Page 1 Diesel Engine WORKSHOP MANUAL 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...
Page 2 Information contained in this Workshop Manual is the latest available at the time of publication. Ingersoll-Rand reserves the right to make changes at any time without prior n o t i c e . This Workshop Manual is applicable to 1999 and later models.
Page 3 TABLE OF CONTENTS SECTION 1. G E N E R A L I N F O R M A T I O N ..............5 SECTION 2.
Page 4 GENERAL INFORMATION SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS ITEM P A G E G e n e r a l r e p a i r i n s t r u c t i o n s ......................5 N o t e s o n t h e f o r m a t o f t h i s m a n u a l .
Page 5 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 INGERSOLL-RAND industrial engine or engines which is or are stated i n t h e t i t l e .
Page 6 GENERAL INFORMATION 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. 6.
Page 7 GENERAL INFORMATION...
Page 8 GENERAL INFORMATION 9. Measurement criteria are defined by the terms “standard” and “limit”. A measurement falling within the “standard’ range indicates that the applicable part or parts are serviceable. “Limit” should be thought of as an absolute value. A measurement which is outside the “limit” indicates that the applicable part or paas must be either repaired or replaced.
Page 9 GENERAL INFORMATION...
Page 10 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
Page 11 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
Page 12 GENERAL INFORMATION...
Page 13 GENERAL INFORMATION...
Page 14 GENERAL INFORMATION...
Page 15 GENERAL INFORMATION...
Page 16 GENERAL INFORMATION...
Page 17 GENERAL INFORMATION...
Page 18 GENERAL INFORMATION...
Page 19 MAINTENANCE SECTION 2 MAINTENANCE TABLE OF CONTENTS ITEM P A G E M o d e l i d e n t i f i c a t i o n ........................2 0 I n j e c t i o n p u m p i d e n t i f i c a t i o n .
Page 20 MAINTENANCE Servicing refers to general maintenance procedures to be performed by qualified service personnel. Maintenance interval such as fuel or oil filter changes should be refered to “INSTRUCTION MANUAL”. MODEL IDENTIFICATION Engine Serial Number The engine number is stamped on the rear left hand side of the cylinder body.
Page 21 4 . C l e a n t h e o i l c o o l e r f i t t i n g f a c e . MAINTENANCE T h i s w i l l a l l o w t h e n e w o i l f i l t e r t o s e a t p r o p e r l y . 5.
Page 22 MAINTENANCE Air Bleeding 1 . For the engine equipped with in-line type injection pump I) Loosen the priming pump cap on the injection pump 2) Loosen the fuel return eye bolt on the fuel filter. 3) Operate the priming pump until there are no more bubbles visible in the fuel being discharged from the f u e l r e t u r n e y e b o l t o n t h e f u e l f i l t e r .
Page 23 MAINTENANCE Injection Nozzle Injection Nozzle Inspection Use a nozzle tester to check the injection nozzle opening pressure and the spray condition. If the opening pressure is above or below the speci- fied value, the injection nozzle must be replaced or reconditioned.
Page 24 MAINTENANCE COOLING SYSTEM Cooling Fan Drive Belt Fan belt tension is adjusted by moving the alternator. A. Crankshaft damper pulley B. Alternator pulley C. Cooling fan drive pulley D. Depress the drive belt mid-portion with a 98 N (IO k g f / 2 2 I b . f t ) f o r c e . Drive Belt Deflection MM (IN.) 10.0 (0.39)
Page 25 MAINTENANCE VALVE CLEARANCE ADJUSTMENT 1. Retighten the rocker arm shaft bracket bolts in sequence as shown in the illustration. Rocker Arm Shaft Bracket Bolt Torque N-m (kgf-m/lb.ft) 49-59 (5-6/36-43) 2. Bring the piston in either the No. 1 cylinder or the No.
Page 26 MAINTENANCE Rotate the crankshaft 360 degree. Realign the crankshaft damper pulley TDC line with the timing pointer. Adjust the clearances for the remaining valves as shown in the illustration. (At TDC on the compression stroke of the No. 4 stroke) INJECTION TIMING Injection Timing Confirmation Procedure 1 .
