engine oil level is low, fill the oil pan with the specified engine oil to the specified level through the filler port.
Page 32: Inspection After Initial 50 Hours Operation
IMPORTANT: If the cooling water runs short quickly or when the radiator runs short of water with the sub-tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the sub-tank water level during operation is not abnormal. The increased water in the sub-tank returns to the radiator when the engine is cooled down.
Page 33 In early period of use, the engine oil gets dirty rapidly because of the initial wear of internal parts. Replace the engine oil earlier. Engine oil filter should also be replaced when the engine oil is replaced. Engine oil and engine oil filter replacing procedures are as follows.
Page 34 (2) Checking and adjusting radiator fan V-belt When there is not enough tension in the V-belt, the V-belt will slip making it impossible for the alternator to generate power and cooling water pump and cooling fan will not work causing the engine to overheat. Check and adjust the V-belt tension (deflection) in the following manner.
Page 35: Inspection Every 50 Hours
2.2.3 Inspection every 50 hours Be sure to check the following points every 50 hours operation. Inspection Item Draining of the fuel tank Draining of the oil/water separator Bleeding the fuel system Battery Inspection (1) Draining of the fuel tank 1) Prepare a waste oil container.
Page 36 (3) Bleeding the fuel system Bleed the fuel system according to the following procedures. When there is air in the fuel system, the fuel injection pump will not be able to function. 1) Check the fuel oil level in the fuel tank. Refuel if insufficient.
Page 37 Battery structure (1) Electrolyte level Check the level of fluid in the battery. When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode.
Page 38 (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20°C as the standard. Since the specific gravity increases or decreases by 0.0007 when the temperature varies by 1°C, correct the value according to the equation below.
Page 39: Inspection Every 250 Hours Or 3 Months
2.2.4 Inspection every 250 hours or 3 months Be sure to check the following points every 250 hours or 3 months operation, whichever comes first. Inspection Item Oil and filter replacement Inspection and cleaning of radiator fin Adjustment of governor lever and accelerator device Air cleaner element cleaning Fan belt tension inspection and adjustment (1) Oil and filter replacement (The second replacement and after)
Page 40 (3) Adjustment of governor lever and accelerator device The governor lever and accelerating devices (accelerating lever, pedal, etc.) of the machine unit are connected by an accelerating wire or rod. If the wire becomes stretched or the connections loose, the deviation in the position may result and make operation unsafe.
Page 41 3) Blow air [0.29 0.49MPa (3.0 5.0kgf/cm from inside the element to blow dust off as shown in the illustration right. Apply the air blowing pressure as low as possible so as not to damage the element. If having the air cleaner with double elements, never remove and clean the inner element.
Page 42: Inspection Every 500 Hours Or 6 Months
Applicable fuel filter Part No. 3IRH2N 22226369 4IRH8N 4IRI8T 22226377 5) Bleed the fuel system. Refer to 2.2.3.(3) IMPORTANT: Be sure to use genuine Ingersoll-Rand part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shortens engine life.
Page 43 (3) Cleaning oil/water separator Periodically wash the oil / water separator element and inside cup with clean fuel oil. 1) Prepare a waste oil container. 2) Close the fuel cock. 3) Loosen the drain cock and drain. Refer to 2.2.3.(2) 4) Turn the retaining ring counter-clockwise and remove the cup.
Page 44: Inspection Every 1,000 Hours Or One Year
2.2.6 Inspection every 1,0 00 hours or one year Be sure to check the following points every 1,000 hours or one year operation, whichever comes first. Inspection Item Replacing cooling water Washing turbocharger blower Injection pressure and spray pattern of fuel injection valve Measuring and adjusting Valve Clearance (1) Replacing cooling water Cooling water contaminated with rust or water scale...
Page 45 (2) Washing turbocharger blower When engine speed seems sluggish or the exhaust color looks poor, the blades of the turbocharger-blower may be dirty. Wash the turbine blower in such a case. (a) General items 1) As for washing, use washing liquid and clear water. 2) Washing time is the time when about 10% of the boost pressure decreases more than that of usual operation state as a standard.
Page 46 (3) Inspection and adjustment: Injection Pressure and Spray Pattern of Fuel Injection Valve Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it.
Page 47 [Informative: Fuel injection valve structure] (b) Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness. Seat oil tightness check After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1.96 Mpa(20kgf/cm ), and check to see that oil does not drip from the tip end of the nozzle.
Page 48 Spray and injection states Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection. If normal injection as shown below cannot be obtained, replace the fuel injection valve. No extreme difference in angle( ) No extreme injection angle difference( ) Finely atomized spray Excellent spray departure...
Page 49 (4) Measuring and adjusting Valve Clearance Make measurement and adjustment while the engine is cold. (a) Valve clearance measurement 1) Remove the bonnet above cylinder head. 2) Set the No.1 cylinder in the compression TDC Turn the crankshaft to bring the piston of the No.1 cylinder to its compression top dead center while watching the rocker arm motion, timing scale and the top mark position of the crankshaft...
Page 50 In case of 3-cylinder engines, turn the crankshaft 240° and make adjustment for the No.3 cylinder. Then adjust the No.2 cylinder in this order. The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead center after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240°...
Page 51 Push the bridge head so that a valve bridge and two valve stem heads may contact each other uniformly, and adjust an adjusting bolt so that a gap of the valve stem head may become 0. Tighten a locknut after a valve bridge is fixed with a wrench.
