Ingersoll-Rand 4IRD5T Operation Manual
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Ingersoll-Rand 4IRD5T Operation Manual

Ingersoll-Rand 4IRD5T Operation Manual

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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.
Book: 22787584 (4/07) Rev. B
Revised (10-12)
Engine Operation Manual
For Engine Models
4IRD5T
4IRD5AE
4IRD5TE
6IRF8AE4
6IRF8AE
6IRF8TE

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  • Page 1 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.
  • Page 2 C A LIFO R N IA P roposition 65 Warning D iesel engine exhaust and som e of its constituents are know n to the State of C alifornia to cause cancer, birth defects, and other reproductive harm .

  • Page 3: Forward

    CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instrum ents are optional equipm ent on Ingersoll-Rand OEM Engines. An equipm ent m anufacturer other than of Ingersoll - Rand m ay provide these accessories. This operator’s m anual applies only to the engine and those options available through...

  • Page 4: Table Of Contents

    Contents INTRODUCTION Forward 4IR D 5T E 4.5 L ENGINES WITH ELECTRONIC FUEL SYSTEMS (TIER II EMISSION CERTIFIED), (TWO-VALVE CYLINDER HEAD MODELS444 Pages 4, 5 and 6 deleted. Do not apply. 6IR F 8T E 6.8 L ENGINES WITH ELECTRONIC FUEL SYSTEMS (TIER II EMISSION CERTIFIED), (TWO-VALVE CYLINDER HEAD MODELS) CONTENTS RECORD KEEPING...
  • Page 5 Service Engines Safely Wear Protective Clothing Protect Against Noise Handle Chemical Products Safely Practice Safe Maintenance Work In Ventilated Area Avoid High-Pressure Fluids Avoid Heating Near Pressurized Fluid Lines Remove Paint Before Welding or Heating Install Fan Guards Avoid Hot Parts Service Cooling System Safely Avoid Harmful Asbestos Dust Prevent Battery Explosions...
  • Page 6 Bio-Diesel Fuel Handling And Storing Bio-Diesel Fuel Filling Fuel Tank Minimizing the Effect of Cold Weather on Diesel Engines Use Grade No. 1-D Fuel Air Inlet Heater Aids Coolant Heaters Seasonal Viscosity Oil and Proper Coolant Concentration Diesel Fuel Flow Additive Winter fronts Radiator Shutters Diesel Engine Break-In Oil...
  • Page 7 ENGINE OPERATING GUIDELINES Normal Engine Operation Engine Break-In Service Starting The Engine Cold Weather Starting Stopping the Engine Using a Booster Battery or Charger LUBRICATION AND MAINTENANCE Observe Service Intervals Use Correct Fuels, Lubricants, and Coolant Lubrication and Maintenance Service Interval Chart—Standard Industrial Engines Lubrication &...
  • Page 8 Flushing and Refilling Cooling System Testing Thermostats Opening Temperature Testing Thermostats Opening Temperature To Install Thermostats Check and Adjust Valve Clearance Service As Required Do Not Modify Fuel System Adding Coolant Replacing Radial Seal Air Cleaner Filter Element Replacing Fan and Alternator Belts Bleed the Fuel System (Engines with Electronic Fuel Systems and Stanadyne DE10 Pump) Bleeding the Fuel System (Engines with Electronic Fuel Systems and Bosch VP44 Pump) TROUBLESHOOTING...

  • Page 9: Record Keeping

    R ecord K eeping A m edallion is located on the rocker arm cover, which identifies each engine. E ngine S erial N um ber Plate Each engine has a 13-digit engine serial num ber. The first two digits identify the factory that produced the engine.

  • Page 10: Engine Option Codes

    E ngine O ption C odes In addition to the serial num ber plate, OEM engines have an engine option code label affixed to the rocker arm cover. These codes indicate which of the engine options were installed on your engine at the factory.
  • Page 11 NOTE: Your engine option code label m ay not contain all option codes if an option has been added after the engine left the producing factory. O p tio n C o d es D escrip tio n O p tio n C o d es D escrip tio n Rocker Arm Cover Cylinder Block and Cam shaft...

