Cummins B Series Engines by Ant Dove

Table of Contents SECTION

SECTION

PAGE

____________________________________________________________ 1.0

ILLUSTRATIONS

2.0

GENERAL SAFETY INSTRUCTIONS

3.0

DEFINITION OF TERMS

4.0

ENGINE & COMPONENT IDENTIFICATION 4.1 GENERAL SPECIFICATIONS (NON AUTOMOTIVE ENGINES) 4.2 EXTERNAL ENGINE COMPONENTS

5 5 7

5.0

OPERATING INSTRUCTIONS 5.1 GENERAL INFORMATION 5.2 COLD WEATHER OPERATION 5.2.1 WINTERFRONTS 5.2.2 SHUTTER 5.3 COLD WEATHER STARTING 5.4 STARTING PROCEDURE AFTER EXTENDED SHUTDOWN OR OIL CHANGE 5.5 OPERATING THE ENGINE 5.6 ENGINE OPERATING RANGE 5.7 ENGINE SHUTDOWN

9 9 11 12 12 12

6.0

MAINTENANCE GUIDELINES 6.1 GENERAL INFORMATION 6.2 TOOL REQUIREMENTS 6.3 MAINTENANCE SCHEDULE

15 15 15 16

7.0

DAILY MAINTENANCE PROCEDURE 7.1 GENERAL INFORMATION 7.2 FUEL WATER SEPARATOR 7.3 OIL LEVEL 7.4 COOLANT LEVEL 7.5 DRIVE BELT 7.6 COOLING FAN

17 17 17 18 18 20 20

8.0

MAINTENANCE PROCEDURES AT 10,000 KM [6,000 MILES] 250 HOURS OR 3 MONTHS 8.1 GENERAL INFORMATION 8.2 LUBRICATING OIL AND FILTER CHANGE INTERVAL 8.3 LUBRICATING OIL AND FILTER 8.4 AIR INTAKE SYSTEM 8.5 CHANGE AIR COOLER 8.6 AIR CLEANER RESTRICTION

21 21 21 22 27 28 29

13 13 14 14

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____________________________________________________________ 9.0

10.0

11.0

12.0

13.0

MAINTENANCE PROCEDURES AT 19,000 KM [12,000 MILES] 500 HOURS OR 6 MONTHS 9.1 FUEL FILTER 9.2 FUEL SYSTEM 9.3 LOW PRESSURE LINES & FUEL FILTERS 9.4 INJECTION PUMP 9.5 HIGH PRESSURE LINES (ROTARY AND IN-LINE PUMPS) 9.6 RE-TIGHTEN LINE FITTINGS 9.7 ANTI-FREEZE CONCENTRATION

31 31 33 34 35 37 38 38

MAINTENANCE PROCEDURES AT 38,000 KM [24,000 MILES] 1,000 HOURS OR 1 YEAR 10.1 VALVE 10.1.1 ADJUSTMENTS 10.1.2 FOUR CYLINDER ENGINE ADJUSTMENT 10.1.3 SIX CYLINDER ENGINE ADJUSTMENT 10.2 DRIVE BELT TENSION 10.3 DRIVE BELT

39 39 39 41 43 44 45

MAINTENANCE PROCEDURES AT 77,000 KM [48,000] 2,000 HOURS OR 2 YEARS 11.1 COOLING SYSTEM MAINTENANCE 11.1.1 COOLANT DRAINING 11.1.2 COOLING SYSTEM FLUSHING 11.1.3 COOLANT SYSTEM FILLING 11.2 VIBRATION DAMPER (RUBBER)

47 47 47 49 51 53

SYSTEM DIAGRAMS 12.1FUEL SYSTEM 12.2 HYDRAULIC COLD START INJECTION ADVANCE (ROTARY AUTOMOTIVE PUMPS ONLY) 12.3 LUBRICATING OIL SYSTEM 12.4 LUBRICATING FOR TURBOCHARGER 12.5 LUBRICATING FOR POWER COMPONENTS 12.6 LUBRICATING FOR OVERHEAD 12.7 COOLANT SYSTEM 12.8 AIR SYSTEM 12.9 AIR SYSTEM – INTAKE AIR

55 55 56 57 57 58 58 59 59 60

TROUBLESHOOTING 13.1 TROUBLESHOOTING PROCEDURE AND TECHNIQUES 13.2 TROUBLESHOOTING SYMPTOMS 13.2.1 ENGINE WILL NOT CRANK OR CRANKS SLOWLY

61 61 61 61

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____________________________________________________________ 13.2.2 ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE PRESENT) 13.2.3 ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST) 13.2.4 ENGINE STARTS BUT WILL NOT KEEP RUNNING 13.2.5 ENGINE WILL NOT SHUT OFF 13.2.6 ROUGH IDLE, WARN ENGINE 13.2.7 ENGINE SURGES AT IDLE 13.2.8 LUBRICATING OIL PRESSURE LOW 13.2.9 LUBRICATING OIL PRESSURE TOO HIGH 13.2.10 LUBRICATING OIL LOSS 13.2.11 COOLANT TEMPERATURE ABOVE NORMAL 13.2.12 COOLANT LOSS 13.2.13 COOLANT TEMPERATURE BELOW NORMAL 13.2.14 COOLANT CONTAMINATED 13.2.15 LUBRICATING OIL CONTAMINATED 13.2.16 FUEL OR OIL LEAKING FROM EXHAUST MANIFOLD 13.2.17 EXHAUST SMOKE EXCESSIVE UNDER LOAD 13.2.18 ENGINE WILL NOT REACH RATED SPEED WHEN LOADED 13.2.19 POWER OUTPUT LOW 13.2.20 ENGINE MISFIRING 13.2.21 FUEL KNOCKS 13.2.22 FUEL CONSUMPTION EXCESSIVE 13.2.23 VIBRATION EXCESSIVE 13.2.24 ENGINE NOISES EXCESSIVE 13.2.25 ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING 13.2.26 WHITE SMOKE EXCESSIVE DURING COLD START 14.0

ADJUSTMENT, REPLACEMENT AND REPAIR 14.1 REPAIR TOOLS REQUIRED 14.2 COOLING SYSTEM REPAIR SUMMARY 14.3 COOLING SYSTEM REPAIR 14.3.1 REPAIR BELT REPLACEMENT 14.3.2 BELT TENSIONER-REPLACEMENT 14.3.3 FAN PULLEY-REPLACEMENT 14.3.4 WATER PUMP-REPLACEMENT 14.3.5 THERMOSTAT-REPLACEMENT 14.4 FUEL SYSTEM REPAIR SUMMARY 14.5 FUEL SYSTEM REPAIR ROTARY PUMP 14.5.1 FUEL SYSTEM COMPONENTS-CLEANING 14.5.2 LOW PRESSURE FUEL LINE REPLACEMENT

62 63 64 65 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 81 82 83 84 85 86 87 87 87 88 88 89 89 91 95 99 100 100 100

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____________________________________________________________ 14.5.3 FUEL FILTER 14.5.4 LIFT PUMP REPLACEMENT 14.5.5 HIGH PRESSURE FUEL LINES-REPLACEMENT 14.5.6 FUEL DRAIN MANIFOLD-REPLACEMENT 14.5.7 INJECTION PUMP SUPPLY LINE REPLACEMENT 14.5.8 INJECTORS-REPLACEMENT 14.5.9 FUEL SHUT OFF SOLENOID-REPLACEMENT 14.5.10 KSB REPLACEMENT 14.5.11 KSB TEMPERATURE SWITCH REPLACEMENT 14.5.12 FUEL PUMP-REPLACEMENT 14.5.13 REMOVING THE FUEL PUMP 14.5.14 INSTALLING THE FUEL PUMP 14.6 FUEL SYSTEM REPAIR IN LINE PUMP 14.6.1 FUEL SYSTEM COMPONENTS-CLEANING 14.6.2 LOW PRESSURE FUEL LINE REPLACEMENT 14.6.3 FUEL FILTER HEAD ADAPTER-REPLACEMENT 14.6.4 LIFT PUMP REPLACEMENT 14.6.5 HIGH PRESSURE FUEL LINES-REPLACEMENT 14.6.6 FUEL DRAIN MANIFOLD-REPLACEMENT 14.6.7 INJECTORS REPLACEMENT 14.6.8 FUEL SHUT OFF SOLENOID-REPLACEMENT 14.6.9 RQVK GOVERNOR SHUT OFF SOLENOID 14.6.10 INJECTION PUMP-REPLACEMENT 14.6.11 INJECTION PUMP REMOVAL 14.6.12 INJECTION PUMP INSTALLATION 14.6.13 INJECTION PUMP TIMING 14.7 AIR SYSTEM REPAIR 14.7.1 AIR CROSSOVER TUBE REPLACEMENT 14.7.2 INTAKE MANIFOLD COVER & GASKET REPLACEMENT 14.7.3 JACKET WATER AFTER COOLER & GASKET REPLACEMENT 14.7.4 CHARGE AIR COOLER LEAK CHECK 14.7.5 INTAKE MANIFOLD PRESSURE CHECK 14.7.6 INTAKE MANIFOLD TEMPERATURE CHECK 14.7.7 TURBOCHARGER REPLACEMENT 14.7.8 EXHAUST MANIFOLD & GASKET-REPLACEMENT 14.8 LUBRICATING SYSTEM REPAIR SUMMARY 14.9 LUBRICATING SYSTEM REPAIR 14.9.1 OIL PRESSURE REGULATOR, VALVE & SPRING REPLACEMENT 14.9.2 OIL COOLER ELEMENT & GASKET REPLACEMENT 14.10 ELECTRICAL SYSTEM REPAIR SUMMARY 14.11 ELECTRICAL SYSTEM REPAIR

101 102 103 104 105 107 110 112 113 113 114 117 123 123 123 124 125 126 127 128 131 131 132 133 134 135 141 141 141 144 146 147 147 149 155 157 157 157 158 162 162

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____________________________________________________________ 14.11.1 STARTING MOTOR REPLACEMENT 14.11.2 ALTERNATOR REPLACEMENT 15.0

SPECIFICATIONS & TORQUE VALUES 15.1 ENGINE SPECIFICATIONS (NON AUTOMOTIVE ENGINES) 15.1.1 BATTERIES (SPECIFIC GRAVITY) 15.2 GENERAL SPECIFICATIONS (AUTOMOTIVE ENGINES) 15.3 FUEL RECOMMENDATIONS / SPECIFICATIONS 15.4 LUBRICATING OIL RECOMMENDATIONS / SPECIFICATIONS 15.4.1 OIL PERFORMANCE RECOMMENDATIONS 15.4.2 OIL VISCOSITY RECOMMENDATIONS 15.4.3 NEW ENGINE BREAK-IN OILS 15.4.4 RECOMMENDED OIL CHANGE INTERVALS 15.4.5 OIL CONSUMPTION 15.4.6 ARCTIC OPERATION 15.5 COOLANT RECOMMENDATIONS / SPECIFICATIONS 15.6 ENGINE COMPONENT TORQUE VALUE 15.7 SEALANTS 15.8 CAPSCREWS MARKINGS & TORQUE VALUES 15.8.1 CAPSCREWS MARKINGS & TORQUE VALUES-METRIC 15.8.2 CAPSCREWS MARKINGS & TORQUE VALUESU.S CUSTOMARY

162 163 166 166 167 168 169 171 171 171 171 171 173 173 173 175 176 177 178 179

1.0

ILLUSTR RATIONS

Use the illustratiions in this manual as aa guide to p perform the e action n or the rep pair described. Many illustrations are genericc and w will not lookk exactly likee the engine or the parrts used in your application. In order tto provide cclarity to illu ustrations, somee illustration ns show parrts removed d that are no ot related tto the sp pecific partss given in th he text. Most of the illustrations con ntain symbo ols to indicaate an actio on required or to in ndicate an acceptable ((OK) or unacceptable OK) conditio on. (not O

2.0

General Safety In nstruction ns

Read and understand d all of the safety preccautions and d warnings before perrforming an ny repair. TThis list contains th he general ssafety precautions thaat must be ffollowed to provide peersonal safe ety. Speciall safety precaution ns are includ ded in the p procedures when they apply. NOTE: It iss not possib ble for Cummins Enginee Company,, Inc. to antticipate every po ossible circu umstance th hat can invo olve a poten ntial hazard d. Warn ning: Disco onnect the b battery and d discharge any capacitors before beginnin ng any repaair work. Diisconnect aat air starterr, if equipped, to prrevent accid dent engine e starting. P Put a “Do N Not Operrate” tag in the operattor’s compaartment or on the conttrols. ning: Use O ONLY the co orrect engin ne barring ttechniques for Warn manually rotating the engiine. Do nott attempt to rotate the e engine by pu ulling or pryying on the e fan. This p practice can n cause seriious perso onal injury,, property d damage, or damage to o the fan blaade (s), causing prematture fan failure. ning: If an engine hass been operrating and tthe coolantt is hot, allo ow the engiine to cool before Warn you sslowly loosen the filler cap and re elieve the p pressure forrm the cooling system m. ning: Do no ot work on anything th hat is suppo orted ONLY Y by lift jackks or a Warn hoistt. Always u use blocks o or correct sttands to support the p product beffore perfo orming anyy service wo ork.

Page 1 of 179

Warrning: To avvoid burns, be alert for hot comp ponent parts after the engine has b been shut o off and for h hot fluids in n lines, tube es and compartments..

Warrning: Relie eve all presssure in the air, the oil and the coo oling system ms before any line e, fittings, or o related items are removed or o disconneected. Be alert for possible presssure when disconnectting any de evice from aa system th hat utilizes pressure. Do not che eck for presssure leaks w with your h hand. High pressure oiil or fuel can cause perrsonal injurry.

Warn ning: To prevent p sufffocation an nd frostbite e, wear pro otective clo othing and ONLY disco onnect liquid d refrigeran nt (Freon) lline s in a w wall ventilated area. U Use a Freon n capture ssystem to p prevent leakaage to the aatmosphere e. If in doubt, contactt your state and local eenvironmen ntal authorities or the EEnvironmen ntal Protecttion Agencyy (EPA) for gguidance ass to proper handling o of Freon. Warning: Corrrosion inhib bitor contaains alkali. Do not ge et the subsstance in your y eyes. Avoid prolo onged or repeated r c contact witth skin. Do D not sw wallow inteernally, in case of co ontact, immediately wash skin with w soap an nd water. In case of contact, im mmediatelyy flood eye es with large e amounts of water fo or a minimu um of 15 m minutes. IM MMEDIATELY CALL A P PHYSICIAN.. KEEP OUT OF REACH OF CHILDR REN. Warning: Alwaays use prop per tools th hat are in go ood condition. Make ssure you un nderstand h how to use tthem before performin ng any servvice work. Warn ning: Alwaays use the same faste ener part n number (orr equivalentt) when rep placing fastteners. Do n not use a fasstener of le esser qualityy if replacements are n necessary. Warn ning: Neve er use gasolline or othe er flammab ble materialls to clean parts. Always use app proved clean ning Solven nts. Warrning: Avoid d prolonged d and repeaated skin co ontact with h used engin ne oils. Succh prolonge ed and repe eated contaact may cau use serious sskin disorders or other serious bo odily injuryy,

‐ ‐

Avoid exccessive conttact. Wash tthoroughlyy after contaact. Keep out of reach of children

E MENT: Han ndling and disposal of used enggine oils may m be subjject to PROTTECT THE ENVIRONM federal, state and a local laaw and reggulation. Use U authorized waste disposal faacilities, inccluding orized facilitties for receipt of used oil. If in doubt, civic amenity siites and garrages proviiding autho contact your sttate and loccal environ nmental autthorities orr the Enviro onmental P Protection A Agency for gguidance as to proper h handling an nd disposal of used enggine oil. Dispo ose of antiifreeze properly. Han ndling and disposal off antifreezee can be su ubject to Fe ederal, State e and Locaal regulatio on. If in doubt, co ontact your state an nd local au uthorities or the Envirronmental Protection Agency (EP PA) for guid dance as to o proper haandling and d disposal o of used antiffreeze.

Page 2 of 179

3.0

DEFINITTION OF TTERMS

AFC

Air Fu uel Control

API

Amerrican Petroleum Institu ute

ASA

Air Signal Attenu uator

ASTM American Society of Tessting and Materials

Ceelsius

CAC

Chargge Air Cooleed

CARB

Califo ornia Air Resources Boaard

C.I.D.

Cubicc Inch Displaacement

Centimeter

CPL

Contrrol Parts List

cSt

Centistokes

DCA

Dieseel Coolant A Additive

E.C.S.

Emisssion Contro ol System

EPA

Environmental P Protection A Agency

Faahrenheit

Ft‐lb

Foot Pound

GVW

Grosss Vehicle W Weight

Merccury

Horseepower

H2O

Wateer

in‐lb

Inch P Pound

Kilogrrams

Kilom meters

km/l

Kilom meters per LLiter

kPa

Kilopascal

KSB

nce Cold Start Advan

Liter

LDA

Air‐Fu uel Control

Meteer

Millim meter

Page 3 of 179

MPa

Megaapascal

MPH

Miless Per Hour

MPQ

Mile Per Quart

N .m

Newtton‐meter

OEM

Origin nal Equipmeent Manufaacturer

ppm

Parts Per Million n

psi

Pounds Per Squaare Inch

RPM

Revolutions Per Minute

S.A.E

motive Engin neers Socieety of Autom

Page 4 of 179

4.0

ENGINEE AND COM MPONENTT IDENTIFICATION

Indusstrial Engine e Nomenclaature The m model namee for Industrial enginess provides th he following engine daata: 4BTA A3.9

placement in Liters Disp

Afteercooled Turb bocharged Engiine Series Num mber of Cylinders

4.1

General Specificaations (No on‐Automotive Enggines)

Gene eral

4B3.9

Engin ne Data

Bore‐‐mm [in.] ‐‐‐‐‐‐‐‐

4BT3.9

4BTA3.9 9

6B5.9

6BT5 5.9

6B BTA5.9

‐‐‐‐‐‐‐ 10 02 [4.02] ‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐ ‐‐‐‐

Stroke‐mm [in.] ‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐ 120 [4.72 2] ‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐ ‐‐‐‐ Displaacement‐litter [in.3]‐‐

3.9 [239 9] ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐ 5.9 [359]

‐‐‐‐‐

Engin ne Weight (D Dry) Less FFlywheel an nd Electrrics kg [lbs.]] 308[680] 320[705] 329[725 5] 388[855 5] 399[8 880] 411[905] Firingg Order ‐‐‐‐‐‐‐‐‐ 1.3.4.2 ‐‐‐‐‐‐‐

‐‐‐‐‐‐‐

1.5.3.6.2.4

‐‐‐‐‐

Valvee Clearancess ‐Intake‐mm [in n.] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 25 [0.01 10] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ n.] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 51 [ 020 0] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ ‐Exhaaust‐mm [in Comp pression Rattio 18.5:1 17.5:1

16.5:1 18.5:1 1

17..5:1 16 6.5:1

Rotattion, viewed d From the Front o of Engin ne ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Clockwise‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Aspiration

‐naaturally Asp pirated

‐Tu urbocharged

‐Affter cooled ‐Ch harge Air Co ooled NOTEE: See addittional pagess for Autom motive Specifications.

Page 5 of 179

LUBRICATION SY YSTEM kPa [[psi] 4B B3.9 Miniimum Allow wable Oil 6 69 [10] Pressure @Idle Miniimum Allow wable Oil 20 07 [30] Pressure @Rate ed Regu ulated Presssure 44 49 [65] Diffe erential Pre essure to Op pen 13 38 [20] Filter Bypass Oil C Capacity L [Q QT] Standard Pan O Only 9.5 [10] Total System (P Pan, Filter, LLines) 10..0 [11.5] No. Q QTS From ""L" to "H" o on [1] Dipstick COO OLING SYSTEEM L [QT] Engin ne Coolant Capacity Therrmostat Mo odulating Raange ˚C [˚FF] Pressure Cap kP Pa [psi] 104 ˚˚C [220 ˚F] 99 ˚C C [210 ˚ F] *Jackket‐water aaftercooled d

4BT3.9

4BTA3.9*

9 6B5.9

6BTT5.9

60 [10]

69 [1 10]

69 9 [10]

69 [10]

207 [30]

449 [65]

138 [20]

9.5 [10] 11 [11.6]

9.5 [10]] 11 [11.6 6]

[1]

14.2 [[15] 14..2 [15] 1 14.2 [15] 16.3 [1 17.2] 16.4 4 [17.3] 16.4 [17.3] [2]]

[2]

9.0 [9 9.5] 9.0 0 [9.5] 7..0 [7.4] 7.9 [8.4] 7.0 [7.4] 83‐95 8 83‐95 83‐95 83‐95 83‐9 95 [18 81‐230] [181‐203] [181‐203 3] [181‐2 203] [181‐203] 10 03 [15] 4 48 [7]

6B BTA5.9*

103 [15] 48 [7]

[2]

9.9 [10.5] 9 83‐95 [181‐203] 103 [15] 48 [7]

INTAKE AIR, EXHAU UST 4B3.9 9 4BT3.9 4BTA3.9 6B5 5.9 6B BT5.9 6 6BTA5.9 UEL SYSTEM AND FU Maximu um Allowable Intake R Restrcition aat Rated Sp peed and Lo oad 508 [20 0] 635 [25] 635 [25 5] 508 [20] 635 5 [25] 6 635 [25] with Dirrty Speed Filter Elementt‐mm H2O [iin. H2O] Maximu um Allowable Exhaust Restriction n at ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 76/.2 2 mm [3 in.]] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Rated Sp peed and Lo oad‐ mm Hg [in. Hg] Maximu um Fuel Pressure ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Drop Accross Filters kPa 34 4 mm [5] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ [psi] Maximu um Allowable ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Return LLine Restriction‐ 518 m mm [20.4 in.] ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ mm Hg [in. Hg] Maximu um Inlet Restriction to fuel ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 100 [4] transferr pump‐mm m Hg [in. Hg] *Typiical light acccessories in nclude altern nator, small steering pump, and d disengaged clutch.

