Ingersoll-Rand 4IRD5AE Operation Manual Download | Manualshive

Page: 1 / 97

background image

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)

1
2
3
...
»

Summary of Contents for 4IRD5AE

Page 1: ...d 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 ...

Page 2: ...2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 3: ... 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 dealer 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 protecti...

Page 4: ...DER 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 Fl...

Page 5: ... 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 ...

Page 6: ... 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...

Page 7: ...justment 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 Check...

Page 8: ... 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 electri...

Page 9: ... 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 Number Record 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 ...

Page 10: ...ators The last two digits of each code identify one specific option provided on your engine such as a 12 volt 70 amp alternator NOTE 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 functional group option code...

Page 11: ...erature Switch 27 Radiator 67 Speed Sensor 28 Exhaust Manifold 68 Crankshaft Rear 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 ...

Page 12: ...icates important set up operating or maintenance information Follow Safety Instructions Carefully read all safety 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 available from your Ingersoll Rand dealer...

Page 13: ...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 accumulated trash grease and debris Always clean ...

Page 14: ...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...

Page 15: ...ice such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises Handle Chemical 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 product...

Page 16: ...nd 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 Work In Ventilated Area ...

Page 17: ...mmediately 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 sol...

Page 18: ... 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 Wear 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 Avoi...

Page 19: ...ed 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 asbestos If not available ...

Page 20: ...f 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 medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 quarts 3 Get medical attention immediately Protect Against High Pressure Spray Spray from high pressure nozzles can penetra...

Page 21: ...ining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your Ingersoll Rand dealer Live With Safety Before returning machine to customer make sure machine is functionin...

Page 22: ...ilter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5 C 9 F below the expected low temperature Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as measured by ASTM D6079 Sulfur content Diesel fuel quality and fuel sulfur content must comply with all existing regulations for the area in which...

Page 23: ...uce performance in fuel injection systems due to inadequate lubrication of injection pump components The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks Use of low lubricity diesel fuels may also cause accelerated wear injection nozzle erosion or corrosion engine speed instability hard starting low power and engine smoke ...

Page 24: ...ll quickly plug fuel filters damage injection nozzles and injection pump DO NOT use brass coated containers for fuel storage Brass is an alloy of copper and zinc Store diesel fuel in plastic aluminum and steel containers specially coated for diesel fuel storage Avoid storing fuel over long periods of time If fuel is stored for more than a month prior to use or there is a slow turnover in fuel tank...

Page 25: ...y concentration in Ingersoll Rand equipment engines These oils do not burn completely and will cause engine failure by leaving deposits on injectors and in the combustion chamber A major environmental benefit of bio diesel fuel is its ability to biodegrade This makes proper storage and handling of bio diesel fuel especially important Areas of concern include Quality of new fuel Water content of th...

Page 26: ...stalled properly to prevent moisture from entering Monitor water content of the fuel regularly Fuel filter may require more frequent replacement due to premature plugging Check engine oil level daily prior to starting engine A rising oil level may indicate fuel dilution of the engine oil The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an origin...

Page 27: ...ing fuel tank or servicing fuel system The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an original vented cap Fill fuel tank at the end of each day s operation to prevent condensation in tank as moist air cools condensation may form and freeze during cold weather ...

Page 28: ...rage Grade No 1 D fuel has a lower BTU heat content rating than Grade No 2 D fuel When using Grade No 1 D fuel you may notice a drop in power and fuel efficiency but should not experience any other engine performance effects Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation Air Inlet Heater Aids Air Heaters in the air inlet are standard eq...

Page 29: ...ll should remain open at all times At no time should the air blockage device be applied directly to the radiator core Radiator Shutters If equipped with a thermostatically controlled radiator shutter system this system should be regulated in such a way that the shutters are completely open by the time the coolant reaches 93 C 200 F to prevent excessive intake manifold temperatures Manually control...

Page 30: ...ed Oils meeting ACEA Specification E4 E5 Other oils may be used if they meet one or more of the following API Service Classification CI 4 API Service Classification CH 4 ACEA Specification E3 Multi viscosity diesel engine oils are preferred Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which the engine operates If diesel fuel with sulfur...

Page 31: ...pecified in this manual Use Ingersoll Rand filters to meet factory performance specifications Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual Some Ingersoll Rand brand coolants and lubricants may not be available in your location Consult your Ingersoll Rand dealer to obtain information a...

Page 32: ... to avoid water and dirt accumulation Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval NLGI Performance Classification GC LB Some types of grease thickener are not com...