Page 52: Inspection Every 2000 Hours Or 2 Years
2.2.7 Inspection every 200 0 hours or 2 years Be sure to check the following points every 2,000 hours or two years operation, whichever comes first. Inspection Item Cleaning of cooling water system, inspection of parts and maintenance Inspection and replacement of fuel pipe and cooling water pipe Lapping the intake and exhaust valves Fuel injection timing inspection and adjustment (1) Cleaning of cooling water system, inspection of parts and maintenance...
Page 53 [NOTICE] Ask Ingersoll-Rand about the fuel Injection angle by offering the fuel pump number when the fuel injection angle on the fuel pump is hard to read. Fuel injection angle difference (cam angle) = (the fuel injection angle of a reassembled fuel pump)
Page 54 (c) Tighten the installation nut of a pump drive gear. Tightening torque Lubricating oil application Model (thread portion, and seat surface) Nm(kgf m) 3IRH2N 8N 78 88 (8 9) Not applied 4IRI8N-8T 113 123 (11.5 12.5) (Footnote) Fuel injection timing is adjusted by changing the installation angle of the fuel pump.
Page 55: Adjusting The No-Load Maximum Or Minimum Speed
2.3 Adjusting the no-load maximum or minimum speed 1) After warming the engine up, gradually raise the speed and set it at the no-load maximum revolution. 2) If the no-load maximum revolution is out of the standard, adjust it by turning the high idle limiting bolt.
Page 56: Sensor Inspection
2.4 Sensor Inspection 2.4.1Oil pressure switch Disconnect the connector from the oil pressure switch. Keep the voltammeter probes in contact with the switch terminal and cylinder block while operating the engine. If is abnormal if circuit is closed. 2.4.2 Thermo switch Place the thermo switch in a container filled with antifreeze or oil.
Page 57: Radiator Cap Inspection
2.6 Radiator cap inspection Install the radiator cap on the cap tester. Set the tester pressure to 0.09±0.015Mpa (0.9±0.15kgf/cm and see that the cap is opened. If the cap does not open, replace the cap since it is abnormal. 2.7 Thermostat Inspection Place the thermostat in a container filled with water.
Page 58: Adjusting Operation
2.8 Adjusting Operation Perform the adjusting operation of a engine as follows after the maintenance job: 1) Supply the fuel oil, lubricating oil and cooling water. Note: Check the levels of the lubricating oil and cooling water again after test running (for about 5 minutes) and add as required.
Page 59: Troubleshooting
3. TROUBLESHOOTING 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting.
Page 61: Quick Reference Table For Troubleshooting
3.2 Quick Reference Table for Troubleshooting The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life. Poor Insufficient Cooling...
Page 62 Poor Insufficient Cooling Trouble symptom Starting failure exhaust Hunting Lubricating oil engine output water intake color Engine starts Exhaust During but stops color work soon. Exhaust Corrective action smoke Cause Excessive cooling effect of radiator Defective thermostat (kept closed) (See 2.2.7 in Chapter2.) Defective thermostat (kept opened)(See 2.2.7 in Chapter2.) Insufficient cooling effect of radiator or slipping fan belt (See 2.2.2-2) in Chapter2.)
Page 63 Poor Insufficient Cooling Starting failure exhaust Hunting Lubricating oil engine output water intake color Engine starts Exhaust During Trouble symptom but stops color work soon. Exhaust Corrective action smoke Cause Clogged air filter Clean. (See 2.2.4 in Chapter2.) Engine used at high temperatures or at high altitude Study output drop and load matching.
Page 64: Troubleshooting By Measuring Compression Pressure
3.3 Troubleshooting by measuring Compression Pressure Compression pressure drop is one of major causes of increasing blow-by gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors: 1) Degree of clearance between piston and cylinder 2) Degree of clearance at intake/exhaust valve seat 3) Gas leak from nozzle gasket or cylinder head gasket...
Page 65 (7) Engine speed and compression pressure (for reference) (8) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective action Air cleaner element Clogged element Clean the element.
Page 66: Disassembly, Inspection And Reassembly Of Engines
4. Disassembly, Inspection and Reassembly of Engines 4.1 Complete disassembly and reassembly 4.1.1 Introduction Make preparation as follows before starting engine inspection and service: 1) Fix the engine on a horizontal base. Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work. 2) Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc.
Page 67: Special Service Tools
4.1.2 Special service tools (9) Special Tools Tool name Applicable model and tool size Illustration Valve guide tool Model (for extracting valve guide) 3IRH2N 4IRI8N (8T) 3/4IRH8N Valve guide tool Model (for inserting valve guide) 3IRH2N 3/4IRH8N 4IRI8T Connecting rod Model bushing replacer (for removal /...
Page 68 Tool name Applicable model and tool size Illustration Stem seal inserter (for inserting stem Model seal) 3IRH2N 15.1 15.8 4IRH8N 16.2 13.5 18.8 Filter wrench (for removal / installation of L.O. filter) Available on the market Camshaft bushing Model tool (for extracting camshaft bushing) 3/4IRH2N...
Page 69 Tool name Applicable model and tool size Illustration Piston insertion tool (for inserting piston) *The above piston insertion tool is applicable to 60-125 mm diameter pistons. Piston ring replacer (for removal / installation of piston ring) Available on the market...