Page 6 of 179

6B5.9 ELECTTRICAL SYSTTEM 4B3 3.9 4 4BT3.9 4BTA3.9 6BT5.9 9 6BTA A5.9 Minim mum Recom mmended Batterry Capacity With Light Accesssories* ‐12 V SStarter 625 CCA 62 25 CCA 625 CCA 800 CCA 800 CC CA 800 CCA ‐24 C SStarter 312 CCA 40 00 CCA 400 Cca 400 CCA 400 CC CA 400 CCA With H Heavy Accessories** ‐12 V SStarter 800 CCA 80 00 CCA 800 CCA 950 CCA 950 CC CA 950 C CCA ‐24 V SStarter 400 CCA 40 00 CCA 400 CCA 475 CCA 475 CC CA 47J5 CCA Maxim mum Allowaable Resistance of Starting Circuitt ‐With 12 V Starteer‐Ohms ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 0.0012 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ ‐With 24 V Starteer‐Ohms ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 0.002 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ **Typ pical heavy accessoriess include hyydraulic pum mp and torq que convertter. Batte eries (Speciffic Gravity) Specific Gravvity a at 27˚C [80˚ ˚F] 1.260‐1.28 80 1.230‐1.25 50 1.200‐1.22 20 1.170‐1.19 90 1.110‐1.13 30

4.2

Staate of Chargge 100% 75% 50% 25% D Discharged

Externaal Engine C Componen nts The illustraations, which, follow show s the lo ocations off the major external eengine components, th he filters, and other service and d maintenaance points. Some exxternal com mponents will be at diffferent locaations for different eengine modeels.

Page 7 of 179

Page 8 of 179

5.0

OPERATTING INSTTRUCTION NS

5.1

General Informattion

Correct carre of your eengine will rresult in lon nger life, bettter perform mance, and more econ nomical opeeration. • Follo ow the dailyy maintenan nce checks listed in Maaintenance G Guidelines, Section 2. • Checck the oil pressure indicators, tem mperature indicators, warning ligghts, and otther gaugess daily to makee sure they are operatiional. Warn ning: DO NOT OPER RATE A DIEESEL ENGIN NE WHERE THERE AR RE OR CAN N BE COMB BUSTIBLE VAPO ORS. These e vapors caan be drawn n through tthe air intake system and cause engine acce eleration and over‐speed ding, which h can resultt in a fire, an explosiion and /or extensive e property damage. merous safety devices are availab ble, such ass air intake shut off deevices, to m minimize th he risk of Num over‐speeding where an n engine, due to itts application, mightt operate in a com mbustible envirronment, such as due to a fuel sspill or gas leak. Reme ember, Cum mmins has no way of knowing the use u you haave for you ur engine. THE EQUIP PMENT OW WNER AND OPERATOR R ARE RESP PONSIBLE FOR SAFE OPEERATION IN N A HOSTILE ENVIRO ONMENT CO ONSULT YO OUR CUMM MINS AUTHORIZED AIR LOCATIO ON FOR FURTHER INFO ORMATION N. REPA Starting Prrocedure

Auto omotive – (B Bosch VE an nd P‐Pumpss with RQV V‐K Governo or) above 16 6 ˚C [60˚F] Foot off throttlee ‐ the VE p pump has aan internal starting circcuit to provvide startingg fuel delivvery. The inlinee pump delivers sufficient fuel to start engine e with throtttle at idle. Auto omotive – (B Bosch VE an nd P‐Pumpss with RQV V‐K Governo or) 16 ˚C [60 0˚F] Foot at full thrrottle whilee cranking ‐ ‐ the VE Pu ump has an n internal ccircuit to provide p starrting fuel delivvery, and op pen throttlee helps keep p the engin ne operatingg, once starrted. The in nline pump requires open n throttle to o position an nd hold thee rack in the e maximum fuel positio on.

Industrial/Marine‐ (Bosch VE, Lucas D DPA, Stanad dyne DP4, N Nippondensso EP‐9) above 0 ˚C [32 2 ˚F] Foot off throttlee – the VE Pump has aan internal starting circuit to provvide starting fuel delivvery. The DPA pump has a metering valve, which, will remain in start s positio on if crankiing speed does d not peed. The EP‐9 pump has a “Starrt Spring” w which autom matically mo oves the rack to the approach idle sp start fuel positio on.

Page 9 of 179

Starrting Proced dure Matrixx

Automotive All p pumps‐abovve 16 ˚C [60 0˚F] All p pumps‐belo ow 16 ˚C [60 0˚F] Indu ustrial/Marrine All p pumps‐abovve 0˚C [32˚FF] All eexcept Boscch VE‐below w 0˚C [32˚F] Boscch VE‐below w 0 ˚C

Idle TThrottle

Full TThrottle

• Disen ngaged the driven unitt, or if equip pped, put th he transmission in neuttral. • Posittion the fuel shut‐off, eelectrical sw witch or mecchanism control to the e RUN positiion. Cauttion: To prevent p dam mage to th he starter, do not en ngage the sstarting mo otor more than 30 seconds. Wait 2 2 minutes b between eaach attemptt to start (e electrical staarting moto ors only.) • If thee engine do oes not start after theeir attemptss, check thee fuel supply system. Absence o of blue or whitee exhaust smoke durin ng cranking indicates no fuel is beiing delivereed. • Move the throtttle position to idle as the engine sstarts. • Engin ne oil pressure must bee indicated on the gauge within 15 seconds aafter startin ng. • When starting a cold enggine, increaase the en ngine speed d (RPM) slowly to make m sure adequate a lubrications available to thee bearings. Cauttion: Do no ot idle the e engine for e excessivelyy long perio ods. Long p periods of id dling (more e than 10 minu utes) can daamage an e engine because comb bustion cham mber temp peratures drop so low w the fuel will n not burn co ompletely. This will ccause carbo on to clog tthe injectorr spray hole es and pistton rings, and can cause tthe valves tto stick. If the engine e coolant te emperaturee becomes too low (60 0 ˚C [140 ˚F]), raw fuel will w wash the t lubricaating oil offf the cylin nder walls and dilute the crankkcase oil; there efore, all m moving partss of engine will not recceive the co orrect amou unt of lubrication. • Idle tthe engine 3 3 to 5 minu utes before operating w with a load. Cauttion: When n using jump per cables tto start the engine, maake sure to connect th he cables in parallel: posittive (+) to p positive (+)) and negattive (‐). W When using an external electrical source to start the engin ne, turn then disconn nect switch to the “OFFF” position n. Removee the key before attacching the jump per cables tto prevent u unintention nal starter e engagemen nt.

Page 10 of 179

5.2

Cold We eather Op peration Starting A Aid Require ements Use tthe followin ng chart as aa referencee for require ed cold weaather startin ng aids: Operration in am mbient tem mperatures below 0˚C [32˚F] can require speecial consid deration be given to engin ne starting.. At tempeeratures below 0˚C [32 2˚F], operate the enggine at mod derate speeeds for 5 minu utes before full loads are applied.

D OIL PAN AND BLOCK HEATERS

STARTING AIDS

32˚˚F

0˚C

UNAIDED D

UNAIDED

SUGG GESTED

‐12 ˚C

10˚˚F

‐18˚C

0˚˚F

‐24˚C

‐10˚˚F

ATTERY CAPACITY BA

STANDARD

SUGGESTED

EXTRA C CAPACITY SUGGESTED

REQUIRED D

REQUIREED

EXTTRA CAPACITY REQUIRED (180‐200 0%)

Page 11 of 179

5.2.1 1 Winterffronts Winterfro onts can bee used on a vehicle equ uipped with h charge airr cooling (CA AC), but mu ust be desiggned to partially cover the frrontal area of the cooling system.. A minimum of 120 sq quare inche es (11 in x 11 in) of frontal arrea must bee left open tto air flow ffor the CAC to function n correctly.

5.2.2 2 Shutterr Installatio ons of CAC C engines with w shutterrs also requ uire an intaake manifold air temp perature sw witch to open thee shutters to o prevent exxcessive inttake manifo old temperaatures. This prevents en ngine damaage due to high in ntake maniffold temperratures as a result of bllocked air fllow, across the CAC.

5.3

Cold We eather Staarting hanical or EElectrical Metering Equ uipment Using Staarting Fluid With Mech • Set the throttle at half speed • Disengagee the driven n unit, or if eequipped, p put the transmission in neutral. • Activate th he switch to o open the fuel pump sshut‐off valve. • While cran nking the en ngine, injecct metered aamounts off starting flu uid. • Engine oil pressure m must be indicated on th he gauge within 30 seco onds after sstarting.

Using Staarting Fluid Without M Metering Equipment Warn ning: Neve er use starrting fluid near n on op pen flame, or with a preheater or flame‐th hrower equipment. This combinattion can cau use an expllosion.

Page 12 of 179

Warn ning: Do no ot breathe starting fluid fumes. SStarting fluid fumes can be harmfful to your healtth. Cauttion: Do no ot use excesssive amou unts of startting fluid w when startin ng an engine. The use e of too much h starting flluid will cau use engine damage. • Sp pray starting fluid into the air cleaaner intake while anoth her person cranks the engine. ning: Do no ot use volatile cold staarting aids iin undergro ound mine,, or tunnel o operations due to Warn the p potential off an explosiion.

5.4

Startingg Procedure‐After EExtended Shutdown n or Oil Ch hange Complete tthe followin ng steps aftter each oil change, or after the engine has b been shut off for more than 7 days to maake sure thee engine recceives the ccorrect oil flow through h the lubricaating oil sysstem:

• •

Disconnecct the electrrical wire fro om the fuel pump soleenoid valve. Rotate thee crankshafft, using the starting motor, m until oil pressu ure appears on the gau uge, or the warnin ng light goees out. Connect the electricaal wire to th he fuel pump solenoid vvalve Start the eengine: refeer to Normaal Starting P Procedures iin this Section. Refer to Fuel System‐‐Bleeding, SSection 5, fo or instructio ons to vent the fuel sysstem.

• • •

5.5

Operatiing the En ngine • • •

Do not operate enggine at full throttle below b torqu ue engine speed (110 00 to 1600 0 RPM, dependen nt on enginee rating) forr extended p periods (mo ore than 1 m minute) of ttime. Allow the engine to id dle 3 to 5 m minutes befo ore shuttling it off afteer a full load d operation.. Monitor the oil presssure and coolant temperature gau uges frequeently. Referr to Lubricatting Oil System or o Cooling System, Section 5, for reco ommended d operatingg pressurees and temperatu ures. Shutt off the engine e if any pressure or temperature do oes not meeet the specificatiions.

eration witth low coo olant temp perature (b below 60˚C [140˚F]) or o high Cauttion: Conttinuous ope coolaant temperrature (abovve 100 ˚C [2 212 ˚F]) can n damage th he engine. •

•

If an overheating co ondition Sttarts to occcur, reducee the poweer output of the enggine by releasing tthe throttlee pressure o or shifting tthe transmiission to a lower gear, or both, un ntil the temperatu ure returnss to normal operating range. If engine e tem mperature does not retturn to normal, sh hut off the engine and d refer to Troublesho T oting, Sectiion T, or co ontact a Cu ummins Authorized Repair Lo ocation. Most failu ures give an n early warrning. Look and listen for changees in perforrmance, sound or engine ap ppearance that t can ind dicate service or engine repair iss needed. Some chan nges to look for arre as follow ws: ‐ Engiine misfiress ‐ Exceessive smokke ‐ Vibrration ‐ Losss of power

Page 13 of 179

‐ ‐ ‐

5.6

Unusual enginee noises ‐ An iincrease in oil consump ption olant leaks ‐ An iincrease in fuel consum mption Fuell, oil, or coo Sudd den changees in engine operating ttemperaturre or oil pressure

Engine O Operatingg Range

Cauttion: Cumm mins engines are design nated to op perate successfully at ffull throttle e under tran nsient cond ditions dow wn to peakk torque en ngine speed d (RPM). This is con nsistent witth recomm mended driving practice es for good fuel econom my. Excessiive full thro ottle operattion below peak torqu ue RPM (peak torque RP PM varies ffrom 1,100 RPM to 1,6 600 RPM, de epending upon rated e engine spee ed) will shortten engine e life to ovverhaul, can cause se erious engin ne damagee, and is co onsidered engine statu us. Cauttion: Operaation of the e engine be elow peak ttorque RPM M Can occur during ge ear shifting due to the d difference o of ratios be etween tran nsmission ggears, but e engine operration mustt not be susstained more e than 1 minute at fulll throttle be elow peak ttorque RPM M. Cauttion: Operrating the e engine beyo ond high idle speed caan cause severe engine e damage. When descending a stteep grade,, use a com mbination of transmisssion gears aand engine or service brakes to co ontrol the vvehicle and engine speed.

5.7

Engine SShutdown n

• •

Allow the engine to iidle 3 to 5 m minutes aftter a full loaad operation before sh hutting it offf. This allows thee engine to cool graduaally and unifformly. Turn the iggnition key switch to the OFF position.

Page 14 of 179

6.0

MAINTEENANCE G GUIDELINEES

6.1

General Informattion

Cummins Engin ne Company, Inc. reco ommends that t the en ngine be m maintained according to the Main ntenance Scchedule in this section. If thee engine is operating iin ambient temperatures consisteently below w ‐18 ˚C [0 ˚˚F] or abovee 83 ˚C [100 ˚F], perfo orm mainteenance at shorter inttervals. Sh horter maintenance intervals arre also required if the eengine is op nt stops are perated in aa dusty envvironment o or if frequen e made. Seee your Cummins Autho orized Repair Location ffor recomm mended inteervals. Use the chart provided at a the end of this se ection as a convenien nt way to keep a reccord of main ntenance peerformed.

6.2

Tool Requiremen nts In the text, a syymbol follow wed by the wrench size or tool deescription iss used to id dentify the tooling required to perfform each sstep. A list of wrench sizes and d descriptionss indicate m more than one tool is needed.

Socke ets 19 mm 17 mm 15 mm

Wren nches 19 mm 17 mm 15 mm 14 mm 13 mm 10 mm

Othe er Tools Fuel line nuts m and 90‐95 mm) Filterr Wrenches (75‐80 mm Ratch het (1/2 inch drive) Torqu ue Wrench Flat B Blade Screw wdriver 5/16 Allen Wren nch Feeleer Gauges (0 0.25 mm an nd 0.51 mm) Engin ne Barring G Gear Part No o. 3377371

Page 15 of 179

6.3

Mainten nance Sch hedule

ng Daily or Refuelin

Checkk • • • •

Oil Level Co oolant Levell Fan‐Inspectio on Drrive Belt‐ Insspection • Fuel Water Trrap

Eve ery 10,000 K Km [6,0 000 Mi], 250 0 Hou urs or 3 Mo onths

Evvery 19,000 0 Km Every 38,000 Km Everry 77,000 Km m [1 12,000 Mi], 500 [24 4,000 Mi] 1 1000 [48,0 000 Mi], 20 000 Ho ours or 6 M Months Ho ours or 12 Hours or 2 Yearrs Mo onths ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Change/R Replace‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐ • Lu ube Oil • Lube Oil • Lub be Oil • Lube e Oil • Lu ube Filter • Lube Filter • Lub be Filter • Lube e Filter • Fueel Filter • Fueel Filter • Fuel FFilter • Antiffreeze ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Adjust‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 2 • Valve Lash V C Clearance ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Check /Inspect‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ • Air Cleaneer • Air Cleaner • Air Cleaner A • Air Cleaner • intake System • intake Systtem • intake i • Ch harge Air S System Co ooler • Antifreeze • Charge Air C • inttake System m • Charge Airr Cooler C Cooler • Charge Air • Antifreeze A • Faan Hub Cooler • Fan Hub • Be elt Tension Be earing • Belt Tension • Be elt Tension Bearing • Belt Tension • Daamper

1. Refer to the Oill Change intterval chartt given in SSection 4 to o find the sp pecific oil change interrval for n. your application 2. Initiaal valve lash clearancee adjustment, subsequ uent adjusttments to b be perform med at 77,0 000 Km [48,0 000 mile] orr every 4th o oil change fo or automotive enginess and, 2000 hour, 2 yeaars interval. 3. Mustt use a heavvy‐duty yeaar around antifreeze th hat meets tthe chemicaal composittion of GM6 6038M. The change inteerval is 2 years or 320 0,000 Km [2 200,000 Mii], whicheveer occurs fiirst. Antifreeze is essen ntial for freeze, overheeat and corrrosion prote ection. 4. Serviice interval is 2 years o or 320,000 K Km [200,000 0 Mi], which hever occurrs first. 5. Serviice interval is every oth her oil chan nge or 19,00 00 Km [12,0 000 miles], 5 500 hours o or 6 months.

Page 16 of 179

7.0

DAILY M MAINTENA ANCE PRO OCEDURE

7.1

General Informattion Preveentive main ntenance begins with day‐to‐dayy awarenesss of the con ndition of the t engine and its systeems. Beforee starting th he engine, ccheck the oiil and coolant levels. LLook for: • Leaks • Loose or d damaged paarts • Worn or d damaged beelts • Any changge in enginee appearancce

7.2

Fuel‐Waater Separator Draining Drain n the waterr and sediment from th he separator daily. Shut off the en ngine. Use yyour hand to open the d drain valve. Turn the vvalve counte erclockwise e approximaately 1½ to 2 turns unttil draining occurs. Drain n the filters sump of water until cllear fuel is vvisible. Cauttions: Do no ot over tigh hten the valve. Over tightening ccan damagee the thread ds. Turn the valve cclockwise to o close the d drain valve..

Page 17 of 179

7.3 Oil Level

Check er operate tthe engine w with the oil level below w the “L” (Lo ow) mark o or above the e “H” (High)) Neve markk. Waitt at least 5 m minutes afteer shutting off the engine to check to oil. This allows tim me for the o oil to drain n to the oil p pan. Note e: The enggine must be b level wh hen checkin ng the oil leevel to make sure the e measurem ment is correect.

Low Mark To High Maark Oil Capaacity 4 Cylindeer‐0.95 Literr [1.0 U.S. Q Quart] 6 Cylindeer‐1.89 Literr [2.0 U.S. Q Quart]

7.4 Coolant LLevel

Check Warn ning: Do no ot remove tthe radiatorr cap from aa hot engin ne. Wait un ntil the temperature iss below 50 ˚C C [120 ˚F], before rem moving the pressure caap. Failure e to do so ccan result iin personall injury from m heated co oolant spraay or steam m. Remove e the fillerr cap slowlyy to relieve coolant system s presssure. Note ed: Never u use a sealingg additive to o stop leakss in the coolant system m. This can result in co oolant systeem pluggingg and inadequate coolaant flow cau using the en ngine to oveerheat. The ccoolant leveel must be cchecked daily.

Page 18 of 179

Caution: Do not add d cold coolaant to a hott engine. EEngine castings can be damaged. Allow the engine to o cool to be elow 50 ˚C [[120 ˚F] beffore adding coolant.

NOTE: O On applicatio ons that usee a coolant recovery syystem, checck to make ssure the coo olant is at the appro opriate leveel on the coolant recovvery tank de epending on n engine tem mperature.

Fill the co ooling systeem with coo olant to the bottom of the fill neckk in the radiiator fill or e expansion tank. NOTE: So ome radiato ors have tw wo fill necks,, both of wh hich must b be filled the cooling sysstem is drained.

Page 19 of 179

7.5 Drive Bellt

Inspection n

Visuaally inspect the belt. C Check the beelt for intersecting craccks. Transverse (across the belt w width) crackks are acceptable. Lon ngitudinal (direction of belt lengtth) cracks th hat intersecct with tran nsverse crackks are not aacceptable. Replace the belt if it iss frayed or has pieces o of material missing. Refer to Adjustm ment and R Replacemen nt

7.6 Cooling FFan

Inspection n Warn ning: Perso onnel injuryy can resultt from a fan n blade failure. Neverr pull or pryy on the fan n. This can d damage the en fan blade e (s) and caause fan failure.

NOTE: Rotate the crankshaaft by usingg the engine e barring gear. n is required daily. Ch heck for craacks, loose rivets, and bet or A vissual inspecttion of the cooling fan loosee blades. Check the fan to make sure it is securelyy mounted. Tighten the t cap screws if neceessary. Replace any fan n that is dam maged.

Page 20 of 179

8.0 MAINTEN NANCE PRO OCEDURESS at 10,000 KILOMEETERS [6,00 00 MILES], 250 HOU URS or 3 MON NTHS

8.1 General IInformatio on

All checks or inspectio ons listed un nder daily o or previous maintenancce intervalss must also be perform med at this time in n addition to those listed under th his maintenance intervval.

8.2 Lubricating Oil and d Filter Ch hange Inte erval

Refer to th he followingg flow chart to determiine the maxximum reco ommended oil and filte er change intervals in n kilometerss, miles, hours or montths; whiche ever comes first. Is yo our vehicle an on High hway application?

