5
GENERAL REPAIR INSTRUCTIONS
1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine INGERSOLL-RAND parts.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are
completely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses. To not do so is extremely dangerous.
11. Always check and recheck your work. No service operation is complete until you have done this.
NOTES ON THE FORMAT OF THIS MANUAL
This workshop manual is applicable to the Ingersoll Rand L series 3 and 4 cylinder industrial engines, namely
the 3IRL2N, 3IRL4N & 4IRL5N models.
A large majority of components, parts and data specifications are common within the L series, and for
simplicity, the illustrations are based on the 4IRL5N engine. Where there are differences or exceptions for
individual models, the relevant illustrations and / or data tables are clearly identified with the appropriate engine
model to which they apply.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications, and tightening
torques are included in the General Information section.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and
reassembly.
4. When the same servicing operation is applicable to several different units, the manual will direct you to the
appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.
GENERAL INFORMATION
Summary of Contents for 3IRL2N
Page 8: ...8 APPEARANCE 1 MODEL 4IRL5N 1 Left side view GENERAL INFORMATION 2 Right side view ...
Page 14: ...14 GENERAL INFORMATION TIGHTENING TORQUE ON MAJOR COMPONENTS 1 COOLING FAN AND WATER PUMP ...
Page 15: ...15 GENERAL INFORMATION 2 CYLINDER HEAD AND CYLINDER HEAD COVER ...
Page 16: ...16 GENERAL INFORMATION 3 CYLINDER BLOCK AND OTHER COMPONENTS 1 N m kgf m ft lb ...
Page 17: ...17 GENERAL INFORMATION 4 CYLINDER BLOCK AND OTHER COMPONENTS 2 Kg m ft lbs 3IRL2N ...
Page 18: ...18 GENERAL INFORMATION 4 CYLINDER BLOCK AND OTHER COMPONENTS 2 3IRL4N 4IRL5N ...
Page 19: ...19 GENERAL INFORMATION 5 CYLINDER BLOCK AND OTHER COMPONENTS 3 ...
Page 20: ...20 GENERAL INFORMATION 6 EXHAUST MANIFOLDAND GASKET ...
Page 21: ...21 GENERAL INFORMATION GASKET LOCATION 1 LOCATIONS WHERE GASKETS ARE USED 3IRL2N ...
Page 22: ...22 GENERAL INFORMATION GASKET LOCATION 1 LOCATIONS WHERE GASKETS ARE USED 3IRL4N 4IRL5N ...
Page 32: ...32 1 EXTERNAL PARTS Right hand side 3IRL2N ENGINE DISASSEMBLY ...
Page 33: ...33 ENGINE 1 EXTERNAL PARTS Right hand side 3IRL4N ...
Page 34: ...34 ENGINE 1 EXTERNAL PARTS Left hand side 4IRL5N ...
Page 39: ...39 ENGINE Internal Parts 1 3 ...
Page 40: ...40 ENGINE Internal Parts 2 3 ...
Page 41: ...41 ENGINE Internal Parts 3 3 ...
Page 44: ...44 ENGINE Timing Gear ...
Page 50: ...50 ENGINE 1 CYLINDER BLOCK ...
Page 74: ...74 ENGINE Internal Parts l 3 ...
Page 75: ...75 Internal Parts 2 3 ENGINE ...
Page 76: ...76 ENGINE Internal Parts 3 3 ...
Page 86: ...86 ENGINE 4 EXTERNAL PARTS Right hand Side 3IRL2N ...
Page 87: ...87 ENGINE 5 EXTERNAL PARTS Left hand Side 3IRL2N ...
Page 95: ...95 LUBRICATING SYSTEM LUBRICATING OIL CIRCULATION DIAGRAM ...
Page 98: ...98 COOLING SYSTEM COOLING WATER CIRCULATION SYSTEM DIAGRAM ...
Page 103: ...103 FUEL SYSTEM FUEL CIRCULATION SYSTEM DIAGRAM 3IRL2N ...
Page 104: ...104 FUEL SYSTEM FUEL CIRCULATION SYSTEM DIAGRAM 3IRL4N 4IRL5N ...
Page 106: ...106 FUEL SYSTEM 2 STRUCTURAL DRAWING OF GOVERNOR 2 ...
Page 113: ...113 FUEL SYSTEM NOZZLE HOLDERASSEMBLY 3IRL2N ...
Page 115: ...115 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING ...
Page 116: ...116 TROUBLESHOOTING ...
Page 117: ...117 TROUBLESHOOTING ...
Page 118: ...118 TROUBLESHOOTING ...
Page 119: ...119 TROUBLESHOOTING ...
Page 121: ...121 ...
Page 122: ...122 ...
Page 123: ...123 ...
Page 124: ...124 ...
Page 125: ...125 ...
Page 126: ...126 ...
Page 127: ...127 ...