. '-" I I I I I I I I I I I I 1 1 ... -I - - --- 11 Ingersoll land OPERATING, MAINTENANCE, PARTS MANUAL MODELS: HP675WCU XP825WCU HP750WCU XP750WCU Code: Code: D - -This manual contains important safety information.- - - - -- - - - ---- - Do not destroy this manual. This manual must be available to the personnel who operate and maintain this machine. 1 . ~~Inger.souftand ,I Portable Power P.O. Box 868 - 501 Sanford Ave Mocksville, N.C. 27028 www.portablepower.irco.com C.C.N. : 22330252 DATE : October 2003
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IIIIIIIIIIII11...-I - - --- 11
IngersolllandOPERATING, MAINTENANCE,
PARTS MANUAL
MODELS:
HP675WCU XP825WCUHP750WCUXP750WCU
Code: Code: D
- -This manual contains important safety information.- - - - -- - - - ---- -Do not destroy this manual.This manual must be available to the personnel who operate and maintain this machine.
FOREWORDNothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied,regarding the Ingersoll-Rand products described herein. Anysuch warranties or other terms and conditions of sale ofproducts shall be in accordance With the standard terms andconditions of sale for such products, which are available uponrequest.
This manual contains instructions and technical data tocover all routine operation and scheduled maintenance tasks byoperation and maintenance staff. Major overhauls are outsidethe scope of this manual and should be referred to an authorisedIngersoll- Rand service department.
All components, accessories, pipes and connectors addedto the compressed air system should be:
of good quality, procured from a reputable manufacturer and,wherever possible, be of a type approved by lnqersoll-Hanc
clearly rated for a pressure at least equal to the machinemaximum allowable working pressure.
compatible with the compressor lubricant/coolant.accompanied with instructions for safe Installation,
operation and maintenance.
Details of approved equipment are available fromIngersoll-Rand Service departments.
The use of repair parts / lubricants / fluids other than thoseincluded within the Ingersoll-Rand approved parts list maycreate hazardous conditions over which Ingersoll- Rand has nocontrol. Therefore Ingersoll-Rand cannot be held responsiblefor equipment in which non-approved repair parts are installed.
Ingersoll-Rand reserves the right to make changes andimprovements to products without notice and without incurringany obligation to make such changes or add suchimprovements to products sold previously.
The intended uses of this machine are outlined below andexamples of unapproved usage are also given, howeverIngersoll-Rand cannot anticipate every application or worksituanon that may arise.
IIF IN DOUBT CONSULT SUFIERVISION.
ThiS machine has been designed and supplied for above groundoperation and only in the fOllowing specified conditions andapplications:
compression of normal ambient air containing no known ordetectable additional gases, vapours, or particles.
Operation within the ambient temperature range specified inthe GENERAL DATA SECTION of this manual.
IIIThe use of the machine in any of the situation types
listed in table 1:-a) Is not approved by lnqersotl-Hand,b) May impair the safety of users and other persons, andc) May prejudice any claims made against Ingersoll-Rand. I
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumptionb) indirect human consumption, without suitable filtration andpuntv checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL DATA SECTION of this manual.
Use of the machine where there is any actual or foreseeable
risk of hazardous levels of flammable gases or vapours.
Use of the machine fitled with non Ingersoll- Rand approvedcomponents / lubricants / fluids
Use of the machine with safety or control componentsmissing or disabled.
Use of the machine for storage or transportation of materialsinside or on the enclosure except when contained within the
toolbox.
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Ingersoll- Rand accepts no responsibility for errors intranslation of this manual from the original English version.
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SAFETY
I General Information
INever operate unit without first observing all safety warnings
and carefully reading the operation and maintenance manualshipped from the factory with this machine.
IEnsure that the operator reads and understands the decals
and consults the manuals before maintenance or operation
IEnsure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Make sure that all protective covers are in place and that thecanopy/doors are closed during operation.
I The specification of this machine ISsuch that the machine isnot suitable for use in flammable gas risk areas. If such anapplication is required then all local regulations, codes ofpractice and Site rules must be observed To ensure that themachine can operate in a safe and reliable manner, additionalequipment such as gas detection, exhaust spark arrestors, andintake (shut-off) valves may be required, dependant on localregulations or the degree of risk involved.
III A weekly visual check must be made on all fasteners/fixing
screws securing mechanical parts. In particular. safety-relatedparts such as coupling hitch, drawbar components,road-wheels, and lifting bail should be checked for totalsecurity.I
IAll components which are loose, damaged or unserviceable,
must be rectified Without delay.
Air discharged from this machine may contaIn carbonmonoxide or other contaminants which will cause serious injuryor death. Do not breathe this air
I This machine produces loud noise With the doors open orservice valve vented. Extended exposure to loud noise cancause hearing loss. Always wear hearing protection when doorsare open or service valve is vented.I
I Never inspect or service unit without first disconnectingbattery cable(s} to prevent accidental starting
I Do not use petroleum products (solvents or fuels) under highpressure as this can penetrate the skin and result in seriousillness. wear eye protection while clearung unit with compressedair to prevent Uebrls from injuring eye(s}.
I Rotating fan blade can cause serious inJUry.00 not operatewithout guard in place.
I Use care to avoid contacting hot surfaces (engine exhaustmanifold and piping, air receiver and air discharge piping, etc.).
I
Ether is an extremely volatile, highly inflammable gas. Whenit is specified as a starting aid, use sparingly. DO NOT USEETHER IF THE MACHINE HAS GLOW PLUGS OR INLETHEATER STARTING AIDS OR ENGINE DAMAGE WILLRESULT
Never operate unit with guards, covers or screens removed.Keep hands, hair, clothing, tools, blow gun tips, etc. well awayfrom moving parts.
Compressed air
Compressed air can be dangerous if incorrectly handled.Before doing any work on the unit, ensure that all pressure isvented from the system and that the machine cannot be startedaccidentally.
Ensure that the machine is operating at the rated pressureand that the rated pressure is known to all relevant personnel.
All air pressure equipment installed In or connected to themachine must have safe working pressure ratings of at least themachines safety valve setting.
If more than one compressor is connected to one commondownstream plant, effective check valves and isolation valvesmust be fitted and controlled by work procedures, so that onemachine cannot accidently bepressurised / over pressurised byanother.
Compressed air must not be used for a direct feed to anyform of breathing apparatus or mask.
High Pressure Air can cause serious injury or death. Relievepressure before removing filler plugs/caps, fittings or covers.
Air pressure can remain trapped In air supply line which canresult in serious injury or death. Always carefully vent air supplyline at tool or vent valve before performing any service.
The discharged air contains a very small percentage ofcompressor lubricating oil and care should be taken to ensurethat downstream equipment is comoanbie.
If the discharged air Is to be ultimately released Into aconfined space, adequate ventilation must be provided
When using compressed air always use appropriatepersonal protective equipment.
All pressure containing parts, especially flexible hoses andtheir couplings, must be regularly inspected, be free fromdefects and be replaced according to the Manual Instructions.
The safety valve located in the separator tank must bechecked periodically for correct operation.
Whenever the machine is stopped, air will flow back into thecompressor system from devices or systems downstream ofthe machine unless the service valve is closed. Install a checkvalve at the machine service valve to prevent reverse flow in theevent of an unexpected shutdown when the service valve isopen.
Disconnected air hoses whip and can cause serious injuryor death. Always attach a safety flow restrictor to each hose atthe source of supply or branch line in accordance with OSHARegulation 29CFR Section 1926.302(b).
Never allow the unit to sit stopped with pressure in thereceiver-separator system
Materials
The following substances may be produced during theoperation of this machine:
brake lining dustangine exhaust fumes
AVOID INHALATION
Ensure that adequate ventilation of the cooling system andexhaust gases is maintained at all times.
The following substances are used in the manufacture of thismachine and may be hazardous to health if used incorrectly:
Should compressor lubricant come Into contact with theeyes, then irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with theskin, then wash off immediately.
Consult a physician if large amounts of compressor lubricantare ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient isunconscious or having convulsions.
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Safety data sheets for compressor and engine lubricantsshould be Obtained from the lubricant supplier.
IDo NOT start or operate this machine in a confined area.Avoid breathing exhaust fumes when working on or near themachine. I
This machine may include such materials as oil, diesel fuel,antifreeze, brake fluid, on/atr filters and batteries which mayrequire proper disposal when performing maintenance andservice tasks. Contact local authorities for proper disposal ofthese materials.
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Battery
IA battery contains sulphuric acid and can give off gaseswhich are corrosive and potentially explosive. Avoid contactwith Skin, eyes and clothing. In case of contact, flush areaimmediately with water IDO NOT AnEMPTTOSLAVE START A FROZEN BATIERYSINCE THIS MAY CAUSE IT TO EXPLODE.
IExercise extreme caution when using booster battery To
jump battery, connect ends of one booster cable to the positive(+) terminal of each battery. Connect one end of other cable tothe negative (-) terminal of the booster battery and other end toa ground connection away from dead battery (to avoid a sparkoccurring near any explosive gases that may be present). Afterstarting unit, always disconnect cables In reverse order
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Radiator IHot engine coolant and steam can cause injury Ensure that
the radiator filler cap is removed with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allowradiator to Cooldown before removing pressure cap.
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Transport
IWhen loading or transporting machines ensure that thespecified lilting and tie down points are used.
When loading or transporting machines ensure that thetowing vehicle, its size, weight, towing hitch and electricalsupply are all suitable to provide safe and stable towing atspeeds either, up to the legal maximum for the country In whichit Is being towed or, as specified for the machine model If lowerthan the legal maximum.
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Do not exceed gross vehicle weight rating. I4
IBefore towing the machine, ensure that:-
I the tires and towing hitch are in a serviceable condition.the canopy is secure.all ancillary equipment is stored in a safe and secure manner.the brakes and lights are functioning correctly and meetnecessary road traffic requirements.break-away cables/safety chains are connected to thetowing vehicle.
II The machine must be towed in a level attitude in order to
maintain correct handling, braking and lighting functions. Thiscan be achieved by correct selection and acjustrnent of thevehicle towing hitch and, on variable height running gear,adjustment of the drawbar.
1. Make sure wheels, tires and tow bar connectors are In safeoperating condition and tow bar is properly connected beforetowing.
2. When parking always use the handbrake and, If necessary,suitable wheel chocks.
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Safety chains/connections and their adjustment wherefined:
IEnsure that the breakaway cable is securely coupled to thetrailer and also to a substantial point on the towing vehicle.
Ensure that the cable length ISas short as possible, while stiliallowing enough slackness for the trailer to articulate without thehandbrake being applied
Loop the chains onto the towing vehicle using the towing vehiclehitch as an anchorage pomt, or any other point of similarstrength.
Ensure that the effective chain length is as short as possiblewhile still allowing normal articulation of the trailer and effectiveoperation of the breakaway cable.
IDECALS ILook for these .Igns on machines manufactured In Europe. which point out potential hazards tothe safety of you and others. Read and understand thoroughly. Heed warnings and followinstructions. If you do not understand. infonn you supervisor. I
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
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Prohibition I Mandatory Information I Instructions Warning I
it A A;\WARNING: Electrical shock risk. WARNING - PrBSSurlsed component or WARNING - Hot surfaco.
WARNING - Hot and harmful oxhauBt WARNING - Maintain correct tyreWARNING - Pressurl_d vessel. pressure. (Refer to the GENERALgas. INFORMATION~on of this mWllolal).
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IIIIIII WARNING - Flammable liquid.
WARNING - Befonl connecting the towbar 01" commencing to tow consult theoperation and maintenance manual.
WARNING - For operating temperaturebelow O"C, consult the opel'lltlon and
maintenance manual.
IIIIII WARNING - Do nat undertake any
maintenance on this machine until theelectrical supply III QillConnBCtod andthe olr pressure I.totally relieved.
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Do not removo the Operatlng andMaintenance manual and manual holder
from this machine.
WARNING - eon.ulttfw operation lindmaintenance manual before
commencing any malntenllnce.
Do not stack.
Do not breathe tl'le compressed alr lromthis machine.
•Do not operate the machine without theguard being fitted.
Look for these signs on machines shipped to markets in North America, which point out potentialhazards to the safety of you and others. Read and understand thoroughly. Heed warnings and followinstructions. If you do not understand, inform you supervisor.
I ADANGER
I(Red Background)
I AWARNING
I(Orange Background)
I ACAUTION
I (Yellow Background)
I NOTICE
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(Blue Background)
DANGER
Discharged air can contain carbonmonoxide or other contaminants.Will cause serious injury or death.
Do not breathe this air.
~WARNINGHot pressurized fluid.Can cause seriousburns.
Donotopen'Qrii~t·~~nwhile hot
Indicates the presence of a hazard which WILL causeserious injury, death or property damage, if ignored.
Indicates the presence of a hazard which CANcause serious injury, death or property damage,if ignored.
Indicates the presence of a hazard which WILL orcan cause injury or property damage, if ignored.
Indicates important set-up, operating or maintenanceinformation.
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&WARNINGTrapped air pressure.Can cause seriousinjury or death.
Close service valve andoperate tool to venttrapped air beforeperforming any service.
&WARNINGHigh pressure air.Can cause seriousinjury or death. ~
,
,
Relieve pressure beforeremoving filler plugs/caps,fittings or covers.
&WARNINGImproper operation of this equipment.Can cause serious injury or death.Read Operator's Manual supplied withthis machine before operation orservicing.
Modification or alteration of this machine.Can cause serious injury or death.Do not alter or modify this machinewithout the express written consent ofthe manufacturer.
&WARNINGRotating fan blade.Can cause seriousinjury.
Do not operate withoutguard in place.
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®8-itWARNING
Falling off machine.
can causa senous 'njury J»'or death.
Access lifting ball frominside machine. I
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~WARNINGDisconnected air hoses whip.
Can cause serious ~injury or death. ;~'~"
"04When using air tools .'"attach safety device @(OSHA Valve) at source ofair supply for each tool.
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&WARNINGDoor under pressure.Can cause serious injury.
Use both hands to open doorwhen machine is running.
DO NOT WELD.ELECTRONIC DAMAGEWILL OCCUR.This engine is equipped with anelectronic engine controller andother electronic components.
IIIII~WARNINGICombustible g8S.
Can cause serious bublindness or death.
IKeep sparks and openflames away from batteries.
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USE DIESELFUEL ONLY
FREE SAFETY DECALS!To promote communication of Safety Warnings onproducts manufactured by the Portable CompressorDivision in Mocksville, N.C., Safety Decals are availablefree of charge. Safety decals are identified by the decalheading: DANGER, WARNING or CAUTION.
Decal part numbers are on the bottom of each decal andare also listed in the compressor's parts manual. Submitorders for Safety Decals to the Mocksville Parts ServiceDepartment. The no charge order should contain onlySafety Decals. Help promote product safety! Assure thatdecals are present on the machines. Replace decals thatare not readable.
IIngersoll-Rand, through its distributors, warrants to the initial user that each portable air compressormanufactured by it, will be free of defects in material and workmanship for a period of the earlier of twelve(12) months from shipment to or the accumulation of 2,000 hours of service by the initial user. IPortable compressor airends will be free of defects in material and workmanship for a period of the earlierof twenty four months from shipment to or the accumulation of 4,000 hours of service by the initial user. Thewarranty against defects will include replacement of the complete airend, provided the original airend is re-turned assembled and unopened.
IPortable Compressor Airend Limited Optional Warranty - The earlier of sixty (60) months from shipment toor the accumulation of , 0,000 hours of service. The optional warranty is limited to defects in rotors, housings,bearings and gears and provided all the following conditions are met:1. The original air end is returned assembled and unopened.2. Continued use of genuine lnqersoil-Ranc parts, fluids, oil and filters.3. Maintenance is performed at prescribed intervals.Oil-Free airends are fee-based and may require a maintenance agreement. Formal enrollment is required.
III
Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part, which is found uponits inspection to be defective in material and workmanship during the period prescribed above. Such part willbe repaired or replaced without charge to the initial user during normal working hours at the place of businessof an Ingersoll-Rand distributor authorized to sell the type of equipment involved or other establishment au-thorized by Ingersoll-Rand. User must present proof of purchase at the time of exercising warranty.
II
The above warranty does not apply to failures occurring as a result of abuse; misuse, negligent repairs, corro-sion, erosion and normal wear and tear, alterations or modifications made to the product without express writ-ten consent of Ingersoll-Rand; or failure to follow the recommended operating practices and maintenanceprocedures as provided in the product's operating and maintenance publications.
II
Accessories or equipment furnished by Ingersoll- Rand, but manufactured by others, including, but not limitedto, engines, shall carry whatever warranty the manufacturers have conveyed to Ingersoll-Rand and whichcan be passed on to the initial user.
ITHIS WARRANTY IS IN LIEU OF ALLOTHERWARRANTIES EXPRESSED OR IMPLIED, (EXCEPTTHATOF TITLE), AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PAR-TICULAR PURPOSE.
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IGENERAL WARRANTY INFORMATION
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GENERAL WARRANTY Extended Coverage
Portable Compressor Package 1 year/2000 hrs
Airend 2 yrs/4000 hrs 5 yrs/10,000 hrsLimited warranty, major compo-nents (refer to operator's manual).
Complete Machine Registration IMachines shipped to locations within the United States do not require a warranty registration unless the machine status changes (i.e.
change of ownership).
IMachines shipped outside the United States require notification be made to initiate the machine warranty.
Fill out the Warranty Registration Form in this section, keep a copy for yourrecords and mail form to:
Ilnqersoll-Hand Company
P.O. Box 868Mocksville, North Carolina 27028
Attn: Warranty Department
INote: Completion of this form validates the warranty. I
1. The Purchaser has been instructed and/or has read the manual and understands proper preventativemaintenance, general operation and safety precautions.
SERVICING DISTRIBUTOR I USER ACKNOWLEDGEMENT
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2. The warranty and limitation of liability has been reviewed and understood by the owner/user.
3. In the event that this unit is to be used within a nuclear facility, the owner/user shall notifyIngersoll- Rand of such use so that Ingersoll-Rand may arrange for appropriate nuclear liabilityprotection from the owner-licensee of the facility.
4. Ingersoll- Rand reserves the right to make design changes or modifications of Ingersoll- Rand productsat anytime without incurring any obligation to make similar changes or modifications on previously soldunits.I
I This section pertains only to machines distributed within theUnited States.
I WARNING II TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof
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(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any deviceor element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use; or (2) the use of the compressor after such device or element of design has been removed or renderedinoperative by any person.
Among those acts included in the prohibition against tampering are these:
I 1. Removal or rendering inoperative any of the following:a. the engine exhaust system or parts thereofb. the air intake system or parts thereofc enclosure or parts thereof
I 2_ Removal of any of the following:a. fan shroudb vibration mountsc. sound absorption materialI 3. Operation of the compressor with any of the enclosure doors open.
ICompressor Noise Emission Control Information
IA. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control deviceor element of design Incorporated into this compressor in compliance with the noise Control act;
B_The use of this compressor after such device or element of design has been removed or rendered inoperative.
Note: the above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency.
I Ingersoll- Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligationto make such changes or add such improvements to products sold previously.
The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.
IUNIT IDENTIFICATIONENGINE MAKE & MODEL: _SERIAL NO.: _PURCHASER OR OWNER _ADDRESS _ I
DATEPURCHASED _
IThe Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured
and sold under the above regulations, specifically the following acts or the causing thereof: I(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any deviceor element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use; or (2) the use 01the compressor after such a device or element 01de:oignhas been removed or renderedinoperative by any person.
II
NOISE EMISSION WARRANTY
The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, builtand equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. EPA Noise Control Regulations. I
This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the design. assembly.or in any part. component. or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissionsto exceed Federal Standards are covered by this warranty for the IIle of the air compressor. (40FR204.58-1).
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20 I
IINTRODUCTION
I The unit for which this Maintenance Log is provided conforms to U S. EPA. Regulations for Noise Emissions, applicable to PortableAir Compressors.
I The purpose of this book is to provide (1) the Maintenance Performance Schedule below for all required noise emission controlsand (2) space so that the purchaser or owner can record what maintenance was done, by whom, where and when. Detailed instructionson the maintenance items below are given on the following page.
Correct all compressed air leaks during the first shutdownperiod after discovery If severe enough to cause serious noiseproblems and efficiency loss, shut down Immediately andcorrect the leak(s).
e. SAFETY AND CONTROL SYSTEMS
Repair or replace all safety and control systems or circuitsas malfunction occurs. No compressor should be operated witheither system bypassed, disabled, or nonfunctional.
C. ACOUSTIC MATERIALS
In dally Inspections, observe these materials. Maintain allacoustic material as nearly as possible in its original condition.Repair or replace all sections that have: 1) sustained damage,2) have partially separated from panels to which they wereattached, 3) are missing, or have otherwise deteriorated due tosevere operating or storage conditions.
D. FASTENERS
All fasteners such as hinges, nuts, bolts, clamps, screws,rivets and latches should be inspected for looseness after each100 hours of operation They should be retightened, repaired, or- if missing - replaced immediately to prevent subsequentdamage and noise emission increase.
E. ENCLOSURE PANELS
Enclosure panels should also be inspected at 100 houroperational intervals. All panels that are warped, punctured,torn, or otherwise deformed, such that their noise containmentfunction is reduced. should be repaired or replaced before thenext operation Interval Doors, access panels, and hatchclosures especially. should be checked and adjusted at this timeto insure continuous sealing between gasket or acousticmaterial and the mating frame.
IF. AIR INTAKE AND ENGINE EXHAUST
Engine and compressor air intake and engine exhaustsystems should be inspected after each 100 hours of operationfor loose, damaged, or deteriorated components. Repairs orreplacements should be made before the next period of use.
IG. COOLING SYSTEMS I
All components of the cooling systems for engine waterand compressor oil should be inspected every 250 hours of use.Any discrepancies found should be corrected before placing theunit back in operation. Unrestricted airflow over the radiator andoil cooler must be maintained at all times during operation.
IH. ISOLATION MOUNTS I
Engine/airend Isolation mounts should be inspected aftereach 250 hours of operation. Those mounts with cracks or splitsin the molded rubber, or with bent or broken bolts due tooperation or storage in severe environments, all should bereplaced with equivalent parts.
II. ENGINE OPERATION I
Inspect and maintain engine condition and operation asrecommended in the manuals supplied by the enginemanufacturer. IJ. FUELS AND LUBRICATES IUse only the types and grades of fuels and lubricantsrecommended in the Ingersoll-Rand Company and EngineManufacturers Operator and Maintenance Manuals>
Upon receipt of the unit, and prior to putting it into service, itis important to adhere strictly to the instructions given below inPRIOR TO STARTING.
Ensure that the operator reads and understands the decalsand consults the manuals before maintenance or operation.
Ensure that the position of the emergency stop device isknown and recognized by its markings. Ensure that It ISfunctioning correctly and that the method of operation is known.
Before towing the unit, ensure that the tyre pressures arecorrect (refer to the GENERAL DATA SECTION of thismanual). Before towing the unit, ensure that the lights arefunctioning correctly (where fitted).
Ensure that all transport and packing materials arediscarded.
Ensure that the correct fork lift truck slots or marked lifting /tie down points are used whenever the machine is lifted ortransported.
When selecting the working position of the machine ensurethat there is sufficient clearance for ventilation and exhaustrequirements.
Adequate clearance needs to be allowed around and abovethe machine to permit safe access for specified maintenancetasks.
Ensure that the machine is positioned securely and on astable foundation. Any risk of movement should be removed bysuitable means, especially to avoid strain on any rigid dischargepiping.
COMPRESSOR MOUNTING
Portable compressors, which are modified to remove therunning gear and mount the machine direct to trailers, truckbeds or frame, etc. may experience failure of the enclosure,frame, and/or other components. It is necessary to Isolate thecompressor package from the carrier base with a flexiblemounting system. Such a system must also preventdetachmentofthe package from the carrier base in the event theisolators fall.Contact Ingersoll- Rand representative for flexiblemounting kits.
Warranty does not cover failures attributable to mounting of thecompressor package to the carrier base unless it is anIngersoll-Rand provided system.
Attach the battery cables to the battery(s) ensuring that theyare tightened securely. Attach the positive cable beforeattaching the negative cable.
WARNING: All air pressure equipment installed in orconnected to the machine must have safe workingpressure ratings of at least the machine safety valvesetting, and materials compatible with the compressorlubricant (refer to the GENERAL DATA SECTION).
WARNING: If more than one compressor is connected toone common downstream plant, effective check valves andisolation valves must be fitted and controlled by workprocedures, so that one machine cannot accidently bepressurised lover pressurised by another.
WARNING:When flexible discharqe hoses are used, it isrl'!comml'!ndl'!d that safety retaining wires are fitted.
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IIIIII T2221
Revision 0012/00
I
2
PRIOR TO STARTING
1. Place the unit in a position that is as level as possible. Thedesign Of the unit permits a 15degree lengthways and sidewayslimit on out of leval operation.
When the unit has to be operated out of level, it is importantto keep tile engine oil level near the high level mark (with the unitlevel).
III 2. Check the engine lubrication 011 in accordance with the
operating instructions in the Engine Operator's Manual orsection.
I 3. Check the compressor oil level in the sight glass located onthe separator tank.
I 4. Check the diesel fuel level. A good rule is to top up at the endof each working day. This prevents condensation fromoccurring in the tank Refer to the engine operator'smanual/section for diesel fuel specification.I
I CAUTION: When refuelling:-switch off the engine.do not smoke.extinguish ai' naked lights.do not allow the fuel to come into contact with hot surfaces.wear personaf protective equipment.I
II
5. Drain the fuel filter water separator of water, ensuring thatany released fuel is safely contained.
6. Open the service valve(s) to ensure that all pressure isrelieved from the system. Close the service valve(s).
7. CAUTION: 00 not operate the machine with thecanopy/doors in the open position as this may causeoverheating and operators to be exposed to high noise levels.
8. Check the radiator coolant level (with the unit level).
Check the air filter restriction indicator(s). Refer to theMAINTENANCE section of trus manual.
When starting or operating the machine in temperaturesbelow or approaching DOC(32DF), ensure that the operation ofthe regulation system, the unloader valve, the safety valve, andthe engine are not impaired by ice or snow, and that all inlet andoutlet pipes and ducts are clear of Ice and snow.
All normal starting functions are incorporated in the keyoperated switch.
Turn the key switch to position I. The diagnostic lamps willflash.
Turn the key switch to crank position (3) (engine startposition)
NOTE: Position (2) not used on this model. Pre-heaters orglow plugs are not fitted on this rncoel.
In cold weather, push Ether Injection Switch once or twiceduring cranking. This injects a measured amount of ether to theengine .•
CAUTION: ETHER is an extremely volatile, highly flammablegas. Use sparingly I If too much is injected, the uncontrolledexplosion may result in costly damage to the engine.
Release to position (1) when engine starts. The engine willnow be running at a reduced speed.
At temperatures below 32"F (O°C) or if there is difficultystarting first time:
Open the manual blowdown valve fully
Complete starting sequence above.
Close manual blowdown valve as soon as engine runsfreely.
Do not allow machine to run for long periods with manualblowdown valve open.
Allow the engine to reach operating temperature
At this point in the operation of the machine it is safe to applyfull load to the engine.
NOTE: Wear hearing protection at all times when the engine IS
started with the manual blowdown valve open and air is flowingfrom the valve.
PUSH AFTER WARM UP INOTE: In order to allow the machine to start at a reduced load,a valve, which is operated by a button located on the instrumentpanel, is incorporated in the regulation system. (The valveautomatically returns to the start position when the machine isswitched off and air pressure relieved from the system).
II
Allow the engine to reach its operating temperature - thenpress the button. I
At this point in the operation of the machine it is safe to applyfull load to the engine. IDUAL PRESSURE REGULATION WHEN FITTED IMachines which operate in excess of 7 bar (100 psi) canoptionally be fitted with a dual pressure switch inside the unit.This switch selects between 7 bar (100 psi) and the machinerated pressure, ctm remains nominally constant.
Starting and stopping are unaffected by the selection and duringnormal running the selector switch may be safely operatedPrecaution must be taken to ensure that downstreamequipment is rated to suit the available pressure.
II
The pressure gauge indicates which setting has been selected. ISTOPPING THE MACHINE
IClose the service valve.
Allow the machine to run unloaded for a short period of timeto reduce the engine temperature. I
Turn the start switch to the 0 (off) position.
IINOTE: As soon as the engine stops, the automatic blowdown
valve will relieve pressure from the system.
If the automatic biowdown valve fails to operate, thenpressure must be relieved from the system by means of themanual blowdown valve(s),
IIICA UTlON: Never allow the machme to stand idle with pressure
in the system.
IEMERGENCY STOPPING
In the event that the unit has to be stopped in an emergency,TURN THE KEY SWITCH LOCATED ON THE INSTRUMENTPANEL TO THE O(OFF) POSITION, Or puSh theEMERGENCY STOP SWITCH (when fined).
II
IRE-STARTING AFTER AN EMERGENCY
I If the machine has been switched off because of a machinemalfunction, then identify and correct the fault before attemptingto re-start.
I If the machine has been switched off for reasons of safety,then ensure that the machine can be operated safely beforere-starting.
I Refer to the PRIOR TO STARTING and STARTING THEMACHINE instructions earlier in this section before ra-startrnqthe machine.IMONITORING DURING OPERATION
I Should any of the safety shut-down conditions occur, the unitwill stop.
I Refer to the diagnostic display page for a listing of shutdownconditions.
I CAUTiON: Toensure an adequate flow of oil to the compressorat low temperature, never allow the discharge pressure to fallbelow 3,5 bar (50 psi)
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DECOMMISSIONING
When the machine is to be permanently decommissioned ordismantled, it is important to ensure that all hazard risks areeither eliminated or notified to the recipient of the machine. Inparticular:-
Do not destroy batteries or components containing asbestoswithout containing the materials safely.
Do not dispose of any pressure vessel that is not clearlymarked with its relevant data plate information or renderedunusable by drilling, cutting etc.
Do not allow lubricants or coolants to be released into landsurfaces or drains.
Do not dispose of a complete machine withoutdocumentation relating to instructions for Its use.
c Operation and Maintenance ManualIndustrial C8.3 Series Engine
Portions of this manual reproduced by permission of Cummins Engine Company, Inc.
Copyrightltl 2002Cummins Inc.All rights reserved
Bulletin 4021330Printed 02102
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ForewordThis manual contains information for the correct operation and maintenance of your Cummins engine. It also includesimportant safety information, engine and systems specifications, troubleshooting guidelines, and listings of CumminsAuthorized Repair Locations and component manufacturers.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i- Introduction.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on informationin effect at the time of printing. Cummins Inc. reserves the right to make changes at any time without obligation. If youfind differences between your engine and the information in this manual, contact your local Cummins Authorized RepairLocation or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components were used to produce this engine. When replacement partsare needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be identifiedby the following trademarks:
NOTE: Note: Warranty information is located in Section W. Make sure you are familiar with the warranty or warrantiesapplicable to your engine.
(om-Irwd)
Table of ContentsSection
Introduction .
Engine Identification .'" .
Operating Instructions 1
Maintenance Guidelines .
Maintenance Procedures at Daily Interval .
Maintenance Procedures at 10,000 Kilometers [6000 Miles], 250 Hours, or 3 Months .
Maintenance Procedures at 19,000 Kilometers [12,000 Miles], 500 Hours, or 6 Months .
Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1000 Hours, or 12 Months .
Maintenance Procedures at 77,000 Kilometers [48,000 Miles], 2000 Hours, or 2 Years .
Adjustment, Repair, and Replacement A
System Diagrams .
Service Literature . L
Component Manufacturers .
Service Assistance .
Troubleshooting Symptoms
Mai ntenance Specifications
Warranty W
Index .
E
2
3
4
5
6
7
o
M
S
TS
V
x
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I Engine Serial Number (ESN)
Control Parts List (CPL)
III
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Important Reference NumbersFill in the part name and number in the blank spaces provided below. This will give you a reference whenever serviceor maintenance is required.
Maintenance Guidelines - Overview... 2-1General Information 2-1
Tool Requirements.. 2-1General Information 2-1
Maintenance Schedule 2-1General Information 2-1
Maximum Oil Drain Intervals .. 2-2
Maintenance Record Form. 2-3Maintenance Data 2-3
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CB.3 IndustrialSection i-Introduction
To the Owner and OperatorPage i-1
To the Owner and OperatorGeneral InformationPreventive maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedulerecommendations outlined in Maintenance Guidelines (Section 2).