YES

Is your veehicle one of tthose below? ‐ Regional Haaul Truck ‐ Coach Bus ‐ Vehicle Acccum. 8000 miles/moth h or more

YES

Change Interval KM MILES HOUR MOS 50 3 17,000 10,000 25

(1) Or whicheever comes first. If your application accumulates high w hours and low mileage, the change interval is determined by hours. Example: Traansit buses and reffuse. Trucks may aaverage 16 Km [10 MPH]] when used in all urban routes. Oil drrain intervals in th hose applications aare 4800 Km [3,000 mi], or less.

Use tthe following oil drain interrvals for your application (1 1): VEH//EQUIP KM MILES HRS. MOS Refuse Trk 0 6,000 250 10,000 3 0 6,000 250 Mixeer/Dumper 10,000 3 Del. Truck 10,000 0 6,000 250 6 0 6,000 250 Shuttle or Transit Bus 10,000 3 ool Bus 10,000 0 6,000 250 Scho 6 Fire TTruck 10,000 0 6,000 250 3 Recreational Vehicle 10,000 0 6,000 250 6

Is your veehicle used in a Construcction, Mining o or Logging A Application?

YES

Is your veehicle used in an Agricultu ural or Stationary Power Ap pplication?

YESS

Change Interval URS MOS KM MILES HOU 0 3 10,000 6,000 250

Use tthe following oil drain interrvals for your application (1 1): VEH//EQUIP KM MILES HRS. MOS Truck Crane 0 6,000 250 10,000 3 10,000 0 6,000 250 Yard Spotter 3 N/A N/A 250 6 Paveer Cranes N/A N/A 250 6 Backkhoe N/A N/A 250 6 Dozeer N/A N/A 250 6 Scrap pper N/A N/A 250 6 Skidd der N/A N/A 250 6 Use the following oil drain intervals for your application (1 1): VEH//EQUIP HRSS. MOS Farm m Tractors 250 0 6 Com mbines 250 0 6 Irrigaation Equip 250 0 6 Geneerator Set 250 0 6 Air C Compressor 250 0 6 Fire Pump 250 0 6 250 0 6 Pleasure Boat Worrk Boat 250 0 3

Page 21 of 179

8.3

Lubricatting Oil an nd Filter Changingg

Cauttion: Avoid prolonged and repeatted skin con ntact with u used enginee lubricatin ng oils. Such h prolo onged and rrepeated co ontact mayy cause skin n disorders o or other bo odily injury. Avoid exceessive contaact‐wash th horoughly after contactt. ‐ ‐ Keep out o of reach of children. RONMENT: Handling aand disposaal of used en ngine lubriccating oil maay be PROTECTT THE ENVIR subject to o federal, sttate and loccal law and regulation. Use autho orized wastee disposal faacilities, includingg civic amen nity sites and garages p providing au uthorized faacilities for rreceipt of used lubricatin ng oil. If in d doubt, conttact your state and local environm mental authorities or th he Environm mental Proteection Agen ncy for guidance as to p proper hand dling and diisposal of used engine oil.

n interval of 10,000 Km m [6,000 miles] 250 hours or 3 NOTE: Iff the enginee is service, the oil drain months o or approved d extended interval fro om the Charrt on Page 2 22) must bee observed.

Change the oil and ffilters to rem move the co ontaminantts suspendeed in the oil.. NOTE: D Drain the oil only when it is hot and d the contaaminants aree in suspension.

Page 22 of 179

17 mm

Cauttion: Hot oiil can cause e personal injury Operrate the en ngine until the water temperatu ure reachess 60 ˚C [14 40 ˚F]. Shu ut the engine off. Remove the oil drain plug. NOTE: Use a co ontainer thaat can hold aat least 20 lliters [15 U.S. qts.] of o oil.

90 to 95 mm Filtter Wrench Clean n the area aaround the lubricating oil filter head. Removve the filter.. Clean the gaskeet surface o of the filter head. NOTE: The o‐rin ng can stickk on the filteer head. Make sure it iis removed before instaalling the neew filter.

Page 23 of 179

Make sure the co orrect oil filtter is used. The filter for the six‐cylinderr engine is lo onger than the filter fo or the four‐ccylinder enggine. A = Sttandard for four‐cylinder applicatiions B = Staandard for ssix‐cylinder application ns NOTE:: A 6‐cylind der oil filter can be used d on a 4 cylinder engin ne. Do not u use a 4‐cylin nder oil filteer on a 6‐cylin nder enginee.

NOTE: Fill the filters with cclean lubricaating oil beffore installaation. Apply a light film m of lubricating oil to the gasket sealing surfaace before installing the filters.

Page 24 of 179

Cauttion: Mechaanical over‐tighteningg can distortt the thread ds or damagge the filter element sseal. Instaall the filter as specified d by the filteer manufaccturer.

17 mm

Checck and clean n the oil draain plug threeads and se ealing surfacce. Instaall the oil drain plug. Torque Value: 8 80 N . m [60 0 ft‐lb.]

Page 25 of 179

NOTE:: Use high q quality multti‐grade lub bricating oil meeting th he American n Petroleum m Institute (A API) classification of C CE/SG as outtlined in Specificationss and Torque Values. d in areas w where CE/SG G oil is not yyet availablee. NOTE:: CD/SF oil can be used If CD/SSF oil is used, change the oil at one‐half the rrecommend ded intervalls

Fill thee engine witth clean oil to the prop per level. Fo our Cylinde er Six Cylinder Pan Caapacity 9.5 liters 14.2 Liters [1 10 U.S. Qts.] 15 U.S. Qts.] [1 10 0.9 Liters 16.3 Liters Total SSystem Capacity [1 11.5 U.S. Qtts.] [1 17.2 U.S. Qtts]

NOTE:: Capacitiess assume standard pan n. Total systtem assumees standard d pan plus filter. Some 6B applicattions used aa reduced caapacity pan n 10.4 Literss [11 U.S. Qtts.] and som me have inccreased capaciity of 16 liteers [17 U.S. Qts.]. Fill q quantities m must be adju usted accorrdingly. 26 Page 26 of 179

Operrate the enggine at idle to inspect ffor leaks at the filters aand the draiin plug.

8.4

Stop the enginee. Wait approximately 5 minutes tto let the oil drain from m the upperr parts of the engin ne. Check tthe oil level again. Add oil as necesssary to brin ng the oil level to the ““H” (High) m mark on the dipstick.

Air Intake System m Inspectio on Inspeect the intake piping fo or cracked h hoses, loose e clamps, orr punctures which can allow dirt aand debrris to enter tthe engine.

Tightten or replaace parts as necessary tto make sure the air in ntake system m does not leak.

Page 27 of 179

8.5

Charge Air Cooler Inspectio on

If thee engine experiences aa turbochargger failure o or any other occasion w where oil orr debris is p put into the C CAC, the CA AC must be ccleaned.

Remove the CAC C from the vvehicle. Reefer to the vvehicle manufacturer’s instruction ns.

oles or damaage. Visuaally inspect the CAC for cracks, ho Inspeect the tubees, fins and welds for tears, breaks or other d damage. Refer to leak check procedure

Page 28 of 179

Clean ning Flush h the CAC internally w with solventt in the opp posite direcction of norrmal airflow w. Shake th he CAC and llightly tap o on the end ttanks with a rubber mallet to disllodge trapp ped debris. Continue flushing until all debris o or oil is removed. Cauttion: Do no ot use causttic cleaners to clean the CAC. Dam mage to thee CAC will rresult. Afterr the CAC haas been tho oroughly cleeaned of all oil and deb bris with sollvent, wash the CAC interrnally with h hot soapy w water to rem move the remaining sollvent. Rinsee thoroughlly with clean wateer. Blow w compresseed air into the CAC in the opposite e direction o of normal aairflow until the CAC is dry interrnally. Refer to the veh hicle manufacturer’s in nstructions ffor installation procedu ures.

8.6

Air Cleaaner Restrriction Check

Page 29 of 179

Maxiimum intakke air restricction is 635 mm [25.0 in.] of waterr for turboccharged enggines. Naturally aspirrated enginees have a m maximum reestriction off 510 mm [2 20.0 in.] of w water. Turbocharged eengines musst be operatted at rated d RPM and ffull load to ccheck maximum intakee air place the airr cleaner eleement when the restriction reaches the maximum allow wable restrriction. Rep limit or clean acccording to tthe manufaacturer’s reccommendations.

NOTE: Fo ollow the m manufactureer’s instructtions when cleaning or replacing the air clean ner elementt.

Check thee air cleaneer service indicator, if eequipped. C Change the filter elemeent when th he red indicatorr flag (2) is aat the raised d position in n the windo ow. (1) After thee air cleanerr has been sserviced, pu ush the buttton (3) to reeset the servvice indicattor.

NOTE: N Never operate the engin ne without an air clean ner. Intake air must bee filtered to prevent dirt and debrris from entering the en ngine and ccausing prem mature weaar.

Page 30 of 179

9.0 MAINTEENANCE P PROCEDUR RES AT 19 9,000 KILO OMETERS [12,000 M MILES], 500 0 HOURS OR 6 NTHS MON 9.1 Fuel Filtter Replacem ment 75‐80 mm and 90‐95 mm Clean n the area aaround the fuel filter head. Remo ove the filteers. Clean th he gasket su urface of th he filter head d.

Replaace the o‐riing

Page 31 of 179

Fill th he new filteer (s) with clean fuel an nd lubricate e the o‐ring seal with clean lubricating oil. • Standard ffilter – used d as secondary filter in dual filter aapplicationss • Fuel water separator – used as p primary filte er in dual fillter applicattions. • Fuel Wateer Separatorr – used in ssingle filter application ns.

Cauttion: Mechanical tighttening will d distort the threads, filter elemen nt seal or filtter can. Instaall the filter as specified d by the filteer manufaccturer.

Page 32 of 179

9.2

Fuel Sysstem Bleeding

Controlled d venting is provided aat the injecttion pump tthrough thee fuel drain manifold. Small amounts of air introdu uced by chaanging the filters or injections pu ump supply line will bee vented au utomaticallyy, if the fuel filter is changed in accordan nce with thee instructions. No man nual bleedin ng of fuel lin nes is requirred. NOTE: Manual bleeding is required if:: • The fuel fiilter is not ffiled prior to o installation. Injection p pump is rep placed. • High presssure fuel lin ne connectio ons are loossened or lin nes replaced d. • Initial engine start up p or start up p after an exxtended period of no eengine operration. • Vehicle fuel tank has run empty.. •

Page 33 of 179

9.3

Low Pre essure Lines and Fu uel Filter (ss) Venting 8 mm

Open n the vent sscrew.

Operrate the plu unger on thee lift pump until the fuel flowing ffrom the fittting is free o of air.

Tightten the bleeed screw. Torque Value: 9 9 N . m [7 ftt‐lb]

Page 34 of 179

9.4

Injection Pump

Venting 8 mm

Bleed d the Lucas CAV pump at the location shown n in the illustration.

Air fu uel can be p pumped fro om this locattion with th he had leverr on the lift pump if the e fuel solen noid valvee is energizeed.

Page 35 of 179

Air can n be vented d from both pumps through the fu uel drain maanifold line by operatin ng the starting motorr.

Cautio on: When u using the starting moto or to vent tthe system,, do not enggage it for m more than 3 30 second ds at a time e: Wait 2 m minutes between engagements. Warniing: It is ne ecessary to put the enggine in the ““Run” posittion. Becau use the enggine may staart, be surre to follow w all the safe ety precauttions. Use tthe normal engine starting proce edure.

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9.5

High Pre essure Lin nes (Rotarry and In‐lline Pump ps) Venting

17 mm, 19 9 mm

ning: The p pressure of the fuel in the line is ssufficient to o penetratee the skin and cause se erious Warn bodily harm. Ventting is accom mplished byy loosening one or morre fittings att the injecto ors and cran nking the en ngine to allow entrapp ped air to bleed from tthe lines.

Page 37 of 179

9.6

Re‐Tighten Line FFittings Torque Value: 3 30 N . m

Warn ning: Do no ot bleed a h hot engine aas this coulld cause fue el to spill on nto a hot exxhaust man nifold creatting a danger of fire. Startt the enginee and vent o one line at aa time until the engine runs smootthly.

9.7

Antifree eze Conce entration Check

Checck the antifrreeze conceentration. U Use a mixturre of 50 percent water and 50 perrcent ethyleene‐ glyco ol base antiffreeze to prrotect the eengine to ‐37 ˚C [‐34 ˚F]] year aroun nd. Antiffreeze is essential in any climate.. It bro oadens the operating ttemperature range by lowering th he coolant freezing point and by raaising its bo oiling point. The ccorrosion in nhibitors, also protectss the coolingg system co omponents from corrossion and pro ovides longeer componeent life.

Page 38 of 179

10.0 MAINTEENANCE P PROCEDUR RES AT 38 8, 000 KILO OMETERS [24,000 M Mi.], 1000 0 HOURS o or 1 R YEAR 10.1 Valve 10.1.1 Adjustments A s

15 mm

Remove the valvve cover.

1 Engine Baarring Gear ½ Inch Drivve, 3377371 Locate Top Dead d Center (TDC) for Cylinder Numb ber 1 by barring enginee slowly while pressing on the eengine timin ng pin.

Page 39 of 179

When the pin en ngages the hole in the camshaft ggear, cylindeer Number 1 is at TDC on the comp pression strroke. Cauttion: To pre event damaage to the e engine or piin, be sure d do disengagge the pin aafter locatin ng TDC.

Page 40 of 179

Feeler Gau uge Intakke Clearancee: 0.254 mm [0.010 IN N] Exhaust Clearan nce: 0.508 m mm [0.020 IN] Checck/set valves with engin ne cold‐below 60 ˚C [1 140˚F] NOTE: The clearance is corrrect when some resisttance is “felt” when the feeler gau uge is slippeed betw ween the valve stem an nd the rockeer level. 10.1.2 2 Four Cylinder Engine Adjustme ents 14 mm, Flaatblade Screwdriver Locate Top Dead d Center (TDC) for Cylinder Numb ber 1. n the illustration (I = In ntake; E = Exxhaust) Checck/adjust the valves as indicated in Tightten the lockknut and meeasure the vvalve lash aagain. Torque Value: 24 N . m [18 8 ft‐lb]

Page 41 of 179

Markk the pulleyy and rotatee the cranksshaft 360 de egrees. Cauttion: To pre event engin ne or pin daamage, be ssure timing is disengagged.

14 mm, Flaat blade Scrrewdriver

Torque Value: 24 N . m [18 8 ft‐lb]

Page 42 of 179

10.1.3 3 Six‐Cylind der Engine Adjustmen nt 14 mm, Flaat‐blade Scrrewdriver Locate Top Dead d Center (TDC) for Cylinder Numb ber 1. Checck/adjust the valves as indicated in n the illustration (I = In ntake; E = Exxhaust) Tightten the lockknut and meeasure the vvalve lash aagain. Torque Value: 24 N . m [18 8 ft‐lb] Makee the pulleyy/vibration damper and d rotate the e crankshaftt 360 degreees. Cauttion: To pre event engin ne or pin daamage, be ssure timing pin is disen ngaged. Adjust the valvees as indicatted in the illustration. Tightten the lockk nut and m measure the valve lash aagain. Torque Value: 24 N . m [18 8 ft‐lb] 15 mm Instaall the valve covers and d tighten capscrews. Torque Value: 24 N . m [18 8 ft‐lb]

Page 43 of 179

10.2 Drive Be elt Tensio on

Check

Measure the beelt deflection at the lon ngest span o of the belt. Maximum Defle ection: 9.5 to 12.7 mm m [3/8 to ½ inch] mmins belt ttension gauge, Part No. ST‐1293 caan be used NOTE: The Cum Gaugge Value: 2 267 to 578 N N [60 to 130 0 Lbf]

Page 44 of 179

elt 10.3 Drive Be

Inspectio on 3/8 Inch Square Drivve, 13 mm

Rem move the drive belt. Lift tthe tensioneer to removve and instaall the belt.

NOTTE: After thee tensionerr has been rraised to rem move/installl the belt, ccheck the to orque of thee tensiioner capscrew. Torque Value: 4 43 N . m [32 2 ft‐lb.]

Page 45 of 179

Inspect the beltt for damagge.

Transsverse (acro oss the belt width) craccks are acce eptable Longgitudinal (direction of belt lenght)) crackks that interrsect with TTransverse ccracks are no ot acceptab ble. Replaace the beltt if it has un nacceptablee cracks, if frrayed or has pieces of material miissing.

Page 46 of 179

11.0 MAINTEENANCE P PROCEDUR RES AT 77,000 KILO OMETERS [[48,000 M Mi] 2,000 H HOURS OR R 2 RS YEAR

11.1 Coolingg System M Maintenan nce

11.1.1 Co oolant Draiining Cauti tion: Avoid d prolonge ed and rep peated skin contact with w used aantifreeze. Such prolonged repeated contacct can cause e skin disorrders or oth her bodily in njury.

• •

Avoid exxcessive con ntact‐wash thoroughlyy after contact. Keep out of reach o of children.

Prote ect the envvironment: Handling and dispo osal of used d antifreezee can be su ubject to fe ederal, state e and local law regulaation. Use authorized d waste disposal facilities, includ ding civic am menity sites and garages providin ng authorized facilitiess for the re eceipt of ussed antifre eeze. If in doubt, contaact your loccal authoriti ties for guid dance as to proper han ndling of ussed antifree eze. tion: Wait until the te emperature e is below 5 50 ˚C [120 ˚˚F] before removing th he coolant ssystem Cauti presssure cap. FFailure to do o so can cau use personaal injury fro om heated ccoolant spray.

Page 47 of 179

Drain n the coolin ng system byy opening the drain valve on the rradiator and d removing the plug in the botto om of the w water inlet. A drain pan n with a cap pacity of 20 liters [5 U.SS. gallons] w will be adeq quate in mo ost applicati tions.

Checkk for damagged hoses and loose orr damaged h hose clamps. Replace as required d. Check thee radiattor for leakss, damage aand build up p of dirt. Cllean and rep pair as requ uired.

Page 48 of 179

11.1.2 Co ooling Syste em Flushingg

Cauttion: Durin ng filling, airr must be vented from m the engine e coolant paassages. Open the engine venting petcockk and the p petcock on tthe aftercooler for afttercooled engines. The system m must be filled d slowly to prevent airr locks. Waait 2 to 3 miinutes to alllow air to b be vented, then and m mixture to brring the level to the to op.

Fill th he system w with a mixtu ure of sodium carbonatte and wateer (or comm mercially avaailable equivvalent). NOTE: Use 0.5 kkilogram [1.0 pound] o of sodium caarbonate fo or every 23 liters [6.0 U U.S. gallons] of wateer. Cauti tion: Do no ot install the e radiator cap. The engine is to b be operated d without th he cap for th his process.

Page 49 of 179

O Operate the engine for 5 5 minutes w with the coo olant tempeerature above 80 ˚C [17 76 ˚F]

Sh hut the enggine oﬀ and drain the cooling syste em.

ng system w with clean w water. Fiill the coolin ure to vent tthe engine aand aftercooler for com mplete filling. NOTE: Be su NOTE: Do no ot install the radiator ccap or the new coolant filter.

Page 50 of 179

Operate tthe engine for 5 minuttes with thee coolant tem mperature above 80 ˚C C [176 ˚F]. Shut the engine oﬀ aand drain th he cooling ssystem. NOTE: If f the water b being drained is still dirty, the systtem must flushed again n until the w water is cleaan.

oolant Systtem Filling 11.1.3 Co The ssystem has a maximum m fill rate of f 14 liters pe er minute [3 3.5 U.S. Gallons per minute]. Do n not exceed this fill rrate.

Page 51 of 179

Caaution: The e system m must be filled d slowly to prevent airr locks. Durring filling, air must be e ve ented from the engine e collant passages. Be sure to ope en the petccock on the aftercoolerr for aft ftercooled e engines. W Wait 2 to 3 m minutes to allow air to o be vented d, then add mixture to bring th he level to tthe top.

Use a mixture o of 50 percen nt water and 50 percen nt ethylene glycol antiffreeze to fill cooling sysstem. Coolant Capacityy Liter L (Engin ne Only) [ [U.S. Quart ts] 4B3.9 4BT3.9 9 7.0 [7.4]

4BTA A3.9* 7.9 [[8.4]

6B5.9 6 6 6BT5.9 9 9 [9.5]

6BTA5.9 9.9 [10.5]

*4BTTA and 6BTA A engines usse a jacket‐w water afterccooler. If a Charge Air Cooler is ussed, the coo olant capacity is the ssame as the naturally aspired or tu urbocharged d only engin nes. Cauti tion: Neverr use water alone for ccoolant. Daamage from m corrosion can be the result of ussing wate er alone forr coolant.

Page 52 of 179

Installl the pressu ure cap. Op perate the eengine until it reaches aa temperatu ure of 80 ˚C C [180 ˚F], and checkk for coolant leaks. Checkk the coolan nt level again to make sure the sysstem is full of coolant, or that the coolant levvel has risen to the hot llevel in the recovery bo ottle on the e system, if so equipped. Warn ning: Beforre removingg theh pressure cap, w wait until the coolant teemperature e is below 5 50 ˚C [120˚˚F]. Failure e to do so caan cause pe ersonal inju ury form heated coolan nt spray.

11.2 Vibratio on Dampe er (Rubberr)

Inspectio on Checkk the index lines (A) on n the dampeer hub (B) aand the inerrtia member (C). If the lines are m more than 1.59 mm [1 1/16 inch] o out of alignm ment, replacce the damp per.

