Ingersoll-Rand 4IRD5T Manuale utente

Book: 22787584 (4/07) Rev. B

4IRD5T

4IRD5AE

For Engine Models

Engine Operation Manual

4IRD5TE

6IRF8AE4

6IRF8AE

6IRF8TE

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 Company or the products of

either.

Revised (10-12)

CALIFORNIA

Propos ition 65 W a rn ing

Dies e l en g ine e xhaust and som e 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 r o d uctive h arm .

Introduction

Forward

THIS MANUAL CONTAINS INFORMATION to operate and service the engine:

READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so

could result in pe rsonal injury or equipment damage.

THIS MANUAL SHOULD BE CONSIDERED a permanent part of your 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 cor rect replacement parts and fasteners. Metric and inch fasteners may require a specific metric or

inch wrench.

WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping

Section. Accurately record all the numbers. Your deale r 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 Ingersoll -Rand OEM Engines. An equipment manufacturer other than of Ingersoll -Rand may provide

these accessories. This operator’s manual applies on ly to the engine and those options available through

the Ingersoll -Rand distribution network.

Contents

INTRODUCTION 3

Forward 3

4IRD5TE

4.5 L ENGINES WITH ELECTRONIC FUEL SYSTEMS (TIER II

EMISSION CERTIFIED), (TWO-VALVE CYLINDER HEAD MODELS444 5

6IRF8TE 6.8

L ENGINES WITH ELECTRONIC FUEL SYSTEMS (TIER II

EMISSION CERTIFIED), (TWO-VALVE CYLINDER HEAD MODELS) 6

CONTENTS 7

RECORD KEEPING 12

Engine Serial Number Plate 12

Record Engine Serial Number 12

Engine Option Codes 13

SAFETY 15

Recognize Safety Information 15

Understand Signal Words 15

Follow Safety Instructions 15

Replace Safety Signs 16

Prevent Bypass Starting 16

Handle Fuel Safely—Avoid Fires 16

Prepare for Emergencies 17

Handle Fluids Safely—Avoid Fires 17

DO NOT USE Starting Fluids 17

Pages 4, 5 and 6 deleted. Do not apply.