Page 33: ...0 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F If protection at lower temperatures is required consult your Ingersoll Rand dealer for recommendations Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate Do not use coo...

Page 34: ...lant Additives Operating without proper coolant additives will result in increased corrosion cylinder wall erosion and pitting and other damage to the engine and cooling system A simple mixture of ethylene glycol and water will not give adequate protection Use of supplemental coolant additives reduces corrosion erosion and pitting These chemicals reduce the number of vapor bubbles in the coolant a...

Page 35: ...ting Supplemental Coolant Additives The concentration of coolant additives is gradually depleted during engine operation For all recommended coolants replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing If other coolants are used consult the coolant supplier and follow the manufacturer s recommendation f...

Page 36: ... used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible Disposing of Coolant Improperly disposing of engine coolant can threaten the environment and ecology Use leak proof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not...

Page 37: ...y signs of part failure Symptoms that may be early signs of engine problems are Sudden drop in oil pressure Abnormal coolant temperatures Unusual noise or vibration Sudden loss of power Excessive black exhaust Excessive fuel consumption Excessive oil consumption Fluid leaks Engine Break In Service The engine is ready for normal operation However extra care during the first 100 hours of operation w...

Page 38: ...ting range Specification Engine1 Oil Pressure at Full Load Rated Speed 345 103 kPa 3 45 1 03 bar 50 15 psi Minimum Oil Pressure at 850 rpm 105 kPa 1 05 bar 15 psi Coolant Temperature Range 82 94 C 180 202 F 1At normal operating temperature of 115 C 240 F oil sump 4 During the first 20 hours avoid prolonged periods of engine idling or sustained maximum load operation If engine will idle longer than...

Page 39: ...umption may be expected when low viscosity oils are used Check oil levels more frequently 6 If air temperature is below 10 C 14 F use an engine block heater 7 Check poly vee belt for proper alignment and seating in pulley grooves ...

Page 40: ...essary to consider using cold weather starting aids Engines are equipped with air inlet heaters NEVER USE ETHER as a starting aid with these glow plug equipped engines As it could cause an explosion and possible personnel injury Additionally your Engine may be fitted with a block heater and increased capacity battery and or lower viscosity oil may also be used See your local Ingersoll Rand distrib...

Page 41: ...opping the generator set Make sure that exhaust stack cap rain cap is in place when engine is not running This will prevent water and dirt from entering engine 2 Fill fuel tank to minimize possible water condensation problems Filling tanks at end of day drives out moisture laden air ...

Page 42: ...nt away from battery Always connect NEGATIVE cable last and disconnect this cable first Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive...

Page 43: ... to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first 24...

Page 44: ...ls are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine Use Correct Fuels Lubricants and Coolant Use only fuels lubricants and coolants meeting specifications outlined in the Fuels Lubricants and Coolant Section when servicing your engine Consult your Ingersoll Rand dist...

Page 45: ...Connections System Replace Fuel Filter and Bleed System Check Manual Belt Tensioner and Belt Wear Check Automatic Belt Tensioner and Belt Wear Check Engine Electrical Ground Connection Check Cooling System Coolant Solution Analysis Add SCA s as required Pressure Test Cooling System Check Crankshaft Vibration Damper 6 8L Engines c Flush and Refill Cooling System Test Thermostats Check and Adjust Va...

Page 46: ...dded at left A or right B side oil filler cap and rocker arm cover filler cap C locations DO NOT add makeup oil until the oil level is BELOW the crosshatch marks on the dipstick A Left Side Oil Filler Cap B Right Side Oil Filler Cap C Cover Oil Filler Cap D Crosshatch On Dipstick DO NOT fill above the top mark on the dipstick Oil levels anywhere within crosshatch D are considered in the acceptable...

Page 47: ... stop to relieve pressure before removing completely 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 manual for recommendations for non Ingersoll Rand supplied accessor...

Page 48: ...or three turns b Loosen air bleed plug B two full turns on fuel filter mounting and drain water from bottom until fuel starts to drain out c When fuel starts to drain out tighten drain plugs securely d After draining water from the fuel filters the filters must be primed by bleeding all air from the fuel system See BLEEDING FUEL SYSTEM in Service As Required Section later in this manual A Drain Pl...

Page 49: ...nd accessory drive belts loose connections and trash build up Remove trash buildup and have repairs made as needed if leaks are found Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination Inspect Radiator for leaks and trash build up Air intake system hoses and connections for cracks and loose clamps Fan alternator and accessory drive belts...