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Inspeect the rubb ber memberr for deterio oration. If p pieces of rub bber are miissing or if tthe elastic member is moree than 3.18 mm [1/8 inch] below tthe metal su urface, replaace the dam mper. NOTEE: Also lookk for forward movemen nt of the damper ring o on the hub. Replace th he damper if any moveement is dettected.

Page 54 of 179

12.0 SYSTEM M DIAGRAM MS 12.1 Fuel Sysstem

Page 55 of 179

12.2 Hydraullic Cold Sttart Injecti tion Advan nce (Rotarry Automo otive Pum mps Only) A hyd draulic cold start injecti tion advancce (KSB) devvice is used on 1988 and later certi tified enginees for whitee smoke control duringg cold starting.

2 1 1 1. KSB Valve K 2. Wiring Harn W ness 3. Temperature T e Switch Wheen the engin ne is cold, th he KSB causses the injecction timingg mechanism m to be fullyy advanced to low speeeds. When then engine reachess normal op perating tem mperature, the KSB iss deactivateed and injecction timing is then advvanced prop portionally tto increased d engine speed. Deacctivation of the KSB is ccontrolled b by a temperrature senso or switch located in the e engine airr intake manifold. A wirring harnesss connects tthe KSB and d temperatu ure switch. If the wirin ng is disconn nected, KSB remainss activated aand the injeection timin ng is fully ad dvanced. the K

Page 56 of 179

ting Oil Syystem 12.3 Lubricati Rotor Lubricatting Oil Pump p (1) Pressu ure Regulating Valve ((2) ting for th he Turboch harger 12.4 Lubricati

Lu ubricating Oill Co ooler (3); Fu ull Flow Filter (4)

Filter Bypaass Valve (5)

Page 57 of 179

ting for th he Power Compone ents 12.5 Lubricati To Valve Train From Oil Cooler ting for th he Overhe ead 12.6 Lubricati

Main n Oil Rifle

Main n Oil Rifle e

Page 58 of 179

12.7 Coolantt System

12.8 Air System

Page 59 of 179

e Air 12.9 Air System‐Intake

Page 60 of 179

13.0 TROUBLLESHOOTIING eshooting Procedure and Techniques 13.1 Trouble

This guide describes some typical engine and d operatingg problems, their causees and some e acceptablee correctionss to those p problems. U Unless notes otherwise e, the probleems listed aare those w which an opeerator can diagno ose and repair. See a C Cummins Au uthorized Repair Locati tion for diaggnosis and rrepair of pro oblems not listed. Follow the suggestions below to d develop goo od troublesshooting pro ocedure: • • •

blem thorou ughly beforee acting. Study the prob Do the easiest and obviou us things firrst. Find and correect the basicc cause of th he problem m.

13.2 Trouble eshooting Symptom ms

Use the chaarts given o on the follow wing pages to help find d the cause and correcti tion of a maalfunction. Read each row or blo ocks from to op to bottom m. Follow tthe arrows through th he chart to iidentify corrrective action.

Enggine Will N Not Crankk or Crankks Slowly 13.2.1 Co orrection Cause En ngine Drive Un nits Engaged

OK Cran nkshaft Rotation Restricted

OK Sttarting Circuitt Con nnections Loose o or Corroded

OK Batttery Charge Lo ow

OK No V Voltage to Staarter Solenoid

Disengagge driven units and check for loading fro om maalfunctioning a accessories.

Rotate the crankshafft to checkk for rotationaal r resistance.

Checck and tighten n connections

Cause

Correction

So olenoid or Staarting M Motor Malfunc ction

Replace startin R ng motor.

OK Remove the starting heck for motor and ch broken teeth h on the flywheel or broken or spring starting moto

Starting Mottor O Operating But t Not Cranking the En ngine

OK Contact an n A Authorized Re epair Facility

Checkk battery voltaage

Ch heck voltage to o solenoid

Page 61 of 179

13.2.2

Enggine Hard to Start o or Will No ot Start (Exxhaust Sm moke Preseent) Cause

Correctio on

Incorrecct Starting Procedure

Reefer to the Staarting Pro ocedure Matriix Page

OK Engine Cranking Speeed too Slow

Checkk engine crankking RPM. Refeer to “Engine W Will Not Crank or Cranks SSlowly”

OK Starting Aid Needed ffor cold Weatheer or is Not Working Properly

Checkk repair or rep place cold starrting aid, if necessary

OK Bleed the fuel systtem and n leaks cheeck for suction

Air in tthe Fuel Systeem

OK Clean n or replace pre‐filters and sscreens and ch heck fuel lin nes for restricctions

Fuel Su upply Restrictted

OK Intake A Air System Resstricted

Ch heck Intake Syystem

Veriffy by operating engine from m a temporaryy supply tank.

Fueel Contaminateed

OK Injecttion Pump Tim ming Incorrect

Check injection pum mp timing.

OK Valves Incorrectly Ad djusted

Adjust Valvees

OK One or M More Injectorss Worn or M Malfunctionin ng

Cheeck/Replace In njectors

OK Contact aan Authorized d Repair Facility

Page 62 of 179

13.2.3

Enggine Crankks But Will Not Starrt (No Smo oke From Exhaust) Cause

Correctio on

Incorrecct Starting Procedure

Reefer to the Staarting Pro ocedure Matriix Page

OK No Fuel in Tankk

Add Fuel

OK Electrical or Manuall Fuel pen Shuttdown Not Op

Checkk for loose wires and verifyy that solenoid is ffunctioning. Checkk to be sure manual shut‐offf leveer is in the “Ru ub” position.

OK If the Condition occurs nitial start, folllowing during in an Extended Period o of Non use or affter replacemeent of a fuel systtem componeent, air in tthe Fuel system

Bleeed the fuel syystem.

OK Loosen the bleed plug at the Operate the filterr head end. O hand primer on the lift pump to check for fuel. Clean replace lifft pump if neccessary.

If Prrevious Enginee Operaation had beeen normall, Injection Pump Nott Getting Fuel

Draiin fuel‐water sseparator or replace fuel filter.

Fuel Filter Plugged W With Waater or Other Contamination

Worn o or Malfunction ning Injeection Pump

OK Injectio on Pump Timing Incorrect

Checkk the injection pump timingg.

Looseen the high prressure line at tw wo injectors and visually cheeck fuel deliveery while crankking the engin ne. Replace the p pump if fuel iss not being d li d

Contacct an Authorizzed Reepair Facility

Page 63 of 179

13.2.4

Enggine Starts But Willl Not Keep p Runningg

Cause

Correctio on

Idle SSpeed Too Low w

Adjust idle sp peed.

Disenggaged driven u units and check for loading fro om nctioning acceessories. malfun

Engin ne Driven Unitts Engaged

OK Malfun nctioning engine shutt down devicee

Make sure shutdow wn is not occurrring too soon

OK Bleed the fuel systeem and check for suction leaks

Air in tthe Fuel Systeem

OK Fuel ffilter plugged or Fuel Waxing due to old weather co

Drain ffuel‐water sep parator or replace filter. Check for fuel waxingg in cold weatther.

Clean or replace pree‐filters and ns and check ffor fuel line screen restricctions.

Fuel supply restricted

Verify by operating engine from aa temporary supply tank.

Fuel contaminated d

OK Injectio on Pump Timing Incorrect

Check injection pum mp timing.

OK Contacct an Authorizzed Reepair Facility

Page 64 of 179

13.2.5

En ngine Will Not Shutt Oﬀ Correcction

Cause Electricall or manual fu uel shutoff nott closing

Verify the ssolenoid is no ot being energgized by a short iin the wiring. Check the lin nkage to the shuttoff lever for b blinding. Checck for the ability of the spring in the pump tto pull the levver to the shuttoff position.

Engine ru unning on fum mes drawn into air intakee

Locate an nd isolate thee source of fum mes

OK Fuel leaking to intaake manifold

13.2.6

OK Contact aan Authorized d Repair Facilitty

Rou ugh Idle, W Warm Enggine

Cause

Check/adjust low idle screw settingg.

Air in FFuel System

Bleed the fueel system and check forr suction leaks.

Injection n pump timingg incorrect

O OK

Cause

Corre ection

Injection pump malfunctioning or worn

Remove e injection pump. Ch heck pump calibration.

OK Contacct an Authorizzed Re epair Facility

Check/correcct injection pum mp timing

Injecttor Nozzles plugged o or inoperativee

Corre ection

Idle speed too low

Check for p porosity between the fuel ffilter mounting tto the intake m manifold.

Replace injecctors.

Injecttor Nozzles plugged o or inoperativee

Replace mou unts.

O OK

Page 65 of 179

13.2.7

Enggine Surge es at Idle Corrrection

Cause Low fuel level in the Tank

Fill supply tank

OK Check/aadjust low idlee s screw.

Idle speed too low

OK Bleed the fuel system and check forr suction leakss.

Air iin the Fuel Sysstem

OK Fuel supply restriicted

Clean or reeplace pre‐filters and screen ns and check ffuel lines fo or restriction

Check/reeplace injectorrs

Malfu unctioning Injectors

OK Removee pump. Havee pump reecalibrated orr replace injection pump

IInjection pum mp malfunctioning or worn

OK Conttact an Autho orized Repair Facilityy

Page 66 of 179

13.2.8

Lub bricating O Oil Pressu ure Low

Cause

Correction n

Incorrect O Oil Level

Ad dd or drain enggine oil.

OK Oil d diluted with fu uel but enginee operation normal

Removee and check lifft pump plunger seal. Replace leaaking pump change oil.

Oil diluted with fueel accompanieed Rough Engine Operation orr by R Low Power

Check for a stuck injecto or nozzle. If injectorss are okay, cheeck/repair injectio on pump. Chan nge Oil

Oil diluted w with water

Check forr missing rain ccaps, oil fill caps dipstick, etc. ch hange oil.

Oil specification ns incorrect

Checkk oil specificattions

Check for external leakk at rear of head. Along fu uel pump cylinder h side of blo ock, oil cooler cover and gear housingg

Oil visccosity low duee to operatingg above n normal coolan nt temperaturre raange of 100 ˚C C [212 ˚F]

Refer to ““Coolant Temp perature Abovve Normal” ch hart.

Lo oose or missin ng pipe plug

OK Oil Prressure Gaugee Malfunction n

Check oil pressure ggauge.

OK Regulatin ng valve stuckk open or brokken springg

Ch heck and clean n. Replacce spring if bro oken.

OK Oil filter plu ugged

Change oil and replacce filter.

Contact an Authorized Repair Facility

Page 67 of 179

13.2.9

Lu ubricating Oil Pressu ure Too High Cause

C Correction

Oil Pressure Gauge Malfunctioning

Check o oil pressure gaauge.

OK Engine running to oo cold

Refer to tro oubleshootingg logic for coolant temp perature below normal.

OK Oil sp pecifications incorrect

Check oil specificatiion.

OK Pressuree relief valve sstuck closed

Check/replace valvve.

OK Contacct an Authorizzed Repair Facility

Page 68 of 179

13.2.10

Lu ubricatingg Oil Loss

Co orrection

Cause

Visuallyy inspect for oil leaks

External leaaks

OK Cran nkcase being o overfilled

Verify that the dipstick iss correctly marked

OK Oil sspecification incorrect

Checck all specification

OK Look for rreduced viscosity from dilution with fueel. Review/rreduce the oill change intervals

Check ffor oil in the ccoolant

Oil Cooler Leeak

OK If Equipped, Air Com mpressor Pum mping Oil

Check/reeplace air com mpressor

OK Higgh Blowby Forrcing Oil out the Breatther

OK Turbocharger Leaaking Oil t to the Air Inta ke or Exhaust

Check the breather tubee area for oil loss. Meassure the signs of o blowby and d perform thee required repairs.

Inspect thee turbocharger inlet and outlet for eevidence of oiil transfer.

OK Co ontact an Auth horized Repair Facillity

Page 69 of 179

13.2.11

Coolant Temperaturre Above N Normal Caause C Correction Cau use Temperrature A Add coolant. Coolan nt Level Low Gauge Malfun nction OK OK K Rad diator Fins In nspect radiato or Dam maged or finss clean or repaair Incorrrect Obstrructed with if necessary. Thermostat D Debris OK K OK In nspect hoses. Over fueled Radiator Hose Replace if n Pump Injection ollapsed Co necessary. OK K OK Add or drain Vehiicle Incorreect Oil Level engine oil. Overlo oaded OK OK K Cooling Fan In nspect shroud; Water Pump ud Damaged Shrou rep pair, replace o or Malfunc tioning orr Missing install. OK K OK Loosee Fan Drive C Check the belt t Belt tensioner. Air In C Cooling OK Systtem OK Fan N Not Engaging Ch heck fan senso or OK

Inccorrect or Malffunctioning Rad diator Cap OK Radiaator Shutters are n not Opening Com mpletely or Cold d Weather Radiator Cover Closed

Cheeck the radiattor c cap. Replace if f necessary.

Test the gauge‐ or replace if repair o neccessary.

Check/replace therrmostat.

Removve injection Pum mp. Check caliibration

Reduce load or ower gear. use lo

Measu ure cylinder blocck coolant prressure. Checck/replace watter pump. Check h hose clamps for leeaks on the suction n side of the p pump. Ch heck for compression leak ugh cylinder throu heaad gasket.

Plugged C Cooling Passages in Radiator, Cylinder Head, Head Gasket er Block or Cylinde

Inspect the shu utters. Repairr or replace if neecessary. Opeen r radiator cover r

Corrrection

Flush the cooling systeem, fill with new w coolant.

OK O Contaact an Authorized Repair Faccility

Page 70 of 179

13.2.12

Coolant Lo oss Cause

Corrrection

Radiattor or cab heater leaking

Viisually inspectt the radiator heater, ho oses and conn nections to loccate the leak

If oil is present in the coolant, check or a transmission or lube oil cooler fo leak.

Viisually inspectt the radiator heater, ho oses and conn nections to loccate the leak

Exterrnal engine leaak

Overheeating or leakking compression gasees ng in loss through resultin the raadiator overflo ow

Review th he operation ffor ovverheating an nd low power.. (Refer to the troubleshooting loggic or co oolant temperature above normal

If equipped, transmisssion c cooler leak

Check for mixxing of coolan nt and transm mission fluid

If equip pped with a water cooled d air compresssor, leakin ng head or heaad gasket.

Check for ccoolant in the oil. Check/replace head or gasket.

OK Check/replaace the oil coo oler. Look for co oolant in the o oil.

Lubee oil cooler leaak

OK Contacct an Authorizzed Reepair Facility

Page 71 of 179

13.2.13

Coolant Te emperaturre Below N Normal

Cause

Correction

Radiaator Shutter SStuck in n Open Positio on

Insp pect the shuttters. Repair or replace if necessary.

Check fan forr conttinuous operation.

Faan malfunctio on

OK Che eck/clean sensor and coolant passaage.

Tem mperature Sen nsor Malfunction

OK Test/replace sensor.

Tem mperature Gau uge Malfunction

Testt the gauge‐reepair or replace if necesssary.

Therrmostats Incorrrect or Malfunctioning

Checck thermostatss and replace if necessary.

OK Conttact an Authorized Repair Facilityy

Page 72 of 179

13.2.14

Coolant Co ontaminatted

Cause

Correctiion

Rusty Coolant, Operation Without Correct Mixture of A Antifreeze and d Water

Drain and flush the cooling system. Fill with correct miixture of antifreeze and a d water.

OK Review the co oolant change inteerval.

If Equipped, Leeaking Traansmission Oiil Cooler

Check/replacce oil co ooler. (Refer to o Equip‐ ment Manufac m cturer’s procedurees).

Refer to o Troubleshootin ng Logic for “Lubricatiing Oil Loss”

Oil Leaks From m Oil C Cooler, Head G Gasket, Head and Cylinder Block

Co ontact an Auth horized Repair Facility

Page 73 of 179

13.2.15

Lu ubricatingg Oil Contaminated d

Cause

Correctio on

Coolant in the Oil, Internal Enggine Component LLeaks

Refer to Trou uble‐ shooting Loggic for “Coolant Lo oss”.

OK Review Oil and R d filter change interrvals.

E Excessive Oil S Sludge

OK Make sure the M correct oil is being u used.

Fu uel in the Oil, Engine O Operating too o Cold

OK Lifft Pump Seal LLeaking

Review the Tr R ouble‐ shooting Loggic for “C Coolant Temperature mal. Below Norm

Replace lift p pump.

Injjector Needlee Valves Not Seatin ng

Locate and reeplace maalfunctioning injector

Worn Injection W n Pump Plungerss

Remove injection Pump. Check p P pumps calibration.

Co ontact an Auth horized Repair Facillity.

Page 74 of 179

13.2.16

Fuel or Oil Leaking from Exhaaust Maniffold Causse

Correcction

Intake Air Reestriction

Check/replaace filter elemeent.

OK K Review operration for excessive idling.

Injector Neeedle Valve Stuck O Open

Locate and replace malfunctionin m ng injector

Obstructed d Turbo‐ charger Drrain line

Check/cleaan line.

Turbochargger Seals Leakingg Oil

Check/reeplace turbochaarger

Contact an A Authorized Repair Faacility

Page 75 of 179

Exxhaust Sm moke Exce essive Und der Load 13.2.17 Correcttion Cause Lu ugging Enginee

OK Bleed fuel system and check for suction leaks.

Inspect air cleaner. Clean and replace.

Air C Cleaner Plugged

Check therrmostat and coolingg system.

Remove in njection pump. Checck pumps calibrattion.

Con ntact Authorizzed Repair Facility R y

In njection Pump p Tim ming Incorrecct

Check injection ming. pump tim

Airr Leak betweeen Turrbocharger an nd Intake or Exhausst Manifold

Engine Running TToo Cold

AFFC Malfunction n/ In njection Pump p Overfueled

Correcttion

Lu ugging Enginee

Use lower gear.

Cause

Correct leak.

Morre than One Seal W Washer under r In njector Nozzlee

In njector Nozzlee M Malfunctioning g

Remove an nd have nozzles tested. Replace inffectors if necesssary.

OK TTurbocharger M Malfunctioning g

Check injection pump tim ming.

Replaace turbocharger.

Page 76 of 179

13.2.18

Engine Will Not Reach Rated Speed Wh hen Loade ed

Cause

Co orrection

Vehicle Ovverloaded

Redu uce load or usee lo ower gear.

OK K

Fuel Transfeer Pump Malfunctioning

Throttle Linkage Adjustmen nt Wrong

OK K

Cheeck throttles linkage adjustmen nt ull travel to the for fu high idle stop screw w.

Corre ection

Cause e

Check/re eplace fuel transfe er pump.

Remove e injection pump p. Check calib bration.

Injection Pump Malfunctioning

OK Tachom meter Malfuncctioning

Check with hand o or digitaal tachometerr.

OK K Air fuel Con ntrol Tube Leaking and/or Restriicted

Contact Autthorized Repair Faacility

Tighten fittings. Replace tube if n necessary.

OK K Air Flow R Restricted Through C Charge Air Coo oler

Inspeect cooling finss. Cleaan or replace.

OK K

Chaange the fuel filter and check fueel d line, pre‐filter and screens for reestrictions.

High Speaak Screw Incorrect Adjusted

Checck/adjust high h sp peed screw

Fuel Supply Restricted

OK K Partially Engaged Shutdow wn Lever

Ch heck/adjust shu utdown lever.

Page 77 of 179

Power Outtput Low 13.2.19 Correction Causse Reducee load or use low wer gears.

Vehicle Oveerloaded

Cause

Air in the FFuel System m

Bleed tthe fuel system aand check for suction leaks.

Lubricating Oil Level Too High

Drain o oil to proper level.

Fuel Qualityy Poor

Throttle LLinkage Adjustment Wrong

Corre ection

Checkk and adjust throttlee linkage for full travvel of the fuel conttrol level.

Verify by operating e from a engine temporaryy tank that contains good fuel and referr to fuel oil specificcations.

Fuel Sup pply Restricted

Clean per‐filters and screens aand check fuel line for ns. Replace restriction fuel filter.

OK Mechanicall Shutoff Lever Partially Engagged

OK K

Check/aadjust shutoff lever.

Intake or EExhaust System Resstricted

Checkk intake and exhaustt systems for restrictions. Inspect air filterr and replace as necessary.

OK K

Tighteen fittings. Replaace tube if neccessary.

OK K

Inspectt cooler fins. Cleaan/repair.

OK K

Air Leak between Turbocharrger and Intake Maanifold

OK Lift Pum mp Malfunctioning

Check/re eplace lift pu ump.

High Intakke Air Temperatu ure ‐17 Deg. C [160 Deg F] mbient Above Am

Use outtside air to turbocharger in weather. warm w

OK Air Flow Reestricted Through Ch harge Air Cooleer

Check fu uel return line from m pump to tank forr damage/ restrictio on, replace line.

OK Air Fuel C Control Tube Leakin ng and/or Restriccted

Injection Pum mp Fuel Return LLine Restrictted

OK K

High Fuel TTempe‐ ratures (Ab bove 71 Deg. C [160 Deg. F]

Fill tankks, turn off fuel heater.

OK Corrrect leak

Page 78 of 179

ntinuation n) Power Outputt Low (Con Causse

Correction

Injection Pump Timing Incorrect

Checck Injection Pum mp timing.

OK K

Checck/replace sensing line for damaage or leaks. Check//adjust waste gate ccontrol rod.

Turbochargger Worn or Malfunctioning

Replace R turb bocharger

Turbochargger Waste gate Malfunction

OK K Adju ust Valves. Inspecct push rods, sprring, etc.

Valves N Not set Propeerly

OK K Injector N Nozzles Malfuncttioning

Remo ove nozzles. Test aand repair.