Keep records of regularly scheduled maintenance.
Use the correct fuel, lubricating oil, and coolant in your engine as specified in Maintenance Specifications (SectionV).
Cummins Inc. uses the latest technology and the highest quality components to produce its engines. Cummins Inc.recommends using genuine Cummins new parts and ReCon® exchange parts.
Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support.If you have a problem that can not be resolved by a Cummins Authorized Repair Location, follow the steps outlinedin the Service Assistance (Section S).
Product coverage, warranty limitations and owner responsibilities are available in Warranty (Section W).
A CAUTION ADisconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle.Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connectthe ground cable of the welder to the ECMcooling plate or ECM. Welding on the engine or engine mountedcomponents is not recommended.
About the ManualGeneral InformationThis manual contains information needed to correctly operate and maintain your engine as recommended by CumminsInc. For additional service literature and ordering locations, refer to Service Literature (Section L).
This manual does not cover vehicle, vessel, or equipment maintenance procedures. Consult the original vehicle, vessel,or equipment manufacturer for specific maintenance recommendations.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S.customary in brackets.
Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to Symbols in thissection for a complete listing of symbols and their definitions.
Each section of the manual is preceded by a Section Contents to aid in locating information.
How to Use the ManualGeneral InformationThis manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenanceschedule, that states the required intervals and maintenance checks, is located in Maintenance Guidelines (Section2). Locate the interval at which you are performing maintenance; then follow the steps given in that section for all theprocedures to be performed.
Keep a record of all the checks and inspections made. A maintenance record form is located in Maintenance Guidelines(Section 2).
Engine troubleshooting procedures for your engine are located in Troubleshooting Symptoms (Section TS).
Specifications for your engine are located in Maintenance Specifications (Section V).
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I SymbolsPage i-2
IGeneral Information
Symbols
I
C8.3 IndustrialSection i-Introduction
The following symbols have been used in this manual to help communicate the intent of the instructions. When oneof the symbols appears, it conveys the meaning defined below:
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WARNING - Serious personal injury or extensiveproperty damage can result if the warninginstructions are not followed.
CAUTION - Minor personal injury can result or apart, an assembly, or the engine can be damagedif the caution instructions are not followed.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly
Indicates that a WRENCH or TOOL SIZE will begiven.
TIGHTEN to a specific torque.
&. PERFORM an electrical MEASUREMENT.
~ Refer to another location in this manual or another~ publication for additional information
The component weighs 23 kg [50 lbs] or more. Toreduce the possibility of personal injury, use a hoistor get assistance to 11ft the component. 17800009
CB.3 IndustrialSection i-Introduction
IllustrationsGeneral InformationSome of the illustrations throughout this manual are ge-neric and will not look exactly like the engine or parts usedin your application. The illustrations can contain symbolsto indicate an action required and an acceptable or notacceptable condition.
The illustrations are intended to show repair or replace-ment procedures. The procedure will be the same for allapplications, although the illustration can differ.
IllustrationsPage i-3
ce Sve C
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General Safety InstructionsPage i-4
C8.3 IndustrialSection i-Introduction
General Safety InstructionsImportant Safety Notice
A WARNING AImproper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation orother personal injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains thegeneral safety precautions that must be followed to provide personal safety. Special safety precautions are includedin the procedures when they apply.
• Work in an area surrounding the product that is dry. wen ut, ventilated. free from clutter. loose tools, parts, ignitionsources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.• Rotating parts can cause cuts, mutilation or strangulation.• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tagin the operator's compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate thecrankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the fillercap to relieve the pressure from the cooling system.
• Always use blocks or proper stands to support the product before performing any service work. Do not workon anything that is supported ONLY by lifting jacks or a hoist.
• Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removedor disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizespressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquidrefrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems mustbe properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) intothe atmosphere. Federal law requires capturing and recycling refrigerant.
• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh23 kg [50 Ib] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition andareof the correct capacity. Make sure hooks arepositioned correctly. Always use aspreader bar when necessary.The lifting hooks must not be side-loaded.
• Corrosion inhibitor, a component of SeA and lubricating oil, contains alkali. Do not get the substance in eyes.Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately washskin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimumof 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow themanufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OFCHILDREN.
• Toreduce the possibility of burns, be alert for hot parts on products that have just been turned off, and hot fluidsin lines, tubes, and compartments.
• Always use tools that are in good condition. Make sure you understand how to use the tools before performingany service work. Use ONLY genuine Cummins or Cummins ReCone") replacement parts.
• Always use the same fastener part number (or equtvalent) when replacing fasteners. Do not use a fastener oflesser quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.• Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinoqenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contactwith used engine oil.
• Liquified petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas.• Natural gas is lighter than air and can accumulate under hood and awnings.• Toreduce the possibility of suffocation and frostbite, wear protective Clothing and ONLYdisconnect natural gas
and liquified petroleum gas tines in a well ventilated area.• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.
CB.3 IndustrialSection i-Introduction
General Repair InstructionsPage i-5
General Repair InstructionsGeneral InformationThis engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired usingnormal repair practices performed to quality standards.
• Cummins Inc. does not recommend or authorize any modifications or repairs to engines or componentsexcept for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related components can cause perscnal injury or death. Below is apartial listing of components classifiedas safety-related:Air CompressorAir ControlsAir Shutoff AssembliesBalance WeightsCooling FanFan Hub AssemblyFan Mounting Bracket(s)Fan Mounting CapscrewsFan Hub SpindleFlywheelFlywheel Crankshaft Adapter
• Follow all safety instructions noted in the procedures
Follow the manufacturer's recommendations for cleaning solventsand other substances used during therepair of the engine. Some solvents and used engine oil havebeen identified by government agencies astoxic or carcinogenic. Avoid excessive breathing, ingestion andcontact with such substances. Always usegood safety practices with tools and equipment.
• Provide a clean environment and follow the cleaning instructions specified in the procedures
- The engine and its components must be kept clean during any repair. Contamination of the engine orcomponents wilt cause premature wear. .
• Perform the inspections specified in the procedures
• Replace all components or assemblies which are damaged or worn beyond the specifications
• Use genuine Cummins new or ReConCi<Jservice parts and assemblies
The assembly instructions have beenwritten to useagain asmanycomponentsand assemblies as possible.When it is necessary to replace a component or assembly, the procedure is based on the use of newCummins or Cummins ReConl!<)components. All of the repair servicesdescribed in this manual areavailablefrom all Cummins Distributors and most Dealer locations.
• Follow the specified disassembly and assembly procedures to reduce the possibility of damage to thecomponents
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a CumminsAuthorized Repair Location. Refer to Section L - Service Literature for ordering instructions.
Welding on a Vehicle with an Electronic Controlled Fuel System
A CAUTION ADisconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle.Attach the welder ground cable no more than 0.61 meters [2 feet1 from the part being welded. Do not connectthe ground cable of the welder to the ECMcooling plate or EcM. Welding on the engine or engine mountedcomponents is not recommended or damage to the engine or components can reSUlt.
General Cleaning InstructionsSolvent and Acid CleaningSeveral solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the bestresults can beobtained using a cleaner that canbe heated to 90 to 95 degreesCelsius [180 to 200 degrees Fahrenheit].A cleaning tank that provides a constant mixing and filtering of the cleaningsolutionwill give the best results.Cummins
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General Cleaning InstructionsPage i-G
C8.3 IndustrialSection i-Introduction
Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Removeall the gasket material, o-nnqs, and the deposits of sludge, carbon, etc., with a wire brush or scraper beforeputting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean theparts before putting them in the cleaning tank.
A WARNING AAcid is extremely dangerous and can cause personal injury and damage the machinery. Always provide a tankof strong soda water as a neutralizing agent. Wear goggles and protective clothing to reduce the possibility ofserious personal injury.
Rinse all of the parts in hotwater after cleaning. Dry completely with compressed air. Blowthe rinse water from all ofthe capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. Therustproofing compound must be removed from the parts before installation on the engine.
Steam CleaningSteam cleaning can be usedto removeall types of dirt that can contaminate the cleaning tank. It is a good way to cleanthe oil drillings.
A WARNING AWhen using a steam cleaner.weer safety glasses or a face shield, as well as protective clothing. Hot steam cancause serious personal injury.
Do not steam clean the following parts:1. Electrical Components2. Wiring3. Injectors4. Fuel Pump
5. Belts and Hoses6. Bearings7. Electronic Control Module (ECM)8. ECM Connectors
Glass or Plastic Bead CleaningGlass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaningprocess is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time.
A CAUTION ADo not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead cleaning onaluminum ring grooves. Small particles of glass or plastic will embed in the aluminum and result in prematurewear. Valves, turbocharger shafts, etc., can also be damaged. Follow the cleaning directions listed in theprocedures.
NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum ring grooves. Do not use anybead blasting media on pin bores or aluminum skirts.
Follow the equipment manufacturer's cleaning instructions. The following guidelines can be used to adapt to manu-facturer's instructions:
1. Bead size:a. Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No. 3822735.b. Use U.S. size No. 70 for piston domes with glass media.c. Use U.S. size No. 60 for general purpose cleaning with glass media.
2. Operating Pressure:a. Glass: Use 620 kPa [90 psi} for general purpose cleaning.b. Plastic: Use 270 kPa [40 psi} for piston cleaning.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads aftercleaning. Rinse with hot water. Dry with compressed air.
4. Do not contaminate the wash tanks with glass or plastic beads.
C8.3 IndustrialSeetion i-Introduction
Acronyms and AbbreviationsPage i-7 I
Acronyms and Abbreviations IGeneral InformationThe following list contains some of the acronyms and abbreviations used in this manual.
American Petroleum InstituteAmerican Society of Testing and MaterialsCelsiusCalifornia Air Resources BoardCubic Inch DisplacementCompressed Natural GasControl Parts ListCentistokesElectronic Control ModuleExhaust Gas RecirculationEnvironmental Protection AgencyFahrenheitFailure Mode IndentifierGross Vehicle Weightliquified Petroleum GasMercuryHorsepowerWaterIgnition Control ModuleKilometers per LiterKilopascalliquid Natural GasLow Temperature AftercoolingMegapascalMiles Per HourMiles Per QuartNewton-meterNatural GasOriginal Equipment ManufacturerParameter Identification DescriptionsParts Per MillionPounds Per Square InchPower TakeoffRevolutions Per MinuteSociety of Automotive EngineersSupplemental Coolant AdditiveStep Timing ControlSubsystem Identification DescriptionsVariable SpeedVehicle Speed Sensor
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CB.3 IndustrialSection E - Engine and System Identification Page E-a
Section E - Engine and System IdentificationSection Contents
The engine dataplates show specific information about your engine. The engine serial number and control parts list(CPL) provide information for ordering parts and service manuals.
NOTE: The engine dataplate must not be changed unless approved by Cummins Inc.
The dataplate is located on the top side of the gear housing. Have the following engine data available when com-municating with a Cummins Authorized Repair Location. The information on the dataplate is mandatory when sourcingservice parts.1. Control parts list (CPL) 4. Emissions certification
2. Model 5. Horsepower and rpm rating.
3. Engine serial number
4 1 2 3
\ \ \ \/"
C Cummins Engine Company, Inc -, fCh ~ne Ser1a1\o. fEl EP;"CIDIL.Columbus, indiana
\ cJ\47202·3005 Family No.Assembled In U.S.A ,
Engn~ModoI------------------------------------------- Pmo Warnings: Inlury can result and warranty is voided Valve lash linch 1nI. Ext1 Timing· c--lII rual rata rpm or alutudas axooed publishedmaximum values lor this modal and application. Cold I !.1M Inl Ext1 Full! rate 31ratlKl HPlKw mm3Jst
------------------------------------------- Firing Order 153624 FR ILow Idle RPM
Date 01MFG. 20010501 Gross Rated HP~ at RPM"- Assembled In U.S.A. 3284906
\5
00l00075
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II
Engine IdentificationPage E-2
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CB.3 IndustrialSection E - Engine and System Identification
The following example shows a model name of an enginefor industrial applications:
Example: 6CTAA8.3
8.3 = displacement in liters
AA = charge air aftercooled
T = turbocharged
C = engine series
6 = number of cylinders
Fuel Injection Pump DataplateThe Bosch" fuel injection pump dataplate is located on theside of the injection pump. It provides information for fuelpump calibration.
The Cummins part number for the fuel pump-governorcombination is located on the governor dataplate.
CB.3 IndustrialSection E - Engine and System Identification
Engine DiagramsPage E-3 I
Engine Diagrams IEngine ViewsThe following drawings illustrate the major components. You must be familiar with each component to conduct themaintenance and service procedures discussed in this manual.
NOTE: The drawings in this section reflect a standard configuration. Your engine will possibly be equipped with optionalaccessories such as port- or starboard-side dipsticks. Location of optional items can be different from those shown.
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00900322 IFuel Pump Side View
1. Engine air inlet 10. Lubricating oil dipstick
2. Shutoff solenoid 11. Front engine mounting bracket
3. M22 x 1.5 (air) 12. Engine dataplate
4. Rear lifting bracket 13. Fuel injection pump
5. Fuel filter 14. Delivery valve
6. Fuel/water separator 15. Fuel drain line
7. Fuel transfer pump 16. High-pressure fuel lines
B. 3/4 x 16-inch UNF tap for magnetic pickup 17. 1/2-inch NPTF (air)
9. lubricating oil pan drain plug 1B. Intake air heater.
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I Engine DiagramsPage E·4
CB.3 IndustrialSection E - Engine and System Identification
I
I5
1
I
I 2
II 3
I 00900321
Rear View
I 1. Turbocharger exhaust outlet
2. Flexplate mounting holes
3. Flywheel housing
4. Flywheel
5. Crankcase breather tube
6. Rear engine lifting bracket.IIIIIIIIII
CB.3 IndustrialSection E - Engine and System Identification
Engine DiagramsPage E-5 I
I
12
34
567
III
11 8 II
9 00900323 IExhaust Side View
1. Front engine lifting bracket
2. Water/coolant outlet connection
3. Lubricating oil pressure (atter filter)
4. Lubricating oil pressure (betore tilter)
5. Coolant heater port
6. Lubricating oil cooler
7. Water/coolant inlet
8. Lubricating oil filter
9. Lubricating oil pan drain plug
10. Turbocharger oil drain
11. Coolant tilter
12. Starting motor
13. Rear engine litting bracket
14. Turbocharger exhaust outlet
15. Turbocharger wastegate actuator
16. Turbocharger air outlet
17. Engine oil till.
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II
Engine DiagramsPage E-6
CB.3 IndustrialSection E - Engine and System Identification
12 13 1
I
II
III
7 '------=~:.-_-- 600900320
Front View
I
I
1. Engine air inlet
2. Fan pulley
3. Fuel pump drive cover
4. Front gear cover
5. Drive belt
6. Lubricating oil pan drain plug
7. Vibration damper
8. Fan belt tensioner
9. Water pump
10. Alternator
11. Turbocharger air outlet
12. Turbocharger air inlet
13. Engine oil fill.
I
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CB.3 IndustrialSection E - Engine and System Identification
Engine Operating Range .. 1-8General Information 1-8
Engine Shutdown........... 1-8General Information 1-8
Normal Starting Procedure...... 1-2General Information 1-2Jump Starting 1-4
Operating Instructions - Overview. 1-1General Information 1-1
Operating the Engine 1-5Ambient Temperature 1-7
o to -32°C [32 to -25°F] 1-7-32 to -54°C [-25 to -65°F] 1-7
Cold Weather 1-7Normal 1-5
Starting Procedure After Extended Shutdown or Oil Change 1-5General Information 1-5
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CB.3 IndustrialSection 1 - Operating Instructions
Operating Instructions - OverviewGeneral InformationCorrect care of your engine will result in longer life, betterperformance, and more economical operation.
Follow the daily maintenance checks listed in MaintenanceGuidelines (Section 2).
The new Cummins engine associated with this manualdoes not require a "break-in" procedure. This section of themanual provides all of the necessary information requiredfor proper engine operation.
Check the oil pressure indicators. temperature indicators, ~ __warning lights, and other gauges daily to make sure they ~~are operational.
.A WARNING .ADO NOT OPERATE A DIESEL ENGINE WHERE THEREARE OR CAN BE COMBUSTIBLE VAPORS. The vaporscan be sucked through the air intake system and causeengine acceleration and overspeeding that can result ina fire, an explosion, and extensive property damage.Numerous safety devices are available, such as air in-take shutoff devices, to minimize the risk of overspeed-ing where an engine, due to its application, due to a fuelspill or gas leak. Remember, Cummins has no way ofknowing the use you have for your engine. THE EQUIP-MENT OWNER AND OPERATOR ARE RESPONSIBLEFOR SAFE OPERATION IN A HOSTILE ENVIRONMENT.CONSULT YOUR CUMMINS AUTHORIZED REPAIR LO-CATION FOR FURTHER INFORMATION.
Cummins recommends the installation of an air intakeshutoff device or a similar safety device to minimize the riskof overspeeding where an engine, due to the vehicle, vesselor equipment being operated in a combustible environ-ment, such as due to a tuel spill or gas leak.
Operating Instructions - OverviewPage 1-1 I
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I
III, I '
~--
// I -.I "Il8g"',
-, I /il--/ I -., i
, I '~-~--/ I -., i
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Normal Starting ProcedurePage 1-2
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oq8gask
III
CB.3 IndustrialSection 1 - Operating Instructions
A CAUTION J::,.Do not expose the engine to cerroeive chemicals. Cor·rosive chemicals can damage the engine.
Normal Starting ProcedureGeneral Information
.A WARNING .ADo not depress the accelerator pedal or move the ac-celerator lever from the idle position while cranking theengine. This can result in engine overspeed and severedamage to the engine.
A CAUTION ATo prevent damage to the starting motor, do not engagethe starting motor for more than 30 seconds. Wait 2minutes between each attempt to start (electrical start-ing motors only).
NOTE: Engines equipped with air starting motors requirea minimum of 480 kPa [70 PSI].
• Disengage the driven unit, or if equipped, put thetransmission in neutral.
• With the accelerator pedal or lever in the idle posi-tion, turn the key switch to the ON position, and waitfor the WAIT-TO-START lamp to go out; then, turnthe key to the START position.
• If the engine does not start after three attempts,check the fuel supply system. Absence of blue orwhite exhaust smoke during cranking indicates nofuel is being delivered.
@ A. CAUTION ll.The engine must have adequate oil pressure within 15seconds after starting. If the WARNING lamp indicatinglow oil pressure has not gone out or there is no oilpressure indicated on a gauge within 15 seconds, shutoff the engine immediately to avoid engine damage.The low oil pressure troubleshooting procedure is lo-cated in Troubleshooting Symptoms (Section TS).
tri I ctionsca.3 Ind~s ~~e ratinq lnstru . with a load. (5)',Section • b tore operatinq \[)
. 3 to 5 minutes eIdle the engine
. speedengine. increase the h bearings. a cold engine, te lubrication to t eAfter start:n~o provide adequa:
ostabilize.
(rpm) slow y he oil pressureand to allow t
A CAUTION I:l.. eriods wit~Llo. "die for lon~ ~ m speer-Oneat low I the mlnlr!1u V) ThisDo not ope~:~~~en~~era~ur:C?f~~~~ons (Section "engine ':00 aintenance" p "
fication In ~ the following" . oilcan result In . n of the lubricating
• Fuel Dilutio . the cylindern build up In .
• Carbo I e stickingI· der head va v• Cy In
rformance• Reduced pe
Normal Startmg Page 1-3 I" Procedure
I
III
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II Normal Starting Procedure
Page 14
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sbgcoqb
SeriesConnectionI
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CB.3 IndustrialSection 1 - Operating Instructions
Jump Starting
A WARNING ABatteries can emit explosive gases. To avoid personalinjury, always ventilate the compartment before servic-ing the batteries. To avoid arcing, remove the negative(-) battery cable first and attach the negative (-) batterycable last.
A CAUTION AWhen using jumper cables to start the engine, makesure to connect the cables in parallel: Positive (+) topositive (+) and negative (-) to negative (-). When usingan external electrical source to start the engine, turnthe disconnect switch to the OFF position. Remove thekey before attaching the jumper cables.
A CAUTION ATo avoid damage to engine parts, do not connect jumperstarting or battery charging cable to any fuel system orelectronic component.
The accompanying illustration shows a typical parallel bat-tery connection. This arrangement doubles the crankingamperage.
This illustration shows a typical series battery connection.This arrangement, positive (+ ) to negative (-), doubles thevoltage.
CB.3 IndustrialSection 1 - Operating Instructions
Cold Weather StartingGeneral InformationFollow the Normal Starting Procedures in this section. Incold weather, the Wait-To-Start lamp will stay on longer.
Using Starting Aids
• WARNING ADo not use starting fluids with this engine. This engineis equipped with an intake air heater; use of startingfluid can cause an explosion, fire, personal injury, se-vere damage to the engine and property damage.
Cold weather starting aids are available for your engine.Contact the local Cummins Authorized Repair Location formore information.
Starting Procedure After ExtendedShutdown or Oil ChangeGeneral InformationFollow the Normal Starting Procedure in this section. Theengine will not start until the minimum cranking oil pressureis detected by the ECM. It can take more cranking time tostart the engine after an extended shut down or oil change.
Operating the EngineNormalIf equipped, monitor the oil pressure and coolant tempera-ture gauges frequently. Refer to Lubricating Oil Systemspecifications and Cooling System specifications, in Main-tenance SpeCifications (Section V) for recommended op-erating pressures and temperatures. Shut off the engine ifany pressure or temperature does not meet the specifica-tions.
Continuous operation with engine coolant temperatureabove or below the engine coolant temperature specifica-tions listed in Maintenance Specifications (Section V) candamage the engine.
COld Weather StartingPage 1-5 I
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C8.3 IndustrialSection 1 - Operating Instructions
If an overheating condition starts to occur, reduce the poweroutput of the engine by releasing the accelerator pedal orlever or shifting the transmission to a lower gear, or both,until the temperature returns to the normal operating range.If the engine temperature does not return to normal, shutoff the engine, and refer to Troubleshooting Symptoms(Section TS), or contact a Cummins Authorized RepairLocation.
Most failures give an early warning. Look and listen forchanges in performance, sound, or engine appearancethat can indicate service or engine repair is needed. Somechanges to look for are:
• Engine misfires
• Vibration
• Unusual engine noises
• Sudden changes in engine operating temperaturesor pressures
• Excessive smoke
• Loss of power
• An increase in oil consumption
• An increase in fuel consumption
• Fuel, oil, or coolant leaks.
C8.3 IndustrialSection 1 - Operating Instructions
Cold Weather
Operating the EnginePage 1-7
It is possible to operate diesel engines in extremely cold environments if they are properly prepared and maintained.Satisfactory performance of a diesel engine in low ambient temperature conditions requires modification Ofthe engine,surrounding equipment, operating practices and maintenance procedures.
The correct engine coolant lubricating oil and fuels must be used for the cold weather range in which the engine isbeing operated. Below are the recommendations for these critical engine fluids:
Ambient Temperaturea to -32°C [32 to -25°FlUse 50-percent ethylene glycol antifreeze and 50-percent water for the engine coolant mixture.
Refer to Maintenance Specifica.tions (Section V) Lubricating Oil recommendations for the correct specifications.
The Diesel fuel must have maximum cloud and pour points 6°C [100F] lower than the ambient temperature in whichthe engine operates.
-32 to -54°C [-25 to .65°F]Use 60-percent ethylene glycol antifreeze and 40-percent water tor the engine coolant mixture.
Refer to Maintenance Specifications (Section V) Lubricating Oil recommendations for the correct specifications.
The Diesel fuel must have maximum cloud and pour points 6°C [10°F) lower than the ambient temperature in whichthe engine operates.
The following cold weather operating aids are required for cold weather situations:
Cold Weather Operating Aids
TemperatureUrkle-r-
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C8.3 IndustrialSection 1 - Operating Instructions
Wintertronts and shutters can be used on a vehicle orequipment to reduce air flow through the radiator core intothe engine compartment. This can reduce the time re-quired to warm the engine and help maintain the enginecoolant temperature. The engine coolant temperature speci-fications are in the Maintenance Specification (Section V).
Engine Operating RangeGeneral Information
1l.. CAUTION ll..Do not operate the engine at full throttle operationbelow peak torque rpm (refer to engine dataplate forpeak torque rpm) for more than 30 seconds. Operatingthe engine at full throttle below peak torque will shortenengine life to overhaul, can cause serious engine dam-age, and is considered engine abuse.
Cummins engines are designed to operate successfully atfull throttle under transient conditions down to peak torqueengine speed. This is consistent with recommended op-erating practices.
1l.. CAUTION 1l..Donot operate the engine beyond the maximum enginespeed. Operating the engine beyond the maximum en-gine speed can cause severe engine damage. Useproper operating techniques for the vehicle, vessel, orequipment to prevent engine overspeed. The maximumengine speed specification is listed in MaintenanceSpecifications (Section V).
Engine ShutdownGeneral InformationAllow the engine to idle 3 to 5 minutes before shutting it offafter a full-load operation. This allows adequate cooldownof pistons. cylinders, bearings, and turbocharger compo-nents.
Turn the ignition keyswilch to the OFF position. If the en-gine does not shut down. refer to TroubleshootingSymp-tom (Section TS).
CB.3 IndustrialSection 2 - Maintenance Guidelines Page 2-a
Tool Requirements.............................................................................. 2-1General Information 2-1
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CB.3 IndustrialSection 2 - Maintenance Guidelines
Maintenance Guidelines - OverviewPage 2-1
Maintenance Guidelines ..OverviewGeneral InformationCummins Inc. recommends that the engine be maintained according to the Maintenance Schedule in this section.
If the engine is operating in ambient temperatures below -18DC [O°Fl or above 38°C [100°F], perform maintenanceat shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a dusty environmentor if frequent stops are made. Contact your local Cummins Authorized Repair Location for recommended maintenanceintervals.
Some of these maintenance procedures require special tools or must be completed by qualified personnel. Contactyour local Cummins Authorized Repair Location for detailed information.
If your engine is equipped with a component or accessory not manufactured by Cummins Inc., refer to the componentmanufacturer's maintenance recommendations.
Use the chart provided in this section as a convenient way to record maintenance performed.
Tool RequirementsGeneral InformationThe maintenance schedules must be used for routine and periodic maintenance. Perform each function at the indicatedtime interval. The intervals stated are for normal operating conditions. Service the unit more frequently under severeconditions. Neglecting maintenance can result in failures or permanent damage to the engine. If the engine is operatingin ambient temperatures consistently below ·1B"C [OaF] or above 38°C [100°FJ, perform maintenance at shorterintervals.
Sockets1/2-lnch Drive 3/8-lneh Drive
Wrenches Other Tools
19 mm17 mm15 mm
14 mm13 mm10 mm8 mm
7/16 deep socket3/8 inch5/16 inch
28 mm19 mm18 mm17 mm15 mm14 mm13 mm10 mm8 mm
7/8 inch11/16 inch9/16 inch1/2 inch7/16 inch3/8 inch1/4 inch
Maintenance Schedule
Ratchets, 1/2- and 3/B-inch driveSocket extensions, 1/2- and 3/8-inch long and shortSocket universal joint, 3/8-inch driveAdapter, 1/2-inch female-to-3!8-inch male socket
_Torque wrench, 1/2-inch drive, 100 ft-Ib capacityBreaker bar, 1/2-inch drivePlastic hammer5/16-inch allen hex keySpray can of silicone lubricantFlat blade screwdriverBrass rod, 4.76-mm (3/16-in) diameterDCA4 test kit, Fleetquardv Part Number CC-2602JEngine barring gear, Part Number 3377371Filter wrenches (75- to 80-, 90- to 95-, and 118- to 131-mm)
General InformationFor your convenience. listed below are the section numbers that contain specific instructions for performing themaintenance checks listed in the maintenance schedule.
Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all previousChecks that are due for scheduled maintenance.
Every 10,000 km [6000 mil, 250 Hours, or 3 Months - Maintenance Check" 4 ...•..............•...........•... Section 4• Air Compressor Mounting Hardware - Check/Correct• Air Cleaner Restriction· Check/Correct• Charge Air Cooler - Check/Correct• Charge Air Piping - Check/Correct• Lubricating Oil and Filters· Change
Every 19,000 km [12,000 mil, 500 Hours, or 6 Months - Maintenance Check2, 3,4 Section 5• Coolant Filters - Replace• Supplemental Coolant Additives (SCA) and Antifreeze - Check• Fuel Filter (Spin-On Type) - Replace
Every 38,000 km [24,000 mil, 1000 Hours, or 12 Months - Maintenance Check" Section 6• Fan Belt Tensioner - Check/Correct• Overhead Set - Adjust
Every 77,000 km [48,000 mil, 2000 Hours, or 2 Years - Maintenance Check2, 3, 4 Section 7• Air Compressor Discharge Lines _Check/Correct• Cooling System - Drain, Flush, and Fill• Vibration Damper, Rubber - Check
Notes:
1. The lubricating oil and lubricating oil filter interval can be adjusted based on fuel consumption, gross vehicle weight,and idle time. Refer to Oil Drain Intervals in this section.
2. Test the SCA concentration level every 6 months unless concentration is over three units; then check at every oildrain interval until concentration is below three units.
3. Antifreeze check interval is every oil change or 19,000 km [12,000 mil. 500 hours or 6 months, whichever occursfirst. The operator must use a heavy-duty year-round antifreeze that meets the chemical composition of GM603BM.The antifreeze change interval is 2 years or 77,000 km [48,000 mil. whichever occurs first. Antifreeze is essentialtor freeze, overheat, and corrosion protection.
4. Follow the manufacturer's recommended maintenance procedures for the starter, alternator, generator, batteries,electrical components, engine brakes, exhaust brake, charge air cooler, air compressor, air conditioner compressor,and fan clutch, Refer to Section M for addresses and telephone numbers.
Maximum Oil Drain Intervals
Refer to the following flowchart to determine the maximum recommended oil change and filter change intervals inkilometers, miles, hours, or months, whichever comes first.
Is the vehicle one of those listed below?
• Truck crane/yard spotter
• Paver/crane/backhoe
• DozerJscrape/skipper
If Yes-
Select the correct oil drain interval trorn Table 1.
If No-I Is the vehicle one of those listed below?
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Maintenance SchedulePage 2-2
C8.3 IndustrialSection 2 - Maintenance Guidelines
• Tractor/combine/irrigation equipment
• Genset/air compressor/rue equipment
If Yes -
Select the correct oil drain interval from Table 2.If No-
Select the correct oil drain interval from Table 3.
Key to table headings: A ... DateB =: km [Miles], Hours or Time IntervalC =: Actual km [Miles] or HoursD => Maintenance Check PerformedE => Check Performed ByF '" Comments
A B C D E F
(Continued)
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CB.3 IndustrialSection 3 • Maintenance Procedures at Daily Interval Page 3-a I
ISection 3 - Maintenance Procedures at Daily IntervalSection Contents
CB.3 IndustrialSection 3 - Maintenance Procedures at Daily Interval
Daily Maintenance Procedures - OverviewPage 3-1
Daily Maintenance Procedures - OverviewGeneral InformationPreventative maintenance begins with day-to-day awareness of the engine and its system. Before starting the engine.check the oil and coolant levels. Look for:
• Leaks• Loose or damaged parts
• Worn or damaged belts
• Any change in engine appearance.
• Odor of fuel
Engine Operation ReportThe engine must be maintained in top mechanical condition if the operator is to get optimum satisfaction from its use.The maintenance department needs daily running reports from the operator tomake necessary adjustments in the timeallocated. The daily running report also helps to make provisions for more extensive maintenance work as the reportsindicate the necessity.
Comparison and intelligent interpretation of the daily report, along with a practical follow-up action, will eliminate mostfailures and emergency repairs.
Report to the maintenance department any of the following conditions:
• Low lubricating oil pressure
• Low power
• Power increases or engine surge
• Erratic or no accelerator control or response
• Any warning lights flashing or staying on
• Abnormal water or oil temperature
• Unusual engine noise
• Excessive smoke
• Excessive use of coolant, fuel, or lubricating oil
• Any fuel, coolant, or lubricating oil leaks
• Loose or damaged parts
• Worn or damaged belts
Unusual Engine NoiseDuring daily maintenance checks. listen for any unusualengine noise that can indicate that service is required.