Page 70 (10) Measuring instruments Instrument name Application Illustration Measurements of shaft bending, and strain and gap of surfaces Dial gage Measurements of narrow or deep portions that cannot be measured by dial gage Test indicator For holding the dial gage when measuring using a dial gage, standing angles adjustable Magnetic stand...
Page 71 Instrument name Application Illustration For measuring shaft bend V-block For tightening nuts and bolts to the specified torque Torque wrench For measuring gaps between ring and ring groove, and shaft joints during assembly Thickness gage For checking water leakage Cap tester For checking concentration of antifreeze and the battery electrolyte charge status Battery coolant tester...
Page 72 Instrument name Application Illustration For measuring revolution by contacting the mortise in the revolving shaft Contact type Speedometer For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft Photoelectric type For measuring resistance, voltage and continuity of electrical circuits Circuit tester For measuring compression pressure...
Page 73: Complete Disassembly
4.1.3 Complete disassembly Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application. Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed. Step Removal Parts Remarks...
Page 74 Step Removal Parts Remarks 1) Disconnect cooling water pipe from the cooling water pump. 2) Remove thermostat assembly. 3) Remove cooling water pump. 1) Remove cylinder head tightening bolt. 1) Lay a cardboard or the like on the floor and 2) Remove cylinder head assembly.
Page 75 Step Removal Parts Remarks 1) Remove lubricating oil pump. 1) Remove starting motor from flywheel housing sing. 1) Remove flywheel mounting bolt. 1) Carefully protect the ring gear from damage 2) Remove flywheel. mage. 1) Remove flywheel housing. 1) Carefully protect the oil seal from damage. 2) Remove oil seal case with a screwdriver or the like by utilizing grooves on both sides of oil seal case.
Page 76 Step Removal Parts Remarks 1) Remove main bearing cap bolt. While 1) Before extracting crankshaft, measure the shaking main bearing cap, remove main bearing side gap around it. cap together with lower main bearing metal. 2) Extract crankshaft, taking care not to damage 3) Remove upper main bearing metal.
Page 77: Precautions Before And During Reassembly
4.1.4 Precautions before and during reassembly To reassemble engine components, reverse the procedure of disassembly. However, follow the precautions below and the precautions from in chapter 4 to in chapter 7 particularly before and during reassembly. (11) Cleaning the component Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft.
Page 78: Cylinder Head: Disassembly, Inspection And Reassembly
Cylinder Head: Disassembly, Inspection and Reassembly 4.2.1 Components (2-valve cylinder head) 4.2.2Disassembly procedure: Disassemble in the order of the numbers shown in the illustration. 1) Remove the alternator assy. (Point1) 2) Remove the fan, pulley and V belt. 3) Remove the thermostat case. (Point2) 4) Remove the fuel filter and fuel oil piping.
Page 79: Reassembly Procedure
4.2.3Reassembly procedure: Reverse order of the disassembly procedure. 4.2.4Servicing points Point 1 [Disassemble] Loosen the mounting bolt while supporting the alternator. Do not tilt the alternator toward the cylinder block in haste since it may damage the alternator or pinch a finger.
Page 80 Point 2 [Reassemble] Check the thermostat function. (See3.9 in Chapter 3 for the check procedure.) Pont 3 [Reassemble] Replace the fuel filter element with a new one. [Disassemble] Cover the fuel pipe opening with tape to prevent intrusion of foreign matters. Point 4 [Reassemble] Replace the oil filter with a new one.
Page 81 Point 7 [Disassemble] Keep the removed push rods by attaching tags showing corresponding cylinder Nos. [Reassemble] Always apply oil to the contact portions of the push rods and clearance adjusting screws. Point 8 [Disassemble] Loosen the cylinder head bolts in two steps in the illustrated order.
Page 82 Point 10 [Disassemble] When removing each intake/exhaust valve from the cylinder head, use a valve spring compressor (see 11.1-4 in Chapter 11) and compress the valve spring and remove the valve cotter.) Keep each removed intake/exhaust valve after attaching a tag showing the corresponding cylinder No.
Page 83: Parts Inspection And Measurement
4.2.5 Parts Inspection and measurement (13) Cylinder head Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove carbon deposit and bonding agent, and check the surface state. (a) Appearance check Check mainly discoloration and crack. If crack is suspected, perform color check.
Page 84 (14) Valve guide Mainly check damage and wear on the inside wall. Apply the service part code when replacing a part. Model Service part code Suction 124060-11800 3IRH2N (2-valve) Exhaust 119802-11810 Suction 120130-11860 3/4IRH8N (2-valve) Exhaust 129150-11810 4IRI8T Suc./Exh. 129907-11800 (4-valve) Valve stem clearance Model...
Page 85 (15) Intake/exhaust valve Mainly clean and check damage and wear at the valve stem and seat. (a) Seat contact: See (1)-(d) above. (b) Stem outside diameter: See (2) above. (c) Valve head thickness Model Part Standard Limit Intake 1.34 0.50 3/4IRH2N-8N Exhaust 1.45...
Page 86 (17) Valve rocker arm Mainly inspect valve head cap contact surface, inside surface defects and wear. Slight surface defects shall be corrected with an oilstone. Model Items Standard Limit Arm hole 16.00 16.02 16.07 diameter 3/4IRH2N-8N Shaft O.D. 15.97 15.98 15.94 Clearance 0.016 0.054...