OK K Injection n Pump Worn n or Malfuncttioning

Remo ove injection pum mp. Check callibration.

OK K Contacct an Authorized d Repair Facility

Page 79 of 179

13.2.20

Engine Missfiring

Correction C

Caause Fuel Con ntaminated

O OK Air in Fuel System

O OK Fuel Injeection Lines Leeaking

Veriify by operatin ng from a temporarry supply tank. s Ble eed fuel system m and check for a suction leaks. Insp pect and replace broken lines. b

O OK Fuel Traansfer Pump Malfu unctioning

Check/ replace fu uel trransfer pump.

O OK Incorrrect Valve Adju ustment

Insp pect push rods, sprring and adjusst valves.

O OK Injecto or Nozzles Plugged or perative Inop

Replace injectorrs

O OK Injecttion Pump Timingg Incorrect

Ch heck injection n pump timing. p

OK Con ntact an Authorrized Repair Facility

Page 80 of 179

13.2.21

Fuel Knockk

Correctio on

Cause Engin ne Overloaded d

Use lower gear.

OK Fuell Quality Poor

Drain tank; fill with correct fueel.

OK Air in n Fuel System m

OK Incorrrect Injection n Pu ump Timing

Bleed fuel system and check ffor suction leaks.

Check pump t C timing

OK Inco orrect Nozzless Maalfunctioning

Remove nozzles. Test & repaair.

C Contact an Auth horized Repairr Facility

Page 81 of 179

13.2.22

Fuel Consu umption EExcessive

Caause Fueel Leak

O OK Addition nal Loading from Malfunctioning Acceessories

Fuel Qu uality Poor

Operato or Technique Inccorrect

OK Excessivve Intake Air or EExhaust Resstriction

OK Fuel Injeection Pump Timingg Incorrect

Correction Check/correct th he source of the leak Check/repair accessories and vehicle componeents. (Refer to the Equipment M Manufacturer’ ’s Procedures).

Verrify by operating e engine from a a tem mporary tank tthat contains good fu uel d refer to fuel oil and specificationss

Causse

Correction

Worn or Mal‐ functioningg Injectors

Remo ove injectors. Te est/repair.

OK K Valves Nott Seating

Check//adjust valves.

OK K Contacct an Authorized Repair Facillity

Reeview operatio on fo or correct geaar shiffts, deceleratiion, and idling.

Refer to Troubleshootin ng Loggic for “Excesssive Exhaust Smokee”

Check the injecttion pump timing.

Page 82 of 179

13.2.23

Vibration EExcessive

Cause

Correcction

Enggine Not Runn ning Smoothly

Refer to hooting Troublesh Logic for ““Rough Idle, Warn Engine”.

EEngine Mountts Loose or Brokeen

D Damage Fan o or Malfunctionin M ng Accessories

Viibration Damp per M Malfunctionin ng

Check/reeplace engine m mounts (refer to o the Equipm ment Manufactturer’s Service Instructiions). Check/replace the vibration component (refer to ment Equipm Manufactturer’s Service Instructiions). Inspect/rep place the vibration d damper.

OK Alternator Bearring W Worn or Damag ged

Check/replace the alternaator.

OK Contact an Au uthorized Rep pair Facility

Page 83 of 179

13.2.24

Engine Noiises Excesssive

Cause

Correcction

D Drive Belt Sque eal, Inssufficient Tension orr Abnormally H High Loading

Drive Belt Squeal, Insufficientt Tension or Abnorm mally High Loading

In ntake Air Exhaaust Leaks

OK Valve Lash Excesssive

Tu urbocharger N Noise

G Gear Train No ise

Check the ttension of accessorry drive belts. (Refeer to the Equipm ment Manufaccturer’s Procedures). Make sure the acccessories turn freely. Referr to Troublesh hooting Logic for ““Exhaust Smoke Exxcessive Under LLoad”. Adjust valvves. Make sure the push rods are not bent or the rocker levers are not severelyy worn. Check turbocharger impeller and turbine wheel for housing contaact. Check/reeplace vibration d damper.

Contact an Authorized Rep A pair Facility

Page 84 of 179

13.2.25

Alternator Not Charrging or In nsufficientt Chargingg

Caause

Correction

Battery C Connections Loose o or Corroded

Clean/tighten C n batttery connectio ons.

Altern nator Belt Sliipping

Check/replace b belt tensioner.

Alternaator Pulley Loosee on Shaft

Tighten pulley T y.

Gaugee or Lamp Malffunction

Ch heck/replace the gauge or lamp g p.

Alteernator Malfu unctioning

Rep place alternattor.

Con ntact an Authorized Repair Faacility

Page 85 of 179

13.2.26

W White Smo oke Excesssive Durin ng Cold Staart

Cau use

Co orrection

Improperr Starting Proceedure

Veerify proper starting proceduree

OK K Coo olant temperature Too ow Lo

Refeer to Trouble‐ shooting Logic Charrt or “Coolant fo Temp perature below w Normal”.

OK K Intakke Air Temperature Too ow Lo

OK K

Fuel Quaality Poor

OK K

Injection Pump ncorrect Timing In

OK K

KSB Pressure Holding Vaalve Open

OK K

Corrrection

Injector Insstalled with more th han One or Wrong Size Sealing Waasher

Remo ove extra washerr. Check for prope er washer.

OK Injectors oning Malfunctio

Removve nozzles. Test aand repair.

OK Reffer to vehicle operration manuall for shutter operation. Check intake air heater peration (if op e equipped).

Coolant Leakking into Combusttion Chamb ber

Refer to Trouble‐ shooting Logic for olant Loss Coo

Verifyy by operatingg engine from a orary tank witth tempo good d quality fuel.

Injection P Pump Malfunctio oning

Checck/time pump

Contact an Authorized Repair Facility

OK K Temperatu ure Switch for the K KSB has Electrical Short or oo soon. Closes to

Cause e

Remo ove pump. Have calibration hecked. ch

Check voltage to KSSB. Replace tempeerature switch h if volttage is present beffore coolant temperature reaaches 160 0F Reemove the injeection pump. Haave the KSB reepaired or r replaced.

Page 86 of 179

14.0 ADJUSTTMENT, REEPLACEMEENT AND REPAIR

uired 14.1 Repair TTools Requ

Socke et 10 mm 12 mm 13 mm 15 mm 17 mm 18 mm 19 mm 22 mm 27 mm

Wrenches W 8 mm 8 10 0 mm 13 mm 15 mm 17 mm (open n end) 19 9 mm 22 mm 24 4 mm

otherr Allen Wrenc A h (8 mm) Breaker Bar (½ in. sq. drriver) Flat screwdriver Ratchet (3/8 8 in. sq. driver) Ratchet (1/2 in. sq. driver) Filter Wrenches (75‐80 mm and 90 0‐95 mm) Drill Motor ( D 1/4 inch) Drill Bit (3 m D m) Slide Hammeer Flat Chisel T‐Bar Puller (75 mm) Sheet Metal Screw (#10 0) To orque Wren nch Pliers Engine Barrin ng Gear 337 77371

14.2 Coolingg System R Repair Sum mmary

Componen nt to Be Replace ed

Toolss

Drive Belt

Breakker Bar (3.8 inch Square driver)

Belt Tensio oner

Ratch het (3/8 inch drive) Torqu ue Wrench Wrench 10 mm Socket/W

Remove drive belt

Wrench 10 mm Socket/W

olant and re emove drivee belt Drain coo

10 mm, 18 mm aand 19 mm Socket/W Wrench

Drain coo olant, remo ove drive beelt, loosen alternato or link, remo ove alternattor mountingg capscrew,, remove thermosttat housing

Preparattory Steps

Remove drive belt aand pulley

Page 87 of 179

14.3 Coolingg System R Repair 14.3.1 Repair Be elt‐Replace ement 3/8 inch square drivve he tensioner arm and p pulley to rem move and in nstall the be elt. Lift th The b belt tension ner widns in n the directi tion that th he spring taang is bent over the teensioner bo ody. To loossen ten tensio on on the belt, rotate tthe tensioneer to wind tthe spring ti tighter. Applying excessive forcee in the opp ppostie direction of win nd up or after the tensiioner has beeen wound‐up to the p positive stop p can cause e the tensioner arm to break.

Page 88 of 179

14.3.2 2 Belt Tenssioner‐Replacement Preparatory Step: • Remove the drivve belt 13 mm Reemove the belt tension ner from the bracket. In nstall the beelt tensioner. To orque Value e: 43 N . m [32 ft‐lb.] 14.3.3 3 Fan Pulle ey – Replace ement Preparatory Steps: • Remove the drivve belt. w before reemoving the e belt and to orque the ccapscrew aft fter the belt is NOTE: Loosen tthe capscrew installed

Page 89 of 179

10 mm and d 13 mm Remove tteh four cap pscrew, fan and spacerr. Replace tthe fan pulleey.

To orque Value es:

8 mm Capscrrew‐24 N . m m [18 ft‐lb] 10 0 mm Capsccrew‐43 N . m [32 ft‐lb]]

Page 90 of 179

14.3.4 4 Water Pu ump‐Replaccement Preparatory Steps: olant. • Drain the coo • Reemove the d drive belt 10mm Remove tthe water p pump Clean the sealing ssurface on tthe cylinderr block.

Page 91 of 179

Install a n new o‐ring iinto the gro oove in the w water pump p. Install thee water pum mp. Torque Vaalue: 24 N . m [18 ft‐lb b]

Lift th he tensioner arm and p pulley to insstall the drivve belt.

Page 92 of 179

Cauti tion: The syystem mustt be filled slowly to pre event air lo ocks. Duringg filling, airr must be ve ented from m the engine coolant p passages. B Be sure to open the pettcock on th he aftercooler for aftercooled enggines.

The ssystem has a maximum m fill rate of 14 liters p per minute 9 93.5 U.S. gaallons per m minute]. Do o not exceed the fill rate. Wait 2 2 to 3 minu utes to allow w air to be vvented. Th hen add coo olant to brin ng the level to the top. Closee the drain vvalves. Fill the coolingg system witth a mixturee of 50% eth hylene‐glyco ol type antiffreeze. Thiss will provide freeze pro otection to ‐37˚C [‐34 ˚˚F]

4B3.9 4BT3.9 6BTA5.9** 7.0 [7.4]

Coolant C Capacity (Engine Only) 4BTA3.9*

7.9 [8.4]

Liters [U.S. Quarts] 6B5.9 6BT5.9 9 [9.5] 9.9 [10.5 5]

Page 93 of 179

4BTA and 6BTA enginess use a jacket‐water aft ftercoolers. If a charge air aftercoo oler is used, the *4 co oolant capaacity is the ssame as thee naturally aaspirated or tubochargeed only enggines.

Instaall the pressure cap. Op perate the eengine until it reaches a temperatture of 80 ˚C C [180˚F] an nd check for coolan nt leaks.

Page 94 of 179

14.3.5 5 Thermosstat – Replacement Preparatory Steps: • Disconnect thee negative b battery cablle. • Draain 2 liters (2.1 U.S. Quarts) of coo olant. • Rem move the raadiator hosee form the o outlet connection • Rem move the beelt. 14 m mm, 16 mm Loosen th he lower altternator link capscrew. Remove tthe upper aalternator m mounting capscrews Lower the alternator

Page 95 of 179

10 mm

Remove the theermostat ho ousing, liftin ng bracket, tthermostat and thermo ostat level.

Clean the gaskeet surfaces. NOTE: Do not leet any debrris fall into tthe thermosstat cavity w when cleaning gasket surface. Cauti tion: Alwayys use the correct thermostat and d never ope erate the en ngine witho out a therm mostat. An n incorrect tthermostat can cause the engine to overheaart or run to oo cold. The engin ne will overrheat if ope erated without a therm mostat becaause the coolant flowss back to the inlet of the water pump instead of through the rradiator forr cooling. Assemble the reemoved parrts in the revverse orderr of removal w holes. Makee sure the ggasket is aliggned with the capscrew Instaall the capsccrews and use your finggers to tightten. The n notched end of the rub bber thermo ostat seal p points away from the cyylinder head d. Tighten all Capsscrew Torqu ue Value: 24 4 N . m [18 ft‐lb]

Page 96 of 179

14 mm, 1 16 mm

Positi tive the alteernator and install the m mounting capscrew. Torqu ue Value: (A) 24 N . m [18 ft‐lb] m (B) 43 N . m [32 ft‐lbl] m ]

13 mm Instaall the drive belt.

NOTE: After the tension ner has beeen raised to remove/insstall the bellt, check the e torque of the teensioner cap pscrew. To orque Value e: 43 N . m [32 ft‐lb]

Page 97 of 179

Fill the co ooling systeem. Operatee the engine and checkk for leaks.

Caaution: Be sure to ven nt the engin ne and aftercooler durring filling, tto remove aair from the e co oolant syste em or coverr‐heating w will result.

Page 98 of 179

14.4 Fuel Sysstem Repaair Summaary Comp ponent to Be Re eplaced Lift Pu ump High Pressure Lin nes Injecttor Fuel Draain Maniffold Injecttors Injecti tion Pump Fuel SSolenoid Fuel FFilter Head

Tools 13, 14 an nd 17 mm W Wrenches 13 mm Socket, 14,17 7 and 19 mm Open En m nd Wrenchees and a Torque Wrench h

10 mm and 19 mm O Open End W Wrenches, 10 mm and 13 mm SSockets, and d a Torque Wrench

Ratchet, 24 mm Socket (deep w well) and a Wrench Torque W

D Disconnect tthe high p press lines and fuel drain manifo old.

Injector b bore cleanin ng brush 10 mm W Wrench, Ratchet, 22 mm m Socket, 75 mm T‐Bar Puller (w/2 8 mm capscrews)) ½ in. opeen end wren nch flat scre ewdriver 13 mm Sockket, 13 mm Wrench, Haammer, flat Chisel an nd a Torque Wrench.

R Remove high h pressure lines, su upply line aand return liine. R Remove the AFC air linee, oil in ne (s), fuel sshutoﬀ solenoid A And control linkage.

Robert Bosch 24 mm m Wrench, LLucas CAV 22 mm W Wrench

Laabel and dissconnet wirring.

24 mm, 7 75‐80 mm aand 90‐95 m mm Filter Wrench

C Clean Debriss.

P Preparatory Steps C Clean Debriss. C Clean Debriss

Page 99 of 179

14.5 Fuel Sysstem Repaair Rotaryy Pump 14.5.1 Fuel Systtem Compo onents‐Cleaning Thorough hly clean alll fittings and d componen nts before rremoval. M Make sure th hat the debrris, water, steam, or cleanin ng solution does not reeacoh the in nside of the e fuel system m. 14.5.2 2 Low Presssure Fuel LLine‐Replace ement Preparatory Step: • Cleean all debriis from arou und the fittings. 17 mm 14 mm, 1

Page 100 of 179

100

Disconneect the fuel line from th he lift pump p and filter h head. Use ttwo wrench hes to disconnect the liine from the lift pump. Install thee fuel line to the lift pu ump and filtter head. Use two wrenches to tigghten the co onnection tto the lift pu ump. NOTE: D Do not overti tighten the connection. Fuel leakss can result from overti tightening. . Torque V Value: 24 N m [18 ft‐lb b] 3 Fuel Filte er Head Adaapter‐Replaacement 14.5.3 Preparatory Steps: • Cleean debris • Rem move fuel fi filters 24 mm Remove tthe retainin ng nut, filterr head adap pter and seaaling washers. Install in the reversee order of reemoval. Torque V Value: 32 N . m [24 ft‐lb b]

Page 101 of 179

101

14.5.4 4 Lift Pump p Replacem ment Preparatory Steps: d the lift pum mp. • Cleean debris frrom around 14 mm, 17 7 mm Disconnect the fuel lines. 10 mm nd clean the mountingg surface on n the cylindeer block. Reemove the lift pump an In nstall the lift ft pump and d a new gaskket. Co onnect the fuel lines To orque Value e: 24 N . m [[18 ft‐lb]

Page 102 of 179

102

14.5.5 5 High Presssure Fuel LLines – Replacement Preparatorry Steps: • Cleean all debriis from arou und the fittings. 17 mm NOTEE: If individual lines aree to be repllaced, remo ove the supp port clamp from the le et of lines contaaining the liine to be reeplaced. Disco onnect the line (s) from m the injecto ors. Disco onnect the line (s) from m the fuel pump. Install protectivee covers to the injectorrs and delivvery valvees to preven nt the entryy of dirt into o the system m. tion: Installl the support clamp in original po osition and, to preventt damage frrom high Cauti frequ uency vibraation, make e sure the lin nes have no ot been ben nt or do nott contact eaach other o or anotther commp ponent onnected to the injecto ors and fuel NOTE: To preveent damage to the fuel lines, they must be co injecction pump in a free staate without forcing the e connectingg nuts. Thee fuel lines aare correctlyy sized d for each ap pplication aand bendingg the lines iss not accep ptable. Instaall th elines in the reverrse order orr removal. Torque Value: (LLine Fittingss) 30 N . m [2 22 ft‐lb] . (SSupport Clamp) 6 N m [4 ft‐lb] (SSupport Bracket) 24 N . . m [18 ft‐lb]

Page 103 of 179

103

14.5.6 6 Fuel Draiin Manifold d‐Replacement Preparatory Steps: n debris • Clean 10 mm Reemove the capscrew frrom the holld‐down claamp. Reemove the banjo fitting screw and d washers.

Page 104 of 179

104

17 mm Disconnect the drain line fitting fro om the injecction pump.. NOTE: Use n new seals an nd sealing w washers. Assemble thee drain line and fuel drrain manifolld in the revverse order of removal. To orque Value e: (B Banjo fittingg view) 15 N . m [11 ft‐lb b] (B Banjo fittingg) 9 N . m [ 7 ft‐lb]] (C Clamp screw w) b] 24 N . m [18 ft‐lb 14.5.7 7 Injection Pump Supply Line‐Re eplacement w banjo fitting. Reemove the bleed screw 17 mm ngines rated d at 2500 RPM and abo ove require En Additional fu uel line supp port. Install as Illlustrated. To orque Valuee: 24 N . m [[18 ft‐lb]

Page 105 of 179

105

14 mm, 16 mm, 17 mm m Remo ove the supply line (Bosch Injectio on Pump).

Replaace the seals (1) in thee fittings if th he line is disassembled d. 14, 16, 19 and 24 mm m pump has tw wo fittings ffor the supp ply line. The LLucas CAV p

ttings if the line is disasssembled. Replaace the seals in the fitti Replaace the ban njo fitting seealing washers (1) and ferrules (2) each time tthey are rem moved. Torque Value: 3 32 N . m [24 4 ft‐lb]

Page 106 of 179

106

14.5.8 8 Injectorrs – Replaccement Preparatorry Steps: • Thorroughly celaan around th he injectorss • Disco onnect the high pressu ure fuel liness • Disco onnect the ffuel drain m manifold. 16 mm, 24 4 mm Box W Wrench Cauti tion: The in njector musst not rotate e in the borre of the cyllinder head d. This will damage the e cylinder head. move the injeectors. Rem Hold d the injecto or body with h the 16 mm m wrench w while you loosen the ho old‐down nut with 24 m mm box eend wrench h. n the injector nozzle bo ore using Seervice Tool No. 382250 09. Clean Remove the injeect hold dow wn nut and apply a coaat of anti‐seeize compou und to injecctor surface (A). Avoid d getting an nti‐seize com mpound in tthe fuel draail hole (B). Instaall the hold‐down nut o on the injecttor body.

Page 107 of 179

107

Instaall a new o‐ring into thee recessed groove on tthe top of th he hold‐dow wn nut. Maake sure thee o‐ ring is not cut o or twisted w when installling (BOSCH and Stanadyne). CA AV injectorss retain thee o‐ring inside the hold‐down nut. ompound to the threads of the injector hold‐‐down nut. Apply a coat of aanti‐seize co Assemble the in njector and new copper washer. Use o only one co opper washeer. Serviice Tip: A light coat o of clean 15W W40 engine e oil between the wassher and injjector can h help to keep p the washer from fallin ng during in nstallation.

Page 108 of 179

108

24 mm

In nstall the In njectors

Th he protrusio on on the siide of the n nozzle fits in nto a notch in the head to orient th he injector. Tiighten the injector nozzzle nuts.

To orque Value e: 60 N . m [44 ft‐lb] m

10 mm

In nstall the fuel drain manifold.

To orque Value e: 9 N . m [7 7 ft‐lb]

Page 109 of 179

109

17 mm In nstall the higgh pressuree fuel lines. To orque Value e: 30 N . m [22 ft‐lb] 14.5.9 9 Fuel Shutt oﬀ Soleno oid – Replaccement Preparatory Steps: • Labeel and discon nnect the w wiring. Bosch and CAV 22 mm –– CAV 24 mm –– Bosch n around th he valve. Clean WHEEN REMOVING THE VA ALVE, BE CAR REFUL NOT TO DROP TTHE PISTON N AND SPRIN NG. Replaace the valvve and conn nect the electrical wire.

Page 110 of 179

110

Stanaadyne DB4 • • • • •

Rem move the electrical wirring Rem move the fu uel drain line Rem move the th hrottle shutoﬀ linkage Rem move teh fu uel injection n pump top cover Disaassemble th he fuel injecction pump p top cover..