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C8.3 IndustrialSection 3 - Maintenance Procedures at Daily Interval
Air Intake PipingMaintenance CheckVisually inspect the intake piping daily for wear points anddamage to piping, loose clamps, or punctures that candamage the engine.
Replace damaged pipes, and tighten loose clamps, asnecessary, to prevent the air system from leaking.
Torque Value: 8 N.m [72 in-Ib)
Check for corrosion under the clamps and hoses of theintake system piping. Corrosion can allow corrosive prod-ucts and dirt to enter the intake system. Disassemble andclean, as required.
Coolant LevelMaintenance Check
.A WARNING £.Do not remove a pressure cap from a hot engine. Waituntil the coolant temperature is below 50°C [120°F]before removing the pressure cap. Heated coolant sprayor steam can cause personal injury.
l:t.. CAUTION J::".Never use a sealing additive to stop leaks in the coolingsystem. This can result in cooling system plugging andinadequate coolant flow, causing the engine to over-heat.
The coolant level must be checked daily.
A CAUTION A.Do not add cold coolant to a hot engine. Engine cast-ings can be damaged. Allow the engine to cool to below50°C (120ClF] before adding coolant.
Make up coolant added to the engine must be mixed withthe correct proportions of antifreeze, supplemental coolantadditive, and water to avoid engine damage.
Coolant recommendations and specification details on cor-rect mixing of coolant can be found in Maintenance Speci-fications (Section V).
CB.3 IndustrialSection 3 •Maintenance Procedures at Daily Interval
Fill the cooting system with coolant to the bottom of the fill ~.,neck in the radiator fill or expansion tank. DNOTE: Some radiators have two fill necks, both of whichmust be filled when the cooling system is drained.
Drive BeltsMaintenance CheckPoly-Vee Belt
Inspect the belts daily.Check the belt for intersecting cracks.Traverse (across the belt width) cracks are acceptable.Longitudinal (direction of belt length) cracks that intersectwith transverse cracks are not acceptable. Replace the beltif it is frayed or has pieces of material missing. Refer toSection A for belt adjustment and replacement procedures.
Belt damage can be caused by:
• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the side of belts.
Cogged Belt
Inspect the belts daily. Replace the belts if they are cracked,frayed, or have chunks of material missing. Small cracksare acceptable.
Adjust the belts that have a glazed or shiny surface, whichindicates belt slippage. Correctly installed and tensionedbelts will show even pulley and belt wear. Refer to SectionA for belt adjustment and replacement procedures.
Belt damage can be caused by:
• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the belts
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CB.3 IndustrialSection 3 - Maintenance Procedures at Daily Interval
Measure the belt tension in the center span of the pulleys.
Refer to the Belt Tension Chart in Section V tor the correctgauge and tension value for the belt width used.
An alternate method (deflection method) can be used tocheck belt tension by applying 110 N [25 lbf] force betweenthe pulleys on v-belts. If the deflection is more than one beltthickness per foot of pulley center distance, the belt tensionmust be adjusted.
Refer to Section A for adjustment procedures.
For cogged belts, make sure that the belt tension gauge ispositioned so that the center tensioning leg is placed di-rectly over the high point (hump) of a cog. Other positioningwill result in incorrect measurement.
Fan, CoolingInspect for Reuse
... WARNING .A.Do not rotate the engine by pulling or prying on the fan.The fan blade(s) can be damaged and cause the fan tofall and cause personal Injury Or property damage. Usethe accessory drive shaft to rotate the crankshaft.
A visual inspection of the cooling fan is required daily.Check for cracks, loose rivets, and bent or loose blades.Check the fan to make sure it is securely mounted. Tightenthe capscrews, if necessary.
CB.3 IndustrialSection 3 - Maintenance Procedures at Daily Interval
... WARNING ...Do not straighten a bent fan blade or continue to use adamaged fan. A bent or damaged fan blade can failduring operation and cause personal injury or propertydamage.
Replace original equipment fan that is damaged with a fanof the identical part number. Cummins Engine Company,Inc. must approve any other fan changes to be coveredunder warranty.
Refer vehicle or equipment manufacturers specificationsfor capscrew torque.
Fuel-Water SeparatorDrain
... WARNING ADrain the water-fuel separator into a container and dis-pose of in accordance with local environmental regu-lations.
Cummins Inc. requires a fuel-water separator or fuel filterbe installed in the fuel supply system.
Drain the water and sediment from the separator daily.
Canister Type
Shut off the engine.
Pull up on the drain valve lever until fluid drains out of thedrain tube. Drain the filter sump until clear fuel is visible.
Push up on the drain valve until fluid drains out of the draintube.
Fuel·Water SeparatorPage 3-5 I
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CB.3 IndustrialSection 3 - Maintenance Procedures at Daily Interval
Spin-on Type
Shut off the engine.
Use your hand to open the drain valve. Turn the valvecounterclockwise approximately 3'/2 turns until the valvedrops down 25.4mm [1 in] and draining occurs.
Drain the filter sump until clear fuel is visible.
A CAUTION AWhen closing the drain valve, do not overtighten thevalve. Overtightening can damage the threads.
To close the valve, lift the valve and turn clockwise until itis hand-tight.
Lubricating Oil LevelMaintenance Check
A CAUTION ANever operate the engine with oil level below the L (low)mark or above the H (high) mark. Poor engine perfor-mance or engine damage can occur.
The engine must be level when checking the oil level tomake sure the measurement is correct.
Shut off the engine for an accurate reading.
Wait at least 15 minutes after shutting off the engine tocheck the oil level. This allows time for the oil to drain intothe oil pan.
For additional lubricating oil recommendations and oil pancapacity information, refer to Maintenance Specifications(Section V).
Crankcase Breather TubeMaintenance CheckInspect the breather tube for sludge, debris, or ice in thetube.
Inspect the tube more frequently in icy conditions.
CB.3 IndustrialSection 3 - Maintenance Procedures at Daily Interval
Air Tanks and ReservoirsDrainIf automatic purging or spitter valves are used, confirm thevalves are operating correctly. If a manual drain valve isused on the wet tank, open the draincock on the wet tankto drain any moisture accumulated in the air system. If oilis present, the air compressor system must be checked.Contact your Cummins Authorized Repair Location.
Air Tanks and ReservoirsPage 3-7 I
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CB.3 IndustrialMaintenance Procedures at 10,000 km [6000 mi] Page 4-8
Maintenance Procedures at 10,000 Kilometers [6000 Miles],250 Hours, or 3 Months
lubricating Oil and Filters.. 4-3Drain 4-3Fill 4-5Install 4-4Remove 4-4
Maintenance Procedures - Overview.. 4-1General Information 4-1
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CB.3 IndustrialMaintenance Procedures at 10,000 km [6000 mil
Maintenance Procedures - OverviewGeneral InformationAll maintena.nce checks and inspections listed in previousmaintenance intervals must also be performed at this time,in addition to those listed under this maintenance interval.
Air CompressorMaintenance CheckNOTE: Depending on application, all engines will possiblynot be equipped with an air compressor.
Inspect compressor housing for cracks and damage.
Inspect hydraulic pump couplings for cracks, wear, or dam-age (if equipped).
Inspect air plumbing for splits or cracks.
Inspect the air compressor mounting nuts, including sup-port bracket, for loose or damaged hardware.
Operate the engine and check for correct compressor op-eration and air, oil, and coolant leaks.
Torque Value:Mounting 18mm 77 N·m [57 ft-Ib]
Torque Value:Bracket 10 mm 45 N·m [33 ft-Ib]
Air Cleaner RestrictionMaintenance CheckMechanical Indicator
NOTE: Do not remove the felt washer from the indicator.The felt washer absorbs moisture.
A mechanical restriction indicator is available to indicateexcessive air restriction through a dry-type air cleaner. Thisinstrument can be mounted in the air cleaner outlet or onthe instrument panel. The red flag (1) in the window gradu-ally rises as the cartridge loads with dirt. After changing orreplacing the cartridge, reset the indicator by pushing thereset button.
Restriction or vacuum indicators need to be installed asclose as possible to the turbocharger air inlet in order toobtain a true indication of restrictions.
Maintenance Procedures· OverviewPage 4-1 I
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CB.3 IndustrialMaintenance Procedures at 10,000 km [6000 mi]
Vacuum Indicator
Vacuum switches actuate awarning light on the instrumentpanel when the air restriction becomes excessive.
Charge-Air CoolerMaintenance CheckInspect the charge-air cooler (CAG) for dirt and debrisblocking the fins. Check for cracks, holes, or other damage.If damage is found, refer to the vehicle, vessel, or equip-ment manufacturer.
Charge-Air PipingMaintenance CheckInspect the charge-air piping and hoses for leaks, holes,cracks, or loose connections. Tighten the hose clamps ifnecessary. Refer to the vehicle or equipment rnanutactur-er's specifications for the correct torque value.
CB.3 IndustrialMaintenance Procedures at 10,000 km [6000 mi]
Lubricating Oil and FiltersPage 4-3 I
Lubricating Oil and Filters IDrain
.A WARNING A ISome state and federal agencies have determined that used engine oil can be carcinogenic and cause repro-ductive toxicity. Avoidinhalation of vapors, ingestion, and prolonged contactwith used engine oil. If not reused,dispose of in accordance with local environmental regulations.PROTECTTHE ENVIRONMENT: Handling and disposal of used lubricating engine oil is subject to federal, state, andlocal laws and regulations. Use authorized waste disposal facilities, including civic amenity sites and garages providingauthorized facilities for receipt of used lubricating oil. If in doubt, contact your state and local environmental authoritiesor the Environmental Protection Agency for guidance as to proper handling and disposal of used lubricating engineoil.
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CB.3 IndustrialMaintenance Procedures at 10,000 km [6000 mil
NOTE: If the engine is in service, under no circumstancescan the lubricating oil drain interval extend beyond theintervals given in the charts.
Change the lubricating oil and filters to remove the con-taminants suspended in the lubricating oil.
NOTE: Drain the lubricating oil only when it is hot and thecontaminants are in suspension.
A. WARNING A.To avoid personal injury, avoid direct contact of hot oilwith your skin.
NOTE: Use a container that can hold at least 25 liters [26qt] of lubricating oil.
Operate the engine until the water temperature reaches60°C [140°F]. Shut the engine off. Remove the lubricatingoil drain plug.
RemoveClean the area around the lubricating oil filter head. Re-move the filter. Clean the gasket surface of the filter head.
NOTE: The o-rinq can stick on the filter head. Make sureit is removed.
InstallNOTE: Fill the filters with clean lubricating oil before in-stallation.
NOTE: The LF3000 lubricating oil filter has two gaskets.Lubricate both gaskets.
Apply a light film of oil to the gasket sealing surface beforeinstalling the filters.
C8.3 IndustrialMaintenance Procedures at 10,000 km [6000 mi]
a CAUTION aMechanical overtightening can distort the threads ordamage the lubricating oil filter element seal.
Install the lubricating oil tilter as specified by the filtermanufacturer.
Check and clean the lubricating oil drain plug threads andsealing surface.
FillNOTE: Use a high-quality 15W-40 multiviscosity lubricat-ing oil, such as Cummins Premium Bluew, or equivalent, inCummins engines. Choose the correct oil for your operat-ing climate as outlined in Section V.
Fill the engine with clean lubricating oil to the proper level.
System Capacity:
23.8 liters [25.1 qt]
Lubricating Oil and FiltersPage 4-5 I
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CB.3 IndustrialMaintenance Procedures at 10,000 km [6000 mil
Operate the engine at low idle to inspect for leaks at thelubricating oil filter and the drain plug.
Stop the engine. Wait approximately 15 minutes to let thelubricating oil drain from the upper parts of the engine.Check the level again.
Add oil as necessary to bring the oil level to the H (high)mark on the dipstick.
CB.3 IndustrialMaintenance Procedures at 19,000 km [12,000 mil Page 5-a
Maintenance Procedures at 19,000 Kilometers [12,000Miles], 500 Hours, or 6 Months
C8.3 IndustrialMaintenance Procedures at 19,000 km [12,000 ml]
Maintenance Procedures - OverviewGeneral InformationAll maintenance checks and inspections listed in previousmaintenance intervals must also be performed at this time,in addition to those listed under this maintenance interval.
Coolant FilterRemove
.. WARNING ..
Wait until the coolant temperature is below 50°C [122°F]before removing the pressure cap. Remove the coolantsystem pressure cap and close the shutoff valve beforeremoving the coolant filter. Failure to do so can resultin personal injury from heated coolant spray.
Turn the shutoff valve to the OFF position by rotating theknob from vertical to horizontal in the direction shown.
Remove and discard the coolant filter.
CleanClean the gasket surface.
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CB.3 IndustrialMaintenance Procedures at 19,000 km [12,000 mi]
Install
A. CAUTION A.Do not allow oil to get into the filter. Oil will damage theDCA.
A. CAUTION A.Mechanical overtightening can distort the threads ordamage the filter head.
Apply a thin film of lubricating oil to the gasket sealingsurface before installing the new coolant filter.
Install the coolant filter on the filter head. Tighten the filteruntil the gasket contacts the filter head surface.
Tighten the coolant filter an additional 1/2 to 3/4 of a turn,or as specified by the filter manufacturer.
A. CAUTION A.The valve must be in the ON position to prevent enginedamage.
Turn the shutott to the ON position by rotating the knob fromhorizontal to vertical in the direction shown.
~ Install the coolant system pressure cap.
~
CB.3 IndustrialMaintenance Procedures at 19,000 km [12,000 mil
Operate the engine and check for coolant leaks.
After the air has been purged from the system, check thecoolant level again.
Check the SeA concentration level:• At least twice a year• At every subsequent oil drain interval if the concen-
tration is above 3 units• Whenever coolant is added to the cooling system
between filter changes.
Use Fleetguard®coolant test kit, Part No. CC2602, to checkthe SCA concentration level. Instructions are included withthe test kit. Refer to Coolant Recommendations and Speci-fications in Maintenance Specifications (Section V) for thecorrect SCA and antifreeze level.
Antifreeze
A CAUTION AOverconcentration of antifreeze or use of high-silicateantifreeze can damage the engine.
Check the antifreeze concentration. Use a mixture of 50-percent water and 50-percent ethylene glycol or propyleneglycol-based antifreeze to protect the engine to -32°C[-26°F] year-around.
The Fleetguard® refractometer, Part Number C2BOO,pro-vides a reliable, easy-to-read, and accurate measurementof freezing point protection and glycol (antifreeze) concen-tration.
Antifreeze is essential in every climate.
Antifreeze broadens the operating temperature range bylowering the coolant freezing point and by raising its boilingpoint.
The corrosion inhibitors also protect the cooling systemcomponents from corrosion and prolong component life.
SCA and Antifreeze ConcentrationPage 5-3 I
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Fuel Filter (Spin-On Type)Page 5-4
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CB.3 IndustrialMaintenance Procedures at 19,000 km [12,000 mi]
Fuel Filter (Spin-On Type)CleanClean the area around the fuel filter head.
Remove75- to 80-mm and 90- to 95-mm Wrenches
Remove the fuel filter. Clean the gasket surface of the fuelfilter head.
InstallReplace the a-ring.
Fill the new fuel filter(s) with clean fuel, and lubricate thea-ring seal with clean lubricating engine oil.
ll.. CAUTION s:To reduce the possibility of fuel leaks, make sure thefuel filter is installed tightly but not too tightly. Me-
~ chanical overtightening will damage the fuel filter.
Install the fuel filter as specified by the filter manufacturer.
CB.3 IndustrialMaintenance Procedures at 19,000 km [12,000 mil
PrimeControlled venting is provided at the injection pump throughthe fuel drain manifold. Small amounts of air introduced bychanging the fuel filters or fuel injection pump supply linewill be vented automatically if the fuel filter is changed inaccordance with the instructions.
NOTE: Manual bleeding is required if:
• The fuel filter is not filled prior to installation
• Fuel injection pump is replaced
• High-pressure fuel line connections are loosened orfuel lines replaced
• Initial engine start up or start up after an extendedperiod of no engine operation occurs
• Vehicle fuel tank has been run until empty.
Open the bleed screw.
Fuel Filter (Spin-On Type)Page 5-5 I
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Operate the plunger on the fuel transfer pump until the fuel ~flowing from the fitting is free of air. ~
Tighten the bleed screw.
Torque Value: 9 N·m [80 in-lb]
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Fuel Filter (Spin-On Type)Page 5-6
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CB.3 IndustrialMaintenance Procedures at 19,000 km [12,000 mil
.. WARNING AThe pressure of the fuel in the line is sufficient to pen-etrate the skin and cause serious personal injury. Weargloves and protective clothing.
17-mm (PES.A, PES.MW) and 19-mm (PES.P) Wrenches
Loosen the fittings at the injectors, and crank the engine toallow entrapped air to vent from the lines. Tighten thefittings.
.. WARNING AIt is necessary to put the engine in the run position.Because the engine could start, be sure to follow all thesafety precautions. Use the normal engine starting pro-cedure.
Start the engine and vent one line at a time until the engineruns smoothly.
NOTE: Do not engage the starter for more than 30 secondseach time when it is used to vent the system: Wait 2 minutesbetween engagements.
C8.3 IndustrialMaintenance Procedures at 38,000 km [24,000 mil Page 6-a
Maintenance Procedures at 38,000 Kilometers [24,000Miles], 1000 Hours, or 1 Year
Section ContentsPage
Cooling Fan Belt Tensioner 6-1Maintenance Check ---- 6-1
Maintenance Procedures - Overview ----------6-1General Information -----__--- -------- 6-1
Overhead Set ---- 6-2Adjust ------ 6-2
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Check that the bottom tensioner arm stop is in contact with (~ _the bottom tensioner arm stop boss on the tensioner body. VIf these two are not touching, the tensioner must bereplaced.
CS.3 IndustrialMaintenance Procedures at 38,000 km [24,000 mil
Maintenance Procedures - OverviewGeneral InformationAll maintenance checks and inspections listed in previousmaintenance intervalsmust alsobe performed at this time,in addition to those listed under this maintenance interval.
Cooling Fan Belt TensionerMaintenance CheckEvery 48,000 km [30,000 mil. 1000hours, or 1 year,which-ever occurs first, inspect the automatic belt tensioner.
With the engine turned off, check that neither the top norbottom tensioner arm stop is touching the cast boss on thetensioner body. If either of the stops is touching a boss, thealternator belt must be replaced. Check to make sure thecorrect belt part number is being used if either conditionexists.
Check the tensioner pulley and body for cracks. If anycracks are noticed, the tensioner must be replaced. Referto a Cummins Authorized Repair Facility. Check thetensioner for dirt buildup. If this condition exists, thetensioner must be removed and steam-cleaned.
Maintenance Procedures - OverviewPage 6-1 I
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Overhead SetPage 6-2
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C8.3 IndustrialMaintenance Procedures at 38,000 km [24,000 mi]
Inspect the tensioner for evidence of the pivoting tensionerarm contacting the stationary circular base. If there is evi-dence of these two areas touching, the pivot tube bushinghas failed and the tensioner must be replaced.
A worn tensioner that has play in it or a belt that "walks" offits pulley possibly indicates pulley misalignment.
NOTE: Maximum pulley misalignment is 3 degrees.
This measurement can be taken with a straightedge and aninclinometer.
Install the belt.
Overhead SetAdjustRemove the air crossover tube from the engine if equipped.
Disconnect the support clamps, hose clamp, and wastegatesensing line. Remove the crankcase vent tube and anyother parts that would prevent removal of the valve cover.
CB.3 IndustrialMaintenance Procedures at 38,000 km [24,000 mi]
Remove valve cover.
Locate top dead center tor cylinder No. 1 by rotating thecrankshaft slowly while pressing on the engine timing pin.
The barring gear inserts into the flywheel housing andengages the flywheel ring gear. The engine can then berotated by hand using a 1/2-inch ratchet or breaker bar.
When the engine timing pin engages the hole in the earn-shaft gear, cylinder No. 1 is at top dead center on thecompression stroke.
A CAUTION ABe sure to disengage the engine timing pin after locat-ing top dead center to prevent damage to the enginetiming pin.
Overhead SetPage 6-3 I
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EngineTiming Pin I
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Page 6-4
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C8.3 IndustrialMaintenance Procedures at 38,000 km [24,000 mil
Intake clearance: 0.30 mm (0.012 in].
Exhaust clearance: 0.61 mm (0.024 in).
Check1setvalves with engine cold· below 60QC [140°FI.
NOTE: The clearance is correct when some resistance isUfelt"when the feeler gauge is slipped between the valvestem and the rocker lever.
Locate top dead center for cylinder No.1.
Check/adjust the valves indicated for STEP A (I = intake;E = exhaust).
After tightening the rocker lever locknut, check the valveclearance to make sure the valve clearance has notchanged.
Torque Value: 24 N.m [212 in-Ib]
~ CAUTION ~Be Sure the engine timing pin is disengaged to preventdamage to the engine timing pin.
Mark vibration damper and rotate the crankshaft 360degrees.
Set the valves indicated for STEP B.
After tightening the rocker lever locknut, check the valveclearance to make sure the valve clearance has notchanged.
Torque Value: 24 N.m (212 in-lb]
C8.3 IndustrialMaintenance Procedures at 38,000 km [24,000 mil
NOTE: If the seal is not damaged, it can be used again. Ifthe seal is damaged, install a new seal.
Install the rubber seal into the groove in the valve cover.Start the installation at the overlap area shown in the il-lustration. Do not stretch the rubber seal.
If the seal has more overlap than shown in the illustration,trim the length to provide the correct overlap.
Install new sealing a-rings on the capscrews.
Install the valve cover and wastegate sensing tube.
Torque Value: 24 N·m [212 in-lb]
Install the crankcase vent tube, and secure with the supportclamps and hose clamp.
Torque Value:AB =
24 N.m [212 in-Ib).43 N·m [32 in-Ib}.
Install the air crossover tube and any other parts previouslyremoved to gain access to the valve cover.
Overhead SetPage 6-5 I
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C8.3 IndustrialMaintenance Procedures at 77,000 km [48,000 mil Page 7-a
Maintenance Procedures at 77,000 Kilometers [48,000Miles], 2000 Hours, or 2 Years
Section ContentsPage
Air Compressor Discharge Lines .... -------- 7-1General Information ------------------------------- 7-1Maintenance Check --------------------------------------- 7-1
Cooling System --------------------------------------- 7-3Drain ------------------------------------------------ 7-3Fill 7-5Flush ----------------------------------- 7-4
Maintenance Procedures - Overview ---------- 7-1General Information ------------------------------------ 7-1
C8.3 IndustrialMaintenance Procedures at 77,000 km [48,000 mil
Maintenance Procedures - OverviewGeneral InformationAll maintenance checks and inspections listed in previousmaintenance intervals must also be performed at this time,in addition to those listed under this maintenance interval.
Air Compressor Discharge LinesGeneral InformationAll air compressors have a small amount of lubricating oilcarryover that lubricates the piston rings and moving parts.When this lubricating-oil is exposed to normal air com-pressor operating temperatures over time, the lubricatingoil will form varnish or carbon deposits. If the followingmaintenance check are not performed, the air compressorpiston rings will wear and not seal correctly.
Maintenance Check
A- WARNING A-Wear appropriate eye and face protection when usingcompressed air. Flying debris and dirt can cause per-sonal injury.
Shut oft the engine.
Open the drain valve on the wet tank to release the systemair pressure.
Remove the air compressor discharge line from the aircompressor. Location of the air compressor discharge linecan be found in Flow Diagram, Compressed Air System inSystem Diagrams (Section D).
Maintenance Procedures - OverviewPage 7-1 I
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Page 7-2
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ID of Carbon Build Up
I
ID of Discharge Line
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CB.3 IndustrialMaintenance Procedures at 77,000 km [4B,000 mi]
Measure the total carbon deposit thickness inside the airdischarge line as shown. If the total carbon deposit (X +X) exceeds 2 mm [1/16 in], clean and inspect the cylinderhead, the valve assembly, and the discharge line. Replaceif necessary. Contact the Cummins Authorized Repair Lo-cation for procedures.
If the total carbon deposit exceeds specifications, continuechecking the air discharge line connections up to the firsttank until total carbon deposit is less than 2 mm [1/16 in].Clean or replace any lines or connections that exceed thisspecification.
Inspect any air driers, splitter valves, pressure relief valves."and alcohol injectors for carbon deposits or malfunctioningparts. Inspect for air leaks. Maintain and repair the partsaccording to the manufacturer's specifications.
.A WARNING .A EtS~Coolant is toxic. Keep away from children and pets. Ifnot reused, dispose of in accordance with local envi-ronmental regulations.Drain the cooling system by opening the drain valve on theradiator and removing the plug in the bottom of the waterinlet hose. A drain pan with a capacity of 19 liters [5 gal) willbe adequate for most applications.
C8.3 IndustrialMaintenance Procedures at 77,000 km [48,000 mil
Cooling SystemDrain
A WARNING.Donot removethe pressure cap from a hot engine.Waltuntil the coolant temperature is below 50°C [120°F]before removingthe pressure cap. Heatedcoolant sprayor steam can cause personal injury .
.A WARNING .ACoolant is toxic. Keep away from children and pets. Ifnot reused, dispose of in accordance with local envi-ronmental regulations.
tl.. CAUTION s:Protect the environment: Handling and dlspo$ing ofused antifreeze is subject to federal, state, and localregulations. Use authorized waste disposal facilities,including civic amenity sites and garages providingauthorized facilities for the receipt of used antifreeze.If in doubt, contact local authorities of the Environ-mental Protection Agency (EPA) for guidance as toproper handling of used antifreeze.
• Avoid excessive contact, and wash thoroughly aftercontact.
• Keep out of reach of children .
Check for damaged hoses and loose or damaged hoseclamps. Replace as required.
Check the radiator for leaks, damage, and buildup of dirt.
C8.3 IndustrialMaintenance Procedures at 77,000 km [48,000 mi]
Flush~ CAUTION A
The system must be filled properly to prevent air locks.During filling, air must bepurged from the engine cool-ant passages. Be sure to open the petcock on theaftercooler for aftercooled engines. Wait 2 to 3 minutesto allow air to be vented; then add mixture to bring thelevel to the top.
NOTE: Adequate venting is provided for a fill rate of 19 liters[5 gal] per minute.
d CAUTION 1l..Do not install the radiator cap. The engine is to beoperated without the cap for this process.
Fill the system with a mixture of sodium carbonate andwater (or a commercially available equivalent).
NOTE: Use 0.5 kg [1 Ib] of sodium carbonate for every 23liters [6 gal] of water.
A WARNING A.Coolant is toxic. If not reused, dispose of in accordancewith local environmental regulations.
Operate the engine for 5 minutes with the coolant tem-perature above BO°C [176°F].
Shut the engine off, and drain the cooling system.
Fill the cooling system with high-quality water.
NOTE: Be sure to vent theengine and aftercooler for com-plete tilling.
NOTE: Do not install the radiator cap or the new coolantfilter.
C8.3 IndustrialMaintenance Procedures at 77,000 km (48,000 mil
Operate the engine for 5 minutes with the coolant tem-perature above BOoC [,76°F].
Shut the engine off, and drain the cooling system.
NOTE: If the water being drained is still dirty, the systemmust be flushed again until the water is clean.
FillA CAUTION A
The system must be filled properly to prevent air locks.During filling, air must be purged from the engine cool-ant passages. Be sure to open the peteoek on theaftercooler for aftercooled engines. Wait 2 to 3 minutesto allow air to be vented; then add mixture to bring thelevel to the top.
The system is designed to use a specific quantity of cool-ant. If the coolant level is low, the engine will run hot
If frequent addition of coolant is necessary, the engine orsystem has a leak. Find and repair the leak.
The system has a designed fill rate of '9 liters (5 gal] perminute.
A CAUTION ANever use water alone for coolant. This can result indamage from corrosion.
Use a mixture of 50-percent water and 50-percent ethyleneglycol or propylene glycol antifreeze to fill the cooling sys-tem.
Coolant Capacity (Engine Only)liters U.S.gal
OSC8.3 10.9 MAX 11.5
.A. WARNING A.Before removing the pressure cap, wait until the cool-ant temperature is below sooe (120°F). Failure to do socan cause personal injury from heated coolant spray.
Install the pressure cap. Operate the engine until the cool-ant reaches a temperature of BO°C [180°F], and check forcoolant leaks.
Check the coolant level again to make sure the system isfull of coolant or that the coolant level has risen to the hotlevel in the recovery bottle on the system, if so equipped.
Cooling SystemPage 7·5
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I50-PERCENT 50-PERCENTWATER WATER
50-PERCENT 50-PERCENTANTIFREEZE ANTIFREEZE I
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Vibration Damper, RubberPage 7-6
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C8.3 IndustrialMaintenance Procedures at 77,000 km [48,000 mi]
Vibration Damper, RubberInspectCheck the index lines (A) in the vibration damper hub (B)and the inertia member (C). If the lines are more than 1.59mm [1/16 in] out of alignment, replace the vibration damper.
Inspect the rubber member for deterioration. If pieces ofrubber are missing or if the elastic member is more than3.18 mm [1/8 in] below the metal surface, replace thedamper.
Look for forward movement on the damper ring on the hub.Replace the vibration damper if any movement is detected.
For vibration damper location, refer to Engine Diagrams inEngine Identification (Section E).
C8.3 IndustrialSection A - Adjustment, Repair, and Replacement Page A-a
Section A - Adjustment, Repair, and ReplacementSection Contents
Charge-Air Cooler A-2Clean A-3General Information A-2Initial Check '" A-2Install A-4Leak Test A-SPressure Test A-4Remove : A-3Temperature Differential Test A-6
Cooling Fan Belt Tensioner A-7Inspect for Reuse A-8Install A-8Preparatory Steps A-7Remove A-7
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
AlternatorPreparatory Steps
A WARNING AAlways connect the ground or negative (-) cable last toavoid arcing that can ignite explosive battery gases.
Disconnect the ground cable from the battery terminal.
Remove and tag all wires.
Remove the drive belt from the alternator pulley.
Refer to the Troubleshooting and Repair Manual, ISC En-gine, Bulletin No. 3666245.
Remove13 mm
Remove the alternator link capscrew.
16 mm
Remove the alternator mounting capscrew.
Remove the alternator.
AlternatorPage A-1 I
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Air in FuelPage A-20
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CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
TestA replacement of fuel supply lines, fuel filters, fuel injectionpump, high-pressure fuel lines, and injectors will let airenter the fuel system. Air in the system will make the enginehard to start. run rough. misfire, produce low power, andcan cause excessive smoke and a fuel knock.
Since the fuel lift pump provides positive pressure throughthe fuel filter and supply line to the fuel injection pump,loose connections or defective seals can show as a fuelleak, not as an air leak.
NOTE: If an excessive amount of air has entered into thesystem, the system will need to be vented.
Loosen the return banjo fitting on the fuel lift pump. Run thefuel lift pump until all the air has been vented. When all theair has been vented, retighten the fitting.
NOTE: To run the fuel pump for 25 seconds, crank theengine for a split second, and leave the key in the ONposition.
If air continues to bubble out of the system for severalminutes, then an air leak is present.
An often overlooked source from which air can enter thefuel system is between the inlet of the fuel transfer pumpand the suction tube in the tank. Fuel tanks that have theoutlet fitting at the top will have a suction tube that extendsto the bottom of the tank. Cracks or pin holes in the weldthat join the tube to the fitting can let air enter the fuelsystem.
Also, check to make sure all the fittings from the fuel supplyline on the tank to the inlet of the fuel transfer pump aretight.
Use a sight glass at the fuel lift pump inlet to check for airin the fuel supply lines.
C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
Since the fuel pump provides a positive pressure throughthe fuel filter and supply line to the fuel injection pump.loose connections or defective seals should show as a fuelleak. not as an air leak.
A stuck-open injector can also blow combustion gas backinto the pump and cause air to be present in the overflow.If the engine seems to be misfiring or running rough, breakall the injector supply lines loose at the pump end. Crankthe engine. and observe the lines. If combustion gas seemsto be blowing back through the line. the injector is stuckopen. Remove the injector. Take the vehicle to an Autho-rized Cummis Repair Facility/Dealer Location for testing.