Page 50: ... overall condition of vibration isolators if equipped Replace isolators if rubber has deteriorated or mounts have collapsed as necessary Servicing Battery Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Always remove grounded NEG...

Page 51: ...aking soda to retard corrosion 3 Keep battery fully charged especially during cold weather If a battery charger is used turn charger off before connecting charger to battery ies Attach POSITIVE battery charger lead to POSITIVE battery post Then attach NEGATIVE battery charger lead to a good ground Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in cloth...

Page 52: ...at least 30 minutes to assure thorough mixing after adding water to battery If necessary to replace battery ies replacements must meet or exceed the following recommended capacities at 18 C 0 F Battery Specifications 12 Volt Standard Duty Starter Cold Cranking Amps 640 12 Volt Heavy Duty Starter Cold Cranking Amps 800 24 Volt Standard Duty Starter Cold Cranking Amps 570 ...

Page 53: ...le from local Ingersoll Rand Dealer or Distributor 2 Loosen cap screws B and C 3 Slide alternator or tensioner bracket D in slot by hand to remove all excess slack in belt Do not pry against alternator rear frame 4 Stretch belt by prying outward on alternator front frame or tensioner bracket Observing tension gauge stretch the belt until specified tension is achieved Specification New Belt Tension...

Page 54: ...screw must remain tight enough to prevent excessive alternator play but allow alternator to pivot by hand 2 Insert JDG1520 Belt Tension Tool C behind belt D and over alternator mounting screw 3 Place torque wrench C on belt tensioning tool B at 90 to tool Pivot alternator A until desired torque is achieved according to specification using the following table Specification New Belt Tension 470 650 ...

Page 55: ...nch and tighten upper alternator bracket cap screw 6 Check position of reference mark to see if alternator moved while tightening If alternator moved loosen upper alternator bracket cap screw and repeat the tension adjustment procedure 7 Remove belt tension tool and tighten lower alternator bracket cap screw D Reference Mark E Alternator Upper Bracket Notch Scribe Reference Mark ...

Page 56: ...ion Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting Ingersoll Rand performance specifications 5 Apply clean engine oil to the new filter at the inner B and outer C seals and to filter threads 6 Wipe both sealing surfaces of the header D E with a clean rag Ensure dust seal F is in place replace if damaged When installing filter element HAND TIG...

Page 57: ...ng any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase within crosshatch marks on dipstick DO NOT overfill 10 Start engine and run to check for possible leaks 11 Stop engine and check oil level after 10 minutes Oil level ...

Page 58: ...1 Inspect hoses C D and G for kinks blockage or other damage 2 Inspect check valve H for damage Valve is installed with black end toward crankcase 3 Verify that Crank case oil drain tube I is not plugged 4 Inspect CCV valve A for cracks or other damage A Closed Crankcase Ventilation CCV Valve B Hose CCV Valve to Intake Manifold C Hose Valve Cover to CCV Valve D Valve Cover Vent Fitting E Intake Ma...

Page 59: ...ose connections causing internal engine damage 3 If engine has a rubber dust unloader valve B inspect the valve on bottom of air cleaner for cracks or plugging Replace as necessary ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H2O is torn or visibly dirty 4 Test air restriction indicator C for proper operation Replace indicator as necessar...

Page 60: ...urgically removed within a few hours by a doctor familiar with this type injury or gangrene may result 1 Close fuel shut off valve if equipped 2 Thoroughly clean fuel filter assemblies and surrounding areas 3 Disconnect water sensor wiring if equipped 4 Loosen drain plugs C and drain fuel into a suitable container NOTE Lifting up on retaining ring A as it is rotated helps to get it past raised loc...

Page 61: ...er element with slots in filter base 9 Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used...

Page 62: ...ace tensioner assembly Checking Belt Wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used 1 Visually inspect cast stops A and B on belt tensioner assembly 2 If the tensioner stop on swing arm A is hitting the fixed stop B check mounting brackets alternator belt tensioner idler pulley etc and...

Page 63: ... as shown 4 Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base 5 Install torque wrench C so that it is aligned with centers of pulley and tensioner Rotate the swing arm using a torque wrench until marks A and B are aligned 6 Record torque wrench measurement and compare with specification below Replace tensioner assembly as required Specification Spring Tension Torque 18 22 N ...

Page 64: ...when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Air must be expelled from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Retighten fitting or plug when all the air has been expelled 1 Visually chec...