Page 27 MAINTENANCE 2 . Distributor type injection pump I) Rotate the crankshaft clockwise to align the cam- shaft gear timing mark “.O” with the timing gear case cover pointer. The No. 1 cylinder will now be at the point where nearly injection timing. 2) Remove injector pump distributor head plug.
Page 28 MAINTENANCE COMPRESSION PRESSURE MEASURE- M E N T 1. Start the engine and allow it to run for several minutes to warm it up. 2. Stop the engine and cut the fuel supply. 3. Remove all of the glow plugs from the engine. Compression Gauge :54368691 Adapter :54368709 4.
Page 29 MAINTENANCE...
Page 30 MAINTENANCE ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit. The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit. 11 . Water pump gasket * 1 . Cylinder head gasket 12 .
Page 31 ENGINE ASSEMBLY (1) SECTION 3 ENGINE ASSEMBLY ( 1) TABLE OF CONTENTS ITEM P A G E G e n e r a l d e s c r i p t i o n ........................3 2 D i s a s s e m b l y .
Page 32 ENGINE ASSEMBLY (1) E N G I N E A S S E M B L Y G E N E R A L D E S C R I P T I O N This illustration is based on the A-4JAl engine in 4J series. The 4J Series of industrial engines features the unique troidal square combustion chamber.
Page 33 ENGINE ASSEMBLY (1) Disassembly Steps - 1 IO. Fuel leak off pipe 1.Cooling fan and spacer *11. Fuel injection pipe with clip 2.Cooling fan drive belt *12 . Injection pump 3.Cooling fan drive pulley 13 . Intake manifold 4.Alternator and adjusting plate 1 4 .
Page 34 ENGINE ASSEMBLY (1) Important Operations (Disassembly Steps - ‘l) 11. Fuel Injection Pipe with Clip I) Loosen the injection pipe sleeve nuts at the delivery valve side. Do not apply excessive force to the injection pipes. 2) Loosen the injection pipe clips. 3) Remove the injection pipes.
Page 35 ENGINE ASSEMBLY (1)
Page 36 ENGINE ASSEMBLY (1)
Page 37 ENGINE ASSEMBLY (1) Important Operations (Disassembly Steps - 2) 4. Injection Nozzle Holder 1 ) Remove the nozzle holder bracket nuts. 2) Use the nozzle holder remover and the sliding hammer to remove the nozzle holder together with the holder bracket. Sliding Hammer: 54368790 7.
Page 38 ENGINE ASSEMBLY (1) 11. Crankshaft Damper Pulley with Dust Seal 1 ) Block the flywheel with a piece of wood to pre- v e n t i t f r o m t u r n i n g . 2) Use the damper pulley remover to remove the damper pulley.
Page 39 ENGINE ASSEMBLY (1) Important Operations (Disassembly Steps - 3) 2. Flywheel 1 ) Block the flywheel with a piece of wood to pre- v e n t i t f r o m t u r n i n g . 2) Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration.
Page 40 ENGINE ASSEMBLY (1) 9. Crankshaft Bearing Cap with Lower Bearing 1) Measure the crankshaft end play at the center journal of the crankshaft. Do this before removing the crankshaft bearing caps. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced.
Page 41 ENGINE ASSEMBLY (1)
Page 42 ENGINE ASSEMBLY (1) Important Operations 1. Rocker Arm Shaft Snap Ring 2. Rocker Arm 3. Rocker Arm Shaft Bracket 1) Use a pair of snap ring pliers to remove the snap rings. 2) Remove the rocker arms. 3) Remove the rocker arm shaft bracket. If the rocker arms and rocker arm shaft brackets are to be reinstalled, mark their installation positions by tagging each rocker arm and rocker...
Page 43 ENGINE ASSEMBLY (1)
Page 44 ENGINE ASSEMBLY (1) Important Operations 1 .Split Collar I) Place the cylinder head on a flat wooden surface. 2) Use the spring compressor to remove the split c o l l a r . Do not allow the valve to fall from the cylinder head.