Service Engines Safely 17

Wear Protective Clothing 18

Protect Against Noise 18

Handle Chemical Products Safely 18

Practice Safe Maintenance 19

Work In Ventilated Area 19

Avoid High-Pressure Fluids 20

Avoid Heating Near Pressurized Fluid Lines 20

Remove Paint Before Welding or Heating 21

Install Fan Guards 21

Avoid Hot Parts 21

Service Cooling System Safely 22

Avoid Harmful Asbestos Dust 22

Prevent Battery Explosions 22

Prevent Acid Burns 23

Protect Against High Pressure Spray 23

Dispose of Waste Properly 24

Live With Safety 24

FUELS, LUBRICANTS, AND COOLANT 25

Diesel Fuel 25

Required fuel properties 25

Sulfur content: 25

Lubricity of Diesel Fuel 26

Diesel Fuel Storage 27

Bio-Diesel Fuel 28

Handling And Storing Bio-Diesel Fuel 29

Filling Fuel Tank 30

Minimizing the Effect of Cold Weather on Diesel Engines 31

Use Grade No. 1-D Fuel 31

Air Inlet Heater Aids 31

Coolant Heaters 31

Seasonal Viscosity Oil and Proper Coolant Concentration 31

Diesel Fuel Flow Additive 31

Winter fronts 32

Radiator Shutters 32

Diesel Engine Break-In Oil 33

Diesel Engine Oil 33

Mixing of Lubricants 34

Oil Filters 34

Alternative and Synthetic Lubricants 34

Lubricant Storage 35

Grease 35

Diesel Engine Coolant 36

Coolant Drain Intervals 36

Diesel Engine Coolants, Supplemental Additive Information 37

Coolant Specifications 37

Replenish Coolant Additives 37

Why Use Supplemental Coolant Additives? 37

Avoid Automotive-Type Coolants 37

Water Quality 37

Freeze Protection 38

Testing Diesel Engine Coolant 38

Supplemental Coolant Additives 38

Operating in Warm Temperature Climates 39

Disposing of Coolant 39

ENGINE OPERATING GUIDELINES 40

Normal Engine Operation 40

Engine Break-In Service 40

Starting The Engine 43

Cold Weather Starting 43

Stopping the Engine 44

Using a Booster Battery or Charger 45

LUBRICATION AND MAINTENANCE 47

Observe Service Intervals 47

Use Correct Fuels, Lubricants, and Coolant 47

Lubrication and Maintenance Service Interval Chart—Standard Industrial

Engines 48

Lubrication & Maintenance/Daily 49

Daily Prestarting Checks 49

Lubrication & Maintenance, 500 Hour/12 Month 53

Checking Engine Mounts 53

Servicing Battery 53

Manual Belt Tensioner Adjustment 56

Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary

Drive) 57

Changing Engine Oil and Replacing Filter 59

Cleaning Crankcase Vent System 61

Checking Air Intake System 61

Checking Air Intake System 62

Replacing Fuel Filter Elements 63

Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) 65

Checking Belt Wear 65

Checking Tensioner Spring Tension 66

Checking Engine Electrical Ground Connections 67

Checking Cooling System 67

Replenishing Supplemental Coolant Additives (SCA s) Between Coolant Changes 68

Testing Diesel Engine Coolant 69

Pressure Testing Cooling System 70

Lubrication & Maintenance, 2000 Hour/ 24 Month 71

Checking Crankshaft Vibration Damper (6-Cylinder Engine Only) 71

Flushing and Refilling Cooling System 72

Testing Thermostats Opening Temperature 75

Testing Thermostats Opening Temperature 76

To Install Thermostats 77

Check and Adjust Valve Clearance 78

Service As Required 81

Do Not Modify Fuel System 81

Adding Coolant 82

Replacing Radial Seal Air Cleaner Filter Element 83

Replacing Fan and Alternator Belts 84

Bleed the Fuel System (Engines with Electronic Fuel Systems and Stanadyne DE10 Pump) 85

Bleeding the Fuel System (Engines with Electronic Fuel Systems and Bosch VP44 Pump) 88

TROUBLESHOOTING 90

General Troubleshooting Information 90

Precautions For Welding On Engines Equipped With Electronic Engine

Control 90

Unit (ECU) 90

Engine cranks but will not start 91

Engine hard to start or will not start 91

Engine knocks 91

Engine runs irregularly or stalls frequently 92

Below normal engine temperature 92

Lack of power 92

Low oil pressure 93

High oil consumption 93

Engine emits white smoke 93

Engine emits black or gray exhaust smoke 93

Engine overheats 93

High fuel consumption 94

Undercharged electrical system 94

Battery uses too much water 94

Batteries will not charge 94

Starter will not crank 95

Starter cranks slowly 95

Entire electrical system does not function 95

Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel

Systems And Stanadyne DE10 Pump) 96

Trouble Codes 96

Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel

Systems And Bosch VP44 Pump) 98

Trouble Codes 98

GENERAL OEM ENGINE SPECIFICATIONS 100

Record Keeping

A medallion is located on the rocker arm cover

which

identifies each engine.

Engine Serial Num ber P late

Each engine has a 13 -digit engine serial number. The

first two digits identify the factory that produced the

engine.

“CD” = Saran, France

“PE” = Torreon, Mexico

“T0” = Dubuque, Iowa

“J0” = Rosario, Argentina

The engine’s serial number plate (A) is located on the

right -hand side of cylinder block behind the fuel filter.

Record Engine Serial Num ber

Reco rd all of the numbers and letters found on your

engine serial number plate in the spaces provided

below.

This information is very important for repair parts or

warranty information.

Engine Serial Number (B)

Engine Model Number (C) Engine Serial Plate

Co efficient of Absorption Value (D)

(Saran Engines Only)

Engine Option Codes

In addition to the serial number plate, OEM engines have an engine option code label affixed to the

rocker arm cover. These codes indicate which of the engine o ptions were installed on your engine at the

factory. When in need of parts or service, furnish your authorized servicing dealer or engine distributor

with these numbers.

The engine option code label includes an engine base code (A). This base code must also be recorded

along with the option codes.

The first two digits of each code identify a specific group, such as alternators. The last two digits of each

code identify one specific option provided on your engine, such as a 12 -volt, 70 -amp alternator.

NOT E: These option codes are based n the latest information available at the time of publication. The

right is reserved to make changes at any time without notice.

If an engine is ordered without a particular component, the last two digits of that functiona l group option

code will be 99, 00, or XX. The list on the next page shows only the first two digits of the code numbers.

For future reference such as ordering repair parts, it is important to have these code numbers available.

To ensure this availability, enter the third and fourth digits shown on your engine option code label in the

spaces provided on the following page.

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