5/16 Inch h

Instaall new insullating tubess onto the terminals on n the termin nal studs of f teh new so olenoid. Instaall the valve into the co over. Torque Value: 1 14 N . m [12 2 in‐lb]

Page 111 of 179

111

Install thee cover and d gasket ontto the fuel in njection pump. NOTE: Exxtreme caree must be taaken in asseembling the e cover to a fuel injectio on pump to o make suree the shuto oﬀ arm is in n proper witth the linkagge hook tab b. Install thee cover to p pump at a download an ngle from th he drive shaaft end of th he fuel injecction pump,, then slidee the cover horiontallyy into positio on. Torque V Value: 4.6 N N . m [41 ft‐lb] 14.5.10 KSB Replacement T30, TOR RX, 12 mm

Page 112 of 179

112

Disconnect the wiring harness for tthe KSB sole enoid (1) Disconnect the fuel line (2). Replacce the KSB, fuel lines and wiring harness.

To orque Value e: Fuel LLine Banjo FFittings: KSB M Mounting Nuts

12 N . m [9 ft‐lb] 9 N . m [[7 ft‐lb]

14.5.11 KSB Tem mperature Switch Rep placement

27 mm

Disconnect the KSB (1) h harness (2) from the sw witch (3). Reeplace the ttemperaturre switch. In nstall the wiiring harnesss. To orque Value e: 24 N . m [18 ft‐lb]

14.5.12 Fuel Pu ump – Replaacement

Preparattory Steps:

• • •

Remove all fuel lines Remove control linkage Remove fuel shu ut oﬀ solenoid.

Page 113 of 179

113

NOTE: A diesel eng A gine cannott tolerate d dirt or water in the fueel system. A tiny piecce of dirt orr a few drops of water in thee injection ssystem mayy stop your unit. Clean all external su urfaces of the injection n pump, inccluding all lline connecctions and fi fittings thatt are to be discon nnected. Clean thee area aroun nd the injecction pump gear cover to prevent dirt from entering the crankcase.

14.5.13 Removving the Fue el Pump Locate TD DC for cylind der numberr 1. Push th he TDC pin iinto the holle in the cam mshaft gearr while slowly baarrign the engine. To preven nt damage tto the timin ng pin, be su ure to disen ngage the piin after locaating TDC. 14 mm Loosen the CAV V injection p pump locksccrew and position thee special waasher, then tightten the lockkscrew again nst the pum mp drivee shaft. Torque Value: 7 7 N . m [5 ft‐‐lb]

Page 114 of 179

114

3/8 in nch Loose thee Stanadynee DB4 fuel injection pump locck screw and position tthe special washer. Tighten theelock screw until contact iss made with h the fuel in njection pump driive shaft. Torque V Value: 12 N . m [9 ft‐lb]] 10 mm 22 mm Remove tthe gear cover access ccap. Remove tthe nut and d washer fro om the fuel pump shaft.

The speccial washer on the Boscch injection pump musst be removved so the lockscrew can n be tighten ned against the drive shaft. Torque V Value: 30 N . m [22 ft‐lb b]

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115

75 mm T‐Bar Puller Pull the ffuel pump d drive gear lo oose from the shaft. Caution: Don not re emove the ccontrol leve er. The leve er is indexed d to shaft d during pump p calibratio on. er will alter the fuel pu ump calibraation and efffect enginee performan nce. Removal of the leve

13 mm

Note e: Do not drop drive gear key when remo oving pump. Remo ove the threee mounting nuts. Remo ove the fuel pump.

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14.5.14 Installin ng the Fuel Pump Makee sure the eengine has ccylinder num mber 1 at TTDC. The keeyway in the e shaft of neew and rreconditioned pumps w will be lockeed in a possition corressponding to o the keywaay in thee drive gearr when cylin nder numbeer 1 is at TDC on th he compresssion stroke.. Afterr verifying th hat Cylinder Number 1 1 if at TTDC, install the pump. Make sure the kkey does nott fall into th he gear housing. Attach th he pump by finger tighttening the tthree mountingg nuts. The pump mustt be free to move in the slots.. 22 mm (CAV Staanadyne), 24 4 mm (Boscch) ump drive sshaft nut an Attach the p A nd spring washer. The w pump mayy rotate sligh htly due to o gear helixx and clearance. This is acceptable p providing th he pump is ffree to move on the m e flange slotts and the crankshaft does not mo ove. Note: Do not N t over tighten. This is n not the final to orque. Torque Value: 15 to 20 N . m [11 to 15‐ft‐lb]

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13 mm If reinstalling the rem moved pum mp, install th he pump onto the engine. Rotate tthe pump to align the scribe marks. Tighten the three mountingg nuts. Caution: The pump shaft must be unlocke ed After insttallation to o prevent pu ump damagge. Torque V Value: 24 N . m [1 18 ft‐lb] 13 mm If a new o or rebuilt pump is bein ng installed, permaneently mark the injection n pump flan nge to match the mark on tthe gear ho ousing.

If insttalling a new w or rebuiltt pump with hout scribee marks, take up gear lash by rotaating the p pump againsst the direction of drivee rotation. Tightten pump reetaining nutts. Torqu ue Value: 2 24 N . m

[18 ft‐lb]]

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14 mm Loosen th he CAV pum mp lock screew and position the special washer b behind the llock screw h head. ock screw. Tighten tthe pump lo Torque V Value: 20 N . m [1 15 ft‐lb] 3/8 In nch 10 mm NOTE: On n the Bosch h pump, thee special washer is wired tto the pump p and must be installed d under thee lock screw w. Tighten tthe pump lo ock screw. Torque vvalue: 13 N . m [1 10 ft‐lb]

oosen the SStanadyne D DB4 fuel inje ection pump lock Lo sccrew and po osition the special wassher behind the lo ock screw head. Tighten the llock screw.

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Note: Be sure to o disengage the timing pin. 10 mm Torque V Value: 24 N . m [1 18 ft‐lb]

Install the injecttion pump ssupport braccket. Fingeer tightens aall cap screw ws before fiinal tighteening. Note e: Tighten the bracket to block moun nting cap sccrew before e tighteningg the brackket to injecttion pump ccap screws.

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22 mm Tighten tthe drive geear mountin ng nut. Install thee access cap p. Torque V Value: Bosch h 60 N . m [48 ft‐‐lb] Stanaadyne 60 N . m [48 ft‐lb] 8 mm m In nstall the so olenoid wiring and all fuel lines. When conneccting the caable/rod to the control lever, adjust the lengtth so the levver has NOTE: W stop‐to‐sstop movem ment.

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NOTE: Sim milarly adju ust the lengtth of the caable/rod to the meechanical sh hutdown levver so theree is a stop‐to‐sstop movem ment.

Bleed all air ffrom the fu uel system.

If necessaary, adjust tthe idle speeed.

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14.6 Fuel Sysstem Repaair‐In‐Line e Pump 14.6.1 Fuel Systtem Compo onents – Cle eaning Thorough hly clean alll fittings and d components before rremoval. M Make sure th hat the debrris, water, steam or cleaning so olution doess not reach the inside o of the fuel ssystem.

14.6.2 2 Low Presssure Fuel LLine‐Replace ement Prepaaratory Step • Clean n debris from m fittings 14 mm, 17 mm, 20 mm Disconneect the fuel line from th he lift pump p and filterr head. Use two wrenches to disconneect the line ffrom the liftt pump.

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14 mm, 17 mm, 20 mm Install thee fuel line to the lift pu ump and filtter head. Usee two wren nches to tigh hten the connectio on to the lifft pump. . Torque V Value: 24 N m [1 18 ft‐lb] 14.6.3 3 Fuel Filte er Head Adaapter‐Replaacement Prepaaratory Steps • Clean n debris. • Remo ove fuel filteers. 24 mm

Remo ove the retaaining nut; ffilter head adapter and sealing washerrs. Install in the revverse order of removal.. . Torqu ue Value: 3 32 N m [24 ft‐lb]]

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14.6.4 4 Lift Pump p‐Replacem ment Prepaaratory Steps: debris. • Clean d • Disconn nect the fueel lines. 10 mm Remove tthe lift pum mp.

Clean n the mountting surface e on the cylinder blockk.

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10 mm Caution: Alternatelly tighten the mountting capscrrews. As th he capscreews are tigghtened, th he fuel transfer pump plun nger is push hed into the e pump. Failure to tighten the caapscrews in n an even m manner unger beingg bent or broken. can resullt in the plu Install thee pump. Torque V Value: 24 N . m [1 18 ft‐lb]

14.6.5 5 High Presssure Fuel LLines‐Replaacement Prepaaratory Steps: • Clean debris. 8 mm m, 17 mm, aand 19 mm NOTE: If individual lines are to be replaced d, remove tthe supportt clamp from m the set off lines containing the line to be rreplaced. Disconneect the line (s) from thee injectors.

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19 mm Disconneect the line (s) from thee fuel pump p. Note: If removed, r reinstall thee support cllamp in the e original position and d make sure e the lines do not contact eeach other or another componen nt. Install a protective cover on th he injectorss and fuel d delivery valves to prevent the entry of d dirt into thee system. Install thee lines in th he reverse o order of rem moval. Torque V Value: . (LLine Fittingss) 30 N m [22 ftt‐lb] . (SSupport Clamp) 6 N m m [4 ft‐lb] . (SSupport Braacket) 24 N m [18 ftt‐lb] 14.6.6 6 Fuel Draiin Manifold d‐Replacem ment Prepaaratory Steps: • Clean debris. 10 mm Remove tthe drain lin ne banjo capscrew from the bracket on the intake cover.

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10 mm ng washers.. NOTE: Usse new seals and sealin Assemblee the drain line and fueel drain man nifold in the revverse order of removall. Torque V Value: . (B Banjo fittingg screw) 15 N m [11 ftt‐lb] . (B Banjo fittingg) 9 N m [7 ft‐lb] . (B Bracket Cap pscrew) 24 N N m [18 ftt‐lb] 14.6.7 7 Injectors‐Replaceme ent Prepaaratory Steps: • Thoroughly clean around thee injectors. • Removve the high pressure fu uel lines. • Removve the fuel drain maniffold.

Remo ove the ban njo capscrew ws from thee injecttors.

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24 mm Remove tthe injectorrs. Injecttor Bore Brush Clean n the injecto or nozzle bo ore, using Service Tool No. 382250 09. h anti‐seize e compound d. Package tthe injector, sealing sleeeve, Lubricatee the sealingg lips of thee sleeve with A new co opper sealin ng washer and the hold d‐down clam mp. Use only one washe er n i5W40 Service TTip: A light ccoat of clean engine oiil between tthe washer and injector ccan help to keep the w washer from falliing during in nstallation.

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24 mm usion Tighten tthe injector nozzle nut.. The protru on the sid de of the no ozzle fits intto a notch in the head to orient th he injector. . Torque V Value: 60 N m [4 44 ft‐lb] 10 mm

Install the injecttor package into the injjector or leak off cconnection must bore.. The injecto be aw way from th he valve covver.

Install the fuel d drain manifo old. . Torqu ue Value: 9 9 N m [7 ft‐lb]

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17 mm, 19 mm 14.6.8 8 Fuel Shuttoff Solenoid‐Replacem ment Prepaaratory Steps: • Label and discon nnect the wiring.

Install the high p pressure fue el lines. ue Value: 3 30 N . m Torqu [22 ft‐lb]]

9 RQVK Go overnor Shu utoff Soleno oid 14.6.9 10 mm unting capsccrews and the fuel shuttoff solenoiid. Remove tthe hitch piin clip, mou Install thee new solen noid in reveerse order o of removal aand connectt the wires. . Torque V Value: 10 N m [8 89 in‐lb]

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10 mm, 16 mm Adjust th he solenoid linkage as n necessary so that th he plunger iis magneticcally held in with the shutoff leveer in the absolute full run posittion. Turn th he large hexx on the end d of the plu unger to maake adjustm ments. on Pump‐Re eplacementt 14.6.10 Injectio Prepaaratory Steps: • Clean n debris • Remo ove all fuel llines. • Remo ove control linkage. • Remo ove fuel shu utoff soleno oid. • Remo ove AFC air line. • Remo ove oil line(s).

ne cannot tolerate dirtt or water in n the fuel syystem. A tin ny piece of d dirt or a few w NOTE: A diesel engin drops of water in the injection system mayy stop your units. Clean all external su urfaces of th he injection pump, including all lin ne connectio ons and fittings that arre to nnected. Cleean the area around th he injection pump gearr cover to prevent dirt from entering be discon the crankkcase.

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14.6.11 Injectio on Pump‐Re emoval 33773 371 Engine Barring Ge ear DC for cylinder No. 1. P Push the TD DC pin into tthe hole in tthe camshaft gear whille slowly baarring Locate TD the engin ne. NOTE: Bee sure to dissengage thee pin after locating TDC C.

10 mm Remove tthe fuel pum mp mountin ng bracket.

30 mm (P7100 P Pump)

Remove the gear cover access cap. Remove the nut and waasher from tthe fuel pum mp sh haft.

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75 mm T‐Bar Puller Pull the ffuel pump d drive gear lo oose from the shaft. 15 mm 14.6.12 Injectio on Pump‐In nstallation 33773 371 Engine Barring Ge ear Make surre the engin nes has cylin nder No. 1 at TDC.

Remo ove the four mountingg nuts. Remo ove the fuel pump.

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14.6.13 Injectio on Pump Tim ming The injecction pump also has a ttiming pin, located in th he governor housing, tto position tthe pump shaft to correspond with TTDC for cylinder No. 1..

24 mm pin. Remove tthe timing p

Remo ove the access plug.

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If the tim ming tooth iss not aligned with the timing pin hole, rotaate the pum mp shaft unttil the timin ng tooth aliggns.

Reverse the position of the pin so the slot h in of thee pin will fitt over the tiiming tooth the p pump. Install and securre the pin w with the acceess plug.

Lubricatee the mountting flange o of the fuel injection pump with h clean engine oil. Caution: The fuel pu ump drive ggear inside diameterr must be clean and drry before installingg the shaft iinto the geaar. he P7100 fu uel injection n pump NOTE: Th driveshafft has a provvision for a Woodruff key, how wever, it is not required d. Timing maark alignmen nt is not req quired for th he P7100 drrive gear.

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Slide the pump through the drivve gear and d position th he pump flaange onto th he mountin ng studs. ward until th he mountingg flange and d o‐ring aree properly fiitted into th he gear Push the pump forw housing b bore.

15 mm Install thee mountingg nuts. . Torque V Value: 43 N m 30 mm (P7100 P Pump)

[fft‐lb]

In nstall the reetaining nut and washe er. .

Torque Value: 10 to 15 N m [7 to 11 ft‐lb] NOTE: Do no N ot exceed th he torque value given. This iss not the fin nal torque value for the e retaining n nut.

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Disengagge the engin ne timing pin. 24 mm m 22 mm or 27 mm Tighten tthe fuel pum mp drive nut. Torque V Value: . P7100 Pu ump, 165 N m [1 122 ft‐lb] Install thee gear coveer access cap hand tight.

Remo ove the fuel pump timiing pin plugg. Reverse the position of the pin and insstall the p pin, plug, an nd sealing w washer. .

Torqu ue Value: 1 15 N m

[11 ft‐lb]]

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10 mm Install the fuel p pump mounting brackeet capsccrews finger tight. To make sure th he alignment is correct,, tighteen the supp port mountiing capscrew ws. . Torqu ue Value: 2 24 N m [18 ft‐lb]] 10 mm Hex Drivve Caution: If a replace ement or re epaired pum mp was insttalled, be su ure to fill th he governorr housing w with engine oil before staarting the e engine. Failure to do so o will resultt in damagee to the govvernor fly weights. Remove tthe access p plug. Oil Caapacity RQVK Go overnor 750 ML [0.71 1 Qt] Install thee access plu ug. . Torque V Value: 28 N m [2 21 ft‐lb]

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Com mponent To Be R Replaced Air C Crossover Tu ubing

Intakke Manifold d Coveer and Gasket Aftercooler and d Gaskket

To ools 8 mm and Co ommon Sccrewdriver an nd Torque W Wrench

Prreparatory SSteps*

10 0 mm Sockeet

Re emove high pressure fu uel lines, dissconnect co old staarting aid, if used, and air crossovver tubing.

8 mm, 10 mm m Socket

Disconnect Cold Startingg aid if used d, remove aiir crossover tub be and drain n coolant.

Turb bocharger, aand/or 10 0 mm, 15 m mm, 16 mm, 7/16‐ Gaskket Inch Wrenchees

Disconnect in ntake and exxhaust pipin ng and re emove crossover tub bing.

Exhaaust Manifo old and//or Gasket

ntake and exxhaust pipin ng, remove Disconnect in airr crossover tub be and remo ove the turb bocharger.

15 5 mm Sockeet

*Rem moval of some chassis parts mayb be necessary to gain acccess to som me engine componentss. Follow thee equipment man nufacturer'ss procedurees and precaautions for removing cchassis partss.

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14.7 Air Systtem Repaiir 14.7.1 Air Crosssover Tube‐‐Replaceme ent 8 mm m or Screwd driver Loosen th he hose clamps and po osition the hose so tthe crossoveer tube can be removeed. 8 mm m or Screwd driver 2 Intake M Manifold Covver and Gassket‐Replaccement 14.7.2 Prepaaratory Steps: • Removve the high pressure fu uel lines. • Discon nnect the co old starting aid, if used d. • Removve the air crrossover tube (Industrial).

Use n new hose, aand clamps as required d to Install the crosso over tube. . Torqu ue Value: 8 8 N m [6 ft‐lb]

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10 mm Clean thee sealing surface. NOTE: Keeep the gassket materiaal and any o other material out of the aair intake.

Remo ove the manifold coverr and gaskeet.

NOTEE: The holess shown in tthe illustrattion are d drilled throu ugh and must be sealed d by applyying liquid TTeflon sealaant to the capsccrews.

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10 mm Install thee cover and d a new gasket. . Torque V Value: 24 N m [1 18 ft‐lb] Install an nd bleed thee high presssure fuel lines.

Assem mble the intake piping and connect the cold startingg aid if used.

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14.7.3 3 Jacket‐W Water Afterccooler and G Gasket Rep placement Replaacement Prepaaratory Steps: • Discon nnect the co old starting aid, if used d. • Removve the air crrossover tube. • Removve high presssure fuel liines. • Drain 2 liters (2.1 U.S. Quarts) of coolan nt. 8 mm m be (1) and Remove tthe coolantt supply tub the coolaant return tube (2).

Remo ove the high h pressure ffuel lines (Refeerence pagee 10‐25).

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10 mm Remove tthe aftercooler housing and gaskeet. 10 mm NOTE: Th he holes sho own in the iillustration are drilled th hrough. App ply liquid Teflon sealantt to the capsccrews. Instaall the afterccooler houssing and a new w gasket. . Torque V Value: 24 N m [1 18 ft‐lb]

Clean n the sealingg surface. NOTEE: Keep the gasket matterial and any otherr material o out of the aiir intake.

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8 mm m Install thee coolant su upply tube (1) and coo olant return tu ube (2). Instaall the air crrossover tube (3). Reinstall and bleed tthe high preessure fuel lines. . Torque V Value: 8 N m [6 6 ft‐lb] Caution: The system m must be ffilled slowlyy to preventt air locks. B Be sure to o open the en ngine and aftercooller vents to o allow air tto escape ass the system m is filled. Fill the co oolant systeem with a m mixture of 50% water and 50% eth hylene‐glyco ol type antiffreeze. 14.7.4 4 Charge A Air Cooler‐Le eak Check NOTE: Th he long term m integrity o of the chargge air coolerr system is tthe responssibility of th he vehicle and compon nent manufaacturers; wing sympto oms can be however,, the follow check by any Cummins Authorized Repair Location::

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14.7.5 5 Intake M Manifold Pre essure‐Checck Install preessure gaugge, Part No ST‐1273, to o the fitting in the turbocharger ou utlet. Install an nother presssure gauge, Part No STT‐1273, in th he intake manifold. Operate the engine at rated RP PM and load d. Record th he readings on the two o gauges. If the diffferential preessure is greater than 21 kPa [3 pssi], check th he charge air cooler forr plugging. C Clean or replace if necessaary. 14.7.6 6 Intake M Manifold Tem mperature‐‐Check Install a ttemperature gauge in tthe intake m manifold. Lock the fan drive in n the ON mo ode to prevent erratic test results. This can b be done by installing a jumper across the teemperaturee switch or ssupplying sh hop air to th he fan. Refeer to the fan n drive manufactturer for locck‐up proceedure. NOTE: So ome trucks have a man nual switch that will locck on the fan.

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Operate the engine at rated RP PM and load d. Record th he intake m manifold tem mperature. Measure the ambien nt temperatture at leasst two feet in front of tthe vehicle.. The maxiimum temp perature diffferential must not be grreater than 250 C [450 FF]. If the tem mperature d differential is greater th han 0 0 25 C [45 5 F], check tthe charge air cooler fo or dirt and d debris on th he fins, and clean as necessaryy. If the pro oblem still eexists, checkk the cooleer for intern nal contamination or plugging..

To ch heck the chaarge air coo oler or crackked tubess or header, remove th he inlet and outleet hoses from the coole er. Remo ove the chaarge air cooller. Install a cap over the outlett side of thee cooleer. Install a pressure gaauge and a sshop air su upply line to o the inlet side of the ccooler

he Apply 276 kPa [40 pssi] of air preessure to th cooler. If f the pressure drop is 3 35 kPa [5 psi] or less in 15 secondss, the cooleer is okay. If the preessure drop is greater tthan 35 kPa [5 psi] in 15 secondss, the charge air coolerr must be repaired or replaced. R Refer to thee CAC man nufacturer fo or repair insstructions. NOTE: A leak tank caan be used to locate the air leak.

