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.

14
NOTE: Your engine option code label may not contain all option codes if an option has been added after
the engine left the producing factory.
Option Codes Description Option Codes Description
11 Rocker Arm Cover 46 Cylinder Block and Camshaft
12 Oil Filler 47 Crankshaft and Bearings
13 Crankshaft Pulley 48 Connecting Rods and Pistons
14 Flywheel Housing 49 Valve Actuating Mechanism
15 Flywheel 50 Oil Pump
16 Fuel Injection System 51 Cylinder Head With Valves
17 Air Inlet 52 Auxiliary Gear Drive
18 Air Cleaner 55 Shipping Stand
19 Oil Pan 56 Paint Option
20 Coolant Pump 57 Coolant Pump Inlet
21 Thermostat Cover 59 Oil Cooler
22 Thermostat 60 Alternator Fan Drive Pulley
23 Fan Drive 62 Alternator Mounting
24 Fan Belt 64 Exhaust Elbow
25 Fan 65 Turbocharger
26 Engine Coolant Heater 66 Coolant Temperature Switch
27 Radiator 67 Speed Sensor
28 Exhaust Manifold 68 Crankshaft R ear Damper
29 Crankcase Vent System 69 Engine Serial Number Plate
30 Starter Motor 74 Air Conditioning (Freon) Compressor
31 Alternator 75 Air Restriction Indicator
32 Instrument Panel 76 Oil Pressure Switch
33 Tachometer 78 Air Compressor
35 Fuel Filter 86 Fan Pulley
36 Front Plate 87 Belt Tensioner
37 Fuel Transfer Pump 88 Oil Filter
39 Thermostat Housing 92 Test Certificate
40 Oil Dipstick 95 Special Equipment (Factory Installed)
43 Starting Aids 97 Special Equipment (Field Installed)
44 Timi ng Gear Cover 98 Lift Straps for Engine
45 Balancer Shafts 99 Service Only Parts and Kits
If option code label is lost or destroyed, consult your servicing dealer or engine distributor selling the
engine for a replacement.
Engine Base C ode
Record Fuel Injection Pum p Model Number
Record the fuel injection pump model and serial
information found on the serial number plate (A).
Model No. RPM
Manufacturer’s No.
Serial No.
A — Serial Number Plate

15
Safety
Recognize Safety Inform ation
This is a safety -alert symbol. When you see this symbol on your machine or in this manual, be alert to the
potential for personal injury.
Follow recommend ed precautions and safe operating practices.
Understand Signal W ords
A signal word — DANGER, WARNING, or CAUTION — is used with the
safety -alert symbol. DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located near specif ic
hazards. General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this manual.
Indicates imp ortant set -up, operati ng or maint enance
information.
Follow Safety Instructions
Carefully read all safe ty messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts
include the current safety signs. Replacement safety
signs are avai lable from your Ingersoll -Rand dealer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may
impair the function and/or safety and affect
machine life.
If you do not understand any part of this manual and need assistance, contact your Ingersoll -Rand dealer.

16
Replace Safety Signs
Replace missing or damaged safety signs. See the
machine operator’s manu al for correct safety sign
placement.
Prevent Bypass Starting
Avoid possible injury or death from engine runaway.
Do not start engine by shorting across starter terminal.
Start engine only from operator’s station.
Handle Fuel Safely — Avoid Fires
Handle fuel with care: it is highly flammable. Do not
refuel the machine while smoking or when near open
flame or sparks.
Always stop engine before refueling machine. Fill fuel
tank outdoors.
Prevent fires by keeping machine clean of accumu lated
trash, grease, and debris. Always clean up spilled fuel.

17
Prepare for Em ergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service,
hospital, and fire depart ment near your telephone.
Handle Fluids Safely — Avoid Fires
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure engine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
DO NOT USE Starting Fluids
DO NOT USE ether -starting fluids with these
air inlet heater - equipped engines as it could
cause an extreme explosion with possible
personnel injury.
Service Engines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
engine tools or moving parts. If these items were to get
caught, severe inj ury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

18
W ear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can caus e
impairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
Operating equipment safely requires the full attention
of the operator. Do not wear rad io or music
headphones while operating machine.
Protect Against Noise
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Handle Chem ical Products
Safely
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with Ingersoll -Rand equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly
what the risks are and how to do the job safely. Then
follow procedures and recommended equipment.
(See your Ingersoll -Rand dealer for MSDS’s on chemical products used with Ingersoll -Rand equipment.)

19
Practice Safe M aintenance
Un derstand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet, and clothing from power -
driven parts. Disengage all power and operate controls
to relieve pressure. Lo wer equipment to the ground. Stop
the engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self -propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical
systems or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
W ork In Ventilated Area
Engine exhaust fumes can cause sickness or death. If it
is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area

20
Avoid High - Pressure Fluids
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relie ving 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.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury
should reference a knowledgeable medical
source.
Avoid Heating Near Pressurized Fluid
Lines
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.

21
Rem ove Paint Before W elding or
Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when welding,
soldering, or using a torch to heats paint. Remove pa int
before heating:
.Remove
paint a minimum of 76 mm (3 in.) from area to
be affected by heating.
.If
you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
.If
you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Do not use a chlorinated solvent in areas where
welding will take place.
Do all work in an area that is well ventilated to
carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Install Fan Guards
Rotating cooling system fans can cause serious injury.
Keep fan guards in place at all times during engine
operation.
We ar close fitting clothes.
Stop the engine and be sure fan is stopped before
making adjustments or connections, or cleaning near
the front of the engine.
Avoid Hot Parts
Avoid skin contact with exhaust manifolds,
turbochargers and mufflers. Keep flamma ble materials
clear of the turbocharger.
External dry exhaust parts become very hot during
operation. Turbochargers may reach temperatures as
high as 500

C (932

F) under full load, and naturally
aspired exhaust manifolds may reach 600

C (1112

F)
under full load. This may ignite paper, cloth or wooden
materials. Parts on engines that have been at full load
and reduced to no load idle will maintain approxima tely
150

C (302

F).

22
Service Cooling System Safely
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing completely.
Avoid Harm ful A sbestos D ust
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause lung cancer.
Components in products that m ay contain asbestos
fibers are brake pads, brake band and lining
assemblies, clutch plates, and some gaskets. The
asbestos used in these components is usually found in
a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing asbestos
is not generated.
Avoid creating dust. Never use compressed air
for cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbes tos. If not available,
apply a mist of oil or water on the material
containing asbestos.
Keep bystanders away from the area.
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away
from the top of battery. Battery gas can explod e.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
the battery to 16

C (60

F).

23
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poiso nous. 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. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyt e is added.
4. Avoiding spilling or dripping electrolyte.
5. U
se proper jump -start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15 — 30 minutes. Get
m edical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not excee d
2 L (2 quarts).
3. Get medical attention immediately.
Protect Against High Pressure
Spray
Spray from high -pressure no zzles can penetrate the
skin and cause serious injury. Keep spray from
contacting hands or body.
If an accident occurs, see a doctor immediately. Any
high -pressure spray injected into the skin must be
surgically removed within a few hours or gangrene may
result.