Page 45 ENGINE ASSEMBLY (1)
Page 46 ENGINE ASSEMBLY (1) Important OperationsImportant OperationsImportant Operations 1. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 2. Piston Ring I) Clamp the connecting rod in a vise.
Page 47 ENGINE ASSEMBLY (1)
Page 48 ENGINE ASSEMBLY (1) Important Operations 1. Camshaft Timing Gear 2. Thrust Plate 1) Clamp the camshaft in a vise. Take care not to damage the camshaft. 2) Use the universal puller 1 to pull out the camshaft timing gear 2. 3) Remove the thrust plate 3 .
Page 49 ENGINE ASSEMBLY ( 2 ) SECTION 4 ENGINE ASSEMBLY ( 2 ) TABLE OF CONTENTS ITEM P A G E I n s p e c t i o n a n d r e p a i r ..... , ....................5 0...
Page 50 ENGINE ASSEMBLY ( 2 ) INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. CYLINDER HEAD Cylinder Head Lower Face Warpage 1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.
Page 51 ENGINE ASSEMBLY ( 2 ) VALVE GUIDE Valve Stem and Valve Guide Clearance Measuring Method - I 1. With the valve stem inserted in the valve guide, set the dial indicator needle to “0”. 2. Move the valve head from side to side. Read the dial indicator.
Page 52 ENGINE ASSEMBLY ( 2 ) Valve Guide lnsttillation 1. Apply engine oil to the valve guide outer circumfer- ence. 2. Attach the valve guide replacer to the valve guide. 3. Use a hammer to drive the valve guide into posi- tion from the cylinder head upper face.
Page 53 ENGINE ASSEMBLY ( 2 ) Valve Depression 1. Install the valve 1to the cylinder head 2 . 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert must be replaced.
Page 54 ENGINE ASSEMBLY ( 2 ) 3. Use a screwdriver 3 to pry the valve seat insert f r e e . Take care not to damage the cylinder head 4 . 4. Carefully remove carbon and other foreign material from the cylinder head insert bore. Valve Seat Insert Installation 1.
Page 55 ENGINE ASSEMBLY ( 2 ) 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while tapping it to fit the valve seat i n s e r t . 6.
Page 56 ENGINE ASSEMBLY ( 2 ) ROCKER ARM SHAFT AND ROCKER A R M Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on a V-block. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press.
Page 57 ENGINE ASSEMBLY ( 2 ) 3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker a r m o i l p o r t . Rocker Arm Correction Inspect the rocker arm valve stem contact surfaces for step wear 1 and scoring 2.
Page 58 ENGINE ASSEMBLY ( 2 ) Cylinder Liner Replacement Cylinder Liner Removal 1. Remove the cylinder body dowel. 2. Set the cylinder liner remover to the cylinder liner. 3. Check that the remover shaft ankle is firmly gripping the cylinder liner bottom edge. 4.
Page 59 Cylinder Liner Grade Selection ENGINE ASSEMBLY ( 2 ) Measure the cylinder body inside diameter and select the proper cylinder liner grade number corresponding to the cylinder body inside diameter. I f t h e c y l i n d e r l i n e r f i t t i n g i n t e r f e r e n c e i s t o o s m a l l , engine cooling efficiency will be adversely affected.
Page 60 ENGINE ASSEMBLY ( 2 ) Cylinder Liner Installation 1. Cylinder Liner installation Using The Special Tool. 1) Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores. 2) Use compressed air to blow-dry the cylinder liner and bore surfaces. Note: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installa-...
Page 61 WARNING: ENGINE ASSEMBLY ( 2 ) DRY ICE MUST BE USED WITH GREAT CARE. CARE-LESS HANDLING OF DRY ICE CAN RESULT IN SEVERE FROSTBITE. Piston Selection Select the same grade number as the one for the cylinder liner inside diameter.