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14.7.7 7 Turbochaarger‐Replaacement Prepaaratory Steps: ove the air ccrossover tu ube. • Remo • Disco onnect the intake and eexhaust piping. 10 mm Remove tthe capscreews from the oil drain ttube. 16 mm

Remo ove the oil ssupply line.

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If equipped with a w waste gate tturbochargeer, manifold preessure supp ply remove tthe intake m line from m the boost ccapsule. mm 15 mm and 11 m Clean thee sealing surface. Inspeect the sealiing surface and mounting studs for damagee.

Remo ove the exh haust clamp, turbocharrger, and ggasket.

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NOTE: If the turboch harger is no ot being imm mediately re eplaced, covver the opeening to pre event any manifold. material from fallingg into the m Install a n new gasket and apply aanti‐seize compoun nd to the mounting stu uds. 15 mm Install the turbocharger and d a new gassket. . ue Value: 3 32 N m [24 ft‐lb]] Torqu

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13 mm If requireed, bend thee lock plates back and loosen th he turbine h housing capscrews and position tthe bearingg housing to o install the turbochaarger drain ttube. 13 mm wdriver Screw Position tthe turboch harger drain n hose to co onnect The drain n tubes; tigh hten the claamps.

In nstall the ho ose and clam mps on the turbochargger drain tube lo oosely. Instaall the drain n tube and ggasket on the turbo ocharger. .

Torque Value: 24 N m

[18 ftt‐lb]

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13 mm, Punch, H Hammer 10 mm If requireed, loosen the compresssor housingg and position tthe housingg to align wiith the crosssover tube. 11 mm, plastic H Hammer

If loo osened, tighten the turbine housin ng capsccrews. Bend d the lock plates onto tthe flats tto prevent loosening.

Tightten the band d clamp to 5.7 N . m [50 in n‐lb]. Tap arround the cclamp with a plasstic hammeer and tighte en again to . 5.7 N N m [5 50 in‐lb]

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Caution: To preventt bearing daamage new w turbochargers must b be prelubriccated beforre start‐up. 3 ounces] off clean engiine oil into tthe oil supp ply fitting. R Rotate the turbine wheeel to Pour 50 tto 60 [2 to 3 allow thee oil to enteer the bearin ng housing.

Install the exhau ust outlet co onnection. Do no ot tighten the two mou unting capsscrews until the band cllamp has be een tightened.

Torqu ue Value: B Band Clamp‐8 N m [6 fft‐lb] . Capscrews ‐43 3 N m [32 fft‐lb]

16 mm Install thee oil supplyy line. . Torque V Value: 15 N m

[1 11 ft‐lb]

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If equipped with a w waste gate tturbochargeer, ply line from m Install thee intake maanifold supp the boostt capsule. 14.7.8 8 Exhaust M Manifold an nd Gaskets – Replacem ment Prepaaratory Steps: ove the air ccrossover tu ube. • Remo • Disco onnect the aair intake an nd exhaust piping • Remo ove the turb bocharger, iif used.

Install the air cro ossover tub be, inlet and d exhaust piping. Operrate the enggine and che eck for leakks.

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15 mm Remove tthe exhaustt manifold aand gasketss. 15 mm Install thee exhaust m manifold and new gaskets. Value: 43 N . m 32 ft‐lb] Torque V [3 Follow th he tightenin ng sequencee shown in the illu ustration, th hen follow tthe same sequencee and tighteen the capsccrews again to tthe same to orque valuees.

Clean n the sealingg surfaces.

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Install thee parts prevviously removed. Operate the engine and check ffor leaks.

14.8 Lubricatting Syste em Repair Summaryy Com mponent To Be R Replaced Oil P Pressure Regu ulator Valve and/or Sp pring

To ools Raatchet, 22 m mm Socket aand Torque W Wrench

Prreparatory Steps Clean debris

Cooler Element Oil C and or Gaskets

6 mm Wrench, Ratchett, 10 mm So ocket 16 an nd To orque Wren nch.

Drrain Coolant Reemove the o oil filter.

em Repair 14.9 Lubricatting Syste 14.9.1 Oil Pressure Regulattor, Valve aand Spring R Replacement Prepaaratory Steps: n debris. • Clean

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22 mm Remove tthe plug and regulatorr valve. 22 mm 14.9.2 2 Oil Coole er Element aand Gaskett‐Replacement Prepaaratory Steps: • Drain n the coolan nt. • Remo ove the oil ffilter.

Clean n and inspecct the bore and regulattor valvee before asssembly. Cautiion: In ordeer to regulate the oil presssure, the vaalve must m move freely in the b bore. Install the regulaator and spring. . Torqu ue Value: 8 80 N m [60 ft‐lb]]

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Clean all debris from m around the oil coolerr. 16 mm 10 mm Remove tthe oil cooler cover, element and gaskets.

Remo ove the turb bocharger o oil supply lin ne from the oil filteer head.

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Clean thee sealing surfaces. 10 mm oler gasket, element, ccooler Assemblee the oil coo cover gassket and cooler cover tto the cylind der block. NOTE: Bee sure to remove the shipping plugs (A) from the new coolerr element. Torque V Value: 24 N . m [1 18 ft‐lb]

Presssurize the element to 6 690 kPa [100 0 psi] to check it for leeaks.

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16 mm Connect the turboch harger oil su upply line. . Torque V Value: 15 N m [1 11 ft‐lb] m must be ffilled slowlyy to Caution: The system prevent aair locks. Be e sure to op pen the afte er‐ cooler ve ents to allow w air to esccape as the system iss filled. Fill the co oolant systeem and opeerate the en ngine to check for leaks. Stop the engine and d check the coolant and d oil level.

Install a new oil filter. Follow the manu ufacturer’s instructionss for tighteening.

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14.10 Electricaal System m Repair Su ummary Com mponent To Be R Replaced Startting Motor

Tools m Socket, 14 4 mm Wren nch, Ratcchet, 17 mm and Torque Wrrench

Prreparatory SSteps Disconnect grround cable e to battery

Alterrnator

Ratcchet, 8 mm,, 14 mm and d 16 mm So ocket and Torque Wrrench, 1/2 in nch Square Drive Breaaker Bar

Disconnect grround cable e to battery nd remove d drive belt. an

m Repair 14.11 Electricaal System 14.11 1.1 Startingg Motor‐Re eplacementt Disconneect the grou und cable fro om the batttery. Identify eeach electrical wire witth a tag indiicating location.

14 mm

Remo ove the battery cable ffrom the solen noid.

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10 mm Remove tthe startingg motor. Install thee starting m motor in thee reverse orrder or removval. . Torque V Value: 43 N m [3 32 ft‐lb] 14.11 1.2 Alternaator – Replaacement 14 mm Remove tthe capscreew from thee alternatorr link.

Disco onnect the gground cable from the batteery terminal. Identify each electriccal wire with a tag indicating lo ocation. Remo ove the drivve belt.

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16 mm Remove the alternator mounting ccapscrews. Remove the alternator. Position tthe alternattor on the b bracket and d secure it with th he mountingg capscrewss. Do not tighten at th his time. Connect the alternator link to tthe alternattor, finger tiighten. NOTE: M Make sure th he alternato or link is pro operly positiioned for co orrect belt aalignment.

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14, 16 6 mm Tighteen the alterrnator mounting capscrew. Torqu ue Value: . A = 24 4 N m [18 ft‐lb] A = 43 3 N . m [32 ft‐lb]

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15.0 Specificcations and Torque Values n‐Automo otive Engin nes) 15.1 Engine SSpecificattions (Non GENER RAL ENGINEE DATA 4BT3..9 4BTT3.9 4B BTA3.9 6B5.9 6 6BT5.9 6BTA5.9 9 Bore‐m mm [in.]…… ……………. ………… ………………… …………………. 102 [4.02] ………………………………… …… Strokee‐mm [in.]… …………………... ………… ………………… ………………....... 120 [4.7 72] …………… …………………… ………….. 3 Displacement‐liteer [in. ] ………… ………. 3.9 [2 239] ………… …….. .…………….. 5 5.9 [359] …… ………… Enginee Weight (D Dry) Less Flyy‐ wheel and Electrics‐Kgg [lbs.] 308 [6 680] 320 0 [705] 32 29 [725] 388 [855] 3 399 [880] 411 [905 5] ………… ……… 1.3.4.2 ……………… …… … ……………… 1 1.5.3.6.2.4 … …………….. Firing Order Valve Clearances ‐Intakee‐mm [in.]… …………….. ………… ………………… ………….. 0.25 5 [0.010] …… ………………… …………………… ‐Exhau ust‐mm [in.]………….. ………… ………………… ………….. 0.51 1 [0.020] …… ………………… …………………… 16.5:1 Compression Ratio………… 18.5:1 1 17.5 5:1 16 6.5:1 1 18.5:1 17.5:1 he Rotation viewed from th Front of the Engin ne……………… … ………… ………………… ……………….. Clockwise … ………………… …………………… ………… Aspiraation ‐Naturrally Aspiratted…………… …. x x x ‐Turbo ocharged…… ………………. x x x x x x ‐Aftercooled……… ………………. ‐Chargge Air Cooleed…………. 4BT3.9 LUBRIC CATION SYSSTEM kPa [p psi] 4BT3.9 9 4BTA3 3.9* 6B5..9 6B BT5.9 6 6BTA5.9 Minimu um Allowab ble Oil Presssure@ Idle 69 [10] 69 [10]] 69 [10 0] 69 [1 10] 69 [10] 6 69 [10] Minimu um Allowab ble Oil Presssure@ Rated d 207 [30]] 207 [30 0] 207 [3 30] 207 [30] 207 [30] 2 207 [30] Regulatted Pressurre 449 [65]] 449 [65 5] 449 [6 65] 449 [65] 4 449 [65] 449 [65] Differential Pressu ure to Open n Filter 138 [20]] 138 [20 0] 138 [2 20] 138 [20] 1 138 [20] Bypass 138 [20] Oil Cap pacity L [QT]] Standard Pan Onlyy 9.5 [10] 9.5 [10 0] 9.5 [10 0] 14.2 2 [15] 14.2 [15] 14.2 [15] 1 Total Syystem (Pan, Filter, Linees) 1.6] 16.3 3[17.2] 16.4[17.3] 16.4[17.3] 1 10.9 [11..5] 11 [11.6] 11 [11 No. QTTS From "L" to "H" on D Dipstick [1] [1] [1] [2] [2] [2] COOLIN NG SYSTEM M L [QT] 7.0 [7.4]] 7.0 [7.4 9.0 [[9.5] Engine Coolant Caapacity 4] 7.9 [8.4] 9.0 0 [9.5] 9 9.0 [9.5] 0 0 Thermo ostat Modu ulating Rangge C [ F] 83‐95 83‐95 5 83‐9 95 83 3‐95 83‐95 8 83‐95 Pressurre Cap kPa [psi] 1040 C [2200F] 990C [2 2100F] *Jackett‐water afteercooled

[181‐230 0]

[181‐20 03]

[181‐203]

[18 81‐203]

[1 181‐203]

103 [15]] 48 [7]

103 [15 5] 48 [7 7]

103 [1 15] 48 [[7]

103 [15] 48 8 [7]

103 [15] 48 [7] 4

103 [15] 1 48 [7]

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HAUST INTAKE AIR EXH AND FUEL SYSTEEM 4B B3.9 4 4BT3.9 4BTA3.9 6B5.9 6BT5.9 6BTA5 5.9 Maximum Allow wable Intakke Restrriction at R Rated Speeed and LLoad with D Dirty Air Filteer Element ‐ mm H H2O [in. 508 [20] 635 [25] 635 [25] 508 [20]] 635 [25] 635 [[25] H2O]… ………………… …………………… … Maximum Allo owable Exx‐ on at Rateed haustt Restrictio Speed d and Load d‐mm Hg [iin. ………………… …………………… …… 76.2 mm m [3 in.] …… …………………… ………………… ……… …… Hg]…………………… …………………… Maximum Allow wable Restricc‐ tion tto Transfer Pump ‐ mm m ………………… …………………… …… 100 mm m [4 in.] ……………………… ………………………. …… Hg [in n. Hg]………… ………………… ….. Maximum Allow wable Return Line R Restriction ‐ mm Hg [in n. …… ………………… …………………… …… 518 mm m [20.4 in.] … ………………… …………………… ……. Hg]…………………… …………………… Maximum Fueel Pressurre Drop Across FFilters kPaa …… ………………… …………………… ………… 34 [5 5] ……………… ………………… ……………….. [psi]… ………………… …………………… …. ELEC CTRICAL SYSSTEM 4B3.9 4BT3.9 4BTA3.9 9 6B5.9 6BT5.9 6BTA5 5.9 Miniimum Reco ommended Battery Capaacity‐With LLight Accesssories* ‐12V Starterr………………… … 625CCA 625CCA A 8CCA 800CC CA 800CC CA ‐2 24V Starterr………………… … 312CCA 400CCA A 400CC C 400CC CA 400CC CA With h Heavy Acccessories** 800CCA 800CCA A 800CCA A 950CC CA 950CC CA ‐12V Starterr……………….. ‐2 24V Starterr……………….. 400CCA 400CCA A 400CC C 475CC CA 475CC CA Maxximum Allow wable Resistance of Startting Circuit 0 0.0012 ‐W With 12 V SStarter‐Ohm ms……… ‐W With 24 V SStarter‐Ohm ms…….. 0 0.0020 *Typ pical light acccessories include alternator, smaall steering p pump, and disengaged d clutch. *Typ pical heavy accessoriess include hydraulic pum mp and torq que converter.

800C CCA 400C CCA 950C CCA 475C CCA

15.1.1 Batteriess (Specific G Gravity) Speccific Gravityy at 27 7 0C [80 0F] State off Charge 1.260‐1.280 10 00% 1.230‐1.250 75 5% 1.200‐1.220 50 0% 1.170‐1.190 25 5% 1.110‐1.130 Disch harged

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15.2 General Specificaations (Au utomotive e Engines) GENEERAL ENGIN NE DATA B5.9‐16 60 B5.9 9‐175 B5.9‐190 B5.9‐21 10 B5.9 9‐230 Bore‐‐mm [in.]…… ………………… ……….. 102 [4.0 02] 102 [4.02] 1 102 [4.02] 102 [4.0 02] 102 [4.02] Strokke‐mm [in.]… ………………… ……….. 120 [4.7 72] 120 [4.72] 1 120 [4.72] 120 [4.7 72] 120 [4.72] Displaacement‐litter [in. 3]…… ……… 5.9 [359 9] 5.9 [359] 5.9 [359] 5.9 [359 9] 5.9 [359] Engin ne Weight (Dry) Less Fly‐wheel and EElectrics‐kg [lbs]………… ……………….. 428 [942] 428 [942] 4 428 [942] 428 [942] 428 [942] Firingg Order……… ………………… ………………… 1‐5‐3‐6‐2 2‐4 1‐5‐3 3‐6‐2‐4 1‐5‐3‐6‐2‐4 1 1‐5‐3‐6‐2 2‐4 1‐5‐3 3‐6‐2‐4 Valvee Clearancess: ‐In ntake‐mm [iin.]…………… ……………….. 0.25 [0.010] 0.25 [[0.010] 0..25 [0.010] 0.25 [0.010] 0.25 [0.010] ‐Exxhaust‐mm [in.]………… ……………….. 0.51 [0.020] 0.51 [[0.020] 0..51 [0.020] 0.51 [0.020] 0.51 [0.020] 17.1:1 Comp pression Ratio…………… ………………. 17.5:1 1 17 7.5:1 17.1:1 1 17 7.1:1 Rotattion, viewed d from the FFront of the Engin ne……………… ……………………………….. Clockwisse Clocckwise C Clockwise Clockwise Clocckwise Aspirration: ‐Naturally Asp pirated……… ……………… x ‐Tu urbocharged d……………………………… x x x x ‐Afftercooled… ……………………………… x ‐ Change Air C Cooled…………………….. x x x x Lubriicating System kPa [pssi] B5.9‐16 60 B5.9 9‐175 B B5.9‐190 B5.9‐21 10 B5.9 9‐230 Min. Allowable P Press. @ Idlle…………. 69 [10]] 69 [10] 69 [10] 69 [10]] 69 [10] Min. Allowable P Press. @ Raated……… 207 [30 0] 207 7 [30] 207 [30] 207 [30 0] 207 7 [30] Regulated Pressure…………… …………….. 449 [65 5] 449 9 [65] 449 [65] 449 [65 5] 449 9 [65] Filterr Bypass Difff. Pressure Oil Capa‐ 138 [20 0] 138 8 [20] 138 [20] 138 [20 0] 138 8 [20] city LL [QT]: ‐Standard Pan n Only………… ……………. 14.2 [15 5] 14.2 2 [15] 14.2 [15] 14.2 [15 5] 14.2 2 [15] ‐To otal System… ………………… ……………. 16.4 [17..3] 16.4 [17.3] 16.4 [17.3] 1 16.4 [17..3] 16.4 [17.3] QTS FFrom “L” to “H” [2] [2] [2] [2] [ [2] COOLLING SYSTEM L [QT] B5.9‐16 60 B5.9 9‐180 B B5.9‐190 B5.9‐21 10 B5.9 9‐230 Engin ne Coolant C Capacity…… ……………… 9.0 [9.5 5] 9.0 [9.5] 9.0 [9.5] 9.0 [9.5 5] 9.0 [9.5] Therm mostat Mod dulating Ran nge: C…………… ………………… … 83‐95 83 3‐95 83‐95 83‐95 83 3‐95 [F]………………………….. [181‐203 3] [181 1‐203] [ [181‐203] [181‐203] [181 1‐203] Presssure Cap kPa [psi]: 0 0 ‐10 04 C [220 F]……………… ……………. 103 [15 5] 103 3 [15] 103 [15] 103 [15 5] 103 3 [15] 0 0 ‐99 9 C [210 F]……………… F ……………… 48 [7] 48 8 [7] 48 [7] 48 [7] 48 8 [7] 168 Page 168 of 179

Intaake Air, Exh haust, and FFuel System m Maximum Allo owable Intake Restriction at Ratted Speed and Load witth Dirty Air Filter Element‐mm H H2O [in. H2O O]……………… … Maximum Allo owable Exhaaust Restricction at Rated Speeed and Loaad‐mm Hg [in. Hg]]………………… ………………… …………………. Maximum Allo owable Restriction to Fuel Transfer Pump p‐With Dirty Filter‐mm m Hg [in. Hg]…………………………… …………… Maximum Allo owable Retu urn Line Resstrict‐ ion‐mm Hg [in. Hg]………… ……… Maximum Fueel Pressure Drop Acrross Filters kPa [psii]

B5.9‐160 B5.9‐175 B5.9‐190 B 0 B5.9‐21 10 B5.9‐‐230 6 635 [25] 635 [25] 635 [25] 635 [25] 635 [25] 152.4 [6] 152.4 [6] 152.4 [6]] 152.4 [[6] 152.4 4 [6] 100 [4] 1 100 [4] 100 [4] 100 [4 4] 100 [4] 51 18 [20.4] 518 [20.4] 518 [20.4 4] 518 [20 0.4] 518 [2 20.4] .…..…………………… 34 [5] … ………………………….

Electrical Sysstem B5.9‐1 160 B5.9 9‐175 B5.9‐190 B5.9‐210 M Minimum Re ecommended Batteryy Capacity‐Witth Light Acccessories*: ‐12 V Starrter…………… ………………….. 800CC CA 800 0CCA 8 800CCA 800CCA ‐24 V Starrter…………… ………………….. 400CC CA 400 0CCA 4 400CCA 400CCA W Wuth heavy Accessoriess**: ‐12 V Starrter…………… ………………….. 950CC CA 950 0CCA 9 950CCA 950CCA ‐24 V Starrter…………… ………………….. 475CC CA 475 5CCA 4 475CCA 475CCA M Maximum Al llowable Reesistance of Sttarting Circuit: ‐With 12 V V Starter‐Ohms .0012 .00 012 .0012 .0012 ‐With 24 V V Starter‐Ohms .0012 .00 012 .0012 .0012 *TTypical light accessoriees include aalternator, ssmall steerin ng pump, and disengagged clutch. **Typical heeavy accesso ories include hydraulic pump and torque converter.

B5.9‐23 30 800CCA A 400CCA A 950CCA A 475CCA A .0012 .0012

15.3 Fuel Reccommend dations / SSpecificattions

Warning: Do not miix gasoline o or alcohol w with diesel fuel. This m mixture can n cause an e explosion. Caution: Due to the e precise tollerances of diesel injecction system ms, it is exttremely imp portant that the fuel be kept clean and free of d dirt or wate er. Dirt or w water in the e system can cause sevvere damagge to both the injection p pump and th he injection n nozzles. Caution: Do not use e diesel fuell blended w with lube oil in enginess equipped with a cataalytic conve ertor (including year 1994 4 and beyon nd). Damagge to legallyy required e emission co ontrol may result.