Page 87: Valve Seat Correction
4.2.6 Valve seat correction [NOTICE] Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder or compound.
Page 88: Valve Guide Replacement
4.2.7 Valve guide replacement 1) Use a valve guide extraction tool(12.1-1 in Chapter 12) and extract the valve guide from the cylinder head. 2) Put liquid nitrogen or ether (or alcohol) with dry ice added in a container and put the valve guide for replacement in it for cooling.
Page 89: Valve Stem Seal Replacement
4.2.8 Valve stem seal replacement Always use a new seal after the intake/exhaust valve is disassembled. Since the one for the exhaust valve is marked with yellow paint, do not confuse the intake and exhaust valves. 1) Apply engine oil to the lip. 2) Push with the inserting tool (Refer to No.5 of 4.1.2 in Chapter 4) for installation.
Page 90: Gear Train And Camshaft
Gear Train and Camshaft 4.3.1 Components 4.3.2 Disassembly procedure: Disassemble in the order of the numbers in the illustration. 1) Perform steps 1) to 12) of the cylinder head disassembly procedure. 2) Remove the cooling water pump. 3) Remove the crankshaft pulley. (Point 1) 4) Remove the gear case cover.
Page 91: Servicing Points
4.3.4 Servicing points Point 1 [Disassemble] Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley set bolt. When removing the pulley using the gear puller, use a pad and carefully operate so as not to damage the thread. Set the gear puller securely to prevent the pulley from being damaged.
Page 92 Point 3: (Refer to 7.2.5 in chapter 7) [Disassemble] Remove the mounting nut of the fuel injection pump drive gear, remove the gear using the gear puller, and remove the fuel injection pump. Do not forget to remove the stay on the rear side. When extracting the gear using the gear puller, use a pad at the shaft and carefully operate so as not to damage the thread.
Page 93 [Disassemble] Since the camshaft gear is shrink-fit, heat it to 180 for extraction. For camshaft removal, raise the engine with its mounting flange at the bottom. After removing the thrust metal mounting bolt from the camshaft gear hole, extract the camshaft carefully so as not to damage the bearing bushing.
Page 94: Parts Inspection And Measurement
4.3.5 Parts inspection and measurement (22) Camshaft Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear damage. (a) Shaft bend measurement Support the camshaft with V blocks. Rotate the camshaft and measure the runout at the center of the camshaft and at each journal with a dial gage.
Page 95 Model Place Item Standard Limit Bushing I.D. 44.990 45.055 45.130 Gear side Camshaft O.D. 44.925 44.950 44.890 Oil clearance 0.040 0.130 0.240 Bushing I.D. 45.000 45.025 45.100 3IRH2N 8N Intermediate position Camshaft O.D. 44.910 44.935 44.875 Oil clearance 0.065 0.115 0.225 Bushing I.D.
Page 96: Oil Seal Replacement
4.3.6 Oil seal replacement 1) Replace the oil seal with a new one when the gear case cover is disassembled. Extract the used oil seal. 2) Insert a new oil seal. 3) Apply lithium grease to the oil seal tips. For the oil seal with double lips dust seal, further, slightly apply engine oil on the oil seal lip so as not to damage them, when installing the pulley.
Page 97: Cylinder Block
Cylinder Block 4.4.1 Components 4.4.2 Disassembly procedure: Disassemble in the order of the numbers in the illustration. Perform steps 1) to 12) in the cylinder head disassembly procedure. Perform steps 1) to 12) in the gear train disassembly procedure. Remove the oil pan. (Point 1) Remove the lubricating oil suction pipe.
Page 98: Servicing Points
4.4.4 Servicing points Point 1: Oil pan [Disassemble] Sealant is applied to the oil pan mounting surface on the block. Carefully operate soas not to damage or distort the bonding surface. [Reassemble] Apply sealant (code No.977770-01212) before reassembly. Point 2: Piston w/rod [Disassemble] Measure the connecting rod side gap.
Page 99 [Reassemble] Apply sealant (code No.977770-01212) and install the mounting flange by matching the two dowel pins. After assembly, raise the engine with its mounting flange on the bottom side. Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully operate so as not to lose balance.
Page 100 [Disassemble] Remove the bearing caps, cap side bearings, and thrust metals. Place each thrust metal with identification of the position and direction. Carefully install each thrust metal so that the grooved one is positioned away from the cap. Do not confuse the upper and lower main bearing metals.
Page 101 Point 6: Piston pin and rings [Disassemble] Using the piston ring replacer (see 4.1.2 in Chapter 4), remove the piston rings. Remove the circlip and remove the piston pin by pushing it out. [Reassemble] Install each piston ring on the piston, with the punched manufacturer’s mark facing upward.
Page 102: Parts Inspection And Measurement
4.4.5 Parts inspection and measurement (25) Cylinder block Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon deposit and bonding agent. (a) Appearance inspection Check if there is any discoloration or crack. If crack is suspected, perform color check.
Page 103 (c) If the limit is exceeded or any surface defect is found, repair by boring and honing. Use an oversized piston (and new piston rings) as required. Oversized piston (0.25 mm, with piston rings) Model Code No. Standard (mm) 3IRH2N 719802-22900 82.250 3/4IRH8N...
