Ingersoll-Rand 4IRS2N Operation & Maintenance Manual

Type
Operation & Maintenance Manual

This manual is also suitable for

Operation & Maintenance Manual
4IRQ2N & 4IRS2N DIESEL ENGINE
T h is m a nua l co n tain s impor tan t s a fe ty in fo rm atio n .
D o no t d es tro y thi s man u al.
T h is m a nua l mus t b e a v ail a bl e to th e p e rso n ne l wh o o p er a te a n d main tai n thi s m a chin e .
P.O. Box 868 - 501 San ford A ve
Moc ksv ille, N.C. 27028
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 C
ompany and Doosan
Company or the products of
e
ith
er.
Revised (10-12)
CALIFORNIA
Propos ition 65 W a rn ing
Dies e l en g ine e xhaust and some of its c onstituen ts are known
to the S tate of California to cau s e
cancer
, birth defec ts, and
oth e r re p ro d uctive h arm.
3
Introduction
Forward
READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so
could result in personal injury or equipment damage.
THIS MANUAL SHOULD BE CONSIDERED a permanent part of you r engine and should remain with the
engine when you sell it.
MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use
only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metri c or
inch wrench.
RIGHT -HAND AND LEFT -HAND sides are determined by standing at the drive or flywheel end (rear) of
the engine and facing toward the front of the engine.
WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Ke eping
Section. Accurately record all the numbers. Your dealer also needs these numbers when you order parts.
File the identification numbers in a secure place off the engine.
SETTING FUEL DELIVERY beyond published factory specifications or otherwise overp owering will result
in loss of warranty protection for this engine.
CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment
on Ingersoll -Rand
supplied e
ngines. These accessories may be provided by the equipment man ufacturer
instead of Ingersoll -Rand. This operators manual applies only to the engine and those options available
through the Ingersoll -Rand distribution network.
Engine Owner
Ingersoll -Rand Equipment Engine Owner:
Dont wait until you need warranty or other service to meet your local Ingersoll -Rand Distributor or Service
Dealer.
Learn who he is and where he is. At your first convenience, go meet him. Hell want to get to know you
and to learn what your needs might be.
4
Engine Details
S4Q2 S4S
1 Water Thermostat
2 Lifting Eye
3 Charge Alternator
4 Fan
5 V-belt
6 Oil sump
7 Flywheel
8 Starter Motor
9 Exhaust manifold
10 Injector
11 Air Inlet Housing
12 Water Drain Plug
13 Oil Filter
14 Oil Drain Plug
15 Dipstick
16 Crankcase Pulley
17 Oil Filler Neck
18 Fuel Pump
19 Water Pump
20 Oil Filler Neck
21 Governor
22 Fuel Feed Pump
23 Engine Serial Number
24 Fuel Filter
25 Oil Pressure Plug
5
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
.............................................................................................................................................16
Recommended Oil Viscosities.............................................................................................................16
Limiting Requirements For Engine Oils...............................................................................................17
Coolant Specifications
..................................................................................................................18
Coolant Quality
..............................................................................................................................18
Coolant Specifications
...............................................................................................................18
Recommended Types of Long Life Coolants (LLC) ............................................................................18
Features of Recommended Brands.................................................................................................18
How to use non-amine type LLC......................................................................................................19
Disposing of Coolant...............................................................................................................................19
Capacity of Cooling and Lubricating Systems ............................................................................................19
Engine Operating Guidelines.....................................................................................................................20
Engine
.................................................................................................................................................20
Oil.........................................................................................................................................................20
Coolant.................................................................................................................................................21
Fuel......................................................................................................................................................22
Starting The Engine ................................................................................................................................23
Cold Weather Starting.............................................................................................................................23
Stopping the Engine................................................................................................................................23
Using a Booster Battery or Charger.......................................................................................................24
Checks, Adjustments and Maintenance Procedures To Be Carried Out After The First 50 Running Hours
....................................................................................................................................................................25
Engine
.................................................................................................................................................25
Cold Engine .........................................................................................................................................25
Warm Engine.......................................................................................................................................25
Preventive Maintnenace..............................................................................................................................26
General Maintenance Instructions
.....................................................................................26
Maintenance Schedule ........................................................................................................................26
Daily Maintenance Checks...............................................................................................................26
General Maintenance Schedule.......................................................................................................27
Engine...........................................................................................................................................27
Battery ..........................................................................................................................................27
Check the electrolyte level and top off..........................................................................................27
Check the state of charge and recharge if necessary..................................................................27
Clean the terminal lugs and grease with silicone grease.............................................................27
Tighten the terminals....................................................................................................................27
Exhaust Muffler.............................................................................................................................27
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...........................................................................................................29
Replacing the Lube Oil and Oil Filter............................................................................................30
Replacing the Fuel Filter...............................................................................................................31
Adjusting the Valve Clearnance ...................................................................................................31
Checking and Cleaning the Injectors............................................................................................31
How to Replace an Injector ..........................................................................................................32
Checking the Condition and the Tension of the V-belt, Replacing the V-Belt..............................33
Checking the Preheating Glow Plugs...........................................................................................34
Cleaning the Air Filter...................................................................................................................34
Cleaning the Radiator and the Fan Blades ..................................................................................35
Radiator:....................................................................................................................................35
Checking the injectors ..................................................................................................................35
Lubricating the water pump..........................................................................................................36
Retightening Fasteners ................................................................................................................36
Draining the Cooling System........................................................................................................36
Filling the cooling system: ............................................................................................................37
Exhaust Muffler.............................................................................................................................37
Troubleshooting ..........................................................................................................................................38
Engine
.................................................................................................................................................38
Engine will not start..............................................................................................................................38
Not enough power................................................................................................................................38
Overheating .........................................................................................................................................38
Too much white or blue smoke............................................................................................................38
Too much black or gray smoke............................................................................................................38
Fault..............................................................................................................................................39
Cause ...........................................................................................................................................39
Action............................................................................................................................................39
Too much black or gray smoke............................................................................................................39
Fuel consumption too high...................................................................................................................39
Fuel of incorrect quality ................................................................................................................39
Change the fuel ............................................................................................................................39
Fuel injection pump faulty.............................................................................................................39
Repair or replace ..........................................................................................................................39
Fuel injectors faulty.......................................................................................................................39
Repair or replace ..........................................................................................................................39
Wrong injection timing ..................................................................................................................39
Adjust............................................................................................................................................39
Oil consumption too high .....................................................................................................................39
Oil pressure too low.............................................................................................................................39
Specifications..............................................................................................................................................40
General Engine Specifications—S4Q2
..........................................................................40
General Engine Specifications—S4S
..............................................................................41
ABBREVIATIONS USED IN THIS Manual .................................................................................................42
7
Safety Symbols
Symbols below point out pote ntial saf ety hazar ds and provide imp ortant infor mation about this
machine. Re ad and understand. H eed warnings and follow instr ucti ons. If
you do not u nders tand, inform your sup ervisor.
Prohibition/ Manda tory Informatio n/Ins tructions W AR N IN G
W ARNING - Read the
operato rs ma nual before
operati ng this machine.
W ARN IN G - Do not open
radiator until radi ator is
cool and pressu re is
relieved.
W ARNING - Read the
op erato rs man ual before
towi ng m achine.
8
W ARNI N G - Diesel fuel is
flammabl e. No open flames or
sparks.
W ARNING - Battery
con tains acid. Gas es are
flammabl e. No open flames or
sparks.
W AR N ING - Do not perf orm
main tenance until all electrical
power has be en
disco nnec ted.
W ARNING - Ro tati ng fan 65 MPH m aximum towing spee d.
9
Safety Symbols
Lo o k for these signs o n mach ines m a nufactured in North America, which
point out pot e ntial h a zards to the saf e ty of you and oth e rs . Read and
understa n d thoroughl y . Heed warnin g s and fo llow in structions. If you do not
und e rs tand, inf o rm your su p ervisor.
!
DANGER
(Red Background)
!
W ARNING
(Orange Background)
!
CAUTION
(Yellow Background)
NOTICE
(Blue Background)
Indicates the prese nce of a hazard which WILL ca use
serious inj ury, dea th or pr operty dam age, if ign ored.
Indicates the presence of a hazard which CAN cause
serious inj ury, dea th or pr operty dam age, if ign ored.
Indicates the presence of a hazard which WILL or can
cause injury or pr operty dam age , if ign ored.
Indicates imp ortant set -up, operati ng or maint enance
information.
Safety De c als area avail a ble free of charge.
Safety decals are ide n tified by the de c al head in g
:
D ANG E R, W A RNING or C AUTION
Dec a l part num b ers are on th e bottom of each decal a nd are lis ted in
th e par ts manual. H e lp promote pr o duct sa fety! Assure th at de c als
are p re sent on the mac h ines. Rep lace d e cals th a t are not le g ible.
10
11
Safety
DANGER
Th is machi n e is not d e signed for op e ra ting life -s ustaining equ ipm e nt. It
is equip p ed with a safety shutd o wn s ystem that will cause the machine to st o p
operating whe n ever a s h utdown conditi o n is pres e nt.
DANGER
Nev e r
operate the engine of this machine inside a building without
ad e quate
ve n tilation. Avoid bre a thi ng exh a ust fumes when w o rk ing on near the m achine.
A
battery contains sulfuric acid and can give off gases, which are
corrosi v e
and pote n tially e x plosiv e . A v oid conta c t with s k in, eye s , a nd cl o thing. In case o f
contact, flush a rea imme d iately with w ater.
Im p ro p er o p eration of this equ ipment can c a use sev e re in jury or d e ath.
Read Operators Manu a l suppli e d with th is mac h ine before o p eration or s e rv ice.
Modificat ion o r alterat ion of this m a chine CAN result in severe injury or de a th. Do
not alt er or modify this mac h ine without the express wr itten co n sent of th e
man u facturer.
12
Exerci s e e x tr e me c aution when using boost e r battery. To ju mp b a ttery, co n nect
e n ds of o ne boo s ter cable to the positive (+) termin a l of e a ch bat tery. Con nect
o ne end o f other cable to the negative (-) terminal o f the bo o ster batt e ry and other
e n d to a ground conne c tion a w ay from d ead bat tery (to avoid a s park o ccurr ing
ne a r any explo s ive gases that may be pres e nt). After starting u nit, always
disconn e ct ca b les in rev e rs e order.
Nev e r in s pect or service unit w ithout first disc o nnecting b attery cabl e (s) to p re v ent
ac c idental starting.
We a r e ye protection while c leaning u n it with co m pressed a ir, to pre v ent de b ris
from injuring eyes.
HOT PRESSUR IZED FLUID - Re m ove c ap s lowly to reli e ve PRESSURE from
HOT
radiator
. Prot e ct
skin and eyes
. HOT
water or steam and
ch e mical additiv e s can
c ause s erious pers o nal injury.
Fl a mmable Fuels - Do not fill ta nk when eng ine is runn ing.
Do not smoke or u se an open fla m e in th e v icinity of the generat o r set or fu e l tank.
Do not permit s moking, o p en flame, o r s p ar k s to occur near the b a ttery, fu e l,
cleaning solvents or other flammable substances and explosive
ga s es.
Do not operate Genset if fuel h a s been spilled inside o r n ear the un it.
13
Disa b le
StartControl
-
Beforeperforminganyserviceormaintenance
op e ra tion, always
d isconn e ct battery c ables to prevent a c cident a l start - up s .
Use
extreme care to avoid contacting hot surfaces
(en g in e
exhaust
m a nifold a n d
piping).
14
HAZARDOUS SUBS TANCE PRECAUTION
Ensure th at adeq uate ventilation of the cooling syst em and exh aust gases is
mai ntain ed at all times.
The following substances are used in the manu facture of this m achine and may be
hazard ous
to heal th if used incorrectly.
Avoid ingestio n, skin contact and breathing fumes for the following substances:
A ntifre eze, Engine Lubricating Oil, Preserv ative Gre ase, Rust Preventative, Dies el
Fuel and Battery El ectrolyte.
The following subst ances m ay be pro duced during the oper ation of this mac hine and
may be h azard ous to health:
Av oid build-up of engi ne ex haust fum es in co nfined sp aces.
Av oid breathing exhaust fumes.
Av oid breathing brake lini ng dust during maint enance.
Always operate in a well ventilated area.
Dispose of waste in a sealed con tainer.
Use w ater to damp down dust.
Av oid inhalation of dust par ticles.
Saf ety data sheets for en gine lubricants should be ob tained from the lubricant supplier.
15
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
Use commercially available diesel fuel with a sulphur content lower than 0.5%.
Gaseous emissions, measured during standard checks, always refer to a standard
diesel fuel recommended by the authorities in charge of these standards
The fuel must be a distillate, and a residual oil or a blend. The user is warned that, although
engines can operate with fuels not complying with specifications mentioned above, this could
lead to excessive wear and damage.
Fuel injection equipment is manufactured in accordance with very precise limits
and the smallest foreign body will affect efficiency.
It is essential to use fuel free from water and other impurities.
Note:
To operate the engine at temperatures below 0ºC (32ºF), use an anti-prafining
additive or use a fuel preheater.
Example: ACCEL additive for cold weather.
Recommended mixture ratio: 1 liter for 1000 liters of diesel fuel. Average operation of
diesel engines guaranteed down to -18ºC.
Recommended oil Specifications
Quality
The oil must be suitable for oil changes as specified in the general maintenance schedule. The
temperatures mentioned in the Oil Viscosity Table below are ambient temperatures during engine start-
up. However, if operating ambient temperatures are much higher than the starting temperatures, a
compromise must be found and high viscosity oil must be used providing the engine starts satisfactorily.
Multi-grade oils can solve this problem provided that they have an appropriate specification. These diesel
engines must be used with heavy duty lubricating oil in compliance with the requirements of the standards
API CC, DEF2101D, MIL-I-2104C or MIL-L-46152A/B for L.E. + S.L + S.Q engines and API CD FOR S.S
engines. Straight minerals oils are not suitable, neither are oils of less detergency than specified.
16
In new or reconditioned engines, 3
rd
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. Note, they must be used when the
fuel sulphur content exceeds 0.5%
Viscosity
The following chart shows the correct oil viscosities for various ambient temperature s from cold start to
maximum operating levels.
Avoid mixing oils of different brands. In most cases, the various oil brands are not
compatible with each other, and when mixed, can seize parts such as piston rings,
cylinders, etc. or abnormally wear moving parts. It is preferable to stick with one and the
same brand of oil at successive service intervals.
Recommended Oil Viscosities
Starting
Temperature
ºC (ºF)
-30
(-22)
-25
(-13)
-20
(-4)
-15
(5)
-10
(14)
-5
(23)
0
(32)
10
(50)
20
(68)
30
(86)
40
(104)
Oil
Viscosities
Type SAE 10W – 30 is the recommended oil for general use.
SAE 30
SAE 40
SAE 5W - 20
SAE 15W - 40
17
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.
The limit of total base number is half of that of a new oil incase of a perchloricacid
analysis method.
Property
Test
Method
LImit
Viscosity
cSt @ 100ºC
(212ºF)
JIS
K 2283
+30%, -15% of new oil
Total Base Number (Hcl) MgKOH/g 2.0 minimum
Total Acid Number MgKOH/g
JIS
K 2501
+3.0% maximum of new oil
Water Content Vol%
JIS
K 2275
0.2 maximum
Flash Point (coc) ºC (ºF)
JIS
K 2265
180 (356) minimum
Pentane Insolubles Wt% 0.5 maximum
Pentane Insolubles Coagulated Wt%
ASTM
D893
3.0 maximum
18
Coolant Specifications
The coolant quality has a significant effect on the efficiency and life of the cooling system. The
recommendations below will help users to keep their cooling system in good condition with
protection against frost and /or corrosion.
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; however they are tolerable up to the limits
shown in the table below.
Main malign effectItem Chemical
Symbol
Unit Limit Recommended
Corrosion
& Rust
Scale
formation
pH, 25ºC (77ºF) - - 6.5 à 8.5 ( 6.5 à 8.0) 0 0
Electrical conductivity,
25ºC (77ºF)
- uΩ/cm < 400(< 250) 0 0
Total Hardness Ca CO
3
PPM < 100 (< 95) - 0
M alkalinity PPM < 150 (, 79) - 0
Chlorine Cl
-
PPM < 100 (< 100) - -
Sulphuric acid ion SO
2-4
PPM < 100 (< 50) 0 -
Total Iron Fe PPM < 1.0 (< 1.0) - 0
Silica SiO
2
PPM < 50 (-) - 0
Residue from evaporation - PPM < 400 (<250) - 0
The values indicated ( ) are the limits set by the manufacturer. In addition to the items specified above,
turbidity is specified to be above < 15 degrees.
Recommended Types of Long Life Coolants (LLC)
For these engines, all-season, non-amine LLC or equivalent is recommended.
Features of Recommended Brands
None of amines (methyl amines, ethyl amines, n-propyl amines, etc., all being derivatives of
ammonia, NH3) are contained.
Silicate and borate are not contained.
Close to neutral on the pH scale, and hence, slightly basic (alkaline).
Balanced additive ingredients, some being substitutes for amines.
Long life. (The coolant with 20% concentration, for example, retains its efficacy for long, not less
than 2 years).
19
LLC is toxic and can cause personal injury if in contact with the skin or eyes. If LLC
enters the eyes, immediately and thoroughly rinse with water and seek medical attention
at once.
How to use non-amine type LLC
1. Engine coolant containing any of the recommended additives should be changed every two
years.
Note:
If any other LLC is used, refer to the coolant mixture chart displayed on the container.
2. Proper concentration of LLC is from 20% to 60% year-round. Aim at a temperature level lower by
5ºC (9ºF) than the expected lowest temperature. An LLC with a concentration below 30% does
not provide sufficient corrosion protection. However, concentrations above 60% affect freeze
protection and heat transfer rates. When adding coolant, use LLC of the same concentration.
RECOMMENDED LLC CONCENTRATIONS (REFERENCE)
Ambient temperature ºC (ºF)
-10
(14)
-20
(-4)
-30
(-22)
-45
(-49)
LLC concentration, % 30 40 50 60
Disposing of Coolant
Improperly disposing of engine coolant can threaten the environment and ecology.
Use leak proof containers when draining fluids. Do not use food or beverage containers that may
mislead someone into drinking from them.
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 environmental or recycling
center, or from your Ingersoll -Rand distributor or servicing dealer.
Capacity of Cooling and Lubricating Systems
Engine S4Q S4S
Water 7.71 L 8.91 L
Oil 8.1 L 10.1 L
20
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
Oil
Check the oil level in the engine sump and top off or fill as
necessary.
Use approved oil (listed above) with a SAE grade suitable to the
ambient temperature conditions.
1. Dipstick
2. Filler hole
1
2
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Ingersoll-Rand 4IRS2N Operation & Maintenance Manual

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Operation & Maintenance Manual
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