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Use A ASTM No. 2 2 D fuel witth a minimu um Cetane number off 40. No. 2 diesel fuel gives the b best econom my and perfo ormance under most operating co onditions. Fu uels with Ce etane numb bers higherr than 40 may be needed in a high aaltitude or eextremely lo ow ambientt temperatu ures to prevvent misfirees, and exceessive smokke. At op perating temperaturess below 0 0C [32 0F], use a blen nd of No. 1 1 D and No o. 2 D fuels, also kno own as “wintterized” No. 2 D. NOTEE: No. 1 D fu uel can be u used, howevver, fuel eco onomy will suffer. Use lo ow sulfur co ontent fuel having a clo oud point th hat is at leaast 10 degreees below th he lowest expected fueel temp peratures. Cloud point iis the temperature at w which were e crystals beegin to form m in diesel fu uel. The vviscosity of tthe fuel mu ust be kept aabove 1.3 centistokes tto provide aadequate fu uel system llubrication at 400C [104 0F]. For a more detaiiled descrip ption of fuel properties, refer to fu uel for Cumm mins Enginees. Bulletin No. 337900 01. The follow wing chart lists acceptaable alternaate fuels forr Mid‐Range e engines. eptable Alte ernate Fuels‐Compone ent Wear/D Durability Acce Fuel B Bosch Nippodenso N Stanaadyne Lucas CAV V Type A P P7100 VE Ep‐9 DB B‐4 DPA D DPS No. 1‐D Diesel OK OK OK OK OK OK O OK No. 2 2 Fuel Oil OK OK OK OK OK OK O OK No. 1‐K Kerosen ne OK OK OK ** * * No. 2 2‐K Kerosen ne OK OK OK ** * * Jet‐A A OK OK OK ** * * Jet A A‐1 OK OK OK ** * * JP‐5 OK OK OK ** * * JP‐8 OK OK OK ** * * Jet ––B N Not Ok N Not Ok No ot Ok Not Ok Not Ok Not Ok No ot Ok JP‐4 N Not Ok N Not Ok No ot Ok Not Ok Not Ok Not Ok No ot Ok Cite N Not Ok N Not Ok No ot Ok Not Ok Not Ok Not Ok No ot Ok *OK Only if 5% new lube oil is blended d with thesee fuels to in ncrease the lubricity to o acceptable e level. Cauttion: Do not use diesel fuel blend ded with lu ube oil in engines eq quipped with a catalytic convvertor (inclu uding all mo odel year 1 1994 and b beyond). Daamage to legally requ uired emisssion conttrol may ressult. NOTTE: Any adju ustment to ccompensatee for reduceed performance with aa fuel systeem using alternate fuel is not warraantable. NOTTE: Wear on n any mid‐raanged fuel p pump comp ponent attributed to th he lack of lubrication in n the fuel is not is no ot a warranttable repairr.

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15.4 Lubricatting Oil Re ecommen ndations // Specificaations 15.4.1 Oil Perfo ormance Recommendaations

The use of quality engine lubricating oils o combined with ap ppropriate oil drain and a filter change c intervals are critical factors in m maintaining engine perrformance aand durabiliity. ompany. Incc. recommeends the use of a high quality SAEE 15W‐40 h heavy duty engine Cumminss Engine Co oil (such as Cummin ns Premium m Blue) whicch meets th he American n Petroleum m Institute ((API) perforrmance classification CE/SG..

NOTE: CC C / CD or CD / CF engine oils can be used in areas where CE oil is not yet avaailable, but the oil change in nterval musst be reduceed to one haalf the interrvals given iin the maintenance sch hedule. A sulfateed ash limitt of 1.0 maass percentt is suggested for optiimum valvee and pisto on deposit and a oil consump ption contro ol. The sulfaated ash mu ust not exce eed 1.85 maass percent. 15.4.2 2 Oil Viscosity Recommendation ns The use of multi‐viscosity lub bricating oil has been n found to improve o oil consump ption contrrol and improve engine crranking in cold temp peratures while w main ntaining lub brication at high opeerating temperattures. While 15 5W‐40 oil is recommen nded for mo ost climates, refer to tthe accomp panying tab ble for oil viiscosity recommeendations fo or extreme climates. B Series NOTE: Limite N ed use of lo ow viscosity oils, such aas 10W‐30 mayy be used fo or easier staarting and providing suffficient oil fflow at amb bient 0 0 te emperaturees below ‐5 C [23 F]. H However, co ontinuous u use of low vviscosity oilss can decreaase engine life d due to wearr. Refer to tthe accomp panying ch hart. 15.4.3 3 New Enggine Break‐In Oils Do not use special ““break‐in” lu ubricating o oils for new w or rebuilt C Cummins Engines. Use e the same ttype of oil duringg the “breakk‐in” as thatt which is used in norm mal operatio on. 4 Recomm mended Oil C Change Inte ervals 15.4.4 Refer to tthe followin ng flowcharrt for the recommende ed oil change interval b based on engine applicaation.

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Is yourr vehicle one of those below? ‐Region nal Haul Trucck e an on YES Y YES Change Interval Is your vehicle ‐Coach h Bus HOURS MO OS KM MILES H Hiighway application? ‐Vehiclle accumulatte. 8000 mile es/mth. 10,00 00 6,000 250 3 3 Or morre

owing oil dra ain intervals for your app Use the foll plication (1):

Is your vehiclee used in a Construction n, Mining orr Logging Application?

YES

NO Iss your vehicle e used in an Agricultural o A or Stationary ation? P Power Applic

YES

QUIP VEHICLE/EQ Refuse TrK Mixer/Dum mper Del. Truck Shuttle or TTransit Bus School Bus Fire Truck Recreationaal Vehicle

RS MOS KM MILES HR 10,000 6,0 000 25 50 3 10,000 6,0 000 25 50 3 10,000 6,0 000 25 50 6 10,000 6,0 000 25 50 3 10,000 6,0 000 25 50 6 10,000 6,0 000 25 50 3 10,000 6,0 000 25 50 6

Use the follo owing oil draain intervals for your app plication (1): KM MIILES HRS MOS VEHICLE/EQ QUIP 3 Truck Cranee 1 10,000 6,0 000 250 3 Yard Spotter 1 10,000 6,0 000 250 6 Paver N/A N/A 250 6 Cranes N/A N/A 250 6 Backhoe N/A N N/A 250 6 Dozer 250 N/A N/A 6 Scraper 250 N/A N/A 6 Skidder 250 N/A N/A Use the following oil draain intervals for your app plication (1): VEHICLE/EQ HOURS MONTHS QUIP 250 6 Farm Tracto ors 250 6 Combines 250 6 Irrigation Eq quip 250 6 Generator SSet 250 6 Air Compressor 250 6 Fire Pump 250 6 Pleasure Bo oat 250 3 Work Boat

C Change Interv val KM MILE ES HOURS MOS 1 10,000 6,00 00 250 3 (1) Or whiichever comes first. If your applicatio on accumulattes high hou urs and low m mileage, the change interrval is determineed by hours. Examples: Transit busses and refusse trucks mayy average 16 6 Km [10 MPH] when useed in all urban routes. Oil drain intervals in those appllications are 4800 Km [3,,800 mi], or lless.

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15.4.5 5 Oil Consu umption In additio on to the information i n that follows, a serviice publicattion entitleed Technicaal Overview w of Oil Consump ption is avaiilable, Bulleetin 3379214 4‐00. Cumminss defines “A Acceptable O Oil Usage” aas outlined in the follow wing table: ACCEP PTABLE OILL USAGE AN NY TIME DU URING COV VERAGE PER RIOD HO OURS HOURS HO H OURS M MILES ENGINE P PER PER PER P PER FAMILY IMP PERIAL L LITER QU UART QT QU UART 4B 6B 6C

10.0 10.0 10.0

10.6 1 1 10.6 1 10.6

12 12 12

400 4 4 400 4 400

MIILES PER LITTER 425 4 425 4 425 4

MILES KILOM K KM KM P PER PER PER PER R IMPERIA AL IMP PERIAL R QUARTT QUART LITER QU UART 475 4 4 475 4 475

650 650 650

675 5 675 5 675 5

775 775 775

15.4.6 6 Arctic Op peration If any engine is operated in am mbient temperatures cconsistentlyy below ‐23 0C [‐10 0F] and there are no provision ns to keep tthe engine warm when n it is not in operation n, use a syn nthetic CE/SSG engine o oil with adequatee low tempeerature pro operties such as; 5W‐30 0. Caution: The use off the synthetic base o oil does nott justify oil change inttervals. Exttended oil cchange intervalss can decreaase engine life due to factors such as; corrossion deposiits and weaars.

15.5 Coolantt Recomm mendation ns / Speciffications •

• •

Antifreeze is esssential in an ny climate. It broadens the operaating tempeerature rangge by lowering the coolaant freezing point and b by raising itts boiling po oint. Do nott use more tthan 50 perrcent antifreeeze in the mixture m unless additio onal freezee protection n is required. Never use more than 68 percent p antifrreeze underr any condittion. Use ssoft water in n the coolan nt mixture. Contaminaants in hard water neuttralize the ccorrosion in nhibitor comp ponents. Water must n not exceed 300 ppm h hardness orr contain m more than 1 100 ppm off either chloride or sulph hate. Use low siliccate antifree eze which m meets ASTM M4985 test (GM6038M M spec.) critteria. Speciifications‐U Conce entration‐A Antifreeze m must be useed in any clim mate for bo oth freeze and boiling p point protecction. Cumm mins recom mmends a 50 percentt concentraation level (40 percent to 60 percent p ran nge) of ethylene glycol or propylene glycol in most climates. c A Antifreeze aat 68 perce ent concentration provides the maaximum freeeze protecction and must m be excceeded und der any con ndition. Anttifreeze Proteection decreeases abovee 68 percent. 173 Page 173 of 179

Etthylene Glyycol 0 0 40 0 % = ‐23 C [‐10 C F] 0 0 50 0 % = ‐37 C [‐34 C F] 0 60 0 % = ‐54 0C [‐65 C F] 0 0 68 8 % = ‐71 C [‐90 C F]

Propyylene Glyco ol 0 40 % = ‐21 C [‐6 6 0F] 0 50 % = ‐33 C [‐2 27 0F] 60 % = ‐49 0C [‐5 56 0F] 68 % = ‐63 0C [‐8 82 0F]

Concentrration Testting‐Antifre eeze concen ntration must m be che ecked using a refracttometer (such as Fleetguarrd Part No. Cc2800). “Floating ball” b type density tessters or hydrometers are not acccurate enough ffor use with h heavy dutyy diesel coo oling system ms. Filterr Selection Oil Filters nder Applicaations A = LF 3345 Standard Four Cylin B = LF 3349 Standard d Six Cylinder Applications Fuel FFilters A = Standard A d Filter used d as secondaary filter in fuel filter applications. or Primary ffilter for fueel B = Fuel Watter Separato filter applications. or used in single filter C = Fuel Watter Separato applications.. 174 Page 174 of 179

15.6 Engine C Compone ent Torque e Value .

Socke et or Wrencch Size MM M (Inch) Torqu ue N m (Ft‐lb) 10 A Aftercooler M Mounting…………………… …………………………………… ……. 24 [18] 8 A Aftercooler W Water Hosee Clamp……… ………………… …………………… …… 5 [4] 13 A Alternator Li nk (Delco 1 10‐15 Sl)……………………… …………………….. 24 [18] [3 3/4] A Alternator Li nk (Delco 2 20‐27 Sl)……………………… …………………….. 43 [32] 15 A Alternator M Mtg. Bolt 10‐‐15 Sl………… ………………… …………………… …… 43 [32] 18 A Alternator M Mtg. Bolt 27 Sl……………… ………………… …………………… …… 77 [57] 10 A Alternator Su upport (Upp per)…………… ………………… …………………… ……. 24 [18] Allen n 5 mm Belt Tensioner Flat Braccket…………… …………………………………… …… 24 [18] 15 Belt Tensioner Mountin ng……………… …………………… ………………… ……. 43 [32] 15 Crankshaft D Damper & Pulley………… …………………… ………………… ……. 137 [101] [5 5/16] Crossover Clamp…………………………… …………………………………… …… 5 [4] 11 Teee Bolt Type Clamp…… …………………… ………………… …………………… ….. 8 [6] 15 Exxhaust Man nifold………… …………………………………… …………………….. 43 [32] 15 Exxhaust Outllet Pipe Mtgg Bracket…… ………………… …………………… ….. 43 [32] (7 7/16) Exxhaust Outllet Pipe, V B Band Clamp p………………… ………………… ……. 8 [6] 10 Faan Bracket Mounting… …………………… ………………… …………………… …… 24 [18] 10 Faan Pulley…… ………………… …………………… ………………… …………………… …… 24 [18] 13 Faan Pulley…… ………………… …………………… ………………… …………………… …… 43 [32] 19 Fllywheel……………………… …………………………………… ……………………… 137 [101] ‐‐ Frront Cover Clamp Acceess Cap……… …………………………………… …… ‐‐‐‐‐Hand Tigghten‐‐‐‐ 17 Fu uel Drain Line Banjo Sccrew (Rotary Pump)…… …………………… …… 15 [11] 17 Fu uel Banjo Sccrew (in Filtter Head)…… ………………… …………………… ….. 24 [18] 10 Fu uel Vent Screw (in Ban njo)…………… …………………… ………………… …….. 9 [7] 10 Fu uel Banjo Sccrew (Injecttor)…………… …………………………………… ……. 9 [7] 75 5‐85 Fu uel Filter…… …………………………………… …………………………………… …… 3//4 Turn Afte er Contact 24 Fu uel Filter Ad dapter Nut… ………………… …………………… ………………… …….. 32 [24] 17 or 19 Fu uel Line Fittting (High Pressure)…… …………………… ………………… ……. 30 [22] 22 Fu uel Pump D Drive Gear (w with Pump Unlocked) R Rotary……… ……… 65 [48] 22 Fu uel Pump D Drive Gear (P Pump Unloccked) Nippo odenso……… …….. 123 [92] 30 Fu uel Pump D Drive Gear (P Pump Unloccked) Bosch h Inline……… ……. 165 [122] 10 Fu uel Pump Lo ock (Bosch)) Rotary……… ………………… …………………… …… 30 [22] Fu uel Pump U Unlock (Boscch) Rotary… …………………… ………………… …….. 13 [10] 14 Fu uel Pump Lo ock (CAV)…………………… …………………………………… …… 7 [5] 20 Fu uel Pump U Unlock (CAV V)………………………………… …………………….. [15] 24 13 Fu uel Pump M Mounting Nu uts (Bosch R Rotary)……… ……………………… [18] 43 15 Fu uel Pump M Mounting Nu uts (Bosch In‐Line, Nippodenso…… ……. [32] 30 13 Fu uel Pump M Mounting Nu uts (CAV)…… ………………… …………………… …… [22] 13 Fu uel Pump Support Braccket…………… ………………… …………………… ……. 24 [18] 24 In njector Retaaining Nut… …………………… ………………… …………………… ……. 60 [44] 13 In ntake Maniffold…………… …………………………………… ……………………… 24 [18] 10 Liift Pump/Co over Plate… …………………… ………………… …………………… ……. 24 [18] 18 Liifting Brackeet (Rear)…… …………………………………… …………………….. 77 [57]

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Socke et or Wrench Size MM (Inch) Torq que N m (Ft‐lb) 78‐85 ……………..…… …………………………………… ……………………. 3 3/4 Turn After Contaact Oil Filter……… 24 1 10 Oil Cooler Asssembly……… ………….……… …………………… ………………… …… [18] 80 1 17 Oil Pan Drain Plug………… …………..……… …………………………………… ….. [60] 80 2 27 Oil Pan Heateer Plug………………..……… …………………… ………………… ….. [60] 80 1 19 Oil Pressure R Regulator Pllug…………… …………………… ………………… …… [60] 9 1 10 Reeal Seal Hou using…………..……………… …………………… ………………… …… [7] 1 14 Ro ocker Lever Nut…………… ………………… …………………… ………………… …… 24 [18] 1 10 Staarter Mounting…………… …..……………………………… …………………… 43 [32] 1 10 Tappet Coverr/Fuel Drain Line Suppo orts…………… ……………………. 24 [18] 1 10 Th hermostat H Housing……… ……..…………… ………………… …………………… …. 24 [18] 1 13 Tu urbine Housing.…………… ………………… …………………… ………………… …… 11 [8] 1 10 Tu urbo Compressor Housiing Clamp… …………………… ………………… ….. 6 [5] 1 15 Tu urbo Mounting Nuts….… ………………… …………………… ………………… …… 32 [24] 1 13 Tu urbo Drain TTube…………………………… …………………………………… …… 24 [18] 1 16 Tu urbo Oil Sup pply (Both Ends)…………………………… ……………………. 24 [18] 1 15 Waater Inlet Connection… …………………………………… ……………………. 43 [32] 24 1 13 Waater Pump Mounting.… …………………………………… ………………… …… [18] 24 1 15 Vaalve Cover… …………………… ………………… …………………… ………………… …… [18] ‐ ‐‐ Vaalve Cover O Oil Fill………… …………………………………… …………………… ‐‐‐‐‐Hand Tigghten‐‐‐‐

15.7 7 Sealan nts Use thee sealants listed below or sealantss containingg equivalentt propertiess. Descrip ption

Sealing Method

1. Pipe Plugs

d teflon or p pipe sealer. Precoated

2. Cup P Plugs

Loctite 277 or 11,264 4

3. O‐Rin ngs

No sealantt required.

4. Rear Camshaft EExpansion P Plug

Precoated d or Loctite 5 59,241 liquid teflon.

Pump Studss 5.Fuel P

Loctite 609.

6. Turbo Drain in B Block

Loctite 277 or 11,264 4

7. Frontt Seal in Gear Cover

Loctite 277 or 11,264 4

8. Rear Seal in Reaar Cover

No sealantt

9. Oil Paan at T‐Join nt

3‐Bond 12 207C (P/N 3823494)

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15.8 8 Capscre ew Markings and TTorque Values Caution n: When rep placing capsscrews, alw ways use a ccapscrew off the same measurem ment and strrength as the ccapscrew be eing replace ed. Using in ncorrect cap pscrews can n result in eengine dam mage. Mosst of the cap pscrews useed on the B Series engiine are mettric. Some componentss, such as th he air comp pressor and fuel pump, are installeed using U.SS. Customarry capscrew ws. Metric capscrew ws and nuts are identified by thee grade num mber stamp ped on the h head of the e capscrew,, or on ntified by radial lines sstamped on n the head of the the surface of tthe nuts. U.S. Customaary capscreews are iden capsscrew. The following eexamples ind dicate how capscrews are identified. Metric (M8‐1.25X25) U.S. C Customary (5/16x8x1 1/2 18 1 1/2 1.25 25 5/16 M M8 M Major Distance Length Major Num mber Lenggth Between in Thread Thread d Threeads in n meter in Threads in T Millimeters Diameterr in per Inch Inch hes Diam Inchess Note es: 1. Allways use a torque values listed in n the follow wing tables w when speciffic torque values are not availablee. 2. Do o not use th he torque values in plaace of thosee specified in n other secttions of thiss manual. 3. Th he torque vvalues in thee table are b based on th he use of lub bricated thrreads.

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8.1 Capsccrews Markings and d Torque Values‐M Metric 15.8 Com mmercial Ste eel Class 8.8 10.9 12.9 9 Capsscrews Heaad Markingss

Body B S Size Diaam.

Torque Caast Iron

Torque e

Torqu ue Aluminum

C Cast Iron

Alumin num

C Cast Iron

Aluminum

mm m 6 6 7 7 8 8 1 10 1 12 1 14

N . m m 9 14 4 25 5 40 0 70 0 115 5

ft‐lb 7 10 18 30 22 85

N . m 7 11 18 30 55 90

ft‐lb 5 8 13 22 40 66

N . m 12 2 18 8 32 2 60 0 10 05 16 60

ft‐lb 9 13 23 45 77 118

N . m 7 11 18 30 55 90

ft‐lb 5 8 13 22 40 66

N . m 1 12 2 23 3 36 7 70 12 25 19 95

ft‐lb 9 18 27 50 95 145

N . m 7 11 18 30 55 90

ft‐lb 5 8 13 22 40 66

16 1 1 18

180 0 230 0

133 170

140 180

103 133

24 40 32 20

177 236

140 180

103 133

29 90 40 00

210 290

140 180

103 133

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8.2 Capsccrew Markings and d Torque V Values – U U.S. Custom mary 15.8 SAE GRADE Number 5 8 The ese are all SAE Grade 5 5 (3) line Cap pscrew Head d Markingss

Capscrew Torque‐Graade 5 Capsccrew Capsscrew Bodyy Size

Cast Iron n .

1//4 ‐ 20 ‐ 20 5/16 ‐ 18 ‐ 24 3//8 ‐ 16 ‐ 24 7/16 ‐ 14 ‐ 20 1//2 ‐ 13 ‐ 20 9/16 ‐ 12 ‐ 18 5//8 ‐ 11 ‐ 18 3//4 ‐ 10 ‐ 16 7 7/8 ‐ 9 ‐ 14 1 ‐ 8 ‐ 14

N m 9 12 20 23 40 40 60 65 95 100 135 150 180 210 325 365 490 530 720 800

ft‐lb 7 9 1 15 1 17 3 30 3 30 4 45 5 50 7 70 7 75 100 110 135 155 240 270 360 390 530 590

Capscrew Torq que‐Grade 8 8 Capscrew

Aluminum .

N m m 8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650

ft‐lb 6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310 420 480

Cast Iro on .

N m 15 18 30 33 55 60 90 95 130 150 190 210 255 290 460 515 745 825 1100 1200

Alu uminum N . m m 12 2 14 4 24 4 25 5 40 0 45 5 65 5 75 5 100 0 120 0 150 0 170 0 205 5 230 0 365 5 410 0 600 0 660 0 890 0 960 0

fft‐lb 11 13 22 24 40 45 65 70 95 1 110 1 140 1 155 1 190 2 215 3 340 3 380 5 550 6 610 8 820 8 890

ft‐lb 9 10 18 19 30 35 50 55 75 90 110 125 150 170 270 300 440 490 660 710

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