  • Page 12: Safety

    Keep your m achine in proper working condition. Unauthorized m odifications to the m achine m ay im pair the function and/or safety and affect m achine life. If you do not understand any part of this m anual and need assistance, contact your Ingersoll-Rand dealer.

  • Page 13: Replace Safety Signs

    R eplace S afety S igns Replace m issing or dam aged safety signs. See the m achine operator’s m anual for correct safety sign placem ent. P revent B ypass S tarting Avoid possible injury or death from engine runaway. Do not start engine by shorting across starter term inal.

  • Page 14: Prepare For Emergencies

    P repare for E m ergencies Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep em ergency num bers for doctors, am bulance service, hospital, and fire departm ent near your telephone. H andle Fluids S afely— A void Fires W hen you work around fuel, do not sm oke or work near heaters or other fire hazards.

  • Page 15: Wear Protective Clothing

    That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recom m ended equipm ent. (See your Ingersoll-Rand dealer for M SDS’s on chem ical products used with Ingersoll-Rand equipm ent.)

  • Page 16: Practice Safe Maintenance

    P ractice S afe M aintenance Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust m achine while it is m oving. Keep hands, feet, and clothing from power- driven parts. Disengage all power and operate controls to relieve pressure.

  • Page 17: Avoid High-Pressure Fluids

    A void H igh-P ressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

  • Page 18: Remove Paint Before Welding Or Heating

    R em ove P aint B efore W elding or H eating Avoid potentially toxic fum es and dust. Hazardous fum es can be generated when welding, soldering, or using a torch to heats paint. Rem ove paint before heating: Remove paint a m inim um of 76 m m (3 in.) from area to be affected by heating.

  • Page 19: Service Cooling System Safely

    S ervice C ooling S ystem S afely Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only rem ove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before rem oving com pletely.

  • Page 20: Prevent Acid Burns

    P revent A cid B urns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.

  • Page 21: Dispose Of Waste Properly

    D ispose of W aste P roperly Im properly disposing of waste can threaten the environm ent and ecology. Potentially harm ful wastes used with Ingersoll-Rand equipment include such item s as oil, fuel, coolant, brake fluid, filters, and batteries.

  • Page 22: Fuels, Lubricants, And Coolant

    Fuels, Lubricants, and C oolant D iesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low tem perature requirem ents of the geographical area in which they are m arketed.

  • Page 23: Lubricity Of Diesel Fuel

    Lubricity of D iesel Fuel Diesel fuel m ust have adequate lubricity to ensure proper operation and durability of fuel injection system com ponents. Diesel fuels for highway use in the United States and Canada require sulfur content less than 0.05% (500 ppm ).

  • Page 24: Diesel Fuel Storage

    D iesel Fuel S torage Handle fuel carefully. Do not fill the fuel tank when engine is running. DO NOT sm oke while you fill the fuel tank or service the fuel system . Fill the fuel tank at the end of each day’s operation to prevent water condensation and freezing during cold weather.

  • Page 25: Bio-Diesel Fuel

    B io-D iesel Fuel Consult your local fuel distributor for properties of the bio-diesel fuel available in your area. Bio-diesel fuels m ay be used ONLY if the bio-diesel fuel properties m eet the latest edition of ASTM D6751, DIN 51606, EN14214 or equivalent specification. It has been found that bio-diesel blends up to 5% by volum e in petroleum diesel fuel (or B5) m ay im prove lubricity and with no harm ful effects.

  • Page 26: Handling And Storing Bio-Diesel Fuel

    H andling A nd S toring B io-D iesel Fuel H an d le fu el carefu lly. D o n o t fill th e fu el tan k w h en en g in e is ru n n in g . D O N O T sm o ke w h ile yo u fill th e fu el tan k o r service th e fu el system .