Page 104 (26) Crankshaft Mainly check seizure and wear of the crankpins and journals. Since the crankshaft gear is shrink-fitted, heat to 180 to 200 when extraction is necessary. (a) Shaft portion color check After washing the crankshaft, inspect it by means of color check or a magnaflux inspector.
Page 105 Crankpin Model & Item Standard Limit Pin outside diameter 42.952 42.962 42.902 3IRH2N Metal thickness 1.487 1.500 Oil clearance 0.038 0.090 0.150 Pin outside diameter 47.952 47.962 47.902 3/4IRH8N Metal thickness 1.492 1.500 Oil clearance 0.038 0.074 0.150 Pin outside diameter 57.952 57.962 57.902 4IRI8N...
Page 106 Crank journal Model Item Standard Limit Journal O.D. 46.952 46.962 46.902 3IRH2N Metal thickness 1.987 2.000 Oil clearance 0.038 0.080 0.150 Journal O.D. 53.952 53.962 53.902 3/4IRH8N Metal thickness 1.995 1.990 (Selective assembly) Oil clearance 0.038 0.068 0.150 Journal O.D. 64.952 64.962 64.902 4IRI8N...
Page 107 Dimension R and finishing precision of crankshaft journal and pin As for grinding processing of journal and pin, machine it by using the grinding wheel of the dimension R of below table. Surface finishing precision standard on journal and pin: Ry=0.8S super polishing Surface finishing precision standard on the thrust side of crankshaft arm:...
Page 108 (28) Piston Especially clean the combustion surface, circumference, ring grooves and piston pin bosses, and check after removing any carbon deposit. Any burr at a ring groove or snap ring groove shall be removed. If crack is suspected, inspect by color check.
Page 109 (c) Piston ring, ring groove and end clearance measurement Except for the top ring, to measure the piston ring groove width, first measure the width of the piston ring. Then insert the piston ring into the ring. Then insert the piston ring into the ring groove. Insert a thickness gage in between the piston ring and groove to measure the gap between them.
Page 110 Piston ring dimension Model Part Item Standard Limit Ring groove width 2.065 2.080 Ring width 1.970 1.990 1.950 Top ring Side clearance 0.075 0.110 End clearance 0.200 0.400 0.490 Ring groove width 2.035 2.050 2.150 Ring width 1.970 1.990 1.950 3IRH2N Second ring Side clearance...
Page 111 (29) Connecting rod (a) Appearance inspection Inspect the portion near the boundary of the chamfered portion and I-beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks, deformation, and discoloration.
Page 112 (d) Rod big end measurement Measure the crankpin and bushing according to 4.4.5.(2)(c) described above. Calculate the oil clearance of a crank pin metal and a crank pin from the measured values of the crank pin metal inner diameter and the crank pin outside diameter.
Page 113: Cylinder Bore Correction
(30) Tappet Mainly check the tappet contact surface with the cam and push rod. Slight surface defects shall be corrected with an oilstone. (a) Tappet stem outside diameter measurement Model Item Standard Limit Tappet 12.04 12.000 12.025 hole I.D. 11.95 3/4IRH8N Stem O.D.
Page 114: Piston Pin Bushing Replacement
Apply the honing fluid to the Flex-Hone and turn the electric drill at 300 to 1200 rpm. Then insert the Flex-Hone into the cylinder bore while turning it, and move it up and down for about 30 sec. to obtain a honing mark with a cross hatch angle of 30 to 40 .
Page 115: Lubrication System
5. LUBRICATION SYSTEM 5.1 Lubrication System Diagram Note: It varies in the specifications of each model whether Oil cooler and Piston cooling of the * mark are attached.
Page 116: Trochoid Pump Components
5.2 Trochoid Pump Components Trochoid pump (3IRH2N-3/4IRH8N) Trochoid pump (4IRI8N) 5.3 Disassembly(Reverse the procedure below for assembly) 1) Loosen the belt, and remove the radiator pulley, fan and V-belt. See 4.2.2. 2) in Chapter 4. 2) Remove the crankshaft pulley. See 4.3.2. 3) in Chapter 4. 3) Remove the gear case cover.
Page 117: Parts Inspection And Measurement
5.5 Parts Inspection and Measurement 5.5.1 Trochoid pump inspection and measurement (31) Outside clearance and side clearance of outer rotor Insert a gap gage between a outer rotor and a pump body, and measure the clearance. Outside clearance Model Standard Limit 3IRH2N 0.12 0.21...
Page 118 (33) Rotor shaft clearance Measure the outside diameter of rotor shaft and the shaft hole diameter of gear case. Calculate the clearance from that difference. Model Inspection item Standard Limit Gear case bearing I.D. 13.0 13.02 13.05 4IRI8N Rotor shaft O.D. 12.955 12.965 12.955 Rotor clearance...
Page 119: Cooling System
6. COOLING SYSTEM 6.1 Cooling Water System 6.2 Cooling Water Pump Components...
Page 120: Disassembly (Reverse The Procedure Below For Assembly)
6.3 Disassembly (Reverse the procedure below for assembly) 1) Remove the alternator. See 4.2.2. 1) in Chapter 4. 2) Remove the fan, V-belt and pulley. See 4.2.2. 2) in Chapter 4. 3) Remove the cooling water pump. (Point 1, in below 6.4) 4) Remove the thermostat.