Page 62 ENGINE ASSEMBLY ( 2 ) Piston Grade Selection Measure the cylinder liner bore. Then select the appropriate piston grade for the installed cylinder l i n e r . 1. Measure the cylinder liner bore. There are two measuring points ( 1 and 2 ). Measure the cylinder liner bore in four different direction (W - W, X - X, and Z - Z) at both mea-suring p o i n t s .
Page 63 ENGINE ASSEMBLY ( 2 ) TAPPET AND PUSH ROD Visually inspect the tappet camshaft contact surfaces for pitting, cracking, and other abnormal conditions. The tappet must be replaced if any of these condi- tions are present. R e f e r t o t h e i l l u s t r a t i o n a t t h e l e f t . I P i t t i n g 2 Cracking 3 Normal contact...
Page 64 ENGINE ASSEMBLY ( 2 ) Push Rod Curvature 1. Lay the push rod on a surface plate. 2. Roll the push rod along the surface plate and mea- sure the push rod curvature with a thickness gauge. If the measured value exceeds the specified limit, the push rod must be replaced.
Page 65 ENGINE ASSEMBLY ( 2 ) Cam Height Measure the cam height (H) with a micrometer. If the measured value is less than the specified limit, the camshaft must be replaced. Camshaft Run-Out 1. Mount the camshaft on V-blocks. 2. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the camshaft must be replaced.
Page 66 ENGINE ASSEMBLY ( 2 ) Camshaft Bearing Installation 1. Align the bearing oil holes with the cylinder body oil holes. 2. Use the camshaft bearing replacer installer to install the camshaft bearing. Bearing Replacer: 54368741 Camshaft End Play 1. Before removing the camshaft gear 0, push the thrust plate @ as far as it will go toward the cam- s h a f t gear 0.
Page 67 CRANKSHAFT AND BEARING ENGINE ASSEMBLY ( 2 ) Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. Note: To increase crankshaft strength, tufftriding (Nitrizing Treatment) has been applied.
Page 68 ENGINE ASSEMBLY ( 2 ) Crankshaft Thrust Clearance Set the dial, indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, re- place the thrust bearing as a set. Crankshaft Run-Out 1.
Page 69 ENGINE ASSEMBLY ( 2 ) Crankshaft Journal and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankshaft journal diameter ex- ceeds the specified limit, the bearing and/or the crankshaft must be replaced. Connecting Rod Bearing Inside Diameter 1.
Page 70 ENGINE ASSEMBLY ( 2 ) Crankpin and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replaced. Clearance Measurements (With Plastigage) Crankshaft Journal and Bearing Clearance 1.
Page 71 ENGINE ASSEMBLY ( 2 ) 9. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter.
Page 72 ENGINE ASSEMBLY ( 2 ) CRANKSHAFT BEARING SELECTION When installing new crankshaft bearings or replacing old bearings, refer to the slection table below. Select and install the new crankshaft bearings,paying close attention to the cylinder body journal hole diameter size mark and the crankshaft journal diameter size mark.
Page 73 ENGINE ASSEMBLY ( 2 ) CRANKSHAFT PILOT BEARING Check the crankshaft pilot bearing for excessive wear and damage and replace it if necessary. Crankshaft Pilot Bearing Replacement Crankshaft Pilot Bearing Removal Use the pilot bearing remover to remove the pilot bear-ing.
Page 74 ENGINE ASSEMBLY ( 2 ) FLYWHEEL AND RING GEAR Flywheel 1. Inspect the flywheel friction surface for excessive wear and heat cracks. 2. Measure the flywheel friction surface wear amount (depth) The flywheel friction surface area actually making contact with the clutch driven plate (the shaded area i n t h e i l l u s t r a t i o n ) w i l l b e s m a l l e r t h a n t h e o r i g i n a l machined surface area.
Page 75 ENGINE ASSEMBLY ( 2 ) Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200°C (390°F). 2 . i n s t a l l t h e r i n g g e a r w h e n i t i s s u f f i c i e n t l y h e a t e d . The ring gear must be installed with the chamfer facing the clutch.