  • Page 27: Filling Fuel Tank

    Filling Fuel Tank H an d le fu el carefu lly. D o n o t fill th e fu el tan k w h en en g in e is ru n n in g . D O N O T sm o ke w h ile fillin g fu el tan k o r servicin g fu el system .

  • Page 28: Minimizing The Effect Of Cold Weather On Diesel Engines

    M inim izing the E ffect of C old W eather on D iesel E ngines Diesel engines are designed to operate effectively in cold weather. However, for effective starting and cold weather operation, a little extra care is necessary. The inform ation below outlines steps that can m inim ize the effect that cold weather m ay have on starting and operation of your engine.

  • Page 29: Winter Fronts

    If air-to-air after cooling is used, the shutters m ust be com pletely open by the tim e the intake m anifold air tem perature reaches the m axim um allowable tem perature out of the charge air cooler. For m ore inform ation, see your Ingersoll-Rand distributor or servicing dealer.

  • Page 30: Diesel Engine Break-In Oil

    Diesel fuel with sulfur content greater than 1.0% (10,000 ppm ) is not recom m ended. Extended service intervals m ay apply when Ingersoll-Rand preferred engine oils are used. Consult your Ingersoll-Rand dealer for m ore inform ation. DO NOT use break-in oils in these engines.

  • Page 31: Mixing Of Lubricants

    Conditions in certain geographical areas m ay require lubricant recom m endations different from those printed in this m anual. Som e Ingersoll-Rand brand coolants and lubricants m ay not be available in your location. Consult your Ingersoll-Rand dealer to obtain inform ation and recom m endations.

  • Page 32: Lubricant Storage

    Lubricant S torage Your equipm ent can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. W henever possible, store lubricants and containers in an area protected from dust, m oisture, and other contam ination. Store containers on their side to avoid water and dirt accum ulation.

  • Page 33: Diesel Engine Coolant

    A 50% m ixture of ethylene glycol engine coolant in water provides freeze protection to -37 C (-34 F). If protection at lower tem peratures is required, consult your Ingersoll-Rand dealer for recom m endations. W ater quality is im portant to the perform ance of the cooling system . Distilled, deionized, or dem ineralized water is recom m ended for m ixing with ethylene glycol base engine coolant concentrate.

  • Page 34: Diesel Engine Coolants, Supplemental Additive Information

    D iesel E ngine C oolants, S upplem ental A dditive Inform ation Engine coolants are a com bination of three chem ical com ponents: ethylene glycol (antifreeze), inhibiting coolant additives, and quality water. C oolant S pecifications Som e products are fully form ulated coolants that contain all three com ponents in their correct concentrations.

  • Page 35: Freeze Protection

    Freeze P rotection The relative concentrations of ethylene glycol and water in the engine coolant determ ine its freeze protection lim it. E th ylen e G lyco l F reeze P ro tectio n L im it -24 C (-12 F) -37 C (-34 F) -52 C (-62 F) DO NOT use a coolant-water m ixture greater than 60% ethylene glycol.

  • Page 36: Operating In Warm Temperature Climates

    O perating in W arm Tem perature C lim ates Diesel engines use Ingersoll-Rand equipm ent are designed to operate using glycol base engine coolants. Always use a recom m ended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

  • Page 37: Engine Operating Guidelines

    100-hour period, a longer break-in period m ay be required. In these situations, an additional 100-hour break-in period is recom m ended using a new change of ENGINE BREAK-IN OIL and a new Ingersoll-Rand oil filter.
  • Page 38 A — C ro ssh atch P attern O n D ip stick 3. Check engine oil level m ore frequently during engine break-in period. If oil m ust be added during this period, Ingersoll-Rand ENGINE BREAK-IN OIL is preferred. See ENGINE BREAK-IN OIL, in Fuels, Lubricants, and Coolant Section.
  • Page 39 Som e increase in oil consum ption m ay be expected when low viscosity oils are used. Check oil levels m ore frequently. 6. If air tem perature is below -10 C (14 F), use an engine block heater. 7. Check poly-vee belt for proper alignm ent and seating in pulley grooves.

