Ingersoll-Rand 4IRS2N Operation & Maintenance Manual

Brand: Ingersoll-Rand

Model: 4IRS2N

Type: Operation & Maintenance Manual

This manual is also suitable for

4IRQ2N

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

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.

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 operator’s manual applies only to the engine and those options available

through the Ingersoll -Rand distribution network.

Engine Owner

Ingersoll -Rand Equipment Engine Owner:

Don’t 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. He’ll want to get to know you

and to learn what your needs might be.

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

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

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

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 r’s 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 r’s man ual before

towi ng m achine.

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.

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.

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.

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 Operator’s 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.

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.

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).

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.

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.

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. 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)

(32)

(50)

(68)

(86)

(104)

Oil

Viscosities

Type SAE 10W – 30 is the recommended oil for general use.

SAE 30

SAE 40

SAE 5W - 20

SAE 10W - 30

SAE 15W - 40

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

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

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

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).

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

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

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Ingersoll-Rand 4IRS2N Operation & Maintenance Manual

Brand: Ingersoll-Rand

Model: 4IRS2N

Type: Operation & Maintenance Manual

This manual is also suitable for

4IRQ2N

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Ingersoll-Rand 4IRS2N Operation & Maintenance Manual

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Ingersoll-Rand 4IRS2N Operation & Maintenance Manual

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