Torque Value: 24 N.m [212 in-Ib)
NOTE: Use two wrenches when loosening the lines at thefuel pump: One to hold the delivery valve and one to loosenthe fuel line.
Disconnect the fuel line from the outlet of the fuel filter.
Attach a preferably clear hose to the outlet of the fuel filter.(Do not use pressure test fitting.) Place a pressure gaugeon the inlet side of the fuel filter and a vacuum gauge onthe inlet side to the transfer pump.
Air in FuelPage A-21 I
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Air in FuelPage A-22
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C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
Insert a hose into an empty 3.8-liter [t-qal] container,
Operate the fuel lift pump by bumping the starter. (The liftpump should run for 25 to 30 seconds.) Check for bubblesin fuel.
Record filter inlet pressure and transfer pump inlet restric-tion.
If filter inlet pressure is greater than 34.8 kPa [5 psi], thefilter element must be replaced. Repeat test.
If inlet restriction is greater than 152.4 mm Hg [6 in Hg] or155.1 mm Hg [3 psi]. then excessive restriction exists be-tween fuel in the tank and the transfer pump, which mustbe repaired (e.g., fuel line or tank module). Repeat test.
If bubbles are present, check for air leaks in the tuel supplycircuit.
Measure the amount ot tuel in the container. If more than1.33liters [45 tl oz] are collected and the tuel is bubble-tree,then it is unlikely the low-pressure fuel system is the causeof engine operational problems.
Reconnect the lift pump that is retaining the fuel filterpressure connections. Running engine at high idle, thefilter inlet pressure should be greater than 42.3 kPa [6 psi];otherwise. there is a fuel lift pump malfunction.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
If the fuel transfer pump does not run, check electricalcircuits, and verify voltage is present at lift pump connector.
NOTE: When an engine is not running, with key on, the liftpump will run less than 2 seconds (varies with ECM cali-bration); with starter bump, about 25 to 30 seconds. Ifvoltage is present, replace fuel transfer pump. Resistancemeasurement across the transfer pump terminals can bemade for confirmation of pump malfunction. Resistancegreater than 200 ohms or less than 0.2 ohm does confirman electrical fault when voltage is present but the fuel pumpis not running.
Air in FuelPage A-23 I
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CB.3 IndustrialSection D - System Diagrams Page O-a
Section D - System DiagramsSection Contents
PageFlow Diagram, Air Intake System 0-11
General Information 0-11
Flow Diagram, Compressed Air System 0-13General Information 0-13
General Information .. 0-13
Flow Diagram, Cooling System 0-7General Information 0-7
General Information 0-7
Flow Diagram, Exhaust System 0-12General Information 0-12
Flow Diagram, Fuel System .. 0-2General Information 0-2
General Information 0-2
Flow Diagram, Lubricating Oil System 0-3General Information 0-3
General Information 0-3
System Diagrams - Overview.. 0-1General Information 0-1
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CB.3 IndustrialSection D - System Diagrams
System Diagrams - OverviewPage D-1
System Diagrams - OverviewGeneral InformationThe following drawings show the flow through the engine systems. Although the parts can be different for variousapplications and installations, the flow remains the same. The systems shown are
• Fuel system
• Lubricating oil system
• Coolant system
• Intake air system
• Exhaust system
• Compressed air system.
Knowledge of the engine systems can help in troubleshooting, servicing, and general maintenance of the engine.
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Flow Diagram, Fuel SystemPage 0-2
C8.3 IndustrialSection 0 - System Diagrams
Flow Diagram, Fuel SystemGeneral InformationGeneral Information
3. Pressure regulating valve open 10. Filter bypass valve open
4. From lubricating oil pump 11 . To lubricating oil filter
5. To lubricating oil cooler 12. Full-flow lubricating oil filter
6. To lubricating oil pump oil pan 13. From lubricating oil filter
7. Lubricating oil cooler 14. Main lubricating oil rifle.
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Flow Diagram, Lubricating Oil SystemPage D-4
C8.3 IndustrialSection D - System Diagrams
3 I
1--+l
4
1. Lubrication oil filter
2. Turbocharger lubricating oil supply
3. Turbocharger lubricating oil drain
4. To main lubricating oil rifle.
C8.3 IndustrialSection D - System Diagrams
Flow Diagram, Lubricating Oil SystemPage 0-5 I
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07dOOU01 I1. From lubricating oil cooler
2. Main lubricating oil rifle
3. To camshaft
4. To piston cooling nozzle
5. From main lubricating oil rifle
6. To connecting rod bearing. IIIIIIIIIII
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Charge-Air CoolerPage A-2
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C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
InstallTo install the alternator, the alternator mounting compo-nents must be tightened in the following sequence:
1. Alternator-to-alternator bracket capscrew
2. Lower brace-to-alternator capscrew
3. Lower alternator brace-to-water pump capscrew
4. Water inlet-to-block capscrews.
NOTE: The wrench size and torque value is determined bythe make and model of the alternator. Refer to the Trouble-shooting and Repair Manual, ISC Engine, Bulletin No.3666245.
To install the alternator, the alternator mounting compo-nents must be tightened in the following sequence:
1. Alternator-to-alternator bracket capscrew
Torque Value: 43 N.m [32 ft-Ib)
2. Lower brace-to-alternator capscrew
Torque Value: 24 N·m [18 ft-Ib)
3. Lower alternator brace-to-water pump capscrew
Torque Value: 24 N·m [18 tt-lb]
4. Water inlet-to-block capscrews.
Torque Value: 24 N·m [18 ft-Ib)
Charge-Air CoolerGeneral InformationThe long-term integrity of the charge air cooler system isthe responsibility of the vehicle and component manufac-turers; however, the following can be checked by any Cum-mins Authorized Repair Facility.
NOTE: If the engine experiences a turbocharger failure orany other occasion where oil or debris is put into the chargeair cooler, the charge air cooler must be cleaned.
Initial CheckInspect the charge air cooter for cracks, holes, and dam-age.
Inspect the tubes, fins, and welds for tears, breaks, or otherdamage. If any damage causes the charge air cooler to failthe air leak check, the charge air cooler must be replaced.
Inspect the charge air cooler plumbing for cracks anddamage.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Remove
A. WARNING A.
Charge-Air CoolerPage A-3 I
ICoolant is toxic. Keep away from children and pets. Ifnot reused, dispose of in accordance with local envi- ~ronmental regulations .
.. WARNING ..
Wear appropriate eye and face protection when usingcompressed air. Flying debris and dirt can cause per-sonal injury.
Use compressed air to clean debris from the outside of thecharge air cooler.
Drain the coolant. Refer to Section 7.
Remove the charge air cooler plumbing.
Remove the charge air cooler. Refer to the OEM servicemanual.
CleanNOTE: If the engine experiences a turbocharger failure orany other occasion where oil or debris is put into the chargeair cooler, the charge air cooler must be cleaned.
Remove the charge air cooler piping and charge air coolerfrom the vehicle. Refer to the original equipment manu-facturer's instructions.
A. WARNING A.When using solvents, acids, or alkaline materials forcleaning, follow the manufacturer's recommendationsfor use. Wear goggles and protective clothing to reducethe possibility of personallnlury.
A CAUTION ADo not use caustic cleaners to clean the charge aircooler. Damage to the charge air cooler will result.
Flush the charge air cooler internally with solvent in theopposite direction of normal airflow. Shake the charge aircooler and lightly tap on the end tanks with a rubber malletto dislodge trapped debris. Continue flushing until all de-bris or oil is removed (i.e.• the water runs clear).
NOTE: Make sure that the tubes are in the vertical directionwhen flushing.
If the debris can not be totally removed from the charge aircooler, the charge air cooler must be replaced.
~:
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ICharge-Air CoolerPage A·4
C8.3 IndustrialSection A - Adjustment, Repair, and ReplacementI
~ A WARNING AWear appropriate eye and face protection when usingcompressed air. Flying debris and dirt can cause per-sonal injury.
IA WARNING A
When using solvents, acids, or alkaline materials forcleaning, follow the manufacturer's recommendationsfor use. Wear goggles and protective clothing to reducethe possibility of personal injury.
ll.. CAUTION s:The charge air cooler must be rinsed, dried, and cleanedof solvent, oil, and debris, or engine damage will result.
After the charge air cooler has been thoroughly cleaned ofall oil and debris with solvent, wash the charge air coolerinternally with hot, soapy water to remove the remainingsolvent. Rinse thoroughly with clean water.
Blow compressed air through the inside of the charge aircooler in the opposite direction of normal airflow until thecharge air cooler is dry internally.
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Install~WI Install the charge air cooler.
Install the charge air cooler plumbing.
~ Refer to the OEM service manual for instructions.01,--- I-- ,---J
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10dOOO30
IPressure TestPressure Gauge, Part Number ST-1273
Install the pressure gauge, Part Number ST-1273, to thefitting in the turbocharger outlet.
Install another pressure gauge, Part Number ST·1273, inthe intake manifold.
Operate the engine at rated rpm and load. Record thereadings on the two gauges.
If the differential pressure is greater than 21 kPa [3 psi),check the charge air cooler for plugging. Clean or replaceif necessary.
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CB.3 IndustrialSection A - AdjL~stment, Repair, and Replacement
leak Test
A- WARNING A-To reduce the possibility of injury if either plug blowsoff during the test, secure safety chains on the testplugs to any convenient capscrew on the radiator as-sembly. This test must not be performed without se-curely fastened safety chains.
Tocheck the charge air cooler for cracked tubes or header,remove the inlet and outlet hoses from the cooler. Thecharge air cooler does not have to be removed from thechassis.
Install a plug or cap over the outlet side of the cooler. Installa pressure gauge and a regulated shop air supply line witha shutoff valve to the inlet side of the cooler.
Charge-Air CoolerPage A-5
Apply air pressure to the cooler until the pressure gauge ~reads a steady 207 kPa [30 psi] of air pressure. ~
Shut off the airflow to the cooler and start a stopwatch atthe same time. Record the leakage at 15 seconds.
If the pressure drop is 48 kPa (7 psi) or less in 15 seconds,the cooler is operational.
If the pressure drop is greater than 48 kPa [7 psi] in 15seconds, check all connections again.
Determine if the pressure drop is caused by a leaky charge ~air cooler or a leaky connection. Spray soapy water on all ®hose connections, and watch for bubbles to appear at thelocation of the leak.
If the pressure drop is caused by a leaky connection, repairthe connection and repeat the test. If the leak is within thecharge air cooler, repeat the test to verify the accuracy ofthe pressure drop measurement. Similar pressure dropreadings must be obtained in at least three consecutivetests before the reading can be considered accurate.
NOTE; If a charge air cooler leaks more than 48 kPa [7 psi]in 15 seconds, it will appear as a major leak in a leak tank.
If the pressure drop is greater than 48 kPa [7 psi] in 15seconds, the charge air cooler must be replaced.
Refer to the equipment manufacturer's service manual forreplacement instructions.
NOTE: Charge air coolers are not designed to be 100-percent leak free. If the pressure drop is less than 48 kPa(7 psi] in 15 seconds, then the charge air cooler does notneed to be replaced.
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Drive Belt, Cooling FanPage A-6
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Temperature Differential TestInstall a temperature gauge in the intake manifold.
Lock the fan drive in the ON mode to prevent erratic testresults. This can be done by installing a jumper across thetemperature switch or supplying shop air to the fan. Referto the fan drive manufacturer for lockup procedure.
NOTE: Some trucks have a manual switch that will lock thefan on.
Operate the engine at rated rpm and load. Record theintake manifold temperature.
Measure the ambient temperature at least 2 feet in front ofthe vehicle.
The maximum temperature differential must not be greaterthan 25°C [45°F].
If the temperature differential is greater than 25°C [45°F],check the charge air cooler for dirt and debris on the fins,and clean as necessary. If the problem stili exists, checkthe cooler for internal contamination or plugging.
NOTE: The belt tensioner winds in the direction that thespring tang is bent over the tensioner body. To loosen thetension on the belt, rotate the tensioner to wind the springtighter.
ll.. CAUTION ll..Applying excessive force in the OPPOSite direction ofwind~up or after the tensioner has been wound up to thepositive stop can cause the tensioner arm to break.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Cooling Fan Belt TensionerPageA-7
Inspect for ReuseInspect the drive belt for:
• Cracks
• Glazing
• Tears or cuts
• Hardening
• Excessive wear.
Install
ll.. CAUTION aThe belt tensioner is spring-loaded and must be piv-oted away from the drive belt. Pivoting in the wrongdirection can result in damage to the belt tensioner.
3/8.lnch Square Drive
Lift the tensioner to install the drive belt.
Cooling Fan Belt TensionerPreparatory StepsRemove the drive belt.
Removell.. CAUTION a
The belt tensioner is spring loaded and must be pivotedawayfrom the drive belt. Pivoting in the wrong direction rc::<3can damage the belt tensioner. '\l53/8-lnch Square Drive
Lift the belt tensioner to relieve tension in the belt. andremove the belt.
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II
Cooling Fan Belt TensionerPage A-8
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C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
15 mm
Remove the capscrew and belt tensioner from the bracket.
Inspect for ReuseInspect the tensioner bushing between the arm and thespring case.
Install15 mm
Install the belt tensioner and capscrews.
Torque Value: 43 N·m [32 tt-lb]
3/B-lnch Square Drive
Lift and hold the tensioner. Install the drive belt, and releasethe tensioner.
Service Tip: If difficulty is experienced installing the drivebelt or if the belt seems too short, position the belt over thegrooved pulleys first; then, while holding the tensioner up,slide the belt over the water pump pulley.
The belt tensioner is spring-loaded and must be piv-oted away from the drive belt. Pivoting in the wrong ~<!Jdirection can result in damage to the belt tensioner. \l:/3/B-lnch Square Drive
Lift the tensioner to relieve tension in the belt. Remove thebelt.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Fan Spacer and PulleyPreparatory StepsRemove the drive belt.
Loosen the capscrews before removing the belt, and tightenthe capscrews after the belt is installed.
RemoveA CAUTION 1l.
Remove the fan capscrews, fan, and spacer.
Remove the fan pulley.
Inspect tor ReuseInspect the tan pulley for cracks near bolt holes.
Check for cracks, loose rivets, and bent or loose blades.
Fan Spacer and PulleyPageA-9 I
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II
Fuel Filter AdapterPage A-10
IIIIIIIIIIIIIIIII
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Install13mm
Install the fan pulley.
Install the spacer, fan, and fan capscrews.
Torque Value: 24 N·m [212 in-Ib]
3IB-lnch Square Drive
Lift the tensioner, and install the belt.
Service Tip: If difficulty is experienced installing the drivebelt or if the belt seems too short, position the belt over thegrooved pulleys first; then, while holding the tensioner up,slide the belt over the water pump pulley.
Remove the retaining nut, fuel filter head adapter, andsealing washers.
CB.3 Industrial Fuel Lift Pump ISection A - Adjustment, Repair, and Replacement Page A-11
Install IBosch®
Install in the reverse order of removal.
Torque Value: 32 N·m [24 ft-lbJ II
-.
I 11900ma IIFuel Lift Pump
~Preparatory StepsClean all debris from the fuel lift pump. I
IIs90Qea I
IDisconnect the fuel supply lines.
IIIIRemove
~~
) IH
Remove the two fuel lift pump mounting capscrews. I
Remove the fuel lift pump. I
U Ie I
II
II
Fuel Manifold (Drain)Page A-12
III
fs9DOec
IIIIIIIIIIIIII
C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
CleanClean the fuel transfer pump mounting surface on thecylinder block.
Install
A CAUTION AFailure to tighten the fuel transfer pump mountingcapscrews alternately can result in broken lift pumpflanges.
Install a new fuel transfer pump gasket.
Alternately tighten the mounting bolts.
Torque Value: 24 N.m [212 in-Ib]
Connect the fuel lines.
Fuel Manifold (Drain)Preparatory StepsClean all debris from around the fuel drain manifold.
RemoveRemove the banjo capscrews from the injectors and fuelfilter head.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
InstallInstall the fuel drain manifold in the reverse order of re-moval.
Torque Value:Filter Head BanjoInjector Banjo
15 N·m [133 in-Ib]9 N·m [80 in-Ib].
Fuel Shutoff ValvePreparatory StepsLabel and disconnect the wiring.
RemoveRemove the two mounting capscrews, and remove thesolenoid from the bracket
1. Synchro-start
2. Trombetta
3. Direct link.
InstallNOTE: Make sure the acorn nut is tightened to be snuglyon the fuel shutoff solenoid shaft (Synchro-start only).
Install the new fuel shutoff solenoid to the bracket, andconnect the wires. Make sure the wiring harness one theTrombettasolenoid is installed in the six-o'clock position.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Activate the switch and check the plunger travel.
Direct linkSynchro- Trombettastart
A::: 86.8 mm 91.4 mm[3.4 in] [3.6 in]
B = 60.2 mm 63.5 rnrn(2.4 in) (2.5 in)
117.1 mm[4.61 in}
The plunger must be retracted when the fue! shutoff so-lenoid is activated to the RUN position B. The fuel shutoffsolenoid must operate without binding.
Remove the hitch pin clip, the mounting capscrews, andthe fuel shutoff solenoid.
Install the new solenoid in reverse order of removal, andconnect the wires.
Torque Value: 10 N·m [89 in-Ib)
Adjust the solenoid linkage as necessary so that the plungeris magnetically held in with the shutoff lever in the absolutefull-run position. Turn the large hex nut on the end of theplunger to make adjustments, and secure in place with alocknut.
A WARNING A.When using solvents, acids, or alkaline materials forcleaning, follow the manufacturer's recommendationsfor use. Wear goggles and protective clothing to avoidpersonal injury.
Clean the area around the pressure regulator plug withsolvent to prevent debris from falling into the plunger borewhen the plug is removed.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
RemoveRemove the threaded plug, spring, and plunger.
Service Tip: The plunger normally can be removed byinserting one finger into the plunger bore until snug, andpulling up. If the plunger can not be removed in this man-ner, the plunger is probably stuck and will require removalof the housing for plunger removal and cleaning.
CleanClean and inspect the bore and regulator valve beforeassembly.
InstallNOTE: The valve must move freely in the bore.
Install the regulator, spring, and plug.
Torque Value: 80 N·m [59 ft-Ib]
Lubricating Oil ThermostatPreparatory StepsClean debris from oil thermostat.
Lubricating Oil ThermostatPage A-15 I
I
I-, I
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II
Starting MotorPage A-16
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C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
RemoveRemove the lubricating oil thermostat.
CleanClean and inspect the lubricating oil thermostat bore beforeassembly.
InstallInstall and tighten the oil cooler bypass valve.
Torque Value: 50 N·m [37 ft-Ib)
Starting MotorInitial CheckIf the starter solenoid is making a sound but the engine isnot rotating, remove the starter motor and check for brokenring gear teeth or a broken starter motor spring.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Remove
A WARNING ABatteries can emit explosive gases. To reduce the pos-sibility of personal injury, alwaysventilate the compart-ment before servicing the batteries. To avoid arcing,remove the negative (-) battery cable first andattach thenegative (-) battery cable last.
A WARNING AAcid is extremely dangerous and can damage the ma-chinery and can also cause serious burns. Always pro-vide a tank of strong soda water as a neutralizing agentwhen servicing the batteries. Wear goggles and pro-tective clothing to reduce the possibility of seriouspersonal injury.Remove the electrical connections from the batteries, nega-tive (-) cable first.
Remove the electrical connections from the starter motor.
Identify each wire with a tag indicating location on startermotor.
Remove the capscrews from the flywheel housing.
Remove the starter motor.
InstallInstall the starter motor.
Install and tighten the mounting capscrews.
Torque Value: 43 N·m [32 ft-Ib]
Starting MotorPage A-17 I
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~ ~~~~ S_~_~~h. I
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II
Starting MotorPage A·18
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C8.3 IndustrialSection A - Adjustment, Repair, and Replacement
NOTE: Use the location tags to help identity where eachwire connection goes.
Install the starter motor electrical connections.
A. WARNING A.Batteries can emit explosive gases. To reduce the pos-sibility of personal injury, always ventilate the compart-ment before servicing the batteries. To avoid arcing,remove the negative (-) battery cable first and attach thenegative (-) battery cable last.
A. WARNING A.Acid is extremely dangerous and can damage the ma-chinery and can also cause serious burns. Always pro-vide a tank of strong soda water as a neutralizing agentwhen servicing the batteries. Wear goggles and pro-tective clothing to reduce the possibility of seriouspersonal injury.Clean the inside of the battery terminal with a brush beforeconnecting to battery.
Install battery cables, connecting the negative (-) cable last.
Rotation CheckIf the starter motor solenoid makes a sound, turn thekeyswitch tothe OFF position, and attempt to bar the crank-shaft in both directions.
Barthe engine using the barring tool, Part Number 3824591.
CB.3 IndustrialSection A - Adjustment, Repair, and Replacement
Bar the crankshaft as follows:
1. Direction of engine rotation
2. Direction opposite engine rotation
3. Direction of engine rotation.
If the crankshaft will bar over, attempt to start the engine.If the starter motor cranks the engine, check the startermotor pinion gear and flywheel ring gear for damage.
Air in FuelGeneral Information
~ WARNING ~Fuel is flammable. Keep all cigarettes, flames, pilotlights, arcing equipment, and switches out of the workarea and areas sharing ventilation to reduce the pos-sibility of severepersonal injury or death when workingon the fuel system.
A WARNING ADo not vent the fuel system on a hot engine; this cancause fuel to spill onto a hot exhaust manifold, whichcan cause a fire.
The low-pressure fuel system for Cummins diesel installedin the vehicle consists of the fuel tank, lines between tankand engine, transfer pump and lines, and fuel filter andlines. Air or bubbles at the injection pump can cause no orerratic engine operation and/or subsequent malfunction ofthe fuel injection pump. Air can be introduced by leaks inthe fuel system prior to the transfer pump since fuel pres-sure is a vacuum. Bubbles can result from any number ofrestrictions in the system:
• Plugged fuel filter• Crimped fuel line• Stopped-up tank module• Inoperative transfer pump.
If sufficient fuel reaches the injection pump from the low-pressure system, then solutions to engine operational prob-lems are elsewhere. The following steps will aid in evalu-ating low-pressure fuel system performance in absence offault codes.
NOTE: For cold-start/performance problems, perform thefollowing steps:
• Leave vehicle outside in cold environment for atleast 12 hours.
• Perform outlined test.• If the system fails to meet test criteria, replace the
fuel lift pump.
Air in FuelPageA-19 I
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II
Flow Diagram, Lubricating Oil SystemPage 0-6
CB.3 IndustrialSection 0 - System Diagrams
II [
~~"_-~~o._ I .,';-~----....., .:-. \,,--,
~--~~
07dOOO02
IIIII 1. From cam bushings
2. Transfer slot
3. Rocker lever support
4. Rocker lever shaft
5. Rocker lever bore
6. Rocker lever,
IIIIIIIIII
CB.3 IndustrialSection D - System Diagrams
Flow Diagram, Cooling SystemPage 0-7 I
IFlow Diagram, Cooling SystemGeneral InformationGeneral Information I
IIIII
OS9002()1 ICylinder Block
1. Coolant inlet
2. Water pump impeller
3. Coolant flow to oil cooler
4. Coolant flow past oil cooler
5. Upper coolant manifold
6. Coolant flow to cylinder head.
IIIIIIIIII
II
Flow Diagram, Cooling SystemPage D-8
C8.3 IndustrialSection D - System Diagrams
I
2III
1
II
08900203
I Cylinder Head
I1. Flow from upper coolant manifold
2. Flow to liner cavity
3. Cylinder head gasket
4. Coolant flow orifice.
IIIIIIIII
CB.3 IndustrialSection D - System Diagrams
2
Flow Diagram, Cooling SystemPage 0-9 I
IIIIIIIIIIIIIIIIII
1. Flow past cylinder liners 2. Lower coolant manifold.
08900200
II Flow Diagram, Cooling System
Page 0-10CB.3 Industrial
Section D - System Diagrams
I
I
7II
I /'."~?""~-:-~~~J
(
i' .'--':,,\Q ,,\ \
·/o~:~( 1,\""U'-'~ ,-J- I
: v 'T.~~,"". ))
/'~;>I
IClosed
I08900202
I Thermostat
I 1. Thermostats
2. Flow to water pump inlet
3, Bypass passage open
4. Flow from lower coolant manifold
5. Partial coolant flow to radiator
6. Restricted flow to bypass
7. Flow to radiator
8. Bypass closed.IIIIIIIII
Flow Diagram, Air Intake System
II
CB.3 Industrial Flow Diagram, Air Intake SystemSection D - System Diagrams Page 0-11
General Information
2 1 I4 I
IIII
10900277 I1. Intake air inlet to turbocharger
2. Turbocharger air to charge air cooler
3. Charge air cooler
4. Intake manifold - integral part of cylinder head
5. Intake valve.
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Flow Diagram, Exhaust System CB.3 IndustrialPage 0-12 Section 0 - System Diagrams
Flow Diagram, Exhaust SystemGeneral Information
3
'. \ \.' \ \
~-
,,900058
1. Exhaust valve
2. Exhaust manifold- pulse-type
3. Dual entry to turbocharger
4. Turbocharger exhaust outlet.
CB.3 IndustrialSection D - System Diagrams
Flow Diagram, Compressed Air SystemPage D-13 I
Flow Diagram, Compressed Air System IGeneral InformationGeneral Information I
IIIII
12900074 I1. Compressor 8. Economy valve line
2. Compressor intake 9. Air drainer
3. E-type unloader 10. Check valve (built into dryer)
4. Reservoir line 11. Reservoir (wet tank)
5. Governor 12. Check valve
6. Discharge line 13. Secondary pressure line.
7. Splitter valve line
IIIIIIIIII
II Flow Diagram, Compressed Air System
Page D-14CB.3 Industrial
Section D - System Diagrams
I
I 6
II
II 1290JD30
1. Air in
2. Air out
3. Coolant out
4. Coolant in
5. Lubricating oil in
6. Lubricating oil out.
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CB.3 IndustrialSection L - Service Literature
General Information
Additional Service LiteraturePage L-1 I
Additional Service Literature IThe following publications can be purchased by contacting the nearest local distributor. IBulletin Number366600336660083666021337900136661323379009381034036661093379000
Title of PublicationC Series Troubleshooting and Repair ManualC Series Engine Shop ManualC Series Specifications ManualFuel for Cummins Engines BulletinCoolant Requirements and Maintenance BulletinOperation, Cold WeatherCummins Engine Oil Recommendations BulletinAlternative Repair Manual, Band C Series EnginesAir for Your Engines
IIIIIIIIIIIIIIII
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Service Literature Ordering LocationPage L-2
CB.3 IndustrialSection L - Service Literature
Service Literature Ordering LocationContact Information
Region
United States and Canada
Ordering Location
Cummins Distributorsor
Credit Cards at 1-800-646-5609or
Order online at www.powerstore.cummins.com
Cummins Engine Co., Ltd.Royal Oak Way SouthDaventryNorthants, NN11 5NU, England
C8.3 IndustrialSection M - Component Manufacturers
Component Manufacturers' AddressesPage M-1 I
Component Manufacturers' Addresses IGeneral InformationNOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cumminsengines. Suppliers can be contacted directly for any specifications not covered in this manual.
Air CompressorsBendix Heavy Vehicles SystemsDiv. of Allied Automotive901 Cleveland StreetElyria, OH 44036Telephone: (216) 329-9000
Nelson DivisionExhaust and Filtration Systems1801 U.S. Highway 51 P.O.Box 428Stoughton, WI 53589Telephone: (608) 673-4200Walker Manufacturing3901 Willis RoadP.O. Box 157Grass Lake, MI 49240Telephone: (517) 522-5500
Hydraulic and Power Steer-ing PumpsHoneywell Control Systems Ltd.Honeywell HouseArlington Business PlaceBracknellBerks RG12 1EBTelephone: (0)1344-656000
Sperry VickersPO. Box 302Troy, MI 48084Telephone: (313) 280-3000
RadiatorsJB Radiator Specialties, Inc.PO. Box 292087Sacramento, CA 95829-2087Telephone: (916) 381-4791
The G&O Manufacturing Company100 Gando DrivePo. Box 1204New Haven, CT 06505-1204Telephone: (203) 562-5121Young Radiator Company2825 Four Mile RoadRacine, WI 53404Telephone: (910) 271-2397
Land M Radiator, Inc.1414 East 37th StreetHibbing, MN 55746Telephone: (218) 263-8993
Throttle AssembliesWilliams Controls, Inc.14100SW 72nd AvenuePortland, OR 97224Telephone: (503) 684-8600
Torque ConvertersTwin Disc International S.A.Chaussee de NamurNivellesBelgiumTelephone: 067-224941
Component Manufacturers' AddressesPage M-3 I
Twin Disc Incorporated1328 Racine StreetRacine, WI 53403-1758Telephone: (414) 634-1981Rockford Powertrain, Inc.Off-Highway Systems1200 Windsor RoadP.O.Box 2908Rockford, IL 61132-2908Telephone: (815) 633-7460
Modine Mfg. Co.1500 DeKoven AvenueRacine, WI 53401Telephone: (414) 636-1640
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CB.3 IndustrialSection S - Service Assistance Page S-a
Section 5 - Service AssistanceSection Contents
Page
Distributors - International S-18Locations..................................... S-18
Distributors and Branches...................................................................................................................... S-3Australia S-12Canada S-10New Zealand S-14United States........................................................................................................................ S-3
Division and Regional Offices........... S-2Locations......................................................................................... S-2
Emergency and Technical Service.................................................................................................................. S-1General Information S-1
Problem Solving S-1General Information S-1
Regional Offices - International S-15Locations........................................................................................ S-15
Routine Service and Parts................................................................ S-1General Information S-1
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CB.3 IndustrialSection S - Service Assistance
Routine Service and PartsPage S-l
General InformationRoutine Service and Parts
II
Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your engine. ICummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained toprovide sound advice, expert service, and complete parts support. Check the telephone directory yellow pages or referto the directory in this section for the nearest Cummins Authorized Repair Location.
Emergency and Technical Service IGeneral InformationThe Cummins Customer Assistance Center provides a 24-hour, toll free telephone number to aid in technical andemergency service when a Cummins Authorized RepairLocation can not be reached or is unable to resolve anissue with a Cummins product.
If additional assistance is required, call Toll-Free:
1-800-01ESELS(1-800-343-7357)
• Includes alt 50 states, Bermuda, Puerto Rico, VirginIslands, and the Bahamas.
• Outside of North America contact your RegionalOffice. Telephone numbers and addresses are listedin the International Directory.
General InformationProblem Solving
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a CumminsAuthorized Repair Location in your area. Refer to the telephone directory yellow pages for the one nearest you. If theproblem has not been handled satisfactorily, follow the steps outlined below:
1. If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreement.
2. If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, mostproblems are solved below the Division or Regional office level. Telephone numbers and addresses are listed inthis section. Before calling, write down the following information:
a. Engine model and serial number
b. Type and make of equipment
C. Total kilometers [miles) or hours of operation
d. Warranty start date
e. Nature of problem
f. Summary of the current problem arranged in the order of occurrence
g. Name and location of the Cummins Distributor or Dealer
3. If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location OrDivision Office,write to:
Cummins Customer Assistance Center - 41403, Cummins Inc., Box 3005, Columbus, IN 47202-3005
IIIIIIIIIIIIIII
II Division and Regional Offices
Page S~2
IDivision and Regional Offices
Locations
CB.3 IndustrialSection S - Service Assistance
I United States
NOTE: The following list contains offices in U.S., Canada, Australia, New Zealand, and Puerto Rico.