  • Page 40: Starting The Engine

    A s it co u ld cau se an exp lo sio n an d p o ssib le p erso n n el in ju ry. Additionally, your Engine m ay be fitted with a block heater, and increased capacity battery and/or lower viscosity oil m ay also be used. See your local Ingersoll-Rand distributor or servicing dealer for recom m endations.

  • Page 41: Stopping The Engine

    S topping the E ngine 1. Refer to the G60 Operation and Maintenance Manual for stopping the generator set. M ake su re th at exh au st stack cap (rain cap ) is in p lace w h en en g in e is n o t ru n n in g . T h is w ill p reven t w ater an d d irt fro m en terin g en g in e.

  • Page 42: Using A Booster Battery Or Charger

    U sing a B ooster B attery or C harger A 12-volt booster battery can be connected in parallel with battery (ies) on the unit to aid in cold weather starting. ALW AYS use heavy-duty jum per cables. Exploding Battery G as g iven o ff b y b attery is exp lo sive.
  • Page 43 1. Connect booster battery or batteries to produce the required system voltage for your engine application. A – 12-Volt Machine Battery (ies) B – 12-Volt Booster Battery (ies) C – Booster Cable D – Cable to Starting Motor 24 V System To avoid sparks, DO NOT allow the free ends of jum per cables to touch the engine.

  • Page 44: Lubrication And Maintenance

    F u els, L u b rican ts, an d C o o lan t S ectio n w h en servicin g yo u r en g in e. Consult your Ingersoll-Rand distributor, servicing dealer or your nearest Ingersoll-Rand Parts Network for recom m ended fuels, lubricants, and coolant.

  • Page 45: Lubrication And Maintenance Service Interval Chart-Standard Industrial Engines

    Lubrication and M aintenance S ervice Interval C hart— S tandard Industrial E ngines The service intervals below are for standard industrial engines. See details in the Sections, which follow these charts. Lubrication and Maintenance Service Intervals Item Daily 500 Hour/ 2000 Hour/ As Required 12 Month...

  • Page 46: Lubrication & Maintenance/Daily

    Lubrication & M aintenance/D aily D aily P restarting C hecks Do the following BEFORE STARTING THE ENGINE for the first tim e each day: 1. Check engine oil level on dipstick. Add as required, using seasonal viscosity grade oil. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for oil specifications.) Depending on application, oil m ay be added...
  • Page 47 2. Check the coolant level when engine is cold. Coolant level should be at bottom of filler neck. Fill radiator (A) with proper coolant solution if level is low. (See ADDING COOLANT in Service As Required Section.) Check overall cooling system for leaks. Refer to your vehicle’s operator’s m anual for recom m endations for non-Ingersoll-Rand supplied accessories.
  • Page 48 3. Check the fuel filters for water or debris. If filter is fitted with a see-through bowl, drain as needed based on a daily visual inspection. D rain w ater in to a su itab le co n tain er an d d isp o se o f p ro p erly. a.
  • Page 49 4. If the air cleaner has an autom atic dust unloader valve (A), squeeze the unloader valve on air cleaner assem bly to clear away any dust buildup. If equipped with air intake restriction indicator gauge (B), check gauge to determ ine if air cleaner needs to be serviced.