Page 121: Fuel Injection Pump/Governor
7. FUEL INJECTION PUMP/GOVERNOR Only the outline of the MP fuel pump is explained in this chapter. Refer to the MP pump service manual of the separate volume for the disassembly and assembly. 7.1 Introduction It is described about the features of the fuel injection pump, YDP-MP disassembly, and assembly and adjustment procedure.
Page 122: External View And Components
7.2.2 External view and components 7.2.3Disassembly procedure: Disassembly from the engine body 1) Remove the cooling fan, pulley and V-belt. See 4.2.2. 2) in Chapter 4. 2) Remove the fuel injection pipe, fuel oil piping, fuel return pipe and rear stay. See point 1 of 7.2.5. 3) Remove the fuel injection pump drive gear cover.
Page 123: Assembly Procedure
7.2.4 Assembly procedure Reverse the disassembly procedure. 7.2.5 Servicing points Point 1 [Disassemble] Block an entrance with the tape so that trash may not enter the fuel injection pipe and the fuel injection pump. Point 2 [Disassemble] Remove the fuel injection pump drive gear and idle gear after putting the I.D.
Page 124 Point 3 [Disassemble] There is an acoustic material part to name as fuel pump spacer between the fuel pump and the cylinder block. Loosen fuel pump installation bolts with a closed wrench when disassembling a fuel pump. [Reassemble] When installing a fuel pump on the gear case, put a fuel pump spacer between the cylinder blocks, and install it .
Page 125: Turbochager: Disassembly, Inspection And Reassembly
8. TURBOCHAGER: Disassembly, inspection and reassembly 8.1 Structure and Functions 8.1.1 Main specifications Applicable engine model (application) 4IRI8T(CL, VM) Turbocharger model RHB31 RHB51 RHF5 Turbocharger specification Standard (w/waste gate) Turbine type Radial flow Blower (compressor) type Centrifugal Lubrication method External lubrication Max.
Page 126: Structural And Functional Outline
8.1.3 Structural and functional outline Part name Turbine shaft Oil thrower Turbine side seal ring Seal plate Journal bearing Thrust bearing Compressor housing M5 hexagon bolt M5 spring washer Compressor side clamp Turbine housing M6 hexagon bolt Turbine side clamp Lock washer Bearing housing Retaining ring...
Page 127: Components
8.1.4 Components Part name Part name Turbine shaft Bolt Thrust bushing Lock plate Oil thrower Bearing housing Seal ring Retaining ring Seal ring Screw Seal ring (turbine side) Screw Lock nut Lock washer Impeller Heat protector Seal plate Liquid gasket Journal bearing Waste gate actuator Thrust bearing...
Page 128: Service Standards And Tightening Torque
8.2 Service Standards and Tightening Torque 8.2.1 Service standards (39) RHF5 type Unit: mm Standard dimension Wear limit Turbine shaft journal outside diameter (A) 7.99 8.00 7.98 Turbine shaft seal ring groove width (E) 1.25 1.28 1.29 Turbine Compressor side seal ring groove width (G1) 1.22 1.23 1.31 shaft...
Page 129: Tightening Torque
(40) RHB31/RHB51 type Unit: mm Standard dimension Wear limit RHB31 RHB51 RHB31 RHB51 Turbine shaft journal outside diameter (A) 6.257 6.263 7.99 8.00 6.25 7.98 Turbine shaft seal ring groove width (E) 1.038 1.062 1.25 1.28 1.07 1.29 Turbine Compressor side seal ring groove width (G1) 1.02 1.03 1.22 1.23 1.04...
Page 130: Periodic Inspection Procedure
8.3 Periodic Inspection Procedure 8.3.1 Periodic inspection intervals Periodically inspect the turbocharger for the overall conditions and fouling. The inspection interval varies with the operating conditions, but refer to the table below for the guideline for each application. Application Inspection interval Every 6 months Every 12 months Every 24 months...
Page 131: Inspection Procedure
8.3.2 Inspection procedure (43) Rotor rotation inspection Inspect the rotor rotation by listening to any abnormal sound generation during rotation. For inspection with a sound detecting bar, bring the tip end of the bar into strong contact with the turbocharger case and raise the engine speed gradually. If any high pitch sound is generated at intervals of 2 to 3 seconds, the rotation is abnormal.
Page 132: Waste Gate Valve Adjustment Procedure
8.3.3 Waste gate valve adjustment procedure Rotor play in radial direction It is indispensable to adjust the waste gate valve opening pressure and lift after its overhaul or inner parts replacement. Negligence of this adjustment will adversely affect the engine performance. [NOTICE] If the adjustment is impossible, give up overhaul but replace the whole turbocharger assembly.
Page 133 (b) Measuring instruments and devices Dial gage Capable of measuring 0 to 10 mm (A flat head type is recommendable.) Manometer Mercury column or electrical type (capable of measuring 0 to 1500 mmHg) Pressure regulating valve Allowing gradual adjustment in a range between 0 and 2 kgf/cm (0.196 Mpa) Pressure reducing valve Used for suppressing the air supply pressure at 5 kgf/cm...
Page 134: Disassembly Procedure
8.4 Disassembly Procedure 8.4.1 Preparation for disassembly In addition to the general tools, the following special tools are required for turbocharger disassembly and reassembly: Tool name Illustration For removing thrust bearing and thrust bushing Material: Copper or brass For removing floating bearing circlip Pliers For removing seal ring Pliers...
Page 135: Inspection Before Disassembly
8.4.2 Inspection before disassembly 1) Inspect the turbine wheel and compressor impeller for any undesirable contact and the rotor for smooth rotation. 2) Measure the rotor play as described in section 8.3(2.2). Rotor axial play Wear limit: mm Rotor radial play Wear limit: mm 8.4.3 Disassembly The mounting angles of the turbine housing, bearing housing and compressor housing are determined according to its mounting state on the engine.
Page 136 (53) Floating bearing removal 1) Use the stop ring pliers and remove circlip 16 from bearing housing 15. 2) Remove floating bearing 5 from bearing housing 15. (54) Seal ring removal 1) Remove turbine side seal ring 3 from turbine shaft 1. 2) Remove compressor side seal ring (small) and compressor side seal ring (large) from oil thrower 2.
Page 137: Washing And Inspection Procedure
8.5 Washing and Inspection procedure 8.5.1 Washing (55) Inspection before washing Visually inspect each part before washing to check trace of seizure, wear, foreign matter or carbon adhesion. Carefully inspect for identifying the cause of trouble especially when a fault has occurred. Major inspection items Check point Checking position...
Page 138: Inspection Procedure
8.5.2 Inspection procedure (57) Compressor housing 7 Inspect the compressor housing for any contact trace with the compressor impeller, surface defect, dent or crack at joint surface, and replace it if defective. (58) Turbine housing 11 Inspect any trace of contact with the turbine wheel, exfoliation due to degradation by oxidation of the cast surface, thermal deformation or crack.
Page 139 (62) Thrust bushing, oil thrower 2 and thrust bearing 6 Inspect each part for wear, surface defect and discoloration. Replace with a new one if defective even within the wear limit. (a) Thrust bushing Measure the distance between grooves (K) of the thrust bushing, and replace with a new one if the wear limit is exceeded.
Page 140 (64) Bearing housing 15 1) Inspect the housing for cast surface exfoliation due to oxidation and degradation, dent or crack. 2) Inspect circlip 16 for chipping or crack, and replace with a new one if defective. 3) Measure the (B) and (F) portions of the bearing housing shown in the figure below.
Page 141: Reassembly Procedure
8.6 Reassembly Procedure 8.6.1 Preparation for reassembly 1) Prepare general tools, special tools, liquid gasket (Three Bond No.1207) and Locktite No.242 before reassembling the turbocharger. 2) Always replace the following parts with new ones: Turbine side seal ring 1pc. Compressor side seal ring(large) 1pc. Compressor side seal ring(small) 1pc.
Page 142 (70) Thrust bearing installation 1) Fit thrust bushing on turbine shaft 1. 2) Apply lubricating oil on the bearing portion of thrust bearing 6 and install it in bearing housing 15. 3) Apply Locktite on the threaded portion of M3 Torx T machine screw 17 for thrust bearing installation, and use Torx torque driver for installation by tightening to the specified torque.
Page 143 (72) Compressor impeller installation 1) Fit compressor impeller 18 onto turbine shaft 1. 2) Set a box spanner (10 mm) on the turbine side end of turbine shaft 1, and tighten shaft end nut 19. Note: Since the shaft end nut has left-handed screw, pay attention to the tightening direction.
Page 144: Handling After Disassembly And Reassembly
8.7 Handling after Disassembly and Reassembly When installing the turbocharger on the engine or handling the turbocharger after installation, strictly observe the instructions given below. Especially pay careful attention for preventing foreign matter entrance into the turbocharger. 8.7.1 Instructions for turbocharger installation Lubrication system 1) Pour new lubricating oil through the oil filler port before installation on the engine, and manually turn the turbine shaft to lubricate the floating and thrust bearings.
Page 145: Troubleshooting
8.8 Troubleshooting Sufficient turbocharger performance and required engine output cannot be obtained if there is any fault. In such a case, first check each engine part to see there is no engine fault. Then inspect the turbocharger for troubleshooting according to the procedure shown below. 8.8.1 Excessively exhaust smoke (76) Insufficient intake air volume Cause...
Page 146: Sudden Oil Decrease
8.8.3 Sudden oil decrease Cause Corrective action 1) Excessive bearing wear causing abnormal wear or Turbocharger disassembly and repair damage of seal ring 8.8.4 Decrease in output Cause Corrective action 1) Gas leak from any part in exhaust piping Inspection and repair of defective portion 2) Air leak from discharge side of blower 3) Clogged air cleaner element Element cleaning or replacement...
Page 147: Service Standards
9. SERVICE STANDARDS 9.1 Engine Tuning Reference Inspection item Standard Limit page Gap at intake/exhaust valve heads 3IRH2N 0.15 0.25 2.2.6(4) 4IRI8N Between alternator Used part 10 14 and crank pulley New part 8 12 V-belt tension Used part 7 10 Between alternator 2.2.2.(2)
Page 148: Engine Body
9.2 Engine Body 9.2.1Cylinder head (1) Cylinder head Inspection item Standard Limit Reference page Combustion surface distortion 0.05 or less 0.15 Intake 0.350.55 3IRH2N (2-valve head) Exhaust 0.300.50 4.2.5.(1) Intake 0.300.50 Valve sink 3/4IRH8N (2-valve head) Exhaust 0.300.50 Intake 0.360.56 4IRI8T (4-valve head) Exhaust...