Page 65: ...ester is not available recharge the system per instructions printed on the conditioner label IMPORTANT ALWAYS maintain coolant at correct level and concentration DO NOT operate engine without coolant even for a few minutes If frequent coolant makeup is required the glycol concentration should be checked with a Coolant Battery Tester to ensure that the desired freeze point is maintained Follow manu...

Page 66: ...of 12 months or less and whenever excessive coolant is lost through leaks or overheating Coolant Test Strips Coolant test strips are available from your Ingersoll Rand dealer These test strips provide a simple effective method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting...

Page 67: ... retest cap This will verify that the first measurement was accurate Test Cooling System NOTE Engine should be warmed up to test overall cooling system 1 Allow engine to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level DO NOT apply excessive pressure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator fi...

Page 68: ...le and should be replaced every 4500 hours or 60 months whichever occurs first 3 Check vibration damper radial runout by positioning a dial indicator A so that the probe contacts the damper outer diameter 4 With the engine at operating temperature rotate the crankshaft using a flywheel turning tool 5 Note the dial indicator reading If the runout exceeds the specifications given below replace the v...

Page 69: ...lush the entire cooling system test thermostats and fill with recommended clean coolant as follows 1 Pressure test entire cooling system and pressure cap if not previously done See PRESSURE TESTING COOLING SYSTEM in the Lubrication and Maintenance 500 Hour 12 Month Section 2 Slowly open the engine cooling system filler cap or radiator cap to relieve pressure and allow coolant to drain faster 3 Ope...

Page 70: ...g system with clean water and a heavy duty cooling system cleaner follow the manufacture s directions on the label 11 After cleaning the cooling system drain the cleaner and fill with water to flush the system Run the engine for about 10 minutes remove the radiator cap and pull off the lower radiator hose to drain out the flushing water 12 Close all of the drain valves on the engine and radiator R...

Page 71: ...tem 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 Inspect the fan belt for wear and check the belt tension See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication and Maintenance 500 Hour 12 Month section ...

Page 72: ...valve slowly to relieve pressure 1 Visually inspect area around thermostat housing on top of engine timing gear cover for leaks 2 Remove radiator pressure cap and partially drain cooling system 3 Remove thermostat cover to coolant pump tube A and seal 4 Remove thermostat B with gasket 5 Remove thermostat s 6 Remove and discard all gasket material Clean gasket surfaces 7 Clean and check cover for c...

Page 73: ...rent suppliers initial opening and full open temperatures may vary slightly from specified temperatures THERMOSTAT TEST SPECIFICATIONS Rating Initial Opening Range Full Open Nominal 71ºC 160ºF 69 72ºC 156 162ºF 84ºC 182ºF 77ºC 170ºF 74 78ºC 166 172ºF 89ºC 192ºF 82ºC 180ºF 80 84ºC 175 182ºF 94ºC 202ºF 89ºC 192ºF 86 90ºC 187 194ºF 100ºC 213ºF 90ºC 195ºF 89 93ºC 192 199ºF 101ºC 214ºF 92ºC 197ºF 89 93...

Page 74: ...install the thermostat s and the coolant manifold thermostat cover 5 Tighten the cover cap screws to 70 N m 53 lb ft 6 Lubricate a new O ring with PT507 Multi Purpose Grease Install seal B in the thermostat cover 7 Install coolant manifold thermostat cover to coolant pump tube C Tighten clamps 8 If not already done fill cooling system and check for leaks Air must be expelled from cooling system wh...

Page 75: ...wheel rotation tool These engines may be rotated from front nose of engine using JDG966 Crankshaft Front Rear Rotation Adapter 3 Using JDE83 or JDG281AFlywheel Turning Tool rotate engine flywheel in running direction clockwise viewed from front until No 1 cylinder is at TDC compression stroke Insert JDG1571 Timing Pin in flywheel If No 1 cylinder rocker arms are loose the engine is at No 1 TDC com...

Page 76: ...st Valve Clearance For Adjusting Rocker Arm to Valve Tip Engine Cold Clearance 0 46 mm 0 018 in Rocker Arm Adjusting Screw Jam Nut Torque 27 N m 20 lb ft 6 Replace rocker arm cover and crankcase ventilator tube 4 Cylinder Engine NOTE Firing order is 1 3 4 2 1 Using JDE81 4 Timing Pin lock No 1 piston at TDC compression stroke B 2 Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 i...

