Ingersoll-Rand 4IRQ2N Operation & Maintenance Manual Download | Manualshive

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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

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Summary of Contents for 4IRQ2N

Page 1: ...d Ave Mocksville 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 Company and Doosan Comp...

Page 2: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 3: ...curately 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 overpowering will result in loss of warranty protection for this engine CERTAIN ENGINE ACCESSORIES such as radiator air cleaner and instruments are optional equipment on ...

Page 4: ...wheel 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 ...

Page 5: ...ling 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 Instru...

Page 6: ...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 3...

Page 7: ... Heed warnings and follow instructions If you do not understand inform your supervisor Prohibition Mandatory Information Instructions WARNING WARNING Read the operator s manual before operating this machine WARNING Do not open radiator until radiator is cool and pressure is relieved WARNING Read the operator s manual before towing machine ...

Page 8: ...e No open flames or sparks WARNING Battery contains acid Gases are flammable No open flames or sparks WARNING Do not perform maintenance until all electrical power has been disconnected WARNING Rotating fan 65 MPH maximum towing speed ...

Page 9: ...injury death or property damage if ignored Indicates the presence of a hazard which CAN cause serious injury death or property damage if ignored Indicates the presence of a hazard which WILL or can cause injury or property damage if ignored Indicates important set up operating or maintenance information Safety Decals area available free of charge Safety decals are identified by the decal heading D...

Page 10: ...10 ...

Page 11: ...rking on near the machine A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive Avoid contact with skin eyes and clothing In case of contact flush area immediately with water Improper operation of this equipment can cause severe injury or death Read Operator s Manual supplied with this machine before operation or service Modification or alteration of...

Page 12: ...ng battery cable s to prevent accidental starting Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eyes HOT PRESSURIZED FLUID Remove cap slowly to relieve PRESSURE from HOT radiator Protect skin and eyes HOT water or steam and chemical additives can cause serious personal injury Flammable Fuels Do not fill tank when engine is running Do not smoke or use a...

Page 13: ...art Control Before performing anyservice or maintenanceoperation always disconnect battery cables to prevent accidental start ups Use extreme care to avoid contacting hot surfaces engine exhaust manifold and piping ...

Page 14: ...ng Oil Preservative Grease Rust Preventative Diesel Fuel and Battery Electrolyte The following substances may be produced during the operation of this machine and may be hazardous to health Avoid build up of engine exhaust fumes in confined spaces Avoid breathing exhaust fumes Avoid breathing brake lining dust during maintenance Always operate in a well ventilated area Dispose of waste in a sealed...

Page 15: ...o 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...

Page 16: ... 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 Reco...

Page 17: ... 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 mini...

Page 18: ...ductivity 25ºC 77ºF uΩ cm 400 250 0 0 Total Hardness Ca CO3 PPM 100 95 0 M alkalinity PPM 150 79 0 Chlorine Cl PPM 100 100 Sulphuric acid ion SO2 4 PPM 100 50 0 Total Iron Fe PPM 1 0 1 0 0 Silica SiO2 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 Reco...

Page 19: ... 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 flu...

Page 20: ...ply 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 ...

Page 21: ...en during this operation Note during filling the escaping air trapped in the system can indicate that the system is full Therefore filling should be done in stages After the 1st stage continue to top off until the level stays visible through the filling hole even after a few minutes of observation Operate the engine for 2 to 3 minutes and let it rest for 30 minutes then check the level again and t...

Page 22: ... Bleed the fuel pump by disconnecting the outlet fuel line until air free fuel flows out Bleed the fuel filter 4 by loosening the bleed screw 1 until air free fuel flows out then retighten the bleed screw Repeat the same operation with bleed screw 2 Bleed the injection pump 5 by loosening bleed screw 3 then retighten the bleed screw Start the engine to remove the air contained in the injector pipe...

Page 23: ... it could cause an explosion and possible personnel injury Additionally your Engine may be fitted with a block heater and increased capacity battery and or lower viscosity oil may also be used See your local Ingersoll Rand distributor or servicing dealer for recommendations 1 Perform all prestarting checks outlined in Lubrication Maintenance Daily Section later in this manual 2 Refer to the G60 Op...

Page 24: ...e to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the PO...

Page 25: ...just the valve clearance Check the water level and top off if necessary Check the tightness of bolts and screws and particularly the air and exhaust manifolds and engine support Replace the fuel filter cartridge Warm Engine Start the engine bring it to its normal running temperature and then stop it Drain the oil Replace the oil filter cartridge and fill up with new clean and approved oil to the t...

Page 26: ...intenance periods contact your local Ingersoll Rand dealer Before any maintenance operations occur on the engine disconnect the battery to prevent inadvertent starting Daily Maintenance Checks These checks must be carried out every day or before every start up except repeat starts on the same day Check the oil level in the engine oil sump and top off if necessary Check the fuel level and fill up i...

Page 27: ...ck the injectors Check the condition of the and the tension of the V belt Check the Preheating Glow Plugs Clean or change the air filter Check the starter and charge alternator Clean the radiator depending on clogging Lubricate the water pump Retighten nuts and bolts Drain the Cooling System Battery Check the electrolyte level and top off Check the state of charge and recharge if necessary Clean t...

Page 28: ...ormed Technician 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 5300 5400 5500 5600 5700 5800 5900 6000 6100 6200 6300 6400 6500 6600 6700 6800 6900 7000 7100 7200 7300 7400 7500 Start a new table...

Page 29: ...E OIL and ENGINE COOLANT SPECIFICATIONS in Fuels Lubricants and Coolant section Checking the Coolant level Unscrew the radiator filler cap and visually check the coolant level correct level is at the lower edge of the filler neck If the level is insufficient pour clean water into the radiator up to the lower edge of the filler tube and reinstall the filler cap Air is bleed through the relief valve...

Page 30: ... hand pump until the engine oil sump is completely empty Caution Great care must be taken when draining hot oil risk of scalding Collect the used oil and avoid spillage Used oil must be disposed in accordance with pollution recommendations Loosen the oil filter cartridge and unscrew it Collect any leaking oil Clean the seal surface of the filter holder Lightly coat the rubber seal of the new lubri...

Page 31: ...lacing the Fuel Filter Remove the cartridge with a filter wrench Apply a small amount of fuel to the o ring of the new cartridge Install the new cartridge by hand Do not add fuel to the new cartridge After replacing prime the fuel system Adjusting the Valve Clearnance This operation requires special knowledge and use of special tools contact your local Ingersoll Rand dealer for this service Checki...

Page 32: ...m the injector to the injector pump then remove the pipe If necessary remove the pipe clamps Remove the injector assembly Install a new injector assembly taking care not to the block the injector Reinstall the fuel leak off pipe and clamps if necessary Operate the engine and check for combustion air and fuel leaks ...

Page 33: ...longest straight part of the belt when stationary Belt Tension 13 mm 0 5 inches If necessary readjust the tension of the belt and measure again To retighten or tighten belt Remove the fan and belt guards Undo the charge alternator screws 1 Pull on the alternator until the correct belt tension is achieved Retighten the alternator screws Reinstall the fan and belt guards To replace the belt Remove t...

Page 34: ...ir cleaners not supplied by Ingersoll Rand If engine is NOT equipped with an air restriction indicator replace air filter element every 500 hours of operation or every 12 months whichever occurs first 1 Unlatch and remove dust cup cover A of air cleaner 2 Move end of filter B back and forth gently to break seal 3 Pull filter B off outlet tube and out of housing 4 Thoroughly clean all dirt from ins...

Page 35: ...n working conditions on sites are particularly dusty Cleaning Put a container under the radiator to collect dirt and debris Cleaning with compressed air Clean the radiator with compressed air taking particular care with the cooling fins Rinse with water to remove the remaining dirt Cleaning with a cleaner grease remover Spray the radiator with a cold water high pressure cleaner then wait about tem...

Page 36: ...exible pipe below the radiator and slacken the hose clamps Remove the radiator hoses and let the remaining coolant drain off Allow enough time for the system to drain completely Remove and empty the container into a suitable receptacle complying with pollution regulations Rinsing the cooling system With the lower radiator hose removed rinse the radiator by flushing clean fresh water through the fi...

Page 37: ... 0 5 1 0 inch below its filler neck Run the engine for a short time and check the coolant level IMPORTANT Filling the cooling system Particular care must be taken during this operation During filling escaping air trapped in the system can indicate that the system is full therefore filling must be carried out in two stages After the 1st stage keep on topping off until the level stays visible throug...

Page 38: ...ge the fuel Overheat Rinse the cooling and replace parts as needed Valve clearance incorrect Adjust Not enough power Poor compression cylinders piston rings etc worn Repair or replace Not enough coolant Add coolant Leaks in the cooling system Retighten or repair Loose fan belt Adjust Air flow obstructed in the radiator Remove obstruction clean Water pump faulty Replace Fan Faulty Replace Thermosta...

Page 39: ...clogged Clean or replace Fuel consumption too high Poor compression cylinders piston rings etc worn Repair or replace Too much oil in engine Adjust oil level to proper level Oil viscosity too low Change the oil Leaks in the lubrication system Repair or replace Oil consumption too high Cylinders and piston rings worn valve stem seals worn Repair or replace Not enough oil in the engine Add more oil ...

Page 40: ...el Oil Diesel fuel oil ASTM No 2 D 1500 rpm 20 2 27 0 1800 rpm 24 6 33 0 2000 rpm 27 6 37 0 2200 rpm 30 2 40 5 Continuous Power Rating Output kWm HP 2500 rpm 33 1 44 5 1500 rpm 21 7 29 0 1800 rpm 26 1 35 0 2000 rpm 29 1 39 0 2200 rpm 32 0 43 0 One hour Power Rating Output kWm HP 2500 rpm 35 3 47 5 50 hz 1500 rpm 19 9 26 5 Prime Power kWm HP 60 Hz 1800 rpm 23 9 32 0 50 hz 1500 rpm 21 7 29 0 Stand B...

Page 41: ...esel fuel oil ASTM No 2 D 1500 rpm 29 4 39 5 1800 rpm 34 9 47 0 2000 rpm 38 2 51 0 2200 rpm 41 2 55 5 Continuous Power Rating Output kWm HP 2500 rpm 44 9 60 0 1500 rpm 30 9 41 5 1800 rpm 36 8 49 5 2000 rpm 40 5 54 0 2200 rpm 43 4 58 0 One hour Power Rating Output kWm HP 2500 rpm 47 1 63 0 50 hz 1500 rpm 28 0 37 5 Prime Power kWm HP 60 Hz 1800 rpm 33 5 45 0 50 hz 1500 rpm 30 9 41 5 Stand By kWm HP ...

Page 42: ...ºF Fahrenheit ft lb Foot Pound H2O Water Kg Kilograms KW Kilowatts L h Liter per hour L s Liter per second M Meter mm Millimeter m3 s Cubic Meter per second mm H2O Millimeters of water N m Newton meter Psi Pound per square inch P Power S A E Society of Automotive Engineers t mn Revolutions per minute Tº Temperature x 100 LLC Long life coolant ...

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