ISouthern Division OfficeCummins Engine Company, Inc.425 Franklin Road S.WSuite 500Marietta, GA 30067Telephone: (770) 423-1108FAX: (770) 499-8240
Mobile BranchCummins Alabama, Inc.1924 N. 6eltline Hwy.Mobile, AL 36601-1598Telephone: (334) 456-2236FAX: (334) 452-6419
Mobile Onan/Marine BranchCummins Alabama, Inc.3422 Georgia Pacific AvenueMobile, AL 36617Telephone: (334) 452-6426FAX: (334) 473-6657
Montgomery BranchCummins Alabama, Inc.2325 West Fairview AvenueMontgomery, Al 36108Telephone: (205) 263-2594FAX: (205) 263-2594
AlaskaAnchorage - (Branch of Seattle)Cummins Northwest, Inc.2618 Commercial DriveAnchorage, AK 99501-3095Telephone: (907) 279-7594FAX: (907) 276-6340
Arizona
Phoenix Distributor and BranchCummins Southwest, Inc.2239 N. Black Canyon HgwyPhoenix, AZ. 85009Telephone: (602) 252-8021FAX: (602) 253-6725
Tucson BranchCummins Southwest, Inc.1912 West Prince RoadTucson, AZ 85705Telephone: (520) 887-7440FAX: (520) 887-4173
ArkansasLittle Rock - (Branch of Memphis)Cummins Mid-South, Inc.6600 Interstate 30Little Rock, AR 72209Telephone:Sales: (501) 569-5600Service: (501) 569-5656Parts: (501) 569-5613
FAX: (501) 565-2199
Distributors and BranchesUnited States
California
San Leandro DistributorCummins West, Inc.14nS Wicks Blvd.San Leandro, CA 94577-6779Telephone: (510) 351-6101FAX: (510) 352-3925
Arcata BranchCummins West, Inc.4801 West End RoadArcata, CA 95521Telephone: (707) 822-7392FAX: (707) 822-7585
Bakersfield BranchCummins West, Inc.4601 East Brundage LaneBakersfield, CA 93307Telephone: (805) 325-9404FAX: (805) 861-8719
Fresno BranchCummins West, Inc.2740 Church AvenueFresno, CA 93706Telephone: (209) 495-4745FAX: (209) 486-7402
Kapolei DistributorCummins Hawaii Diesel Power, Inc.91-230 Kalaeloa Blvd.Kapolei, HI 96707Telephone: (808) 682-8110FAX: (808) 682-8477
Idaho
Boise - (Branch of Salt Lake City)Cummins Intermountain, Inc.2851 Federal Way CityBoise, ID 83705Telephone: (208) 336-5000FAX: (208) 338·5436
Pocatello - (Branch of Salt LakeCity)Cummins Intermountain, Inc.14299 Highway 30 WestPocatallo, ID83201Telephone: (20B) 234-1661FAX: (208) 234-1662
Illinois
Chicago DistributorCummins Northern Illinois, Inc.7145 Santa Fe DriveHodgkins, IL 60525Telephone: (708) 579-9222FAX: (708) 352·7547
Bloomington-Normal - (Branch ofIndianapolis)Cummins Mid-States Power, Inc.(at U.S. 51 Nand 1·55)414 W. Northtown RoadBloomington-Normal, IL 61761Telephone: (309) 452-4454FAX: (309)452-1642
Onan BranchCummins/Onan Northern Illinois8745 W. 82nd PlaceJustin, IL 60458Telephone: (708) 563-7070FAX: (708) 563-7095
C8.3 IndustrialSection S - Service Assistance
Harrisburg (Branch of St. Louis)Cummins Gateway, Inc.Highway 45 NorthHarrisburg, IL 62946Telephone: (618) 273-4138FAX: (618) 273-4531
Rock Island - (Branch of Omaha)Cummins Great Plains Diesel, Inc.7820 . 42nd Street WestRock Island, IL 61204Telephone: (309) 787-4300FAX: (309) 787-4397
Onan BranchCummins Gateway, Inc.#1 Extra Mile DriveCollinsville, IL 62234Telephone: (618) 345-0123FAX: (314) 531-6604
Indiana
Indianapolis DistributorCummins Mid-States Power, Inc.P.O. Box 429173762 West Morris StreetIndianapolis, IN 46242-0917Telephone: (317) 243-7979FAX: (317) 240-1925
Evansville - (Branch of louisville)Cummins Cumberland. Inc.7901 Highway 41 NorthEvansville. IN 47711Telephone: (812) 867-4400FAX: (812) ~21-3282
Ft. Wayne BranchCummins Mid·States Power, Inc.3415 Coliseum Blvd. West(At Jet. '·69 & 30133)Ft. Wayne, IN 46808Telephone: (219) 482-3691FAX: (219) 484-8930
Gary - (Branch of Chicago)Cummins Northern illinois, Inc.1440 Texas StreetGary, IN 46402Telephone: (219) 885·5591FAX: (219) 883-4817
Indianapolis BranchCummins Mid·States Power, Inc.P.O. Box 429173621 West Morris StreetIndianapolis, IN 46242-0917Telephone: (317) 244-7251FAX: (317) 240-1215
Cedar Rapids ~(Branch of Omaha)Cummins Great Plains Diesel, Inc.625 - S3rd Avenue SWCedar Rapids, IA 52406Telephone: (S19) 366·7537 (24 hours)FAX: (319) 366-7562
Des Moines· (Branch of Omaha)Cummms Great Plains Diesel, Inc.1680 N.E. 51st AvenueP.O. Box BDes Moines, IA 50313Telephone: (515) 262·9591Parts: (515) 262·9744FAX: (515)262-0626
Des Moines· (Branch of Omaha)Midwestern Power ProductsDivision of Cummins Great Plains Die-sel, Inc.5194 N.E. 17th StreetDes Moines, IA 50313Telephone: (515) 264-1650FAX: (515) 264-1651
KansasColby - (Branch of Kansas City, Mis-souri)Cummins Mid-America, LLC.1880 South RangeColby, KS 67701Telephone: (785) 462-3945FAX: (785) 462-3970
Garden City - (Branch of KansasCity, Missouri)Cummins Mid-America, Inc.1285 AcrawayGarden City, KS 67846Telephone: (316) 275-2277FAX: (316) 275-2533
Wichita - (Branch of Kansas City,Missouri)Cummins Mid-America, Inc.5101 North BroadwayWichita, KS 67201Telephone: (316) 838-0875FAX: (316) 838-0704
Boston DistributorCummins Northeast, Inc.100 Allied DriveDedham, MA 02026Telephone: (781) 329-1750FAX: (781) 329-4428
Springfield BranchCummins Northeast, Inc.177 Rocus StreetSpringfield, MA 01104Telephone: (413) 737·2659FAX: (413) 731-1082
Distributors and BranchesPageS-5 I
MexiCO
Tijuana - (Branch of Los Angeles)Distribuidora Cummins De BajaBlvd. 3ra. Oeste No. 17523Frace. IndustrialGarita de Otay C.P. 22400Tijuana, Baja CaliforniaMexicoTelephone: 011-52-66-238433FAX: 011-52-66-238649
Michigan
Detroit (Novi) DistributorCummins Michigan, Inc.41216 Vincenti CourtNovi, MI 48375Telephone: (248) 478-9700FAX: (248) 478-1570
Blissfield, MichiganDiesel Fuel Systems, Inc.Subsidiary of Cummins Michigan Inc.211 N. Jipson StreetBlissfield, MI 49228Telephone: (517) 486-4324FAX: (517) 486-3614
St. Paul BranchCummins North Central, Inc.2690 Cleveland Ave. NorthS1.Paul, MN 55113Telephone: (651) 636-1000FAX: (65'1) 638-2497
Mississippi
Jackson - (Branch of Memphis)Cummins Mid-South, Inc.325 New Highway 49 SouthJackson, MS 39288-4224Telephone:Admin.: (601) 932-7016Parts: (601) 932·2720Service: (601) 939-1800
FAX: (601) 932-7399
Missouri
IIIIIIIIIIII Kansas City Distributor and Branch
Cummins Mid-America, Inc.8201 NE Parvin RoadKansas City, MO 64161Telephone: (816) 414-8200FAX: (816) 414-8299
Joplin BranchCummins Mid-America, Inc.3507 East 20th StreetJoplin, MO 64801Telephone; (417) 623-1661FAX: (417) 623-1817
Springfield BranchCummins Mid·America, Inc.3637 East KearneySpringfield, MO 65803Telephone: (417) 862·0777FAX: (417) 862-4429
IIIII
St, Louis DistributorCummins Gateway, Inc.7210 Hall StreetSI. Louis, MO 63147Telephone: (314) 389·5400FAX: (314) 389-9671
Columbia BranchCummins Gateway, Inc.5221 Highway 763 NorthColumbia, MO 65202Telephone: (314) 449-3711FAX: (314) 449-3712
Great Falls 4 (Branch of Denver)Cummins Rocky Mountain, Inc.415 Vaughn RoadGreat Falls, MT 59404Telephone: (406) 452·8561FAX: (406) 452-9911
Missoula - (Branch of Seattle)Cummins Northwest, Inc.4950 North Reserve StreetMissoula, MT 59802-1498Telephone: (406) 728-1300FAX: (406) 728-8523
Nebraska
Omaha Distributor and BranchCummins Great Plains Diesel, Inc.55'15 Center StreetP.O. Box 6068Omaha, NE 68106Telephone: (402) 551·7678 (24 Hours)FAX: (402) 551-1952
Kearney BranchCummins Great Plains Diesel, Inc.S15 Central AvenueKearney, NE 68847Telephone: (308) 234-1994FAX: (308) 234-5776
CB.3 IndustrialSection S . Service Assistance
Nevada
Elko ~(Branch of Salt Lake City)Cummins Intermountain, Inc.5370 i;ast Idaho StreetElko, NV 89801Telephone: (n5) 738-6405FAX: (TIS) 738-1719
Las Vegas • (Branch of Salt LakeCity)Cummins Intermountain, Inc.2750 Losee RoadNorth Las Vegas, NV 89030Telephone; (702) 399·2339FAX; (702) 399-7457
Sparks - (Branch of Salt Lake City)Cummins Intermountain, Inc.150 Glendale AvenueSparks, NV 89431Telephone: (775) 331-4983FAX: (775) 331-7429
Oklahoma City - (Branch of Arling-ton)Cummins Southern Plains, Inc.5800 West RenoOklahoma City, OK 73127Telephone: (405) 946-4481 (24 hours)FAX: (405) 946-3336
Tulsa" (Branch of Arlington)Cummins Southern Plains. Inc.16525 East Skelly DnveTulsa, OK 74116Telephone: (918) 234-3240FAX: (918) 234-2342
Oregon
Bend - (Branch of Seattle)Cummins Northwest, Inc.3500 N. Highway 97 (97701-5729)P.O. Box 309Bend, OR 97709·0309Telephone: (541) 389-1900FAX: (541) 389-1909
Distributors and BranchesPage S-7 I
Coburg/Eugene - (Branch of Seattle)Cummins Northwest. Inc.91201 Industrial ParkwayCoburg, OR 97401(Mailing Address)PO. Box 10877Eugene, OR 97440-2887Telephone: (541) S87·0000FAX: (541) 687-1977
Medford - (Branch of Seattle)Cummins NorthWest, Inc.4045 Crater Lake HighwayMedford. OR 97504-9796Telephone: (541) n9-01S1FAX: (541) 772-2395
Pendleton - (Branch of Seattle)Cummins Northwest, Inc.223 S.W 23rd StreetPendleton, OR 97801-1810Telephone: (541) 276-2561FAX: (541) 276-2564
Portland - (Branch of Seattle)Cummins Northwest, Inc.4711 N. Basin AvenueP.O. Box 2710 (97208-2710)Portland, OR 97217-3557Telephone: (503) 289-0900FAX: (503) 286-5938
Pennsylvania
Philadelphia DistributorCummins Power Systems. Inc.2727 Ford RoadBristol, PA 19007Telephone: (215) 785-6005 and
(609) 563-0005FAX: (215) 78504085
Bristol BranchCummins Power Systems. Inc.2727 Ford RoadBristol, PA 19007Telephone: (215) 785-6005 and
(609) 563-0005FAX: (215) 785-4728
Pittsburgh BranchCummins Power Systems, Inc.3 Alpha DrivePittsburgh, PA 15238-2901Telephone: (412) 82()"'B300FAX: (412) 820-8308
Harrisburg BranchCummins Power Systems, Inc.4499 Lewis RoadHarrisburg, PA 17111-2541Telephone: (717) 564-1344FAX: (717) 558-8217
IIIIIIIIIIIIIIIIII
II
Distributors and BranchesPage S~8
Puerto RicoPuerto Nuevo - (Branch of Tampa)Cummins Diesel Power, Inc.#31 Calle "C'EI MataderoPuerto Nuevo, Puerto Rico 00920Telephone: (787) 793-0300FAX: (787) 793-1072
South Carolina
Charleston - (Branch of Charlotte)Cummins Atlantic, Inc.3028 West Montague AvenueCharleston, SC 29418-5593Telephone: (843) 554-5112FAX: (843) 745-0745
Columbia - (Branch of Charlotte)Cummins Atlantic, Inc.1233 Bluff Road (29201)P.O. Box 13543Columbia, SC 29201-3543Telephone: (803) 799-2410FAX: (603) 779-3427
South Dakota
Sioux Falls· (Branch of Omaha)Cummins Great Plains Diesel, Inc.701 East 54th Street NorthSioux Falls, SD 57104Telephone: (605) 336-1715FAX: (605) 336-1748
San Antonio BranchCummins Southern Plains, Inc.6226 Pan Am Expressway NorthPO. Box 18385San Antonio, TX 7821B-0385Telephone: (512) 655-5420 (24 hours)FAX: (512) 655-3865
Houston Onan BranchSouthern Plains PowerA Division of Cummins Southern Plains1155 West Loop NorthHouston, TX 77055Telephone: (713) 956-0020FAX: (713) 956-0266
Utah
Salt Lake City DistributorCummins Intermountain, Inc.1030 South 300 WestSalt Lake City, UT 84101Telephone: (801) 355-6500FAX: (601) 524-1351
Vernal BranchCummins Intermountain, Inc.1435 East 335 SouthVernal, UT 84078Telephone: (435) 789-5732FAX: (435) 789·2853
Virginia
Cloverdale ~(Branch of Charlotte)Cummins Atlantic, Inc.263 Simmons DriveCloverdale, VA 24077Telephone: (540) 966-3169FAX: (540) 966-3749
Richmond ~(Branch of Charlotte)Cummins Atlantic, Inc.3900 Deepwater Terminal RoadRichmond, VA 23234Telephone: (B04) 232-7891FAX: (804) 232·7428
Tidewater - (Branch of Charlotte)Cummins Atlantic, Inc.Atlantic Power Generation3729 Holland 8lvd.Chesapeake, VA 23323Telephone: (757) 485-4848FAX: (757) 485-5085
CB.3 IndustrialSection S • Service Assistance
Washington
Seattle DistributorCummins Northwest, Inc.811 ev« Grady Way (98055-2944)P.O. Box 9811Renton, WA 98057-9811Telephone: (425) 235-3400FAX: (425) 235-8202
Rock Springs - (Branch of Salt LakeCity)Cummins Intermountain, Inc.2000 Foothill Blvd.P.O. Box 1634Rock Springs, WY 82901Telephone: (307) 362-5168FAX: (307) 362-5171
IIIIIIIIIIIIIIIIII
II
Distributors and BranchesPage S-10
I AlbertaEdmonton Distributor and BranchCummins Alberta11751 - '81 StreetEdmonton, AS T5S 2K5Telephone: (7BO)455-2151FAX: (780) 454-9512
Calgary BranchCummins Alberta4887 - 35th Street S.E.Calgary, Alberta T28 3H6, CanadaTelephone: (403) 569-1122FAX: (403) 569-0027
Grande PrairieCummins Alberta - Grande PraireRR2, Site 9, Box 22Sexsmith, AB CN TOH 3COTelephone: (780) 568-3359FAX: (780) 568-2263
Wetherill ParkCummins Engine Company, Pty. Ltd.Private Bag 150Wetherill Park, NSW 2164AustraliaLocation:492-494 Victoria StreetWetherill Park, NSW 2164AustraliaTelephone: (61-2) 9616-5300FAX: (61-2) 9616-5399
Cumbrasa Regional Office - BrazilCummins Brasil S.A.Rua Jati, 26607180-900 GuarulhosSao Paulo, BrazilMailing Address:P.O. Box 1307180-900 GuarulhosSao Paulo, BrazilTelephone: (55-11) 945-9811
CountryCovered: Brazil
Hong Kong Regional Office - Hong KongCummins Engine H.K. Ltd.Unison Industrial Centre15th Floor, Units C & 027-31 Au Pul Wan StreetP O. Box 840 ShatinFo Tan, Shatin, NTHong KongTelephone: (B52) 2606-5678Fax: (852) 2691-1641, 2687-3552
CountryCovered:
II
Hong Kong, Macau IBeijing Regional Office - China
Cummins CorporationChina World Tower, Suite 917China World Trade CenterNo.1 Jian Guo Men WaiBeijing 100004People's Republic of ChinaTelephone: (86-1) 6505-1658Fax: (88-10) 6505-4211
Middle East Regional OfficeCummins Diesel FZEUnits ZF 5 & 6, Jebel Ali Free ZoneDubaiUnited Arab EmiratesTelephone: (971) 4 883-8998Fax: (971) 4 883-8997E-mail: [email protected])
Countries Covered:MIDEAST
AfghanistanBahrainCyprusDjiboutiEgyptIraqIran
JordanKuwaitLebanonOmanPakistanQatarTurkey
Regional Offices - InternationalPage S·16
Seoul Regional Office - KoreaCummins Korea Ltd.5th Floor, Hye Sung Building35-26 Sam Sung Dong, Kang Nam KuSeoul, South KoreaTelephone: (82-2) 516-0431/2/3, 517-3370/1
CountryCovered:
Cummsa Regional Office - MexicoCummins, S.A. de C.v.Arquimedes No. 209Col. Polanco11560 Mexico, D.F.MexicoTelephone: (52-5) 254-382213783/3622MailinglShipping Address:Gonzalez de Castilla Inc.P.O. Box 13914605 Modern LaneModern Industrial ParkLaredo, TX 78040Telephone: (512) 722-5207
Kuala Lumpur (Office In Malaysia)Contact: Scott &English (M) Sdn BhdP.O. Box 1032450710 Kuala LumpurWest MalaysiaLocation:16 Jalan Chan Sow Lin55200 Kuala LumpurWest MalaysiaTelephone: (60-3) 2211033
Guangzhou M South China RegionalOfficeCummins Engine (China) InvestmentCo., Ltd. - GuangzhouRm. 211, Bai Yun Hotel, 367 Huan ShiDong Rd.Guangzhou, 510065People's Republic of ChinaTelephone: (86-20) 83313136, 833131 37Fax: (8&-20) 83313135
IIIIIIIIIIIIIIIII
II
Distributors - InternationalPage $-20
IShenzhen (JV)Shenzhen Chongfs Cummins EngineCo., ltd.Unit D2-F2.6Tian An Che Gong Miao Industrial Es-tateShen Nan Hd.,Shenzhen, 518040People's Republic of ChinaTelephone: (86-755) 3415479Fax: (86-755) 3415480
COMOROS- See Southern Africa Regional Office -Kelvin
IIIIIIIIIIIII
CONGO, PEOPLE'S REPUBLIC
Brussels (Office in Belgium)Bia, SARameistraat, 123B-3090Overijse, BelgiumTelephone: (32-2) 6892811
CORSICA- See France
COSTA RICA
San JoseServicios Unidos, S.A.p.o. Box 559San Jose, Costa RicaLocation:100 metros al este deExcelsior AntiquoCurridabat, San JoseTelephone Office: (506) 53-93-93Telephone Service Shop:
Santo DomingoArgico C. Por A.P.O. Box 292-2 FeriaSanto DomingoDominican Republic, ZP-6Location:Calle Jose A. SolerNo.3, ESQ.Avenida Lope de VegaTelephone: (609) 562-6281
DUBAI- See United Arab Emirates
ECUADOR
GuayaquilMotores Cummins (MOTCUM) SAP.O. Box 1062Guayaquil. EcuadorLocation:Avenida Carlos JulioArosemena Km. 4Telephone: (593-4) 203995/201177
QuitoRectificadora Botar S.A.P.O Box 17-01-3344Quito, EcuadorLocation:Av. 10 de Agosto No. 5980Telephone: (593-2) 465-176/1771
178/195/197
EGYPTCairoADATPO. Box 1572Cairo. EgyptSales and Service Location:25, Pyramid RoadGiza, Cairo, EgyptTelephone: (20-2) 385-4001/214/5/6/8/9
EL SALVADOR
San SalvadorSalvador MachineryCompany. SA de C.V.P.O. Box 125San Salvador, EI SalvadorLocation:Blvd. Ejercito NacionalTelephone: (503) 711022, 228388
ENGLAND• See United Kingdom
EQUATORIAL GUINEA- See NorthNlfestfEast and Central Af-rica Regional Office - Daventry
HONDURAS ITegucigalpaComercial LaeiszHonduras, S.A.P.O Box 1022Tegucigalpa, D.C., HondurasLocation:Zona La Burrera,Blvd. ToncontinFrente a Gasolinera Esso.Telephone: (504) 333570/335615
HONG KONG
III
KowloonCummins Engine H. K. Ltd.P.O Box 840 ShatinN.T., Hong KongLocation:Unison Industrial Centre15th Floor, Units C & D27-31 Au PUI Wan StreetFo Tan, Shatin, Hong KongTelephone: (852) 2606-5678Fax: (852) 2691-1641, 2687-3552
Tel AvivI Service (I) Ltd.298, Perin Nariman Street, Fort, Israel Engines &Bombay 400001, India Trailers Co. Ltd.Telephone: (91-22) 2863566/2862247 Levinson Brothers Engineers
IP. O. Box 390
Calcutta 33 Hahashmal StreetCummins Diesel Sales & Tel Aviv, Israel 61003Service (I) Ltd. Telephone: (972-3) 7106222
I94, Tivoli Court, IIC Bal1ygunge
ITALYCircular RoadCalcutta 700 019 (West Bengal), India MilanTelephone: (91-33) 2478065/24704811
2470774 Cummins Diesel ltaua S.p.A.
I Piazza Locatelli, 8New Delhi Zona Industriale Sesto UlterianoCummins Diesel Sales & 20098 S. GiulianoService (I) Ltd. Milanese (Milan), Italy
IFlat No. 307, Meghdoot Building Telephone: (39-2) 9828-1235/6/794 Nehru Place IVORY COASTNew Delhi 110019, IndiaTelephone: (91-11) 6431051/64457561 - See Cote d' Ivoire
6452817 JAMAICAI Raipur Miami (Office in U.S.A.)Cummins Diesel Sales &Service (I) Ltd. Cummins Southeastern Power, Inc.
LAOS- See South and East Asia Regional Of-fice - Singapore
LATVIA- See Moscow Regional Office - Moscow
LEBANON
BeirutS.E.T.1. Charles KellerSAL.B.P. 16-6726Beirut, LebanonLocation:Corniche du FleuveTelephone: (961-1) 425040/41
LESOTHO- See South Africa
LIBYA- See NorthlWest Africa Regional Office- Oaventry
LlECHTENSTEI N- See Switzerland
LUXEMBOURG
Gross·Gerau (Office in Germany)Cummins Diesel Deutschland GmbHP.O. Box 11 34Odenwaldstrasse 23D·6080 Gross-Gerau, GermanyTelephone: (49-6152) 174-0
MACAU- See Hong Kong
MADAGASCAR• See East and Southern Africa Re-gional Office - Harare
MADEIRA ISLANDS- See Portugal
C8.3 IndustrialSection S •Service Assistance
MALAYSIA
Kuala lumpurCummms Dies61Sales & ServiceDiv. of Scott & English(M) Sdn. Bhd.P.O. Box 1032450710 Kuala Lumpur, West MalaysiaLocation:16 Jalan Chan Sow Lin55200 Kuala LumpurTelephone: (6Q.3) 22110:33
TlalnepantlaDistribuidor CumminsMetropolitana, SA DE c:v.Sor Juana Ines de la Cruz No. 55554000 Tlalnepantia. Edo. de Mexico,MexicoTelephone: (52-5) 327-38-00, 390-64·37,
390-12-27
MOROCCO
CasablancaSoberma (Groupe Auto Hall)Societe SobermaChemin Ain BorjaQuartier BeausiteAin SebaaCasablanca, MoroccoTelephone: (212-22) 66 66 40-43Fax: (212·22) 66 66 45-46
MOZAMBIQUE- See Southern Africa Regional Office -Kelvin
SLOVAKIA• See European Regional Office - Gross-Gerau
SOLOMON ISLANDS· See South Pacific Regional Office -Melbourne
SOMALIA- See East and Southern Africa Re-gional Office - Harare
SOUTH AFRICA
JohannesburgCummins Diesel South Africa Pty. Ltd.Private Bag X7wendywood 2144South AfricaLocation:13 Eastern Service RoadKelvin View 2054Telephone: (27-11) 321 8700
Taipei (JV)Cummins Power Service & Parts Corp.No. 115, Wu Ko tst Rd.,Wu Ku, Industrial DistrictTaipei, Taiwan, R.O.C.Telephone: (886-2) 2290-0331Fax: (886-2) 2290-0393
TANZANIA- See South African Regional Office -Kelvin
THAILAND
BangkokDiethelm & Company Ltd.1696 New Petchburi RoadBangkok 10310, ThailandTelephone: (66-2) 254-4900
CaracasSudimatApartado Postal 1322CarmelitasCaracas 1010VenezuelaLocation:Final Avenida San MartinUrb. la QuebraditaCaracas 1061Telephone: (58-2) 442-6161/2647
Ho Chi Minh CityDiethelm & Co. Ltd. Engineering3rd Floor, IBC Building1 Me Linh SquareDistrict 1Ho Chi Minh City, VietnamTelephone: (84-8) 294·102, 294-103
WESTERN SAMOA- See South Pacific Regional Office -Melbourne
IIIIIYEMEN
Sana'aZubieri Trading Co.P.O. Box 535Sana'a, Yemen Arab RepublicTelephone: (967) 1-223943/224051
Troubleshooting Procedures and Techniques.................................................................................. TS-1General Information .•.. T5-1
Troubleshooting Symptoms Charts T5-1Air Compressor Air Pressure Rises Slowly T5-2Air Compressor Cycles Frequently , TS-3Air Compressor Noise is Excessive............... TS-4Air Compressor Pumping Excess Lubricating Oil into the Air System T5-5Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) '" T5-6Air Compressor Will Not Stop Pumping......................... T5-7Alternator Not Charging or Insufficient Charging...................................... TS-8~~~~~~ioc~~:~rn~r~~~ T1~;5Coolant Loss - ExternaL..... TS-11Coolant Temperature Above Normal - Gradual Overheat.. TS-12Coolant Temperature is Above Normal - Sudden Overheat................ TS-14Coolant Temperature is Below Normal. T8-15Engine Acceleration or Response Poor TS-16Engine Difficult to Start or Witt Not Start (Exhaust Smoke) '" TS-18Engine Difficult to Start or Witt Not Start (No Exhaust Smoke) TS-20Engine Noise Excessive TS-22Engine Noise Excessive - Combustion Knocks TS-24Engine Power Output Low..... TS-25Engine Runs Rough at Idle... TS-28Engine Runs Rough or Misfires TS-29Engine Speed Surges at Low or High Idle... TS-30Engine Speed Surges Under Load or in Operating Range TS-31Engine Starts But Witt Not Keep Running TS-32Engine Vibration Excessive " TS-33Engine Will Not Crank or Cranks Slowly (Air Starter) TS-34Engine Will Not Crank or Cranks Slowly (Electric Starter) TS-36Engine Will Not Reach Rated Speed (RPM) TS-38Engine Will Not Shut Off '" TS-40Exhaust Smoke Excessive Under Load TS-41Fuel Consumption Excessive TS-42Fuel in Coolant. TS-43Fuel in the Lubricating Oil " TS-44Fuel or Lubricating Oil Leaking From Exhaust Manifold TS-45General Information TS-1Intake Manifold Air Temperature Above Specificatlon................................................................................. TS-46Intake Manifold Pressure (Boost) is Below Normal TS-48Lubricating Oil Consumption Excessive.. TS-49Lubricating Oil Contaminated TS-50t~g~:~:::~ggil ~~:~~;~'~e''High::::::::::::::::::::::::::::: ::::::::::::::::::::::::: :::.. .. :::::::.'::::::::::::::::::::::::::::: :::::::::::::: +~~~~Lubricating Oil Pressure Low TS-53Lubricating Oil Sludge in the Crankcase Excessive TS-55Smoke, Black - Excessive............................................................. TS-56Smoke, White - Excessive TS-57Turbocharger Leaks Engine Oil or Fuel. TS-59
Troubleshooting Procedures and TechniquesPage TS-1
Troubleshooting Procedures and TechniquesGeneral InformationThis guide describes some typical engine operating problems, their causes, and some acceptable corrections to thoseproblems. Unless noted otherwise, the problems listed are those which an operator can diagnose and repair .
.A WARNING APerforming troubleshooting procedures NOT outlined in this section can result in equipment damage orpersonal injury or death. Troubleshooting must be performed by trained, experienced technicians. Consult aCummins Authorized Repair Location for diagnosis and repair beyond that which is outlined, and for symptomsnot listed in this section. Before beginning any troubleshooting, refer to General Safety Instructions in Sectioni of this manual.
Follow the suggestions below for troubleshooting:
• Study the complaint thoroughly before acting
• Refer to the engine system diagrams
• Do the easiest and most logical things first
• Find and correct the cause of the complaint
Troubleshooting Symptoms ChartsGeneral InformationUse the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each rowof blocks from top to bottom. Follow through the chart to identify the corrective action .
.A WARNING ATroubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must beperformed by trained, experienced technicians.
Air intake system restriction to air compressoris excessive
OK
Air system leaks
OK
Carbon buildup is excessive in the air dis-charge line, downstream air valves, or cylinder
head
OK
Contact a Cummins AuthorizedRepair Facility
Replace the air compressor air cleaner (ifinstalled). Check the air intake piping. Checkengine air intake restriction if the air compres-sor inlet is plumbed to the vehicle or equip-ment intake system. Refer to Section 4.
Block the vehicle wheels and check the airsystem for leaks with spring brakes appliedand released. Check for leaks from the aircompressor gaskets and the air system hoses,fittings, tanks, and valves. Refer to the OEMservice manuals.
Check for carbon buildup. Replace the aircompressor discharge line and cylinder headassembly if necessary. Refer to Section 7.
OK-Carbon buildup is excessive in the air dis-charge line, check valve, or cylinder head
OK-Air compressor pumping time is excessive
OK-Contact a Cummins AuthorizedRepair Facility
Block the vehicle wheels and check the airsystem for leaks with spring brakes appliedand released. Check for leaks from the aircompressor gaskets and the air system hoses,fittings, tanks, and valves. Refer to the OEMservice manuals.
IIICheck for carbon buildup. Replace the air
compressor discharge line if necessary. Referto Section 7. I
IReplace the desiccant cartridge on theTurbo/CR 2000 air dryer. Refer to the OEMservice manual. Check the air compressor dutycycle. Install a larger air compressor, if neces-sary. Refer to an Authorized Cummins RepairFacility. I
Carbon buildup is excessive in the air dis-charge line, downstream air valves, or cylinder
head
OK-Air compressor is sending air pulses into the
air tanks
OK-Ice buildup in the air system components
OK-Contact a Cummins AuthorizedRepair Facility
Check for carbon buildup. Replace the aircompressor discharge line and cylinder headassembly if necessary. Refer to Section 7.
Install a ping tank between the air dryer andthe wet tank. Refer to the manufacturer'sinstructions.
For all models, check for ice in low spots of theair discharge line, dryer inlet, and elbowfittings. On Holsetv models, also check theEcon valve (if equipped). Refer to the OEMservice manual.
Air Compressor Pumping Excess Lubricating Oil Into the Air SystemCorrection
Lubricating oil drain interval is excessive
OK-Air intake system restriction to air compressor
is excessive
OK-Air compressor pumping time is excessive
OK-Carbon buildup is excessive in the air dis-charge line, check valve, or cylinder head
OK-Contact a Cummins AuthorizedRepair Facility
Verify the correct lubricating oil drain interval.Refer to Section 2.
Replace the air compressor air cleaner (ifinstalled). Check the air intake piping. Checkengine a!r intake restriction if the air compres-sor Inlet IS plumbed to the vehicle or equip-ment Intake system. Refer to Section 3.
Replace the desiccant cartridge on theTurbo/CR 2000 air dryer. Refer to the OEMservice manual. Check the air compressor dutycycle. Install a larger air compressor, if neces-sary. Refer to an Authorized Cummins RepairFacility.
Check for carbon buildup. Replace the aircompressor discharge line if necessary. Referto Section 7.
IIIIIIIIIIIIIIIIIII
II Troubleshooting Symptoms Charts
Page TS-6CB.3 Industrial
Section TS - Troubleshooting Symptoms
Cause
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
CorrectionIAir system leaksI
I OK-I Contact a Cummins AuthorizedRepair Facility
IIIIIIIIIIIII
Block the vehicle wheels and check the airsystem for leaks with spring brakes appliedand released. Check for leaks from the aircompressor gaskets and the air system hoses,fittings, tanks, and valves. Refer to the OEMservice manual.
Air Compressor Will Not Stop Pumping ICause Correction
Air system leaks
Block the vehicle wheels and check the airsystem for leaks with spring brakes appliedand released. Check for leaks from the aircompressor gaskets and the air system hoses,fittings, tanks, and valves. Refer to the OEMservice manual.
'- ~I...."'L __C_h_e_c_k_t_h_e_c_o_n_d_i_ti_o_n_o_f_t_h_e_b_a_t_te_r_ie_s_._R_e_p_l_a_c_e__ ~Batteries have failed the batteries, if necessary. Refer to the OEM
service manual.
OK-Check the voltage regulator. Replace thevoltage regulator, if necessary. Refer to anAuthorized Cummins Repair Facility.
OK-Radiator cap is not correct, is malfunctioning,
or has low-pressure rating
OK-Cooling system hose is collapsed, restricted, or
leaking
OK-Coolant fill line is restricted or obstructed
OK-Coolant is rusty and has debris
OK-
Inspect the engine and cooling system forexternal coolant leaks. Repair if necessary.Add coolant. Refer to the OEM service manual. I
IInspect the engine for coolant leaking fromhoses, draincocks, water manifold, jumpertubes, expansion and pipe plugs, fittings,radiator core, air compressor and cylinder headgaskets, lubricating oil cooler, water pump seal,cylinder block, and OEM-mounted componentsthat have coolant flow.
IIICheck the radiator pressure cap. Refer to the
OEM service manual.
IIInspect the hoses. Refer to Section 7.
ICheck the coolant fill line for restrictions orobstructions. Refer to Section 7.
IDrain and flush the cooling system. Fill withcorrect mixture of antifreeze and water. Referto Section 7.
II
f ..~----------------~O~K----------------~ L ~
Engine is overheating
-Contact a Cummins AuthorizedRepair Facility
Refer to the Coolant Temperature AboveNormal symptom tree. I
OK-Cooling system hose is collapsed, restricted, or
leaking
OK-Coolant temperature gauge is malfunctioning
OK-Charge air cooler fins, radiator fins, or air
conditioner condenser fins are damaged orobstructed with debris
OK-Cold weather radiator cover or wintertront is
closed
OK...Contact a Cummins Authorized
Repair Facility
Check the radiator pressure cap. Refer to theOEM service manual.
Inspect the hoses. Refer to Section 7.
Test the temperature gauge. Repair or replacethe gauge, if necessary.
Inspect the charge air cooler, air conditionercondenser, and radiator fins. Clean, if neces-sary. Refer to Section 4 and the OEM servicemanual.
Open the cold weather radiator cover or thewinterfront. Maintain a minimum of 784 ern"{122 in2), or approximately 28 x 28 cm 111 x 11in], of opening at all times. Refer to Section 1.
Coolant Temperature is Below Normal ICause Correction
Coolant temperature gauge or sensor isr malfunctioning
OK..Engine is operating at low ambient temperature
OK..Fan drive or fan controls are malfunctioning
OK..Coolant temperature gauge is malfunctioning
OK..Thermostat is not correct or is malfunctioning
OK..Contact a Cummins Authorized
Repair Facility
Test the gauge and the sensor. Repair orreplace, if necessary. Refer to OEM servicemanual. I
ICheck the winterfront, shutters, and under-the-hood air. Use under-the-hood intake air in coldweather. Refer to Cold Weather Operation,Bulletin 3387266, and Section 1. I
ICheck the fan drive and controls. Refer to theOEM service manual. I
ITest the temperature gauge. Repair or replacethe gauge, if necessary.
ICheck the thermostat for the correct partnumber and for correct operation. Contact aCummins Authorized Repair Facility. I
OK-Fuel supply line or passage restriction between
the fuel pump and the injectors
OK-Charge air cooler is restricted or leaking
OK...(Continued)
Refer to Section 1, Operating Instructions.
Fill the supply tank. Refer to the OEM servicemanual.
Check the vehicle brakes for dragging,transmission malfunction, cooling fan operationcycle time, and engine-driven units. Refer tothe OEM service manual.
Compare the drivetrain specifications toCummins recommendations. Check the clutchfor correct operation. Refer to the OEM servicemanual.
Check for correct gearing and drivetraincomponents. Refer to the OEM vehiclespecifications.
Refer to the Intake Manifold Air TemperatureAbove Specification symptom tree.
Check the fuel supply line or passage forsharp bends or restriction.
Inspect the charge air cooler for air restrictionsor leaks. Refer to Section 4.
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Correction
Starting procedure is not correct
OK...Fuel level is low in the tank
OK...Starting aid, if necessary for cold weather, is
malfunctioning
OK
Engine block heater is malfunctioning (ifequipped)
OK
Fuel heater is malfunctioning (if equipped)
OK
Battery voltage is low
OK
Keyswitch circuit is malfunctioning
OK
Engine cranking speed is too slow
OK...Vehicle parasitics are excessive
OK...(Continued)
Verify the correct starting procedure. Refer toSection 1.
Fill the supply tank. Refer to the OEM servicemanual.
Check for correct operation of the cold weatherstarting aid. Refer to Cold Weather StartingAids in Section 1. Refer to the manufacturer'sinstructions.
Check the electrical sources and wiring to thecylinder block heater. Replace the block heater,if necessary. Refer to the OEM service manual.
Check the fuel heater and replace, if neces-sary. Refer to the manufacturer's instructions.
Check the batteries and the unswitched batterysupply circuit. Refer to the OEM servicemanual.
Check the vehicle keyswitch circuit. Refer tothe OEM service manual.
If the cranking speed is slower than 150 rpm,refer to the Engine Will Not Crank or CranksSlowly symptom tree.
Check the vehicle brakes for dragging,transmission malfunction, cooling fan operationcycle time, and engine-driven units. Refer tothe OEM service manual.
Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued)
Cause
Fuel leak
OK..Fuel pump overflow valve is malfunctioning
OK..Fuel transfer pump malfunctioning
OK..Throttle linkage adjustment is not correct
OK
Air in the fuel system
OK
Air intake system restriction is above specifica-tion
OK
Fuel grade is not correct for the application, orthe fuel quality is poor
OK
Contact a Cummins AuthorizedRepair Facility
Correction
Check the fuel lines, fuel connections, and fuelfilters for leaks. Check the fuel lines to thesupply tanks. Refer to the OEM servicemanual.
Check the overflow valve. Replace if neces-sary. Refer to the OEM service manual.
Inspect the fuel transfer pump. Replace ifnecessary. Refer to Section A.
Check the fuel pump throttle linkage adjust-ment. Refer to the OEM service manual.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
Check the air intake system for restriction.Clean or replace the air filter and inlet pipingas necessary.Refer to Section 4.
Operate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)ICause
I Starting procedure is not correct
I OK
Fuel level is low in the tankI OK
IFuel shutoff valve is malfunctioning
I OK
I OEM engine protection system is malfunction-ing
I OK
I Battery voltage is low
I OK..Keyswitch circuit is malfunctioningI
IOK..
Air in the fuel system
II
OK..Fuel transfer pump malfunctioning
I OK
Correction
Verify the correct starting procedure. Refer toSection 1.
Fill the supply tank. Refer to the OEM servicemanual.
Check for loose wires and verify that the fuelshutoff valve is functioning. Check to be suremanual shutoff lever is in the run position.Refer to the OEM service manual.
Isolate the OEM engine protection system.Follow the OEM service manuals to check for amalfunction.
Check the batteries and the unswitched batterysupply crrcuu. Refer to the OEM servicemanual.
Check the vehicle keyswitch circuit. Refer tothe OEM service manual.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines fueltank standpipe and fuel filters as nece~sary.Vent air from the system. Refer to Section 5.
Inspect the fuel transfer pump. Replace ifnecessary. Refer to Section A.
I ~ F_u_e_l_d_r~a~in~b_a_C_k_u_P~f······OK ~--------------------------~
I (Continued)
I
Verify the fuel return line is plumbed to thebottom of the fuel tank.
I -Fuel grade is not correct for the application, or
the fuel quality is poor
I OK-I Air in the fuel system
I OK
I Coolant temperature is below specification
I OK-Contact a Cummins AuthorizedRepair Facility
IIIIIIIII
Check the winterfront, shutters, and under-the-hood air. Use under-the-hood intake air in coldweather. Refer to Cold Weather Operation,Bulletin 3387266, and Section 1.
Operate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
Refer to the Coolant Temperature BelowNormal symptom tree.
L- -F_u_e_l_l_ev_e_l_i_s~lo7w~i-n-t-h-e-t-a-n-k---------jf······OK 4- _..Engine is operating above recommended
altitude
OK..Throttle linkage adjustment is not correct
OK-Fuel shutoff lever (mechanical) partially
engaged
OK-Intake and exhaust system restricted
OK-Air intake system restriction is above specifica-
tion
OK..Air intake or exhaust leaks
OK-Air leak between the turbocharger and the
intake manifold
OK- (Continued)
IFill the supply tank. Refer to the OEM servicemanual.
IEngine power decreases above recommendedaltitude. Refer to the Engine Data Sheet forspecifications. I
ICheck the fuel pump throttle linkage adjust-ment. Refer to the OEM service manual.
ICheck or replace shutoff lever in run position. I
ICheck the intake and exhaust systems forrestrictions. Inspect the intake air filter andreplace as necessary.
ICheck the air intake system for restriction.Clean or replace the air filter and inlet pipingas necessary. Refer to Section 4.
II
Check for loose or damaged piping connec-tions and missing pipe plugs. Check theturbocharger and exhaust manifold mounting.Refer to Section 3.
II
Check for leaks in the air crossover tubecharge air cooler connections, hoses, or'through holes in the manifold cover and repairor replace if necessary. Refer to the OEMservice manual.
Check the fuel lines, fuel connections, and fuelfilters for leaks. Check the fuel lines to thesupply tanks. Refer to the OEM servicemanual.
II
Operate the engine from a temporary tank of
'-- F_u_e_1q__Ua_l_it_y_i_S_p_o_o_r ~ L __n_u_m_b_e_r__2_d_ie_s_e_l_f_U_e_I._R__ef_e_r_t_0_t_h_e_O__E_M__s_e_r_vi_c_e~... . manual.
I OK
Fuel supply is not adequateIOK
IFuel return restriction excessive
I OK
I Fuel pump overflow valve is malfunctioning
OK
IFuel lift pump is malfunctioning
I OK
IAir in the fuel system
I OK
IVehicle parasitics are excessive
I OK
I (Continued)
I
Check the flow through the filter to locate thesource of the restriction. Refer to the OEMservice manual.
Inspect the fuel return lines for restrictions.Refer to the OEM service manual.
Check the overflow valve. Replace if neces-sary. Refer to the OEM service manual.
Check the fuel lift pump for correct operation.Check the pump output pressure. Replace thefuel lift pump if necessary. Refer to Section A.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
Check the vehicle brakes for dragging,transmission malfunction, cooling fan operationcycle time. and engine-driven units. Refer tothe OEM service manual.
IInspect the charge air cooler for air restrictionsor leaks. Refer to Section 4.
ICheck the oil level. Verify the dipstick calibra-tion and oil pan capacity. Fill the system to thespecified level. Refer to Section 3. I
IIIIIIIIIIIIII
II Troubleshooting Symptoms Charts
Page TS-28C8.3 Industrial
Section TS - Troubleshooting Symptoms
Cause
Engine Runs Rough at Idle
CorrectionI
l Allow the engine to warm to operating tem-perature. If the engine will not reach operating
'-E__n_g_in~e~is-c-O-I-d--------------~ ······L_t_e_m __p_e_ra_t_u_re_,_r_e_fe_r_t_o_t_h_e_C__o_o_la_n_t_Ti_e_m_p_e_r_a_tu_r_e__ ~. Below Normal symptom tree.
OK...II
Idle speed is set too low for accessories
I OK-I Fuel pump overflow valve is malfunctioning
I OK-Fuel transfer pump malfunctioning
I OK-IAir in the fuel system
I OK
I Fuel supply line or passage restriction betweenthe fuel pump and the injectors
I OK..Engine mounts are worn, damaged, or not
correctI OK...I Fuel grade is not correct for the application, or
the fuel quality is poor
I OK-I
Contact a Cummins AuthorizedRepair Facility
II
Check and adjust the low-idle screw. Refer tothe OEM service manual.
Check the overflow valve. Replace if neces-sary. Refer to the OEM service manual.
Inspect the fuel transfer pump. Replace ifnecessary. Refer to Section A.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
Check the fuel supply line or passage forsharp bends or restriction.
Check the engine mounts. Refer to the OEMservice manual.
Operate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
OK..Fuel supply line or passage restriction between
the fuel pump and the injectors
OK-Fuel grade is not correct for the application, or
the fuel quality is poor
OK..
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
I
II
Check the fuel supply line or passage forsharp bends or restriction. IOperate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
Check the overflow valve. Replace if neces-sary. Refer to the OEM service manual.
Check the fuel lift pump for correct operation.Check the pump output pressure. Replace thefuel lift pump if necessary. Refer to Section A.
Check the engine mounts. Refer to the OEMservice manual.
IIIIIIIII
II Troubleshooting Symptoms Charts
Page TS-30C8.3 Industrial
Section TS - Troubleshooting Symptoms
Cause
Engine Speed Surges at Low or High Idle
CorrectionII
Fuel level is low in the tank I Fill the supply tank. Refer to the OEM service
~ ~~ ~r······L-_m_a_n_u_a_'_. ~
OK-I Engine idle speed is set too low
I OK-I Air in the fuel system
I OK-Fuel supply line or passage restriction between
the fuel pump and the injectorsI OK
I Fuel grade is not correct for the application, orthe fuel quality is poor
I OK-I
Contact a Cummins AuthorizedRepair Facility
IIIIIII
Adjust the idle speed. Refer to Section A.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
Check the fuel supply line or passage forsharp bends or restriction.
Operate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
OK ~------------------------------~...Air in the fuel system
OK...Idling with excessive load
OK...Vehicle parasitics are excessive
OK...Clutch is malfunctioning or is not correct
OK..Fuel grade is not correct for the application, or
the fuel quality is poor
OK..Contact a Cummins Authorized
Repair Facility
IFill the supply tank. Refer to the OEM servicemanual.
ICheck for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5. I
IUse the PTa feature for loaded conditions atlow engine speeds. Refer to Section 1.
IICheck the vehicle brakes for dragging,
transmission malfunction, cooling fan operationcycle time, and engine-driven units. Refer tothe OEM service manual.
IICompare the drivetrain specifications to
Cummins recommendations. Check the clutchfor correct operation. Refer to the OEM servicemanual.
IOperate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
F_u_e_~_~_e_ve_~_·_Is_~_o_W_i_n_t_h_e_t_a_n_k~I L __F_il_l_th_e__s_u_p_P_ly_t_a_n_k_._R_e_f_e_r_to__th_e__O_E_M__ s_e_N__ic_e__ ~. manual.
OKI ..I Idle speed is set too low for accessories
IOK..
Engine-driven units are engaged
I OK
I Fuel shutoff lever (mechanical) partiallyengaged
I OK-I Air in the fuel system
I OK...Fuel filter or fuel suction line is restricted
I OK..I Fuel supply line or passage restriction between
the fuel pump and the injectors
I OK..Fuel grade is not correct for the application, or
the fuel quality is poorIOK
I Contact a Cummins AuthorizedRepair Facility
III
Check and adjust the low-idle screw. Refer toSection A.
Disengage engine-driven units.
Check for correct solenoid operation. Refer tothe OEM service manual.
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
Replace the fuel filter. Refer to the OEMservice manual.
Check the fuel supply line or passage forsharp bends or restriction.
Operate the engine from a tank of high-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V.
Fan is loose, damaged, or has excessive hubbearing end play
OK
Vibration damper is damaged
OK..Alternator bearing worn or damaged
OK-Contact a Cummins AuthorizedRepair Facility
Refer to the Engine Runs Rough or Misfiressym ptorn tree. I
ICheck the fan hub, alternator, freon compres-sor, and hydraulic pump for interference.Isolate belt-driven accessories, and check forvibration. Refer to Section 3 and Section 4. I
IRefer to the Air Compressor Cycles Frequentlysymptom tree.
IICheck the engine mounts. Refer to the OEM
service manual.
ICheck the fan. Refer to Section 3.
IIRefer to the Engine Runs Rough or Misfires
symptom tree.
IInspect the vibration damper. Refer to Section7. I
IClean and replace the alternator. Refer to theOEM service manual.
Engine Will Not Crank or Cranks Slowly (Air Starter)
Correction
Air pressure is low in the air tanks
OK-Enqine-driven units are engaged
OK-Lubricating oil level is above specification
OK-Lubricating oil does not meet specifications for
operating conditions
OK-Electrical system is "open" (blown fuses,
broken wires, or loose connections)
OK-Battery charge is low
OK-Keyswitch circuit is malfunctioning
OK-Starter solenoid is not receiving voltage
OK-(Continued)
Increase air pressure with an external airsource. Refer to the OEM service manual.
Disengage engine-driven units.
Check the oil level. Verify the dipstick calibra-tion and oil pan capacity. Fill the system to thespecified level. Refer to Section 3.
Change the oil and filters. Refer to Section 4.Use the oil recommended in Section V.
Check the fuses, wires, and connections. Referto the OEM service manual and manufactur-er's wiring diagram.
Check battery. If the battery is low, check thealternator for proper charging. Charge thebattery, and replace if necessary. Refer to theOEM service manual.
Check the vehicle keyswitch circuit. Refer tothe OEM service manual.
Check the battery supply to the starter sole-noid. Refer to the OEM service manual.
Engine Will Not Crank or Cranks Slowly (Electric Starter)
Correction
'-- 8_a_t_te_r_ie_s__a_re__c_o_ld ~1 L__C_h_e_c_k__th_e__b_at_t_e~he_a_t_e_~_R__e_fe_r_t_o_t_h_e__m_a_n_u_-__ ~_ r _ tacturer's instructions.
OKIIIIIIIIIIIIIIII
Battery cables or connections are loose,broken, or corroded (excessive resistance)
OK
Electrical system is "open" (blown fuses,broken wires, or loose connections)
OK
Battery charge is low
OK...Keyswitch circuit is malfunctioning
OK
Starter solenoid is not receiving voltage
OK
Engine-driven units are engaged
OK
Lubricating oil level is above specification
OK....(Continued)
Check the battery cables and connections.
Check the fuses, wires, and connections. Referto the OEM service manual and manufactur-er's wiring diagram.
Check battery. If the battery is low, check thealternator for proper charging. Charge thebattery, and replace if necessary. Refer to theOEM service manual.
Check the vehicle keyswitch circuit. Refer tothe OEM service manual.
Check the battery supply to the starter sole-noid. Refer to the OEM service manual.
Disengage engine-driven units.
Check the oil level. Verify the dipstick calibra-tion and oil pan capacity. Fill the system to thespecified level. Refer to Section 3.
Vehicle speed is too low for adequate coolingwith high engine load
OK...Throttle linkage adjustment is not correct
OK
Tachometer is not calibrated or is malfunction-ing
OK
Air-fuel tube leaking, wastegate diaphragmruptured, or wastegate plumbing damaged
OK
Charge air cooler restricted (if equipped)
OK
Fuel supply is not adequate
OK
Fuel shutoff lever (mechanical) partiallyengaged
OK
Exhaust back pressure too high
OK...(Continued)
Reduce the engine load. Increase the engine(fan) rpm by downshifting.
Check throttle linkage adjustment. Refer to theOEM service manual.
Compare the tachometer reading with ahandheld tachometer or an electronic servicetool reading. Calibrate or replace the tachom-eter as necessary. Refer to the OEM servicemanual.
Tighten the fittings, repair plumbing, replacewastegate diaphragm. Refer to the OEMservice manual or an Authorized CumminsRepair Facility.
Inspect the air cooler for internal and externalrestrictions. Replace the restricted cooler ifnecessary. Refer to the OEM service manual.
Check the flow through the filter to locate thesource of the restriction. Refer to the OEMservice manual.
Make sure fuel shutoff lever is in the RUNposition. Replace if necessary. Reter to theOEM service manual.
Measure and correct if above specification.Refer to an Authorized Cummins RepairFacility.
Engine Will Not Reach Rated Speed (RPM) (Continued)
Cause
Fuel transfer pump malfunctioning
OK-Vehicle parasitics are excessive
OK-
Correction
Inspect the fuel transfer pump. Replace ifnecessary. Refer to Section A.
Check the vehicle brakes for dragging,transmission malfunction, cooling fan operationcycle time, and engine-driven units. Refer tothe OEM service manual.
Engine power output is low I Refer to the Engine Power Outlet Low symp-
L_ ~ ······L-_to_m __t_re_e_- ~
OK-Contact a Cummins AuthorizedRepair Facility
IIIIIIIIIIIIIIIIIII
II Troubleshooting Symptoms Charts
Page TS-40CB.3 Industrial
Section TS - Troubleshooting Symptoms
Cause
Engine Will Not Shut Off
CorrectionIFuel shutoff valve is malfunctioningI
I OK-Engine running on fumes drawn into the air
intakeIOK
I -
Check for loose wires and verify that the fuelshutoff valve is functioning. Check to be suremanual shutoff lever is in the run position.Refer to the OEM service manual.
Inspect the air intake ducts. Locate and isolatethe source of the fumes. Make repairs asneeded. Refer to the OEM service manual.
ICheck the fuel lines, fuel connections, and fuelfilters for leaks using the combustible gas
Check for air in the fuel system. Tighten orreplace the fuel connections, fuel lines, fueltank standpipe and fuel filters as necessary.Vent air from the system. Refer to Section 5.
IIIII
Air filter is restricted I Check the air filter for restrictions. Refer to
Check intake and exhaust systems for loose ordamaged piping connections and/or missingpipe plugs. Check turbocharger and exhaustmanifold mounting. Refer to the OEM servicemanual.
III
Monitor the turbocharger boost pressure withan electronic service tool. Refer to the OEMservice manual or an Authorized CumminsRepair Facility.
Allow the engine to warm to operating tem-perature. If the engine will not reach operatingtemperature, refer to the Coolant TemperatureBelow Normal symptom tree.
Check the AFC for leaks. Repair any leaksfound, if necessary. Check and clean AFCtubing and fittings for obstructions. Refer tothe OEM service manual or an AuthorizedCummins Repair Facility.
I OK-I Air intake system restriction is above specifica-
tion
I OK-Equipment and environmental factors are
affecting fuel consumptionIOK
I -Lubricating oil level is above specification
I OK-I Contact a Cummins AuthorizedRepair Facility
III
Check the hubometer and odometer calibra-tions. Calibrate or replace the hubometer orodometer, if necessary. Calculate fuel con-sumption with new mileage figures.
Check for loose or damaged piping connec-tions and missing pipe plugs. Check theturbocharger and exhaust manifold mounting.Refer to Section 3.
Check the air intake system for restriction.Clean or replace the air filter and inlet pipingas necessary. Refer to Section 4.
Consider ambient temperatures, wind, tire size,axle alignment. routes, and use of aerody-namic aids when evaluating fuel consumption.
Check the oil level. Verify the dipstick calibra-tion and oil pan capacity. Fill the system to thespecified level. Refer to Section V.
Low oil and coolant temperatures can becaused by long idle time (greater than 10minutes). Shut off the engine rather than idlefor long periods. If idle time is necessary, raisethe idle speed.
Check the bulk oil supply. Drain the oil andreplace with noncontaminated oil. Replace theoil filter(s). Refer to Section 4.
Fuel or Lubricating Oil Leaking From Exhaust Manifold
Correction IIntake air restriction is high
OK-Turbocharger drain line is restricted
OK-Turbocharger oil seal is leaking
OK-Contact a Cummins AuthorizedRepair Facility
ICheck the air intake system for restriction.Refer to the OEM service manual.
IRemove the turbocharger drain line, and checkfor restriction. Clean or replace the drain line.Refer to the OEM service manual or anAuthorized Cummins Repair Facility. I
ICheck the turbocharger for oil seals and forleaks. Refer to the OEM service manual or anAuthorized Cummins Repair Facility. I
Intake Manifold Air Temperature Above Specification
Correction
Charge air cooler fins, radiator fins, or airconditioner condenser fins are damaged or
obstructed with debris
OK
Cold weather radiator cover or winterfront isclosed
OK
Fan drive belt or water pump belt is broken
OK
Fan shroud is damaged or missing, or the airrecirculation baffles are damaged or missing
OK..Radiator shutters are not opening completely
or the shutterstat setting is wrong
OK
Vehicle speed is too low for adequate coolingwith high engine load
OK..Vehicle cooling system is not adequate
OK
Intake manifold temperature gauge is malfunc-tioning, if equipped
OK
(Continued)
Inspect the charge air cooler, air conditionercondenser, and radiator fins. Clean, if neces-sary. Refer to Section 4 and the OEM servicemanual.
Open the cold weather radiator cover or thewinterfront. Maintain a minimum of 784 ern"[122 in2). or approximately 28 x 28 cm [11 x 11in]. of opening at all times. Refer to Section 1.
Check the fan drive belt and water pump belt.Replace the belts if necessary. Refer toSection A.
Inspect the shroud and the recirculationbaffles. Repair, replace, or install, if necessary.Refer to the OEM service manual.
Inspect the radiator shutters. Repair or replaceif necessary. Refer to the manufacturer'sinstructions. Check the shutterstat setting.Refer to the OEM service manual.
Reduce the engine load. Increase the engine(fan) rpm by downshifting.
Verify that the engine and vehicle coolingsystems are using the correct components.Refer to the OEM vehicle specifications.
Test the temperature gauge. Refer to the OEMservice manual.
OK...Lubricating oil does not meet specifications for
operating conditions
OK...Lubricating oil drain interval is excessive
OK...Lubricating oil leak (external)
OK...Verify the oil consumption rate
OK...Air compressor is pumping lubricating oil into
the air system
OK...Contact a Cummins Authorized
Repair Facility
Check and clean the crankcase breather andvent tube. Refer to Section 3. I
IChange the oil and filters. Refer to Section 4.Use the oil recommended in Section V.
IIVerify the correct lubricating oil drain interval.
Refer to Section 2.
IInspect the engine for external oil leaks.Tighten the capscrews, pipe plugs, and fittings.Replace gaskets, if necessary. Refer to SectionV for specifications. I
OK-Lubricating oil does not meet specifications for
operating conditions
OK-Lubricating oil cooler is leaking
OK-Air compressor is pumping lubricating oil into
the air system
OK-
Inspect the engine for external oil leaks.Tighten the capscrews, pipe plugs, and fittings.Replace gaskets, if necessary. Refer to theOEM service manual.
II
Check the oil level. Verify the dipstick calibra-tion and the oil pan capacity. Fill the system tothe specified level. Refer to Section 3. I
IChange the oil and filters. Refer to Section 4.Use the oil recommended in Section V. I
ICheck the lubricating oil cooler for coolantleaks and cracks. Refer to the OEM servicemanual or an Authorized Cummins RepairFacility. I
ICheck the air lines for carbon buildup andlubricating oil. Refer to the OEM servicemanual or an Authorized Cummins RepairFacility. I
IIL-----------------~O~K~--------------~ L ~..
Blowby excessive
Turbocharger oil seal is leaking
OK-Contact a Cummins AuthorizedRepair Facility
Check for excessive blowby. Refer to the OEMservice manual or an Authorized CumminsRepair Facility.
ICheck the turbocharger for oil seals and forleaks. Refer to the OEM service manual or anAuthorized Cummins Repair Facility.
Engine angularity during operation exceedsspecification
OK-Lubricating oil does not meet specifications tor
operating conditions
OK-Lubricating oil is diluted with water
OK..Lubricating oil viscosity not correct
OK-Lubricating oil filter is plugged
OK-Lubricating oil is contaminated with coolant or
fuel
OK-Lubricating oil leak (external)
OK-Lubricating oil level is above or below specifi-
cation
OK..(Continued)
IRefer to the Engine Data Sheet.
II
Change the oil and tilters. Refer to Section 4.Use the oil recommended in Section V.
Check for a missing dipstick, rain caps, or oilfill caps. Change the oil. Refer to the OEMservice manual.
II
Make sure the correct lubricating oil is beingused. Refer to Section 4. I
IChange the oil and tilter. Refer to Section 4.Verify the oil change interval is correct. Referto Section 2.
IIChange the oil and tilters. Refer to the Lubri-
cating Oil Contaminated symptom tree.
IInspect the engine for external oil leaks.Tighten the capscrews, pipe plugs, and tittings.Replace gaskets, if necessary. Refer to SectionV for specifications. 1
1Check the oil level. Add or drain oil, it neces-sary. Reter to Section 3. Check the dipstickcalibration. 1
OK...Engine is operating at low ambient temperature
OK...Starting aid is malfunctioning
OK...Coolant temperature is below specification
OK...Fuel grade is not correct for the application, or
the fuel quality is poor
OK...Air intake or exhaust leaks
OK...Air intake system restriction is above specifica-
tion
OK
(Continued)
Verify the correct starting procedure. Refer toSection 1. I
IAllow the engine to warm to operating tem-perature. If the engine will not reach operatingtemperature, refer to the Coolant TemperatureBelow Normal symptom tree. I
ICheck the winterfront, shutters, and under-the-hood air. Use under-the-hood intake air in coldweather. Refer to Cold Weather Operation,Bulletin 3387266, and Section 1. I
ICheck for correct operation of cold-starting aid.Refer to Cold Weather Starting Aids in Section1. Refer to the manufacturer's instructions. I
IRefer to the Coolant Temperature is BelowNormal symptom tree.
IOperate the engine from a tank of hiqh-qualityfuel. Refer to Fuel Recommendations andSpecifications in Section V. I
ICheck for loose or damaged piping connec-tions and missing pipe plugs. Check theturbocharger and exhaust manifold mounting.Refer to Section 3. I
ICheck the air intake system for restriction.Clean or replace the air filter and inlet pipingas necessary. Refer to Section 4. I
Turbocharger Leaks Engine Oil or Fuel ICause Correction
Engine is operating for extended periods underlight or no-load conditions (slobbering)
OK-Lubricating oil or fuel is entering the turbo-
charger
OK-Turbocharger drain line is restricted
OK-Turbocharger oil supply line loose or leaking
OK-Contact a Cummins AuthorizedRepair Facility
IReview the engine operating instructions.Refer to Section 1.
IRemove the intake and exhaust piping, andcheck for oil or fuel.
IIRemove the turbocharger drain line, and check
for restriction. Clean or replace the drain line.Refer to an Authorized Cummins RepairFacility.
ICheck and tighten oil supply line fitting(s), ifnecessary. Refer to an Authorized CumminsRepair Facility.
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CB.3 IndustrialSection V - Maintenance Specifications Page V-a
Section V ...Maintenance SpecificationsSection Contents
Page
Air Intake System V-2Specifications V-2
Capscrew Markings and Torque Values '" V-13Capscrew Markings and Torque Values - Metric V-14Ca.pscrewMarkings and Torque Values - U.S. Customary V-1SGeneral Information V-13
Coolant Recommendations and Specifications V-SCooling System Additives V-8Cooling System Soluble Oils V-10Fully Formulated Coolant/Antifreeze V-5
Standard Oil Pan with Cylinder Block Stiffener PlatePan Only 19.9 liters [21 qt]
Oit Pan Low to High:Standard Oil Pan _ 15.1 to 18.9 liters [16 to 20 qt]Standard Oil Pan with Cylinder Block Stiffener Plate 16.1 to 19.9 liters [17 to 21 qt]
NOTE: Some applications have a slightly different oil pan capacity. Contact the local Cummins Distributor if there areany questions.