Page 77: ...xhaust valves and no 1 2 and 4 intake valves 3 Turn crankshaft 360º Lock No 6 piston at TDC compression stroke C 4 Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves 6 Cylinder Engine Valve Adjustment A Front of Engine B No 1 Piston TDC Compression C No 6 Piston TDC Compression E Exhaust Valve I Intake Valve ...

Page 78: ...terminate the warranty obligation to the purchaser In addition tampering with fuel system which alters emission related equipment on engines may result in fines or other penalties per EPA regulations or other local emission laws Do not attempt to service injection pump or fuel injectors yourself Special training and special tools are required See your authorized servicing dealer or engine distribu...

Page 79: ...sen temperature sending unit fitting at rear of cylinder head or plug in side of thermostat housing to allow air to escape when filling system When adding coolant to the system use the appropriate coolant solution See ENGINE COOLANT SPECIFICATIONS in Fuels Lubricants and Coolant Section for mixing of coolant ingredients before adding to cooling system Do not overfill cooling system A pressurized s...

Page 80: ...ll filter B off outlet tube and out of housing 4 Thoroughly clean all dirt from inside housing and from outlet bore Remove secondary safety element C ONLY for replacement DO NOT attempt to clean wash or reuse secondary element Replacement of secondary element is usually necessary ONLY when primary element has a hole in it 5 To replace secondary element C pull filter element out gently Immediately ...

Page 81: ...eplace belt with automatic tensioner release tension on belt using a breaker bar and socket on tension arm To replace belt with manual tensioner release tension at belt tensioner See MANUAL BELT TENSIONER ADJUSTMENT in Lubrication and Maintenance 500 Hour 12 Month Section 3 Remove poly vee belt from pulleys and discard belt 4 Install new belt making sure belt is correctly seated in all pulley groo...

Page 82: ...ccurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Bleed the fuel system anytime the fuel system has been opened up This includes 1 After fuel filter changes 2 After pump or nozzle replacement 3 Anytime fuel lines have been disconnected 4 After engine has run out of fuel The fuel system may be bled at one of several ...

Page 83: ...fuel return line A at fuel injection pump 2 Operate fuel supply pump primer lever or primer button on fuel filter base if equipped 3 As soon as fuel flow is free from air bubbles tighten fuel return line to specifications Primer lever is spring loaded and will return to normal position Specification Fuel Injection Pump Return Line Torque 27 N m 20 lb ft Fuel Supply Pump Primer Lever B Primer Lever...

Page 84: ...starter motor for 15 seconds but do not start engine until fuel free from bubbles flows out of loosened connection Retighten connection to specifications Specification Fuel Injection Nozzle Delivery Lines Torque 27 N m 20 lb ft 3 Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing...

Page 85: ... nozzle replacement 7 Anytime fuel lines have been disconnected 8 After engine has run out of fuel This fuel system can only be bled by the electronic transfer pump or at the injection nozzles BLEEDING SHOULD NOT BE PERFORMED at any location on the Bosch VP44 injection pump Bleed Using the Electronic Transfer Pump The bleed is automatically performed by a small orifice A inside the final fuel filt...

Page 86: ...ver with starter motor for 15 seconds but do not start engine until fuel free from bubbles flows out of loosened connection Retighten connection to specifications Specification Fuel Injection Nozzle Delivery Lines Torque 27 N m 20 lb ft 3 Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized ...

Page 87: ...have electronic control systems which send diagnostic trouble codes to signal problems That requires specialized diagnostic equipment to obtain the codes contact your authorized servicing dealer or engine distributor for assistance Precautions For Welding On Engines Equipped With Electronic Engine Control Unit ECU ALWAYS disconnect Electronic Control Unit ECU connectors and engine control system t...

Page 88: ...ng procedure No fuel Check fuel tank Air in fuel line Bleed fuel line Cold weather Use cold weather starting aids Slow starter speed See Starter Cranks Slowly Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier use proper type fuel for operating conditions Water dirt or air in fuel system Drain flush fill and bleed system Clogged fuel filter Replace filt...

Page 89: ...fuel filter Replace filter elements Improper type of fuel Use proper fuel Overheated engine See Engine Overheats Below normal engine temperature Remove and check thermostat Improper valve clearance See your authorized servicing dealer or engine distributor Dirty or faulty injection nozzles Have authorized servicing dealer or engine distributor check injectors Injection pump out of time See your au...