Page 149 (2) Intake/exhaust valve and guide Reference Inspection item Standard Limit page Guide inside diameter 7.0007.015 7.08 Intake Valve stem outside diameter 6.9456.960 6.90 Clearance 0.0400.070 0.18 3IRH2N (2-valve head) Guide inside diameter 7.0007.015 7.08 Exhaust Valve stem outside diameter 6.9406.955 6.90 Clearance 0.0450.075...
Page 150 (81) Valve spring Reference Inspection item Standard Limit page 3IRH2N (2-valve) 44.4 43.9 Free length 4IRH8N (2-valve) 42.0 41.5 4IRI8T, (4-valve) 39.7 39.2 4.2.5.(4) 3IRH2N (2-valve) Inclination 4IRH8N (2-valve) 4IRI8T, (4-valve) (82) Rocker arm and shaft Reference Model Inspection item Standard Limit page...
Page 151: Gear Train And Camshaft
9.2.2 Gear train and camshaft (1) Camshaft Reference Inspection item Standard Limit page Side gap 0.050.20 0.30 4.3.4 Bending (1/2 the dial gage reading) 00.02 0.05 3IRH2N-3/4IRH8N 38.60038.800 38.350 4.3.5(1) Cam height 4IRI8N 43.40043.600 43.150 Shaft outside diameter / Metal inside diameter Bushing inside diameter 44.99045.055 45.130...
Page 152: Cylinder Block
(2) Idle gear shaft and bushing Inspection item Standard Limit Reference page Shaft outside diameter 45.95049.975 45.900 4.3.5(2) Bushing inside diameter 46.00046.025 46.075 Clearance 0.0250.075 0.175 (3) Backlash of each gear Reference Model Inspection item Standard Limit page Crank gear, cam gear, idle gear, 3IRH2N-8N 0.070.15 0.17...
Page 153 (2) Crankshaft Reference Inspection item Standard Limit page Bending (1/2 the dial gauge reading) 0.02 Pin outside diameter 42.95242.962 42.902 Metal inside diameter 43.00043.042 3IRH2N Metal thickness 1.4871.500 Clearance 0.0380.090 0.150 Pin outside diameter 47.95247.962 47.902 Metal inside diameter 48.00048.026 Crank pin 3/4IRH8N Metal thickness...
Page 154 (3) Thrust bearing Inspection item Standard Limit Reference page Crankshaft side gap All models 0.130.23 0.28 4.4.4 (4) Piston and ring Piston Reference Inspection item Standard Limit page 3IRH2N 81.95081.980 81.905 Piston outside diameter (Measure in the direction 3/4IRH8N 87.94587.975 87.900 vertical to the piston pin.) 4IRI8T...
Page 155 Piston ring Reference Model Inspection item Standard limit page Ring groove width 2.0652.080 Ring width 1.9701.990 1.950 Top ring Side clearance 0.0750.110 End clearance 0.2000.400 0.490 Ring groove width 2.0352.050 2.150 Ring width 1.9701.990 1.950 3IRH2N Second ring Side clearance 0.0450.080 0.200 End clearance...
Page 156 (5) Connecting rod Inspection item Standard Limit Reference page Thrust clearance 0.20.4 4.4.4 Rod small end Reference Model Item Standard Limit page Bushing inside diameter 23.02523.038 23.068 3IRH2N Pin outside diameter 22.99523.000 22.967 Clearance 0.0250.043 0.101 Bushing inside diameter 26.02526.038 26.068 3/4IRH8N Pin outside diameter...
Page 157: Lubricating Oil System (Trochoid Pump)
9.3 Lubricating Oil System (Trochoid Pump) 9.3.1Outside clearance of outer rotor Model Standard Limit Reference page 3/4IRH2N-8N 0.120.21 0.30 5.5.1(1) 4IRI8N 0.1000.155 0.25 9.3.2 Side clearance of outer rotor Model Standard Limit Reference page 3IRH2N88 0.020.07 0.12 5.5.1(1) 4IRI8N 0.050.10 0.15 9.3.3 Inside clearance of inner rotor Reference...
Page 158: Tightening Torque For Bolts And Nuts
10. TIGHTENING TORQUE for BOLTS and NUTS 10.1 Tightening Torques for Main Bolts and Nuts Thread Lubricating oil diameter Tightening torque application Reference Part and engine model pitch (thread portion, page Nm(kgf m) and seat surface) 61.7 65.7 3IRH2N M9 1.25 (6.3 6.7) Cylinder 85.3 91.1...
Page 159: Tightening Torques For Standard Bolts And Nuts
10.2 Tightening Torques for Standard Bolts and Nuts Nominal thread diameter Tightening torque Item Remarks pitch Nm(kgf-m) 9.8 11.8 Use 80% of the value at left M6 1 (1.0 1.2) when the tightening part is aluminum. 22.6 28.4 M8 1.25 Use 60% of the value at left for (2.3 2.9) 4T bolts and lock nuts.

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Ingersoll-Rand IR Series Workshop Manual

1 General

2 Inspection and Adjustment

3 Troubleshooting

4 Disassembly, Inspection and Reassembly of Engines

5 Lubrication System

6 Cooling System

7 Fuel Injection Pump/Governor

8 TURBOCHAGER: Disassembly, Inspection and Reassembly

9 Service Standards

10 TIGHTENING TORQUE for BOLTS and NUTS

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Troubleshooting

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