Oil PressureAt Idle Speed - Minimum - 69 kPa [10 psi]Normal Operating Range 205 to 517 kPa [30 to 75 psi]
Maximum Allowable Oil Temperature 120°C [250°F]
Oil Pan Capacity High/Low _ _ 17/13 liters [18/14 qt]
Total System Capacity (excluding bypass filter) 21.9 liters [23.2 qt]
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Cooling SystemPage V-2
CB.3 IndustrialSection V - Maintenance Specifications
Maximum Operational Angularity of Oil Pan (see Engine Mounting)Front Down 45 degreesFront Up 35 degreesSide to Side 45 degrees
1. The number of plates within a given battery size determines reserve capacity. Reserve capacity is thelength of time for which a battery at 27DC [80°Fl can supply 25 amperes at 10.5 volts or greater.
2. CCA ratings are based on two 12-VDC batteries in series.
Batteries (Specific Gravity)
Specific Gravity at 27°C State of Charge[80°Fj
1.260 to 1.280 100%1.230 to 1.250 750/01.200 to 1.220 50%1.170 to 1. 190 25%1.110 to 1.130 Discharged
Cummins/Fleetguard® SpecificationsGeneral InformationFleetguard® is a subsidiary of Cummins Inc. Heetquardw filters are developed through joint testing at Cummins andFleetquard" Fleetguard® filters are standard on new Cummins engines. Cummins Inc. recommends their use.
Fleetguard® products meet all Cummins Source Approval Test standards to provide the quality filtration necessary toachieve the engine's design life. If other brands are substituted, insist on products that the supplier has tested to meetCummins high-quality standards.
C8.3 IndustrialSection V • Maintenance Specifications
Fuel Recommendations and SpecificationsPage V~3
Cummins can not be responsible for problems caused by nongenuine filters that do not meet Cummins performanceor durability requirements.
Fuel Filters
Fuel Filter:
• Cummins Part Number 3931063
• Fleetquardw Part Number FF5052.
Fuel-Water Separator:
• Cummins Part Number 3930942
• Fleetguard® Part Number FS12BO.
Lubricating Oil Filter
• Cummins Part Number 3401544
• Fleetquardw Part Number LF9D09.
Fuel Recommendations and SpecificationsFuel Recommendations
.& WARNING ADo not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.
A CAUTION ADue to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept cleanand free of dirt or water. Dirt or water in the system can cause severe damage to both the fuel pump and thefuel injectors.
A CAUTION ALighter fuels can reduce fuel economy and can possibly damage the fuel injection pump.
Cummins EngineCompany, Inc. recommends the use of ASTM No. 20 fuel.The useof No.20 fuel will result in optimumengine performance. -
At operating temperatures below DOC[32°F], acceptable performance can be obtained by using blends of No. 20 andNo. 10.
The viscosity of the fuel must be kept above 1.3 cSt at 40°C [104°F] to provide adequate fuel system lubrication.
The following chart lists acceptable alternate fuels for CB.3 Series engines.
Acceptable Substitute Fuels - Cummins C8.3 Fuel System
1 Any adjustment to compensate for reduced performance with a fuel system usmq alternate fuel IS not warrantable.
2. Wlnler blend fuels, such as those found at commercial fuel dispensing outlets, are combinations of No. 10 and No. 2D diesel fueland areacceptable.
Additional information for fuel recommendations and specifications can befound in Fuel for Cummins Engines,BulletinNo. 3379001. See the ordering information in the back of this manual.
Lubricating Oil Recommendations and SpecificationsNew Engine Break-in Oils
A CAUTION AA sulfated ash limit of 1.85 percent has been placed on all engine lubricating oils recommended for use inCummins engines. Higher ash oils can cause valve andlor piston damage and lead to excessive oil consumption.
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Lubricating Oil Recommendations and SpecificationsPage V-4
CB.3 IndustrialSection V - Maintenance Specifications
.6.. CAUTION .6..The use of a synthetic-based oil does not justify extended oil change intervals. Extended oil change intervalscan decrease engine life due to factors such as corrosion, deposits, and wear.
Special "break-in" engine lubricating oils are not recommended for new or rebuilt Cummins engines. Use the sametype of oil during the "break-in" as used in normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the E.M.A. LubricatingOils Data Book for Heavy-Duty Automotive and Industrial Engines. The data book can be ordered from the EngineManufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephonenumber is (312) 644-6610.
Arctic Operation Engine Oil
If an engine is operated in ambient temperatures consistently below -23°C [-9°F). and there are no provisions to keepthe engine warm when it is not in operation, use a synthetic CE/SF or higher API classification engine oil with adequatelow-temperature properties such as 5W-20 or 5W-30.
The oil supplier is responsible for meeting the performance service specification represented with its product.
General InformationMidrange engines with 1999 U.S.A. certification will have 500-hour maximum oil drain intervals using CES20071 (CH-4)or better lubricating oil.
Non-U.S.A. certified engines will have 500-hour oil drain intervals using CES20071 (CH-4) or better lubricating oil.
The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, are criticalfactors in maintaining engine performance and durability.
Cummins Engine Company, Inc. recommends the use of a high-quality SAE 15W-40 muitiviscosity heavy-duty engineoil, such as Cummins Premium Blue"'), that meets the requirements of Cummins Engineering Specification CES20071or CES20076, or the American Petroleum Institute (API) performance classification CG-4 or CH-4.
NOTE: In areas where CG-4 or CH-4 lubricating oils are not available, CES20075 can be used but the lubricating oilchange interval must be reduced to 12,070 km [7500 mil. or 250 hours.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control.The sulfated ash must not exceed 1.85 mass percent.
For further details and discussion of engine lubricating oils for Cummins engines, refer to Cummins Engine OilRecommendations, Bulletin No. 3810340, or a Cummins Authorized Repair Facility.
CB.3 IndustrialSection V - Maintenance Specifications
The API service symbols are shown in the accompanyingillustration. The upper half of the symbol displays the ap-propriate oil categories.
The lower half can contain a description of oil energy con-serving features.
The center section identifies the SAE oil viscosity grade.
As the engine oil becomes contaminated, essential oil ad-ditives are depleted. Lubricating oils protect the engine aslong as these additives are functioning properly. Progres-sive contamination between oil and filter change intervalsis normal. The amount of contamination will vary depend-ing on the operation of the engine, kilometers or [miles] onthe oil, fuel consumed, and new oil added.
Extending oil and filter change intervals beyond the rec-ommendations will decrease engine life due to factors suchas corrosion, deposits, and wear.
Refer to the Oil Drain Interval Chart in this section to de-termine which oil drain interval to use for an application.
Coolant Recommendations andSpecificationsFully Formulated Coolantl AntifreezeCummins Engine Company, Inc. recommends using eithera 50/50 mixture of high-quality water and fully formulatedantifreeze or fully formulated coolant when filling the cool-ing system. The fully formulated antifreeze or coolant mustmeet TMC RP 329 or TMC RP 330 specifications.
Coolant Recommendations and SpecificationsPage V-5 I
·C-40-10-:lO-10 01020 3D 40 SO
OF -40 -22 -4 14 ]7 '0 !l8 liS 10C 122
Wimer Conditions
The use of low-viscosity oils, such as 10W or 10W-30, can ~be used to aid in starting the engine and in providingsufficient oil flow at ambient temperatures below ·5°C[23°F). However, continuous use of low-viscosity oils candecrease engine life due to wear. Refer to the accompa- All SeBliOns
nying chart.
Arctic Conditions_~W.30!l!1I11111I1I1111I11I
·C 4D -30 -20 -10 0 10 20 30 40 50
o~ -40-<2 -4 14 32 so 68 8610',22
Oil Additives in Used Oil
~~~ 11,KmlL
• ~ ~ (400 MPQI
Active Additive ._ ,20 Km/L........_ [1.200 MPQj
Kilometers IMileilgel/Hours-
_--- ------_.--------..-,~~I
"IIi/ /
_i_../
I.(~::.~-,-/-")I/: I
!i k J! ., I
_..--/ lI
i
III
D,900du IIII
07dOOO55 IIIIIIIIIII
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Coolant Recommendations and SpecificationsPage V-6
Water QualityCalcium Maximum 170 ppm
Magnesium as (CaC03 + MgC03)(Hardness)
Chloride 40 ppm as(CI)
Sulfur 100 ppm as (SOJ18200001
se413223
14
'I::. ,~ ....I.....'- 1"- ,I""I III
/'\.\ /
/\.....- .~
".. ,:!, \'nin \, t--
329320311302293284275-~248239230:nl212203194185
5-4
-13-22-31-40·118-67-76-85-tI4
-103 176o 10 zo 30 40 50 60 70 80 90 100 o.solwn
nlBtoda
CB.3 IndustrialSection V - Maintenance Specifications
A CAUTION A.High-quality water is important for cooling system per-formance. Excessive levels of calcium and magnesiumcontribute to scaling problems, and excessive levels ofchlorides and sulfates cause cooling system corrosion.
Cummins Engine Company, Inc. recommends usingFleetquard" Compleat. It is available in both glycol forms(ethylene and propylene) and complies with TMC standards.
Fully formulated antifreeze must be mixed with high-qualitywater at a 50/50 ratio (40- to 60-percent working range). A50/50 mixture of antifreeze and water has a ·3GoG 1-33°F]freezing point and a 110°C [230°F] boiling point, which isadequate for North America. The actual lowest freezingpoint of ethylene glycol antifreeze is at 68 percent. Usinghigher concentrations of antifreeze will raise the freezingpoint of the solution and increase the possibility of a silicategel problem .
A refractometer must be used to measure the freezingpoint of the coolant accurately.
CB.3 IndustrialSection V - Maintenance Specifications
Do not use a floating ball hydrometer. Use of a floating ballhydrometer can give an incorrect reading.
Coolant Recommendations and SpecificationsPage V-7 I
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Coolant Recommendations and SpecificationsPage V~8
CB.3 IndustrialSection V • Maintenance Specifications
Specifications
Use a low-silicate antifreeze that meets ASTM4985 test (GM6038M specification) criteria.
Concentration
Antifreeze must be used in any climate for both treezinq- and boiling-point protection. Cummins recommends a50-percent concentration level (40- to 60-percent range) of ethylene glycol or propylene glycol in most climates.Antifreeze at 58-percent concentration provides the maximum freeze protection and must never be exceeded underany condition. Antifreeze protection decreases above 68 percent.
Antifreeze concentration must be checked using a refractometer (such as Fleetquard" Part No. CC2800). "Floating-Ball"-type density testers or hydrometers are not accurate enough for use with heavy-duty diesel cooling systems.
The coolant must be drained and replaced every 2 years or 385,000 km [239,227 mil to eliminate buildup of harmfulchemicals.
Cooling System AdditivesSupplemental Coolant Additives (SCA)
Supplemental coolant additives (SeA) are recommended for all Cummins cooling systems. Antifreeze alone does notprovide sufficient protection for heavy-duty diesel engines.
DCA4
DCA4 is the recommended SeA for all Cummins engines. Other brands can be used if they provide adequate engineprotection and do not cause seal or gasket degradation or corrosion/fouling.
SeA Concentration
The recommended concentration level of DCA4 is 1.5 units for every 3.7 liters [1 gal). The DCA4 concentration mustnever exceed 3.0 units tor every 3.7 liters [1 gal] nor fall below 1.2 units for every 3.7 liters [1 gal].
DCA4 Filter Change Interval
Supplemental coolant additives deplete during normal engine operation. Cummins recommends that the level bemaintained by installation of a service coolant filter on the engine at every 10,OOO-km[6214 mil. 250·hours, or 3-monthinterval.
DCA4 Concentration Test
As noted above, the primary method is to maintain proper DCA4concentration levels by changing the service coolantfilter at every 10,000 km [6214 mil. 250 hours, or 3 months. Heetquard" DCA4 "dipstick" test kit, Part No. CC2626,or Fleetguardl!<)Monitor C", Part No. CC2700, must be used if testing is deemed necessary due to one of the followingreasons:
• Additio'n of untreated make-up coolant in excess of 5.7 liters [6 qt] between maintenance intervals
• Troubleshooting of cooling system problems in the fleet (such as corrosion or seal leakage)
• An optional program in some fleets to monitor SCA levels to determine if maintenance intervals are acceptable.
NOTE: The practice of using a test kit to determine when to add or change the coolant filter is specifically notrecommended. No other test kit (such as Fleetguard®titration test kit, Part No. 3300846-S or 3825379-S) can be usedon Cummins engines with DCA4.
OCA4 Unit Maintenance Guide
Fleetguard® Part No. I Cummins Part No. I DCA4 UnitsOCA4 liquid
DCA 60L I 3315459 I 4"DCA4 Filter
(Continued)
C8.3 IndustrialSection V - Maintenance Specifications
Coolant Recommendations and SpecificationsPage V-9
Flee!g_uard® Part No. Cummins Part No. DCA4 UnitsWF-2070 3318157 2WF-2071 3315116 4WF-2072 3318201 6WF-2073 3315115 8WF-2074 3316053 12WF-2077 None 0
* If DCA 60L is used, do not use a coolant filter that contains coolant additives. The combination of liquidand filter coolant additives will result in overconcentration.
DCA4 Maintenance Guide
Maintenance IntervalsTotal Cooling System Ca- Initial Charge (8) 10,000 km [6000 mil, 250
pacity Hours, or 3 Months30 to 57 liters [8 to 15 gal] WF-2074 WF-2070
Notes:
IIIIII
A. Consult the vehicle equipment manufacturer's maintenance information for the total cooling system capacity.
B. After draining and replacing the coolant, install the initial per-charge coolant filter to provide the recommended Ilevel of DCA4 concentration.
C. Change the coolant filter at regular intervals to protect the cooling system.
D. Check the coolant additive concentration regularly. Check the cooling system using Fleetquardw DCA4 only with IDCA4 coolant test kit, Part No.CC-2626.
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II
Coolant Recommendations and SpecificationsPage V-10
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CB.3 IndustrialSection V - Maintenance Specifications
Cooling System Sealing Additives
Do not use sealing additives in the cooling system. The useof sealing additives will
• Build up in coolant low-flow areas
• Clog coolant filters
• Plug radiator and oil cooler
• Possibly damage water pump seal.
Cooling System Soluble OilsDo not use soluble oils in the cooling system. The use ofsoluble oils will
• Allow cylinder liner pitting
• Corrode brass and copper
• Damage heat transfer surfaces
• Damage seals and hoses.
CB.3 IndustrialSection V • Maintenance Specifications
Drive Belt TensionPage V-ll
Drive Belt TensionTension Chart
SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used"Click-type Burroughs N Ibf N Ibf
0.380 in 3822524 620 140 270 to 490 60 to 1100.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 11011/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 1107/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 1105 rib 3822524 ST-1138 670 150 270 to 530 60 to 1206 rib 3822525 ST-1293 710 160 290 to 580 65 to 1308 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 20012 rib 3822525 3823138 1330 300 530 to 1070 120 to 24012 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
NOTE: This chart does not apply to automatic belt tensioners .
• A belt is considered used if it has been in service for ten minutes or longer.
• If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Engine Component Torque ValuesTorque Table
Comeonent Wrench Size Torgue Value
Nem ft-Ib in-Ib
Attercooler mounting 10 mm 24 18
Aftercooler water hose clamp 8 mm 5 44
Alternator link (Delco 10-15 SI) 13 mm 24 18
Alternator link (Delco 20-27 SI) 3/4 in 43 32
Alternator mtg. bolt 10-15 SI 15 mm 43 32
Alternator mtg. 27 SI 18 mm 77 57
Alternator support (upper) 10 mm 24 18
Belt tensioner flat bracket Allen 5 mm 24 18
Belt tensioner mounting 15 mm 43 32
Crankshaft damper and pulley 15 mm 137 101
Crossover clamp 5/16 in 5 44
Tee bolt type clamp 11 mm 8 71
Exhaust outlet pipe. v-band clamp 7/16 in 8 71
Fan bracket mounting 10 mm 24 18
Fan pulley 10 mm 24 18
Fan pulley 13 rnrn 43 32
Fuel filter 75 to 85 mm Install as specified by filter manufac-turer.
Fuel filter adapter nut 24 rnrn 32 24
lubricating oil filter 75 to 85 mm 3/4 of a turn after contact
Lubricating oil cooler assembly 10 rnrn 24 18
Lubricating oil pan drain plug 17 rnrn 80 59
(Continued)
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SealantsPage V-12
CB.3 IndustrialSection V - Maintenance Specifications
Component Wrench Size Torque Value
N·m ft-Ib
27 mm 80 59
19 mm 80 59
10 mm 43 32
10 mm 24 18
15 mm 43 32
13 mm 24 18
15 mm 12
19 mm Hand-tighten
Sealants
106
in-Ib
Lubricating oil pan heater plug
Lubricating oil pressure regulator plug
Starter mounting
Thermostat housing
Water inlet connection
Water pump mounting
Rocker lever (valve) cover
Water-in-fuel (WIF) sensor
General InformationUse either the sealants listed below or sealants containing equivalent properties.
Item Description Sealing Method
1. Pipe plugs
2. Gaskets
3. Cups plugs
Precoated Teflon" or pipe sealer
No sealant required
Loctite 277 or Cummins sealant, Part Number3375068
Lubriplate'" 105
Loctite 277 or Cummins sealant, Part Number3375068
Loctite 242
Loctite 277 or Cummins sealant, Part Number3375068
Loctite 277 or Cummins sealant, Part Number3375068
Three-Bond'" sealant, Part Number 3823494
No sealant required
No sealant required
Loctite 277 or Cummins sealant, Part Number3375068
Three-Bond" sealant, Part Number 3823494
4. O-rings
5. Rear camshaft expansion plug
6. Fuel pump studs
7. Turbocharger drain (in block)
8. Dipstick tube (in block)
9. Wet flywheel housing to block
10. Rear seal (in rear cover)
11. Timing pin housing capscrews
12. Side oil fill
13. Oil pan at gear housing joint
CB.3 IndustrialSection V - Maintenance Specifications
Capscrew Markings and Torque ValuesPage V-13 I
Capscrew Markings and Torque Values IGeneral Information
Ii. CAUTION s: IWhen replacing capscrews, always use a capscrew of the same measurement and strength as the capscrewbeing replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surfaceof the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:I
Metric - M8-1 .25 X 25 u.s. Customary [5116 X 18 X 1-112] I5
Major thread diameter in millimeter"s_j
Distance betw ee n Ihrsads in millimelBrll
Length In mllll"","""
5/16 18 1·112
.*,threa • .,._,," inches _j I INumber of threads per Inch
Lenqtb in InchesIINOTES:
1.2.3.4.
Always use the torque values listed in the following tables when specific torque values are not available.Do not use the torque values in place of those specified in other sections of this manual.The torque values in the table are based on the use of lubricated threads.When the ft-Ib value is less than 10, convert the ft-Ib value to in-lb to obtain a better torque with an in-Ibtorque wrench. Example: 6 ft-Ib equals 72 in-lb.
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II Capscrew Markings and Torque Values
Page V-14CB.3 Industrial
Section V - Maintenance Specifications
Capscrew Markings and Torque Values - Metric
I Commercial Steel Class8.8 10.9 12.9
Capscrew Head Markings
~ 0 ~ o ~ 0Bod:l Size Torgue Torgue Torgue
Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
Off..Highway Engines United States and CanadaCoverageProducts WarrantedThis warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, thatare used in industrial (off-highway) applications in the United States' and Canada, except for Engines used in marine,generator drive and certain defense applications, for which different warranty coverage is provided.
Base Engine WarrantyThis warranty covers any failures of the Engine. under normal use and service, which result from a defect in materialor factory workmanship (Warrantable Failures).
Coverage begins with the sale of the Engine by Cummins. Coverage continues for two years or 2,000 hours of operation,whichever occurs first, from the date of delivery of the Engine to the first user, or from the date the unit is first leased,rented or loaned, or when the Engine has been operated for 50 hours, whichever occurs first. If the 2,000 hour limitis exceeded during the first year, Coverage continues until the end of the first year.
Extended Major Components WarrantyThe Extended Major Components Warranty covers Warrantable Failures of the Engine cylinder block, camshaft,crankshaft and connecting rods (Covered Parts).
Bushing and bearing failures are not covered.
This Coverage begins with the expiration of the Base Engine Warranty and ends three years or 10,000 hours of operationfrom the date of delivery of the Engine to the first user, or from the date the unit is first leased, rented or loaned, orfrom when the Engine has been operated for 50 hours, whichever occurs first.
Consumer ProductsThe warranty on Consumer Products in the United States is a LIMITED warranty. CUMMINS IS NOT RESPONSIBLEFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to Consumer Products in theUnited States terminate concurrently with the expiration of the express warranties applicable to the product. In theUnited States, some states do not allow the exclusion of incidental or consequential damages, or limitations on howlong an implied warranty lasts, so the limitations or exclusions herein may not apply to you.
These warranties are made to all Owners in the chain of distribution, and Coverage continues to all subsequentOwners until the end of the periods of Coverage.
Cummins' ResponsibilitiesDuring The Base Engine WarrantyCummins will pay for all parts and labor needed to repair the damage to the Engine resulting from aWarrantable Failure.
Cummins will pay for the lubricating oil, antifreeze, filter elements, and other maintenance items that are not reusabledue to the Warrantable Failure.
Cummins will pay reasonable costs for mechanics to travel to and from the equipment site, including meals, mileageand lodging, when the repair is performed at the site of the failure.
Cummins will pay reasonable labor costs for Engine removal and reinstallation when necessary to repair a WarrantableFailure.
During The Extended Major Components WarrantyCummins will pay for the repair or, at its option, replacement of the defective Covered Part and any Covered Partdamaged by a Warrantable Failure of the defective Covered part.
Owner's ResponsibilitiesDuring The Base Engine WarrantyOwner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items providedduring warranty repairs unless such items are not reusable due to the Warrantable Failure.
During The Extended Major Components WarrantyOwner is responsible tor the cost of all labor needed to repair the Engine, including the labor to remove and reinstallthe Engine. When Cummins elects to repair a part instead of replacing it, Owner is not responsible for the labor needed
3381321
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Cummins WarrantyPage W·2
C8.3 IndustrialSection W - Warranty
to repair the part.
Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and anyCovered Part damaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items replacedduring repair of a Warrantable Failure.
During The Base Engine and Extended Major Components WarrantiesOwner is responsible for the operation and maintenance of the Engine as specified in the applicable CumminsOperation and Maintenance Manual. Owner is also responsible for providing proof that all recommended maintenancehas been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins distributor, authorized dealer or otherrepair location approved by Cummins of any Warrantable Failure and make the Engine available for repair by suchfacility. Locations in the United States and Canada are listed in the Cummins Off Highway Authorized Dealer Directory.
Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of a War-rantable Failure.
Owner is responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, all applicable taxes, allbusiness costs and other losses resulting from a Warrantable Failure.
LimitationsCummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect,including, but not limited to: operation without adequate coolants or lubricants; overfueling; overspeeding; lack ofmaintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdownpractices; unauthorized modifications of the Engine. Cummins is also not responsible for failures caused by incorrectoil or fuel or by water, dirt or other contaminants in the fuel or oil.
For power units and fire pumps (package units), this warranty applies to accessories, except for clutches and filters,supplied by Cummins which bear the name of another company.
Except for power units and fire pumps, this warranty does not apply to accessories which bear the name of anothercompany. Such non-warranted accessories include, but are not limited to: alternators, starters, fans", air conditioningcompressors, clutches, filters, transmissions, torque converters, steering pumps, and non-Cummins fan drives, enginecompression brakes and air compressors.
Cummins Compusave units are covered by a separate warranty.
Before a claim for excessiveoil consumption will be considered, Owner must submit adequate documentation to showthat consumption exceeds Cummins published standards.
Failures of belts and hoses supplied by Cummins are not covered beyond the first 500 hours or one year of operation,whichever occurs first.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins-approved rebuilt parts, or repairedparts. Cummins is not responsible for failures resulting from the use of parts not approved by Cummins.
A new Cummins or Cummins-approved rebuilt part used to repair a Warrantable Failure assumes the identity of thepart it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSeQUENTIAL DAMAGES.
THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS IN REGARD TOTHESE ENGINES. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANT-ABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Emission WarrantyProducts WarrantedThis emission warranty applies to new Engines marketed by Cummins that are used in the United States' in vehiclesdesigned for Industrial off-highway use. This warranty applies to Engines delivered to the ultimate purchaser on or afterApril 1, 1999 for engines up to 750 horsepower, on or after January 1, 2000 for engines 751 horsepower and over.
CB.3 IndustrialSection W - Warranty
Cummins WarrantyPage W-3
CoverageCummins warrants to the ultimate purchaser and each subsequent purchaser that the Engine is designed, built andequipped so as to conform at the time of sale by Cummins with all U.S. Federal emission regulations applicable at thetime of manufacture and that it is free from defects in workmanship or material which would cause it not to meet theseregulations within the longer of the following periods: (A) Five years or 3,000 hours of operation, whichever occurs first,as measured from the date of delivery of the Engine to the ultimate purchaser, or (B) The Base Engine Warranty.
If the vehicle in which the Engine is installed is registered in the state of California, a separate California EmissionWarranty also applies.
LimitationsFailures, other than those resulting from defects in materials, or workmanship, are not covered by this warranty.
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect,including, but not limited to: operation without adequate coolant or lubricants; overfueling; overspeeding; lack ofmaintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdownpractices; unauthorized modifications of the Engine. Cummins is also not responsible for failures caused by incorrectfuel or by water, dirt or other contaminants in the fuel.
Cummins is not responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, all business costsor other losses resulting from a Warrantable Failure.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
* Includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. VirginIslands.
* * Alternators, starters, and fans ARE covered for the duration of the base engine warranty on B3.3 engines.
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Cummins WarrantyPage W·4
CB.3 IndustrialSection W • Warranty
Off ..Highway Engines InternationalCoveragePRODUCTS WARRANTEDThis warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, thatare used in industrial (off-highway) applications anywhere in the world where Cummins-approved service is available,except the United States' and Canada. Different warranty coverage is provided for Engines used in marine, generatordrive and certain defense applications.
BASE ENGINE WARRANTYThis warranty covers any failures of the Engine, under normal use and service, which result from a detect in materialor factory workmanship (Warrantable Failure).
Coverage begins with the saleof the Engine by Cummins. Coverage continues tor two yearsor 2,000 hours of operation,whichever occurs first, from the date of delivery of the Engine to the first user, or from the date the unit is first leased,rented or loaned, or when the Engine has been operated for 50 hours, whichever occurs first. If the 2,000 hour limitis exceeded during the first year, coverage continues until the end of the first year.
EXTENDED MAJOR COMPONENTS WARRANTYThe Extended Major Components Warranty covers Warrantable Failures of the Engine cylinder block, camshaft,crankshaft and connecting rods (Covered Parts).
Bushing and bearing failures are not covered.
This coverage begins with the expiration of the Base Engine Warranty and ends three yearsor 10,000 hours of operation,from the date of delivery of the Engine to the first user, or from the date the unit is first leased, rented or loaned, orfrom when the Engine has been operated for 50 hours, whichever occurs first.
These warranties are made to all Owners in the chain of distribution, and Coverage continues to all subsequentOwners until the end of the periods of Coverage.
Cummins'ResponsibilitiesDURING THE BASE ENGINE WARRANTYCummins will pay for all parts and labor needed to repair the damage to the Engine resulting from aWarrantable Failure.
Cummins will pay for the lubricating oil, antifreeze, filter elements, and other maintenance items that are not reusabledue to a Warrantable Failure.
Cummins will pay reasonable costs for mechanics to travel to and from the equipment site, including meals, mileageand lodging, when the repair is performed at the site of the failure.
Cummins will pay reasonable labor costs for Engine removal and reinstallation when necessary to repair a WarrantableFailure.
DURING THE EXTENDED MAJOR COMPONENTS WARRANTYCummins will pay for the repair or, at its option, replacement of the defective Covered Part and any Covered Partdamaged by a Warrantable Failure of the defective Covered part.
Owner's ResponsibilitiesDURING THE BASE ENGINE WARRANTYOwner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items replacedduring warranty repairs unless such items are not reusable due to the Warrantable Failure.
DURING THE EXTENDED MAJOR COMPONENTS WARRANTYOwner is responsible for the cost of all labor needed to repair the Engine, including the labor to remove and reinstallthe Engine. When Cummins elects to repair a part instead of replacing it, Owner is not responsible for the labor neededto repair the part.
Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and anyCovered Part damaged by a Warrantable Failure of the defective Covered Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items replacedduring repair of a Warrantable Failure.3381322
C8.3 IndustrialSection W - Warranty
Cummins WarrantyPage W-5
DURING THE BASE ENGINE AND EXTENDED MAJOR COMPONENTS WARRANTIESOwner is responsible for the operation and maintenance of the Engine as specified in the applicable CumminsOperation and Maintenance Manual. Owner is also responsible for providing proof that all recommended maintenancehas been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins distributor, authorized dealer or otherrepair location approved by Cummins of any Warrantable Failure and make the product available for repair by suchfacility. Locations are listed in the Cummins International Sales and Service Directory.
Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of a War-rantable Failure.
Owner 15 responsible for non-Engine repairs, "downtime" expenses, cargo damage, fines, alf applicable taxes, allbusiness costs and other losses resulting from a Warrantable Failure.
LimitationsCummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect,including, but not limited to: operation without adequate coolants or lubricants; overfueling; overspeeding; lack ofmaintenance of lubricating. cooling or intake systems; improper storage, starting. warm-up, run-in or shutdownpractices; unauthorized modifications of the Engine. Cummins is also not responsible for failures caused by incorrectoil or fuel or by water, dirt or other contaminants in the fuel or oil.
For power units and fire pumps (package units) the warranty applies to accessories, except for clutches and filterssupplied by Cummins which bear the name of another company.
Starters, alternators, power steering pumps and non-Cummins air compressors supplied by Cummins on B or C SeriesEngines that are not supplied as part of a package unit are covered for six months" from the date of delivery of theEngine to the first user, or the date the Engine is first leased, rented or loaned, or from when the Engine has beenoperated for 50 hours, whichever occurs first.
Except for the accessories noted previously, Cummins does not warrant accessories which bear the name of anothercompany. Such non-warranted accessories include, but are not limited to: alternators, starters, fans', air conditioningcompressors, clutches, filters, transmissions, torque converters, steering pumps, non-Cummins fan drives, and aircleaners.
Cummins Compusave units are covered by a separate warranty.
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to showthat consumption exceeds Cummins published standards.
Failures of belts and hoses supplied by Cummins are not covered beyondthe first 500 hours or one year of operation,whichever occurs first.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins-approved rebuilt parts, or repairedparts. Cummins is not responsible for failures resulting from the use of parts not approved by Cummins.
A new Cummins or Cummins-approved rebuilt part used to repair a Warrantable Failure assumes the identity of thepart it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS IN REGARD TOTHESE ENGINES. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANT-ABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
In case of consumer sales, in some countries, the Owner has statutory rights which cannot be affected or limited bythe terms of this warranty.
Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties.
• Alternators, starters, and fans ARE covered for the duration of the base engine warranty on 63.3 engines.
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California Emission Control System Warranty, Off-HighwayPageW-6
CB.3 IndustrialSection W - Warranty
California Emission Control System Warranty, Off-HighwayProducts WarrantedThis Emission Control System Warranty applies to off-road diesel engines certified with the California Air ResourcesBoard beginning with the year 1996 for engines up to 750 horsepower, beginning with the year 2000 for 751 horsepowerand over. marketed by Cummins, and registered in California for use in industrial off-highway applications.
Your Warranty Rights and ObligationsThe California Air Resources Board and Cummins Engine Company, lnc., are pleased to explain the emission controlsystem warranty on your engine. In California, new off-road diesel engines must be designed, built and equipped tomeet the State's stringent anti-smog standards. Cummins must warrant the emission control system on your enginefor the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air induction system. Alsoincluded may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Cummins will repair your off-road diesel engine at no cost to you includingdiagnosis, parts and labor.
Manufacturer's Warranty CoverageThis warranty coverage is provided for 5 years or 3,000 hours of engine operation, whichever first occurs from the dateof delivery of the engine to the first user. If any emission-related part on your engine is defective, the part will be repairedor replaced by Cummins.