  • Page 50: Lubrication & Maintenance, 500 Hour/12 Month

    Lubrication & M aintenance, 500 H our/12 M onth C hecking E ngine M ounts Engine m ounting is the responsibility of the vehicle or generator m anufacturer. Follow m anufacturer’s guidelines for m ounting specifications. U se o n ly G rad e S A E 8 o r h ig h er g rad e o f h ard w are fo r en g in e m o u n tin g .
  • Page 51 1. On regular batteries, check electrolyte level. Fill each cell to bottom of filler neck with distilled water. Low-m aintenance or m aintenance-free batteries should require little additional service. However, electrolyte level can be checked by cutting the center section of the decal on the dash-line, and rem oving cell plugs.
  • Page 52 1. D rin k larg e am o u n ts o f w ater o r m ilk. 2. T h en d rin k m ilk o f m ag n esia, b eaten eg g s, o r veg etab le o il. 3.

  • Page 53: Manual Belt Tensioner Adjustment

    M anual B elt Tensioner A djustm ent N O T E : There are two types of m anual tensioners shown. N O T E : Inspect belts for cracks, fraying, or stretched-out areas. Replace if necessary. As a reference check, twist belt in the m iddle of a 254— 305 m m (10—...

  • Page 54: Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)

    M anual B elt Tensioner A djustm ent U sing B elt Tension Tool (A lternate M ethod For E ngines W ithout A uxiliary D rive) NOTE: The JD1520 Belt Tension Tool m ay not be com patible with all alternators. In that case, use the preceding m ethod for belt tensioning.
  • Page 55 4. W hile holding tension with torque wrench (B), scribe a reference m ark (D) on alternator in line with notch (E) on upper alternator bracket. 5. Continue to hold tension with torque wrench and tighten upper alternator bracket cap screw. 6.

  • Page 56: Changing Engine Oil And Replacing Filter

    C hanging E ngine O il and R eplacing Filter NOTE: During break-in, change engine oil and filter for the first tim e before 100 hours m axim um of operation. T o ch an g e en g in e o il an d o il filter: 1.
  • Page 57 9. Fill engine crankcase with correct engine oil through rocker arm cover opening (A) or either side oil filler (B) depending on engine application. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for determ ining correct engine oil.) To determ ine the correct oil fill quantity for Filter And M ounting Header your engine, see ENGINE CRANKCASE OIL...

  • Page 58: Cleaning Crankcase Vent System

    C leaning C rankcase V ent S ystem Crankcase vent tube (If equipped) If you operate the engine in dusty conditions, clean the tube at shorter intervals. 1. Rem ove and clean crankcase vent tube (A). 2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover for elbow adapter.

  • Page 59: Checking Air Intake System

    C hecking A ir Intake S ystem T h e air in take system m u st n o t leak. A n y leak, n o m atter h o w sm all, m ay resu lt in in tern al en g in e d am ag e d u e to ab rasive d irt an d d u st en terin g th e in take system .

  • Page 60: Replacing Fuel Filter Elements

    R eplacing Fuel Filter E lem ents Engines m ay be equipped with either a prim ary fuel filter (or pre-filter) with water bowl and a final filter, or only a final filter including water bowl. Both filters are replaced at the sam e 500-hour interval. E scap in g flu id u n d er p ressu re can p en etrate th e skin cau sin g serio u s in ju ry.
  • Page 61 7. Install new filter elem ents onto m ounting bases. Be sure elem ents are properly indexed and firm ly seated on bases. It m ay be necessary to rotate filters for correct alignm ent. If equipped with water separator bowl (E), rem ove filter elem ent from separator bowl. Drain and clean separator bowl.

  • Page 62: Checking Belt Tensioner Spring Tension And Belt Wear (Automatic Tensioner)

    C hecking B elt Tensioner S pring Tension and B elt W ear (A utom atic Tensioner) Belt drive system s equipped with autom atic (spring) belt tensioners cannot be adjusted or repaired. The autom atic belt tensioner is designed to m aintain proper belt tension over the life of the belt. If tensioner spring tension is not within specification, replace tensioner assem bly.

  • Page 63: Checking Tensioner Spring Tension

    C hecking Tensioner S pring Tension A belt tension gauge will not give an accurate m easure of the belt tension when autom atic spring tensioner is used. M easure tensioner spring tension using a torque wrench and procedure outlined below: 1.

  • Page 64: Checking Engine Electrical Ground Connections

    C hecking E ngine E lectrical G round C onnections Keep all engine ground connections clean and tight to prevent electrical arcing, which can dam age electronic com ponents. Also see precautions in Troubleshooting Section when welding on engine or m achine. C hecking C ooling S ystem E xp lo sive release o f flu id s fro m p ressu rized co o lin g system can cau se serio u s b u rn s.

  • Page 65: Replenishing Supplemental Coolant Additives (Sca S) Between Coolant Changes

    R eplenishing S upplem ental C oolant A dditives (S C A s) B etw een C oolant C hanges NOTE: If system is to be filled with coolant that does not contain SCAs, the coolant m ust be precharged. Through tim e and use, the concentration of coolant additives is gradually depleted during engine operation.

  • Page 66: Testing Diesel Engine Coolant

    C o o lan t T est S trip s Coolant test strips are available from your Ingersoll-Rand dealer. These test strips provide a sim ple, effective m ethod to check the freeze point and additive levels of your engine coolant.

  • Page 67: Pressure Testing Cooling System

    P ressure Testing C ooling S ystem E xp lo sive release o f flu id s fro m p ressu rized co o lin g system can cau se serio u s b u rn s. S h u t o ff en g in e. O n ly rem o ve filler cap w h en co o l en o u g h to to u ch w ith b are h an d s. S lo w ly lo o sen cap to first sto p to relieve p ressu re b efo re rem o vin g co m p letely.

  • Page 68: Lubrication & Maintenance, 2000 Hour/ 24 Month

    Lubrication & M aintenance, 2000 H our/ 24 M onth C hecking C rankshaft V ibration D am per ( 6 -C ylinder E ngine O nly) 1. Remove belts (shown removed). 2. Grasp vibration damper with both hands and attempt to turn it in both directions.

  • Page 69: Flushing And Refilling Cooling System

    Flushing and R efilling C ooling S ystem E xp lo sive release o f flu id s fro m p ressu rized co o lin g system can cau se serio u s b u rn s. S h u t o ff en g in e. O n ly rem o ve filler cap w h en co o l en o u g h to to u ch w ith b are h an d s. S lo w ly lo o sen cap to first sto p to relieve p ressu re b efo re rem o vin g co m p letely.
  • Page 70 4. Open radiator drain valve. Drain all coolant from radiator. 5. Rem ove the therm ostats at this tim e, if not previous done. Install the cover (without th erm ostats) using the old gasket and tighten the cap screws to 47 N•m (35 lb-ft). (See TESTING THERMOSTATS OPENING 6.
  • Page 71 14. Run the engine until it reaches operating temperature. This mixes the solution uniformly and circulates it through the entire system. The normal engine coolant temperature range is 82º - 94ºC (180º - 202ºF). 15. After running the engine, check the coolant level and the entire cooling system for leaks. 16.

  • Page 72: Testing Thermostats Opening Temperature

    Testing Therm ostats O pening Tem perature T o R em o ve T h erm o stat E xp lo sive release o f flu id s fro m p ressu rized co o lin g system can cau se serio u s b u rn s. D O N O T d rain co o lan t u n til it h as co o led b elo w o p eratin g tem p eratu re.

  • Page 73: Testing Thermostats Opening Temperature

    Testing Therm ostats O pening Tem perature Rem ove therm ostat(s). 1. Visually inspect therm ostat(s) for corrosion or dam age. If dual therm ostats, replace as a m atched set as necessary. D O N O T allo w th erm o stat o r th erm o m eter to rest ag ain st th e sid e o r b o tto m o f co n tain er w h en h eatin g w ater.

  • Page 74: To Install Thermostats

    To Install Therm ostats In stall m an ifo ld g asket so th at th e sm aller (ro u n d ) h o les are at th e lo w er left an d th e u p p er rig h t co rners o f th e m an ifo ld (m atch in g stu d s A ).

  • Page 75: Check And Adjust Valve Clearance

    C heck and A djust V alve C learance T o p reven t accid en tal startin g o f en g in e w h ile p erfo rm in g valve ad ju stm en ts, alw ays d isco n n ect N E G A T IV E (—...
  • Page 76 5. If valves need adjusting, use the appropriate valve clearance adjustm ent procedure on the next page and adjust to specifications below. Loosen the jam nut (A) on rocker arm adjusting screw. Turn adjusting screw until feeler gauge slips with a slight drag. Hold the adjusting screw from turning with screwdriver and tighten jam nut to specifications.
  • Page 77 6-cylnder Engine: NOTE: FIRING ORDER IS 1-5-3-6-2-4 1. Lock No. 1 piston at TDC compression stroke (B). 2. Adjust valve clearance on No. 1, 3, and 5 exhaust valves and no. 1, 2, and 4 intake valves. 3. Turn crankshaft 360º. Lock No. 6 piston at TDC compression stroke (C). 4.

  • Page 78: Service As Required

    S ervice A s R equired D o N ot M odify Fuel S ystem M o d ificatio n o r alteratio n o f th e in jectio n p u m p (arro w ), th e in jectio n p u m p tim in g , o r th e fu el in jecto rs in w ays n o t reco m m en d ed b y th e m an u factu rer w ill term in ate th e w arran ty o b lig atio n to th e p u rch aser.

  • Page 79: Adding Coolant

    A dding C oolant E xp lo sive release o f flu id s fro m p ressu rized co o lin g system can cau se serio u s b u rn s. S h u t o ff en g in e. O n ly rem o ve filler cap w h en co o l en o u g h to to u ch w ith b are h an d s. S lo w ly lo o sen cap to first sto p to relieve p ressu re b efo re rem o vin g co m p letely.

  • Page 80: Replacing Radial Seal Air Cleaner Filter Element

    O , is to rn , o r visib ly d irty. NOTE: Refer to m anufacturers’ instructions for servicing air cleaners not supplied by Ingersoll-Rand. If engine is NOT equipped with an air restriction indicator, replace air filter elem ent every 500 hours of operation or every 12 m onths, whichever occurs first.

  • Page 81: Replacing Fan And Alternator Belts

    W h en ever th e air clean er h as b een serviced o r co ver h as b een rem o ved , A L W A Y S fu lly d ep ress th e air restrictio n in d icato r reset b u tto n (if eq u ip p ed ) to assu re accu rate read in g s. 8.

  • Page 82: Bleed The Fuel System (Engines With Electronic Fuel Systems And Stanadyne De10 Pump)

    B leed the Fuel S ystem (E ngines w ith E lectronic Fuel S ystem s and S tanadyne D E 10 P um p) E scap in g flu id u n d er p ressu re can p en etrate th e skin cau sin g serio u s in ju ry.
  • Page 83 2. Operate fuel supply pum p prim er lever (B) or prim er button on fuel filter base (if equipped). 3. Tighten bleed plug securely, continue operating prim er until pum ping action is not felt 4. Start engine and check for leaks. Fuel Supply Pum p Prim er Lever B —...
  • Page 84 A t F u el In jectio n N o zzles A lw ays u se a b acku p w ren ch w h en lo o sen in g o r tig h ten in g fu el lin es at n o zzles an d /o r in jectio n p u m p to avo id d am ag e.

  • Page 85: Bleeding The Fuel System (Engines With Electronic Fuel Systems And Bosch Vp44 Pump)

    B leeding the Fuel S ystem (E ngines w ith E lectronic Fuel S ystem s and B osch V P 44 P um p) E scap in g flu id u n d er p ressu re can p en etrate th e skin cau sin g serio u s in ju ry.
  • Page 86 Bleed Fuel System at Fuel Injection Nozzles A lw ays u se a b acku p w ren ch w h en lo o sen in g o r tig h ten in g fu el lin es at n o zzles an d /o r in jectio n p u m p to avo id d am ag e.

  • Page 87: Troubleshooting

    Troubleshooting G eneral Troubleshooting Inform ation A reliable program for troubleshooting engine problem s should include the following basic diagnostic thought process: Know the engine and all related system s. Study the problem thoroughly. Relate the sym ptom s to your knowledge of engine and system s. Diagnose the problem starting with the easiest things first.

  • Page 88: Engine Cranks But Will Not Start

    Dirty or faulty injection nozzles. Have authorized servicing dealer or engine distributor check injectors. Electronic fuel system problem (if See your Ingersoll-Rand equipped) distributor or servicing dealer. Low engine oil level. Add oil to engine crankcase. Low coolant tem perature.

  • Page 89: Engine Runs Irregularly Or Stalls Frequently

    Dirty or faulty injection nozzles. Have authorized servicing dealer or engine distributor check injectors. Electronic fuel system problem See your Ingersoll-Rand distributor or servicing dealer. Defective therm ostat. Rem ove and check therm ostat. Below norm al engine tem perature...

  • Page 90: Low Oil Pressure

    Engine Troubleshooting S ym p to m P ro b lem S o lutio n Low oil level. Add oil. Low oil pressure Im proper type of oil. Drain; fill crankcase with oil of proper viscosity and quality. Crankcase oil too light. Use proper viscosity oil.

  • Page 91: High Fuel Consumption

    Engine Troubleshooting S o lu tio n S ym p to m P ro b lem E n g in e o verh eats Incorrect grade of fuel. Use correct grade of fuel. Im proper type of fuel. Use proper type of fuel. Clogged or dirty air cleaner.

  • Page 92: Starter Will Not Crank

    Engine Troubleshooting S o lu tio n S ym p to m P ro b lem PTO engaged. Disengage PTO. Loose or corroded connections. Clean and tighten loose connections. Low battery output voltage. See your authorized servicing dealer or engine distributor. Starter will not crank Faulty start circuit relay.

  • Page 93: Listing Of Diagnostic Trouble Codes (Dtcs) (Engines With Electronic Fuel Systems And Stanadyne De10 Pump)

    Listing of D iagnostic Trouble C odes (D TC s) (E ngines W ith E lectronic Fuel S ystem s A nd S tanadyne D E 10 P um p) NOTE: Not all of these codes are used on all OEM engine applications. Trouble C odes D T C ’s L istin g in A scen d in g S P N /F M I C o d es S P N...
  • Page 94 T ro u b le C o d es D T C ’s L istin g in A scen d in g S P N/F M I C o d es S P N F M I 2-D ig it C o d es D efin itio n Sensor Supply Voltage High 000620...

  • Page 95: Listing Of Diagnostic Trouble Codes (Dtcs) (Engines With Electronic Fuel Systems And Bosch Vp44 Pump)

    Listing of D iagnostic Trouble C odes (D TC s) (E ngines W ith E lectronic Fuel S ystem s A nd B osch V P 44 P um p) NOTE: Not all of these codes are used on all OEM engine applications. Trouble C odes D T C ’s L istin g in A scen d in g S P N /F M I C o d es S P N...
  • Page 96 T ro u b le C o d es D T C ’s L istin g in A scen d in g S P N /F M I C o d es S P N F M I 2-D ig it C o d es D efin itio n 000627 ECU Unswitched Power M issing...
  • Page 97 G eneral O E M E ngine S pecifications IT E M 4IR D 5T E 6IR F 8T E Num ber of Cylinders Bore 106 m m (4.19 in.) 106 m m (4.19 in.) Stroke 127 m m (5.0in.) 127 m m (5.0in.) Displacem ent 4.5L (276 cu in.)

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