Page 76 ENGINE ASSEMBLY ( 2 ) Piston Ring and Piston Ring Groove Clearance Use a feeler gauge to measure the clearance be- tween the piston ring and the piston ring groove at several points around the piston. If the clearance between the piston ring and the piston ring groove exceeds the specified limit, the piston ring must be replaced.
Page 77 ENGINE ASSEMBLY ( 2 ) PISTON PIN Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points. If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin and Piston Clearance Use an inside dial indicator to measure the piston pin h o l e ( i n t h e p i s t o n ) .
Page 78 ENGINE ASSEMBLY ( 2 ) Connecting Rod Bushing Installation 1. Clamp the connecting rod in a vice. 2. Use the connecting rod bushing installer to install the connecting rod bushing. Connecting Rod Bushing Replacer: 3. Use a piston pin hole grinder 1 fitted with a reamer 2 to ream the piston pin hole.
Page 79 ENGINE ASSEMBLY ( 2 ) Connecting Rod Side Face Clearance 1. Install the connecting rod to the crankpin. 2. Use a feeler gauge to measure the clearance between the connecting rod big end side face and the crankpin side face. If the measured value exceeds the specified limit, the connecting rod must be replaced.
Page 80 ENGINE ASSEMBLY ( 2 ) Idler Gear “A” Inside Diameter 1. Use an inside dial indic ator to measure the idler gear If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the limit, the idler gear must be replaced. Idler Gear Shaft and Idler Gear Idler Gear “B”...
Page 81 ENGINE ASSEMBLY ( 2 ) Oil Seal Installation 1. Apply a coat of engine oil to the oil seal lip circum- ference. 2 . U s e t h e o i l s e a l i n s t a l l e r a n d t h e i n s t a l l e r g r i p t o insert the oil seal 1 mm (0.039 in) into the front por- tion of the timing gear case.
Page 82 SECTION 5 ENGINE ASSEMBLY ( 3 ) TABLE OF CONTENTS ITEM P A G E R e a s s e m b l y ........................... . 8 2...
Page 83 ENGINE ASSEMBLY (3 )
Page 84 ENGINE ASSEMBLY (3 ) Important Operations 1. Rocker Arm Shaft 1) Position the rocker arm shaft with the large oil hole (Dia. 4 mm (0.136 in)) facing the front of the engine. 2) Install the rocker arm shaft together with the rocker arm, the rocker arm shaft bracket, and the spring.
Page 85 ENGINE ASSEMBLY (3 )
Page 86 ENGINE ASSEMBLY (3 ) Important Operations 3. Valve Stem Oil Seal I) Apply a coat engine oil to the oil seal inner face. 2 ) U s e a n o i l s e a l i n s t a l l e r t o i n s t a l l t h e o i l s e a l t o the valve guide.
Page 87 ENGINE ASSEMBLY (3 )
Page 88 ENGINE ASSEMBLY (3 ) Important Operation 1. Piston 2. Piston pin snap ring 3. Connecting rod 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use a pair of snap ring pliers to install the piston pin snap ring to the piston.
Page 89 ENGINE ASSEMBLY (3 ) 6. Piston Ring 1) Use a piston ring replacer to install the three p i s t o n r i n g s . Piston Ring Replacer: Install the piston rings in the order shown in the i l l u s t r a t i o n .
Page 90 ENGINE ASSEMBLY (3 )
Page 91 ENGINE ASSEMBLY (3 ) Important Operations 4. Camshaft Timing Gear 1 ) I n s t a l l t h e t h r u s t p l a t e 1 . 2) Appiy engine oil to the bolt threads 2 . 3) Install the camshaft timing gear with the timing mark stamped side facing out.
Page 92 ENGINE ASSEMBLY (3 )
Page 93 ENGINE ASSEMBLY (3 )
Page 94 ENGINE ASSEMBLY (3 ) Important Operations (Reassembly Step-1) 1. Cylinder Body Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder body, the oil holes, and the water jackets. 2. Tappet 1) Apply a coat of engine oil to the tappet 1 and the cylinder body tappet insert holes 2 .
Page 95 ENGINE ASSEMBLY (3 ) 5. Crankshaft Thrust Bearing I) Apply an ample coat of engine oil to the crank-shaft thrust bearings. 2) Install the crankshaft thrust bearings to the crankshaft center journal. The crankshaft thrust bearing oil groove must be facing the sliding face. 6.
Page 96 ENGINE ASSEMBLY (3 ) 8. Camshaft with Camshaft Timing Gear and Thrust Plate 1) Apply a coat of engine oil to the camshaft and the camshaft bearings. 2) Install the camshaft to the cylinder body. Take care not to damage the camshaft bearings. 3) Tighten the thrust plate to the specified torque.
Page 97 ENGINE ASSEMBLY (3 ) 6) Position the piston head front mark so that it is facing the front of the cylinder body. 7) Use a piston ring compressor to compress the p i s t o n r i n g s . Piston Ring Compressor 8) Use a hammer grip to push the piston in until the connecting rod makes contact with the...
Page 98 ENGINE ASSEMBLY (3 ) 11. Oil Pump with Oil Pipe Install the oil pump with the oil pipe and tighten the bolts to the specified torque. Note: Take care not to damage the O-rings when tightening t h e o i l p i p e b o l t s . 12.
Page 99 ENGINE ASSEMBLY (3 ) 14. Flywheel 1) Block the flywheel with a piece of wood to pre-vent i t f r o m t u r n i n g . 2) Apply a coat of engine oil to the threads of the flywheel bolts.
Page 100 ENGINE ASSEMBLY (3 ) Important Operations (Reassembly Step- 2) 1. Idler Gear Shaft The idler gear shaft oil hole must be facing up. 2. Idler Gear “A” 1) Apply engine oil to the idler gear 1 and the i d l e r g e a r s h a f t 2 . 2) Position the idler gear setting marks “X”...
Page 101 ENGINE ASSEMBLY (3 ) 5. Timing Case Cover 1) Before installing the timing gear case, apply a 3 mm x 5 mm (0.12 in x 0.20 in) strip of sealant to the portion of the feather key indicated by the a r r o w i n t h e i l l u s t r a t i o n .
Page 102 ENGINE ASSEMBLY (3 ) 2. Use a dial indicator to measure the piston head projection at measuring points 1 and 3 on the piston head and measuring points 2 and 4 on the cylinder body. Do this for each cylinder. 3.
Page 103 ENGINE ASSEMBLY (3 ) 11. Rocker Arm Shaft and Rocker Arm Tighten the rocker arm shaft bracket bolts in the numerical order shown in the illustration. 12. Water Pump I) Temporarily tighten the water pump bolt marked with an arrow in the illustration. This bolt will be tightened to the specified to torque when the alternator adjusting plate is i n s t a l l e d .
Page 104 ENGINE ASSEMBLY (3 ) 10.Starter 1.Intake manifold 11.Exhaust manifold 2.Injection pump 12.Cooling water intake pipe 3.Fuel injection pipe with clip 13.cooling water rubber hose 4.Fuel leak off pipe 14.Alternator and adjusting plate 5.Oil pipe (Injection pump to cylinder body) 1 5 . O i l f i l t e r 6 .
Page 105 ENGINE ASSEMBLY (3 ) Important Operations (Reassembly Steps-31 1. Intake Manifold Install the intake manifold gasket with the end having the sharp corners facing the front of the engine. 2. injection Pump 1) Turn the crankshaft slowly clockwise to align the camshaft timing check hole pointer 1 with the camshaft timing gear “0”...
Page 106 ENGINE ASSEMBLY (3 ) 3. Fuel Injection Pipe with Clip 1) Temporarily tighten the injection pipe sleeve nut. 2) Set the clip in the prescribed position. Note: Make absolutely sure that the clip is correctly posi- tioned. An improperly positioned clip will result in injection pipe breakage and fuel pulsing noise.
Page 107 Alternator and Adjusting Plate ENGINE ASSEMBLY (3 ) Tighten the alternator bolts and the adjusting plate bolts to the specified torque. 1 5 . O i l F i l t e r T i g h t e n t h e o i l f i l t e r b o l t s t o t h e s p e c i f i e d t o r q u e . Solenoid 1) Install the solenoid, connect the link rod with the stop lever on the injection pump, and semi-tighten...
Page 108 LUBRICATING SYSTEM SECTION 6 LUBRICATING SYSTEM TABLE OF CONTENTS ITEM P A G E M a i n d a t a a n d s p e c i f i c a t i o n s ..................... . 1 0 9 G e n e r a l d e s c r i p t i o n .
Page 109 LUBRICATING SYSTEM MAIN DATA AND SPECIFICATIONS...
Page 110 LUBRICATING SYSTEM G E N E R A L D E S C R I P T I O N LUBRICATING OIL FLOW This illustration is based on 4J Series engine with oil cooler (option). Lubricating oil flow may vary according to the engine specification. The 4J Series engine lubricating system is a full forced circulation type.
Page 111 LUBRICATING SYSTEM OIL PUMP 4J Series engine are equipped with a trochoid type oil pump.
Page 112 LUBRICATING SYSTEM MAIN OIL FILTER OIL FILTER WITH BUILT-IN OIL COOLER...
Page 113 LUBRICATING SYSTEM OIL PUMP Disassembly Steps 4.Vane 1.Oil Pipe 5.Pump body with rotor pinion 2.Strainer case 3.Pump cover...
Page 114 LUBRICATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-covered during inspection. Vane, Rotor, and Cover Clearance . Use a feeler gauge to measure the clearance be- tween the vane, the rotor, and the cover. If the clearance between the vane, the rotor, and the cover exceeds the specified limit, the rotor set (pin, shaft, rotor, and vane) must be replaced.
Page 115 LUBRICATING SYSTEM R E A S S E M B L Y Reassembly Steps 4.Strainer case 1.Pump body with rotor and pinion 5.Oil pipe 2.Vane 3.Pump cover...
Page 116 LUBRICATING SYSTEM OIL FILTER WITH BUILT-IN OIL COOLER Disassembly Steps 5 . Safety valve 1. Drain plug 6 . R e l i e f v a l v e 2 . C a r t r i d g e o i l f i l t e r 7 .
Page 117 LUBRICATING SYSTEM I N S P E C T I O N A N D R E P A I R Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Regulating Valve 1.
Page 118 LUBRICATING SYSTEM R E A S S E M B L Y Reassembly Steps 1 . O i l f i l t e r b o d y 5 . O i l c o o l e r 2.
Page 119 LUBRICATING SYSTEM Important Operations 2. Regulating Valve Tighten the relief valve to the specified torque. 5. Oil Cooler 1) Align the oil filter holes with the body knock p i n s a t i n s t a l l a t i o n . 2) Tighten the oil cooler to the specified torque.
Page 120 COOLING SYSTEM SECTION 7 COOLING SYSTEM TABLE OF CONTENTS ITEM P A G E M a i n d a t a a n d s p e c i f i c a t i o n s ..................... . 1 2 1 G e n e r a l d e s c r i p t i o n .
Page 121 COOLING SYSTEM MAIN DATA AND SPECIFICATIONS...
Page 122 COOLING SYSTEM G E N E R A L D E S C R I P T I O N COOLANT FLOW The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump and thermostat through the by-pass hose and back to the cylinder body.
Page 123 COOLING SYSTEM WATER PUMP A centrifugal type water pump forcefully circulates the coolant through the cooling system.
Page 124 COOLING SYSTEM T H E R M O S T A T I N S P E C T I O N A N D R E P A I R Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
Page 125 FUEL SYSTEM SECTION 8 FUEL SYSTEM TABLE OF CONTENTS ITEM P A G E M a i n d a t a a n d s p e c i f i c a t i o n s ..................... . 126 G e n e r a l d e s c r i p t i o n .