Page 90: ... air cleaner Service air cleaner Engine overloaded Reduce load Injection nozzles dirty See your authorized servicing dealer or engine distributor Electronic fuel system problem See your authorized servicing dealer or engine distributor Engine emits black or gray exhaust smoke Turbocharger not functioning See your authorized servicing dealer or engine distributor Engine overloaded Reduce load Low c...

Page 91: ...mostat Excessive electrical load from added accessories Remove accessories or install higher output alternator Excessive engine idling Increase engine rpm when heavy electrical load is used Poor electrical connections on battery ground strap starter or alternator Inspect and clean as necessary Defective battery Test battery Undercharged electrical system Defective alternator Test charging system C...

Page 92: ...r or engine distributor Starter will not crank Blown main system fuse MDL 25 Replace fuse Low battery output See your authorized servicing dealer or engine distributor Crankcase oil too heavy Use proper viscosity oil Starter cranks slowly Loose or corroded connections Clean and tighten loose connections Faulty battery connection Clean and tighten connections Entire electrical system does not funct...

Page 93: ...Oil Pressure Input Voltage High 04 24 Engine Oil Pressure Input Voltage Low 000100 18 64 Engine Oil Pressure Moderately Low 03 25 Manifold Air Temperature Input Voltage High 04 26 Manifold Air Temperature Input Voltage Low 000105 16 66 Manifold Air Temperature Moderately High 00 69 Engine Coolant Temperature High Most Severe 03 18 Engine Coolant Temperature Input Voltage High 04 19 Engine Coolant ...

Page 94: ...ol Valve Closure Too Long 01 72 Pump Control Valve Closure Too Short 03 77 Pump Solenoid Current High 05 73 Pump Solenoid Circuit Open 06 74 Pump Solenoid Circuit Severely Shorted 07 75 Pump Control Valve Closure Not Detected 10 76 Pump Solenoid Circuit Moderately Shorted 001076 13 Pump Current Decay Time Invalid 03 Sensor Supply Voltage High 001079 04 Sensor Supply Voltage Low 001109 31 Engine Sh...

Page 95: ...4 Engine Oil Pressure Input Voltage Low 000100 18 74 Engine Oil Pressure Moderately Low 00 56 Manifold Air Temperature Input Voltage Extremely High 03 25 Manifold Air Temperature Input Voltage High 04 26 Manifold Air Temperature Input Voltage Low 000105 16 55 Manifold Air Temperature Moderately High 000107 00 Air Filter Differential Pressure 00 63 Engine Coolant Temperature Extremely High 03 18 En...

Page 96: ...y Engine Shutdown Switch Signal Invalid 000970 31 83 Auxiliary Engine Shutdown Switch Active 000971 31 84 External Engine Derate Switch Active 001069 02 93 Tire Size Error 07 35 Attempting to Fuel without Command 11 68 Pump Supply Voltage Out of Range 12 97 Pump Self Test Error 19 96 Pump Detected Communication Error 001077 31 36 Pump Initiated Engine Protection 07 95 ECU Pump Timing Moderately Ou...

Page 97: ...H20 0 5 kPa 2H20 Vibration Damper Maximum Radial Runout 1 50 mm 0 060 in 1 50 mm 0 060 in Battery Capacities CCA 12 Volt System 24 Volt System 640 570 800 570 Governor Regulation Industrial 7 10 7 10 Governor Regulation Generator 5 5 Thermostat Start To Open Temperature 82ºC 180ºF 82ºC 180ºF Thermostat Fully Open Temperature 94ºC 202ºF 94ºC 202ºF Coolant Capacity 8 5 L 9qt 11 3 L 12 qt Recommended...

Reviews:

No comments

Related manuals for 4IRD5AE

Brand: Wacker Neuson Pages: 44

Brand: Schweigen Pages: 28

Brand: E-MAG Pages: 30

PneuTorque PTS-52-500

Brand: norbar Pages: 30

Brand: Erreka Pages: 30

44 A FOUR-35C THREE

Brand: Westerbeke Pages: 61

MTR-DCI-...IO Series

Brand: Festo Pages: 182

Brand: CAB Pages: 16

MaxxForce 3.2H Euro V

Brand: Navistar Pages: 116

Brand: ABB Pages: 13

Brand: JetCat Pages: 54

Brand: ETQ Pages: 89

Brand: Cobra Garden Machinery Pages: 64

RolloTube S-line Sun DuoFern

Brand: RADEMACHER Pages: 2

Brand: Volvo Pages: 88

Brand: Kärcher Pages: 116

Brand: WEN POWER Pages: 28

Brand: Bticino Pages: 4

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands