Ingersoll-Rand 4IRD5T User manual

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)

2
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 .

3
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.

7
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.

8
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

9
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

10
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

11
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

12
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)

13
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.