Page 126: Main Data And Specifications
FUEL SYSTEM MAIN DATA AND SPECIFICATIONS...
Page 127: G E N E R A L D E S C R I P T I O
FUEL SYSTEM G E N E R A L D E S C R I P T I O N FUEL FLOW The fuel system consists of the fuel tank, the water separator (if so equipped), the fuel filter, the i n j e c t i o n pump, and the injection nozzle.
Page 128: I N J E C T I O N N O Z Z L
FUEL SYSTEM INJECTION NOZZLE A hole (with 5 orifices) type injection nozzle is used. It consists of the nozzle body and the needle valve assembly. The injection nozzle sprays pressurized fuel from the injection pump into the combustion chamber through the nozzle body injection orifice.
Page 129 FUEL SYSTEM FUEL FILTER AND WATER SEPARATOR A cartridge type fuel filter and a water separator are used. As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump.
Page 130 FUEL SYSTEM I N J E C T I O N N O Z Z L E Disassembly Steps 1 . Retaining nut 5 . Spring A 2 . Injection nozzle 6 . Adjusting shim 3 . Spacer 7 . Nozzle holder 4 .
Page 131 FUEL SYSTEM Important Operations Performance this test before disassembling the injection nozzle. 1) Install the injection nozzle to the nozzle tester. 2) Use the nozzle tester to apply compressed fuel at 18.1 MPa (185 kgf/cm*/2,630 psi) to the injection nozzle. 3)Check the area around the nozzle seat for fuel leakage.
Page 132 FUEL SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Injection Nozzle Needle Inspection 1 . Remove the nozzle needle from the nozzle body. 2 . Carefully wash the nozzle needle and the nozzle body in clean diesel fuel.
Page 133 FUEL SYSTEM Reassembly Steps 1 . Nozzle holder 5 . Spacer 2 . Adjusting shim 3 . Spring 6 . Injection nozzle 4 . Spring seat 7. Retaining nut...
Page 134 FUEL SYSTEM Important Operations 3. Adjust Shim 7. Retaining Nut Tighten to the retaining nut to the specified torque. Injection Nozzle Adjustment 1. Attach the injection nozzle holder to the injection nozzle tester. 2. Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure.
Page 135 Without this data, the Service Outlet will be unable to effectively service your injection pump. If you are unable to locate the data applicable to your injection pump, please contact Ingersoll-Rand Co. through your machine supplier. 3. Do not remove the Identification Plate and Product Serial Number from the injection pump.
Page 136 FUEL SYSTEM...
Page 137 FUEL SYSTEM...
Page 138: I N J E C T I O N P U M P C A L I B R A T I O N D A T
TROUBLESHOOTING SECTION 9 TROUBLESHOOTING TABLE OF CONTENTS ITEM P A G E H a r d s t a r t i n g ....................... . . 1 4 0 U n s t a b l e i d l i n g .
Page 139 TROUBLESHOOTING TROUBLESHOOTING Refer to this Section to quickly diagnose and repair engine problems. Each troubleshooting chart has three headings arranged from left to right. (3) Checkpoint (2) Trouble Cause (3) Countermeasure This Section is divided into ten sub-sections: 1 . Hard Starting 1) Starter inoperative 2) Starter operates but engine does not turn over 3) Engine turns over but does not start...
Page 163 SECTION 10 REPAIR STANDARDS TABLE OF CONTENTS ITEM P A G E G e n e r a l r u l e s ..........................1 6 3 R e p a i r s t a n d a r d s c h a r t .
Page 176 SECTION 11 CONVERSION TABLES INDEX CONTENTS P A G E L e n g t h ............................1 7 6 A r e a .

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Ingersoll-Rand 4IRJ7N Workshop Manual

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Summary of Contents for Ingersoll-Rand 4IRJ7N

Page 126: Main Data And Specifications

Page 127: G E N E R A L D E S C R I P T I O

Page 128: I N J E C T I O N N O Z Z L

Page 138: I N J E C T I O N P U M P C A L I B R A T I O N D A T

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