CoverageThis emission control system warranty applies only to the following B5.9, OSB, OSC, OS9 and CB.3 emission controlparts:
Fuel PumpStatic TimingDelivery ValveInjection Control Valve Module
Electronic Control SystemControl ModuleBoost Pressure SensorCoolant Temperature SensorFuel Pressure Sensor
Tu rbochargerCompressor WheelTurbine WheelTurbine Oil SealWastegate Valve
Owner's Warranty ResponsibilitiesAs the off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in yourCummins Operation and Maintenance Manual. Cummins recommends that you retain all receipts covering mainte-nance on your off-road diesel engine, but Cummins cannot deny warranty solely tor the lack of receipts or for your failureto ensure the performance of all scheduled maintenance.
You are responsible for presenting your off-road diesel engine to a Cummins dealer as soon as a problem exists. Thewarranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
As the off-road diesel engine owner, you should also be aware that Cummins may deny you warranty coverage if youroff-road diesel engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operatingin compliance with California's emissions requirements.
If you have any questions regarding your warranty rights and responsibilities, you should contact Cummins CustomerAssistance Department at 1-800-343-7357 (1-800-DlESELS) or the California Air Resources Board at 9528 TelstarAvenue, EI Monte, CA 91731.
C8.3 IndustrialSection W - Warranty
California Emission Control System Warranty, Off-HighwayPage W-7
Prior to the expiration of the applicable warranty, Owner must give notice of any warranted emission control failure toa Cummins distributor, authorized dealer or other repair location approved by Cummins and deliver the engine to suchfacility for repair. Repair locations are listed in Cummins United States and Canada Service Directory.
Owner is responsible for incidental costs such as: communication expenses, meals, lodging incurred by Owner oremployees of Owner as a result of a warrantable failure.
Owner is responsible for business costs and losses, "downtime" expenses, and cargo damage resulting from awarrantable failure. CUMMINS IS NOTRESPONSIBLE FOROTHER INCIDENTALOR CONSEQUENTIAL DAMAGES,INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDE BUT ARE NOT LIMITED TOFINES, THEFT, VANDALISMOR COLLISIONS.
Replacement PartsCummins recommends that any service parts used for maintenance, repairor replacement of emission control systemsbe new, genuine Cummins or Cummins approved rebuilt parts and assemblies, and that the engine be serviced by aCummins distributor, authorized dealer or the repair location approved by Cummins. The owner may elect to havemaintenance, replacement or repair of the emission control parts performed by a facility other than a Cumminsdistributor, an authorized dealer or a repair location approved by Cummins, and may elect to use parts other than newgenuine Cummins or Cummins approved rebuilt parts and assemblies for such maintenance, replacement or repair;however, the cost of such service or parts will not be covered under this emission control system warranty.
Cummins ResponsibilitiesRepairs and service will be performed by any Cummins distributor, authorized dealer or other repair location approvedby Cummins using new, genuine Cummins or Cummins approved rebuilt parts and assemblies. Cummins will repairanyof the emission control parts found by Cummins to be defective without charge for parts or labor (including diagnosiswhich results in determination that there has been a failure of a warranted emission control part).
Emergency RepairsIn the case of an emergency where a Cummins distributor, authorized dealer, or other repair location approved byCummins is not available, repairs may be performed by any available repair location using any replacement parts.Cummins will reimburse the Owner for expenses (including diagnosis), not to exceed the manufacturer's suggestedretail price for all warranted parts replaced and labor charges based on the manufacturer's recommended timeallowance for the warranty repair and the geographically appropriate hourly labor rate. A part not being available within30 days or a repair not being complete within 30 days constitutes an emergency. Replaced parts and paid invoicesmust be presented at a Cummins authorized repair facility as a condition of reimbursement for emergency repairs notperformed by a Cummins distributor, authorized dealer, or other repair location approved by Cummins.
Warranty LimitationsCummins is not responsible for failures resulting from Owner or operator abuse or neglect, such as: operation withoutadequate coolant, fuel or lubricants; overfueling; overspeeding; lack of maintenance of lubricating, cooling or air intakesystems: improper storage, starting, warm-up, run-in or shutdown practices.
The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built,and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and that it is freefrom defects in materials and workmanship which cause the failure of a warranted part.
Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only forregular inspection to the effect of "repair or replace as necessary" is warranted for the warranty period.
Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of timeprior to the first scheduled replacement point for that part.
The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective,if the diagnostic work is performed at a warranty station.
The manufacturer is liable for damages to other engine components caused by the failure under warranty of anywarranted part.
Cummins is not responsible for failures resulting from improper repair or the use of parts which are not genuineCummins or Cummins approved parts.
These warranties, together with the express commercial warranties and emission warranty are the sale warranties ofCummins. There are no other warranties, express or implied, or of merchantability or fitness for a particular purpose.
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I IIIIIII
FIRST CLASS PERMIT NO. 15. COLUMBUS INDIANA
BUSINESS REPLY MAILII
-POSTAGE WILL BE PAID BY ADDRESSEE-
II
CUMMINS INC.MAIL CODE 41302BOX 3005COLUMBUS, IN 47202-3005
Do not use this form to order additional literature. Refer toSection L - Service Literature for literature information.
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Literature Survey FormBulletin No.: 4021330 I
We are always open to any suggestions or recommendations that will aid in improving our manuals. Usethis postage paid survey form to evaluate this manual. Please check the appropriate response and usethe space provided below to list any additional comments:
Yes No IIs the needed information easy to locate in the manual?Is the information easy to read?Is the information easy to understand?Does the information sufficiently cover the subject?Are subjects in the Index specific enough to locate in the manual?Are the important points sufficiently emphasized?Are the illustrations easy to understand?Does the text support the operation being illustrated?Do you use the Table of Contents and Section Contents?Do you use the Index?
Please provide comments on any response(s) marked No in this survey and on any suggestions youfeel could improve our manuals. _
IIIIName:
Company:Street Address:City: State/Province: _Country: Zip/Postal Code: IDo not use this form to order additional literature. Refer toSection L - Service Literature for literature information.
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II About the Manual....... i-,
General Information . 1-'Acronyms and Abbreviations .. 1-7General Information 1-7
Additional Service Llterature L-'General Information L-'
Air Cleaner Restriction .. 4-'Maintenance Check 4-'
Air Compressor.. 4-,Maintenance Check 4-,
Air Compressor Discharge Lines. 7-'General Information 7-'Mamtenance Check 7-'
Air in FueL... A-19General Information A-19Test A-20
Air Intake Plping..... 3-2Maintenance Check 3-2
Air Intake System... V-2Specifications V·2
Air Tanks and Reservoirs.. . 3-73-7A-lA-2
IIII D~n .
Alternator .Install .
I Preparatory Steps A-lRemove A-l
California Emission Control System Warranty, Off-Highway W-6Capscrew Markings and Torque Values V-13Capscrew Markings and Torque Values - Metric . V-14Capscrew Markings and Torque Values - U.S. Customary V-15General Information. V-13
General Cleaning Instructions ..__...... i-5Glass or Plastic Bead Cleaning _ i-6Sol1l.entand Acid Cleaning i-5Steam Cleaning .. --.. 1-6
General Engine ..__........ _ ...._.. V-lSpecifications ..__ ...._.. .. V-l
General Repair Instructions. _ __..__..__...... 1-5General Information .... 1-5Welding on a Vehicle wIth an Electronic Controlled FuelSystem __ __.. _.. __ i-5
General Safety Instructions................. _... 1-4Important Safety Notice _ i-4
How to Use the Manual _ __.. ..._ i-lGeneral Information __.. i-l
Normal Starting Procedure _ _ _................ 1-2General Information _ _................................. 1·2Jump Starting 1-4
Off-Highway Engines Inlernational........................................ W-4Ott·Highway Engines United States and Canada W-1Operating Instructions - Overview..... 1-1General Information 1-1
Operating the Engine.............................................................. 1-5Ambient Temperature 1-7o to -32°C (32 to .250 FJ 1-7-32 to ·MoC (-25 to -65PFJ _.. '·7
Sy5tem Diagrams· Overview _.. ......__ D-1General Information D-l
To the Owner and Operator --..--- _....General Information _.._........... _.._ _ i-l
Tool Requirements _ 2-1General Information _.._ _ 2-1
Trollble ..hooting Procedures and Techniques .._.. ..__ TS-lGeneral Information .._........ .. .._ TS-l
Trollbleshooting Symptoms Charts __ TS-lAir Compressor Air Pressure Rises Slowly __.._.._..__.._.._.._ TS-2Air Compressor Cycles Frequently.. -- _ TS-3Air Compressor NOise is Excessive...... __..__ TS-4 I
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1-51-5 I
Ii-l I
i-34-34-34-54-4
I4-43-6
I
II Air Compressor Pumping Excess Lubricating Oil into the
Air System... . .Air Compressor Will Not Maintain Adequate Air Pressure(Not Pumping Continuously) .Air Compressor Will Not Stop Pumpmg .Alternator Not Charging or Insufficient Charging .Alternator Overcharging..... . .Coolant Contamination .Coolant Loss - External............... . .Coolant Temperature Above Normal - Gradual Overheat.. .Coolant Temperature IS Above Normal - Sudden Over-heat.......... . .Coolant Temperature is Below Norma!. .Engine Acceleration or Response Poor .Engine Difficult to Start or Will Not Start (ExhaustSmoke)... .. .Engine Difficult to Start or Will Not Start (No ExhaustSmoke).. .. .Engine Noise Excessive. .. ..Engine Noise Excessive - Combustion Knocks ..........Engine Power Output Low ..Engine Runs Rough at Idle.......... ..Engme Runs Rough or Misfires .Engine Speed Surges at Low or High Idle ..Engme Speed Surges Under Load or in Operating RangeEngine Starts But Will Not Keep Running ..Engine Vibration Excessive .Engme Will Not Crank or Cranks Slowly (Air Starter).Engine Will Not Crank or Cranks Slowly (Electric Starter) ..Engine Will Not Reach Rated Speed (RPM) ..Engine Will Not Shut Off. .. ..Exhaust Smoke Excessive Under Load .Fuel Consumption Excessive .Fuel in Coolant ..Fuel m the Lubricating Oil ..Fuel or Lubricating 011 Leakmg From Exhaust ManifoldGeneral Information ..Intake Manifold Air Temperature Above Speciticatmn .. ,........Intake Manifold Pressure (Boost) is Below Normal ..Lubricating 011 Consumption ExcesSive ..Lubricating Oil Contaminated " .., .Lubricating Oil Loss .. ..Lubricating Oil Pressure High ..lubricating Oil Pressure Low ..Lubricating Oil Sludge In the Crankcase Excessive ..Smoke, Black - Excess've ,,, ,, .Smoke, White - Excessive ..Turbocharger Leaks Engll16 011 or Fuel .
*Disregard if not appropriate for this particular machine.
(1) or 3000 mlles/5000km whichever is the sooner
(2) or as defined by local or national legislation
C = Check (adjust, clean or replace as necessary)
CST -cneck before towing.
CR = Check and report
D = Drain
G ..Grease
ReReplaoe
T ",Tasl
W I =cr when indicated if earlier.
Refer to specific sections of the operator's manual for more
information.
ROUTINE MAINTENANCE
This section refers to the various components which requireperiodic maintenance and replacement.
The MAINTENANCE CHART indicates the variouscomponents' descriptions and the intervals when maintenancehas to take place. Oil capacities, etc., can be found in theGENERAL DATA SECTION of this manual.
For any specification or specific requirement on service orpreventative maintenance for the engine, refer to the EngineSection.
Compressed air can be dangerous if incorrectly handled.Before doing any work on the unit, ensure that all pressure isvented from the system and that the machine cannot be startedaccidentally.
If the automatic blowdown falls to operate, then pressuremust be gradually relieved by operating the manual blowdownvalve. Suitable personal protective equipment should be worn.
Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.
Prior to attempting any maintenance work, ensurethat:-
all air pressure is fully discharged and isolated from thesystem. If the automatic blowdown valve is used for thispurpose, then allow enough time for It to complete the operation.
the discharge pipe / manifold area is depressurised byopening the discharge valve, while keeping clear of any airflowfrom !t.
WARNING: Pressure will remain in the system between theminimum pressure valve and the service valve after shutdownand operation of the auto blowdown valve.
This pressure must be relieved by :
(a) Disconnecting any downstream equipment.
(b) Opening the discharge valve to atmosphere.
the rnaehtna cannot be started. Post warning signs and/or fitanti-start devices.
Disconn8CI battery Cables.
Prior to opening or removing panels or covers to workInti/de a machine, .nsu...that:.
anyone entering.the machino is aware of the reduced levelof protection and the additional hazards, including hot surfacesand intermittently mOVing parts.
The machine cannot be StBrled.
Prior to attempting any maintenance work on a runningmachine, ensure that:-
• tho work carried out Is lImited to only Ihosa tasks whIchrequire the machine to run.
the work carried out with safety protection devices disabledor removed is limited to only those tasks which require themachine to be running with safety protection devices disabledor removed.
164
. all hazards present are known (e.g. pressurisedcomponents, electrically live components, removed panels,covers and guards, extreme temperatures, inflow and outflow ofair, intermittently moving parts, safety valve discharge etc.).
appropriate personal protective equipment is wom.
loose clothing, jewelry, long hair etc. is made safe.
warning signs Indicating that Mlllrrtenance Worl<" Is InProgress are posted in a position that can be clearly seen.
Upon completion of maintenance tasks and prIor toreturning the machine Into service, ensure that:-
the machine is suitably tested.
all guards and safety protection devices are refitted.
all panels are replaced, canopy and doors closed.
hazardous materials are effectively contnlned and disposedof.
PROTECTNE SHUTDOWN SYSTEM
Refer to the diagnostic display codes table for a listing ofshutdown conditions.
Low eriglne fuel level switch.
Test the low engine fuel level switch circuit as follows:
Start the machine.
.. , Note: Do not press the load button.
Disconnect the switeh, the machine should shutdown.
Ae-connect the switch.
Test the low engine fuel level switch by removing and operat-ing the float manually.
WARNING: Never remove or replace switches when themachine is running.
SCAVENGE LINE
The scavenge line runs from the combined ortftce/drop tubein the separator tllllk, to the orifice fitting located In the airend.
Check that the scavenge line and tube are clear of lillyobstruction each time the compressor lubricant is changed asany blockage will result in oil carryover into the discharge air.
COMPRESSOR OIL FILTER
Refer to the MAINTENANCE CHART in this section for therecommended servicing intervals.
Removal
WARNING: Del not remove the fllter(s) without nrst makingsure that the machine Is stopped and the system has beencompletely relieved of all ai, pressure. (Refer to STOPPINGTHE MACHINE in the OPERATING INSTRUCTIONS sectionof this manual).
---~------~--~----------
IClean the exterior of the filter housing and remove the
spin-on element.
Inspection
Inspect the oil filter head to be sure the gasket was removedwith the oil filter element. Clean the gasket seal area on the oilfilter head.
II
CAUTION: If there is any indication of the formation ofvarnishes, shellacs or lacquers on the filter element, it is awarning that the compressor lubricating and cooling oil hasdeteriorated and that it should be changed immediately. Referto LUBRICATION later in this section.
IIIIIOTlCE: Installing a new oil filter element when the old gasket
remains on the filter head, will cause an oil leak and can causeproperty damage.
Reassembly
Clean the filter gasket contact area and install the newelement.lighten until the gasket makes contact with the filterhousing. Tighten an additiona1'/2 to 3/.. of a revolution.
III
CAU'TtON: Start the machine (refer to PRIOR TO STARTINGand STARTING THE MACHINE in the OPERATINGINSTRUCTIONS secuon of this manual) and check for leakagebefore the machine is put back into service.
COMPRESSOR OIL SEPARATOR ELEMEIIIT . IRefer to the MAINTENANCE CHART in this section for the
recommended servicing intervals. IIf, however, the element hal>to be replaced, then proceed as
follows:
Removal III
WARNING: Do not remove the fllter(s) without first making8'..,. that the machine Is atopped and the ayatltm haa beencompletely relieved of all alr pressure. (Refer to STOPPINGTHE MACHINE in the OPERATING INSTRUCTIONS sectionof this manual).
Disconnect all hoses and tubes from the separator tankcover plate. Remove the drop-tube from the separator tankcover plate and then remove the cover plate. Remove theseparator element
IInspection
Examine the filter element. Examine all hoses and tubes,and replace If necessary.
IIReassembly
Thoroughly clean the orifice/drop tube and filter gasketcontact area before reassembly. Install the new element. IWARNING
Do not remove the staple from the anti-static gasket onthe aepanrtor element sInce It sarva. to ground anypouIble ataUc bulld*up. Do not usa gssket sealant sincethl. will affect electrical conductance.
II165
II
Reposition the cover plate, taking care not to damage thegasket, and replace the cover plate screws tightening in itcriss-cross pattern to the recommended torque (refer to theTORQUE SETTING TABLE later in this section).
I Reconnect all hoses and tubes to the separator tank coverplate.
IReplace the compressor oil (refer to LUBRICATION later in
this section).
I CAUTION: Start the machine (refer to PRIOR TO STARTINGand STARTING THE MACHINE in the OPERATINGINSTRUCTIONS section of this manual) and check for leakagebefore the machine is put back into service.I
I COMPRESSOR OIL COOLER AND ENGINE RADIATOR
IWhen grease, oil and dirt accumulate on the exterior surfacesof the 011 cooler and radiator, the efficiency Is Impaired. It isrecommended that each month the oil cooler and radiator becleaned by directing ajet of compressed air, (carrying if possiblea non-flammable cleaning solvent) over the exterior core of thecooler/radiator. This should remove any accumulation of oil,grease and dirt from the exterior core of the cooler so that theentire cooling area can radiate the heat of tho lubricating andcooling oil/water into the air stream.I
III
WARNING: Hot engine coolant and steam can cause Injury.When adding coolant or entltl'M%8 solution to 'he engineradiatOr, stop the engine at least one minute prior toreleasIng the radiator filler cap. Using a cloth to protect thehand, slowly release the filler cap, absorbing any releaaodfluid with the cloth. Do not remove the flller cap until allexcess fluid Is released and the engine cooling syatem fullydepressurlaed.
II
WARNING: Follow the Instructions provided by theantifreeze supplier when adding or draining the antifreezesolution. It Is advisable to wear personal protectiveequipment to prevent skin and eye contact with thoantifreeze solution.
IAIR Fil TEA ELEMENTS
I The air filter element should be replaced regularly (refer tothe MAINTeNANCE CHART) or when the restriCtion indicatorshows red, whichever cames first. The airciaooer precleanerdumpe shwld be cleaned as indicated in the MAINTENANCECHART (more frequenUy in dusty operating conditions).
I Removal
II
CAUTION; Navel remove and replace element(s) when themachine is running.
Clean the exterior of the fitter housing and remove the fitterelement by releasing the nut.
Reassembly
Assemble the new element into the fitter housing ensuringthat the seal seats property. Secure element by tightening nut.
Before restarting the machine, check that all clamps aretight.
VENTILATION
AJways check that the air inlets and outlets are clear of debrisetc.
COOUNG fAN DRIVE
Periodically check that the fan mounting bolts in the fan hubhave not loosened. If, for any reason, it becomes necessary toremove the fan or re-tighten the fan mounting bolts, apply agood grade of commercially available thread locking compoundto the bolt threads and tighten to the torque value shown in theTORQUE SETTING TABLE later in this section.
The fan belt(s) should be checked regularly for wear andcorrect tensioning.
FUEL SYSTEM
The fuel tank should be filled daily or every eight hours. Tominimise condensation in the fuel tank(s). it is advisable to topup after the machine is shut down or at the end of each workingd.ay. Drain any sediment or condensate that may haveaccumulated in the tank(s). Refer to MAINTENANCE CHART.
FUEL FILTER WATER SEPARATOR
The fuel filter water separator contains a filter element whichshould be replaced at regular intervals (see theSERVICE/MAINTENANCE CHART).
CHARGE AIR COOLER PIPEWORKInspect all hoses and clamps on the charge cooler pipe work.
Engine damage will occur if the charge cooling system leaks.
HOSESAll components of the engine COOling air intake system
should be checked petfodicttlly to keep the engine at peakefficiency.
At the recommended Intervals, (see the MAINTENANCECHART), inspect all of the intake lines to the air filter, and allflexible hoses used fer air lines, all lines and fuellinBS.
Periodically Inspect all pipework for cracks, leaks, etc. andreplace Immediately if damaged.
ELECTRICAL Sysn:M
WARNING: Disconnect the battery cables beforeperforming any maintenance or service.
166
Check the security of electrical terminals on the switchesand relays i.e. nuts or screws loose, which may cause local hotspot oxidation.
Inspect the components and wiring for signs of overheatingi.e. discolouration, charring of cables, deformation of parts,acrid smells and blistered paint.
BATTERY
Keep the battery terminals and cable clamps clean andlightly coated with petroleum jelly to prevent corrosion.
The battery restraint should be kept tight enough to preventthe battery from moving.
PRESSURE SYSTEM
Regularly. it is necessary to inspect the external surfaces ofthe system (from ttle airend through to the discharge valVe(s»including hoses, tubes, tube fittings and the separator tank, forvisible signs of impact damage, excessive corrosion, abrasion,tightness and chafing. Any suspect parts should be replacedbefore the machine is put back into service.
TIRE PRESSURE
See the GENERAL DATA SECTION of this manual.
RUNNING GEAR/WHEELS
Check the wheel nut torque 20 miles (30 kilometres) afterrefitting the wheels. Refer to the TORQUE SETTING TABLElater in this section.
Ufting jacks should only be used under the axle.
The bolts securing the running gear to the chassis should bechecked periodically for tightness (refer to the MAINTENANCECHART for frequency) and re-tighten where necessary. Referto the TORQUE SETTING TABLE later in this section.
LUBRICATION
CAUTION: Always check the ail levels before a new mscnineis put into service.
If, for any reascn. the unit has been drained. it must bere-filled with new oil before it is put into operation.
IENGINE LUBRICATING OIL I
The engine oil and oil filter element should be changed at theengine manufacturer's recommended intervals. Refer to theEngine operator manuaV6ection.
Refer to the Engine operators' manual/section for engine 011specifications.
COMPRESSOR LU8RICATING OIL
IIRefer to the MAINTENANCE CHART in this section for
service intervals.
INOTE: If the machine has been operating under adverseconditions, or has sufTared tong shutdown periOdS, then morefrequent service intervals will be required. IWARNING: DO NOT, under any cIrcumstances, remove anydratn plugs or the 011 filler plug from the compressorlubricating and cooling system without first making surethat the machine Is stopped and the system has beencompletely relieved of all air pressure (refer to STOPPINGTHE MACHINE in the OPERATING INSTRUCTIONS sectionof this manual).
II
Completely drain the receiver/separator system includinqthe piping and oil cooler by removing the drain plug(s} andcollecting the used oil in a suitable container. I
Replace the drain plug(s) ensuring that each one is secure.
INOTE: If the oil is drained immediately after the machine hasbeen running, then most of the sediment will be In suspensionand will therefore drain more readily. ICAUTION: Soma oil mixtures ere incompatible and result in theformation of varnishes, shellacs or lacquers which may beinsoluble. Refer to Portable Compressor Fluid Chart. IRUNNING GEAR WHEEL BEARINGS IWheel bearings should be packed with grease every 12months. The type of grease used should conform tospecification MIL-G-10924. I
IIII
167 I
III Portable Compressor Fluid Chart
IRefer to these charts for correct compressor fluidrequired. Note that the selection of fluid is dependent onthe design operating pressure of the machine and theambient temperature expected to be encounteredbefore the next oil change.
Note: Fluids listed as "preferred" are required forextended warranty.
Compressor oil carryover (oil consumption) maybe greater with the use of alternative fluids.
III Design Operating Ambient Specification
Pressure Temperature
Preferred:100 psi to 300 psi -10°F to 125°F IR Pro-Tec~
(-23°C to 52°C)Alternate:ISO Viscosity Grade 46with rust and oxidationinhibitors, designed forair compressor service.
Preferred:350 psi (-23°C to 5Z0C) IRXHPtIOS
-10·Fto 125°FAlternate:IRXHP405
ISO Viscosity Grade 68Group 3 or 5 wi1h rustand oxidation inhibitorsdesigned for air eemprss-sor service.
Preferred:65°F to 125°F XHP605
(-18"C to 52°C) IR XHP1001
IIIIIIIIIIII
100 - 300 PSI
RATED OPERAT1NG PRESSURE
350 PSI
1 tIR IR
XHPIIO!! XHP 1001IR
1XHP40!5
Preferred Ingersoll-Rand Fluids - Use of these fluids withoriginal I-R filters can extend airend warranty. Refer tooperator's manual warranty section for details or contactyour I-R representative.
Start the machine (Refer to STARTING INSTRUCTIONS inthe OPERATING INSTRUCTIONS section of this manual). INormally, regulation requires no adjusting, but if correct
adjustment is lost, proceed as follows:
Refer to the diagram above.
A. Throttle Arm
B. Adjusting ScI'9WC. Engine Governor
D. Separator Tank
E. Inlet Unloader
Inspect the throttle arm on the engine governor to see thatit is extended in the full speed position when the engine isrunning at full-toad speed and the service valve is fully open,(Refer to the GENERAL INFORMATION section of thismanual).
IIAdjust the service valve on the outside of the machine to
maintain normal operating discharge pressure without thethrottle arm moving from the full speed position before normaloperating discharge pressure is attained. Turn the adjustingscrew clockwise to increase the pressure.Optimum adjustmentis achieved when the throttle arm just moves from its full speedposition and the pressure gauge reas normal operatingdischarge pressure.
Close the service valve. The engine will slow to idle speed.
II
CAunON: Never allow the idle pr~ure to exceed maximumallowable pressure on the pressure gtJuge, otherwise the safetyvalve will operate. I
II
169 I
IIIIIIIIIIIIIIIIIII
TORQUE SETTING TABLE
NOMINAL DESIGN TORQUE
0 (5) CD 0 08AE J249 8AEJ249GRADE 5 GRADES @ 0 0 CD 0
A 36880623 2 COVER , ACCESSB 22231674 2 BELL YPAN , FRONT OUTSIDEC 22231641 BELL YPAN , AIR ENDD 22231682 BELL YPAN , RIGHT MIDDLEE 22231633 BELL YPAN , ENGINEF 22231690 BELL YPAN , LEFT MIDDLEG 22231724 BELL YPAN , REAR DISCHARGE
A 22392153 2 COVER ,HUB U 22392377 2 PIN, BALLB 22392237 2 PIN, COTTER V 22392385 2 NUTC 22392146 2 NUT W 22392393 2 ROD ,TRACKD 22392229 2 WASHER. HUB X 22392427 2 SCREWE 22392138 2 BEARING, OUTER y 22391858 4 CAP, GREASE FITTINGF 22392211 10 NUT, WHEEL Z 22391767 4 FITTING, GREASEG 22392203 10 STUD, WHEEL A1 22392294 BEAM, FRONT AXLEH 22392120 2 FRONT HUB ASSEMBLY 22391726 1 FRONT AXLE ASSEMBLYJ 22392161 2 BEARING, INNER ( INCLUDES ITEMS A-l, P- T, Y-A 1 )K 22392179 2 SEAL 22391734 1 TRACK ROD ASSEMBLYL 22392286 4 BUSHING ( INCLUDES ITEMS U - W )M 22392419 4 NUT, LOCK ITEMS M , N AND X ARE NOT INCLUDEDN 22392401 8 WASHER WITH ABOVE ASSEMBLIES.P 22392187 1 LEFT FRONT AXLE STUB
22392195 1 RIGHT FRONT AXLE STUBQ 22392252 2 SCREWR 22392260 2 NUT, LOCKS 22392245 2 WASHERT 22392278 2 PIN, KING
ELBOWTUBINGVALVE AND BRACKET ASSEMBLYATOMIZERBUSHING ( TO PORT ON ENGINE INTAKE MANIFOLD)SCREWCLAMP, BANDCYLINDER, ETHERSTARTING AID KIT ( INCLUDES ITEMS A - G )
A 95923363 2B 35302835 2C 22177703 1D 35273937 2E 95934253 2F 35834795G 35103852 1H 95220604 8J 96701917 12K 42437566
4243752442437582 1
L 36786572M 36734515 1N 35272558 6
96700901 2P 35358274 4Q 22283758 1R 96701495 4
UANUAl_ NO -- ORAWlNO!IV DATE I RLV
22330252 lOA 8103 A
NUTMOUNT, RUBBERBRACKET, AIR END MOUNTINGWASHERBOLTCOUPLING, AIR END / ENGINEBUSHING, COUPLINGSCREWSCREWAIR END ASSEMBLY ( HP-675)AIR END ASSEMBLY ( HP-750 & XP-750 )AIR END ASSEMBLY ( XP-825 & 9 /235 )GASKET, UNLOADERUNLOADER ASSEMBLYSCREW ( 45 MM )SCREW ( 40 MM )SCREWSUPPORT, WIRE ROUTINGSCREW
CONNECTOR W 35309210TEE X 35581792VALVE, SOLENOID y 95934279TEE Z 22217848CONNECTOR A1 36794147REGULATOR ( XP UNITS) A2 35329309REGULATOR ( HP UNITS) A3 95953956REG. ( 9 BAR UNITS) A4 36757573CONNECTOR A5 35326503NIPPLE A6 95953899TEEBUSHINGPIPE, SAFETY VALVECLAMPSWITCH, TEMPERATURENIPPLEELBOWVAL VE , SAFETYPLUGADAPTERNIPPLETEE
11
@------
A2>-------;!It
------------
OTY DESCRIPTION
1 ELBOW1 VALVE, BALL1 NIPPLE1 VALVE, MIN. PRESS.1 TUBE, SCAVENGE
A 22201578 1 GRILL, LEFT FRONT S 22243307 1 FRAME, DOORB 22211163 2 DOOR, SIDE T 22243273 1 DOORC 22208284 2 PANEL, HSRG ONLY U 22208946 1 COVER, LIFT BAIL0 35130707 4 HANDLE V 22197495 1 PANEL, RIGHT REAR
96702659 8 SCREW W 22203681 1 GRILL, RIGHT FRONT36769743 8 NUT X 36755742 6 FILLER, SIDE RAIL
E 36793602 2 LATCH ASSEMBLY Y 22198188 2 RAIL, TOP SIDE36794816 8 RIVET Z 22198444 2 RAIL, TOP SIDE
F 22197818 1 PANEL, LEFT REAR A1 22244255 2 PANEL,STEER.ONLYG 92912419 2 HINGE, DOOR A2 35337328 8 STUDH 22202048 1 PANEL, FRONT END A3 36881886 8 NUTJ 35310622 3 PLUGS, HOLE A4 36844355 4 SPRING, GASK 22202063 1 GRILL, FRONT END 22068373 2 SEAL,DOORL 22207930 2 BRACE, END PANEL 36895746 NUTSERTM 22197479 1 PANEL, REAR END 35279025 SCREW,8MMN 22300248 2 COVER, END PANEL 36797652 SCREW,6MMP 22208300 PANEL, FRONT TOP A5 22312599 1 PLUGQ 22237564 1 PANEL, TOP MIDDLE A6 95934873 2 SCREW, SHOULDERR 22199020 1 PANEL, TOP REAR 95935029 2 WASHER
95931564 2 NUTA7 35278720 PIN
t.tANUA1 !'O DRAWlNQ f'J), 01TL! !fUN22330252 34 11103 A
A 22201578 GRILL, LEFT FRONT S 22243299 FRAME, DOORB 22211171 2 DOOR, SIDE T 22243281 1 DOORC 22208292 2 PANEL, HSRG ONLY U 22208953 1 COVER, LIFT BAIL0 35130707 4 HANDLE V 22197503 1 PANEL, RIGHT REAR
96702659 8 SCREW W 22203681 1 GRILL, RIGHT FRONT36769743 8 NUT X 36755742 6 FILLER, SIDE RAIL
E 36793602 2 LATCH ASSEMBLY Y 22198196 2 RAIL, TOP SIDE36794816 8 RIVET Z 22198451 2 RAIL, TOP SIDE
F 22197826 1 PANEL, LEFT REAR A1 22244636 2 PANEL ,STEER. ONLYG 92912419 2 HINGE, DOOR A2 35337328 8 STUDH 22202055 1 PANEL, FRONT END A3 36881886 8 NUTJ 35310622 3 PLUGS, HOLE A4 36844355 4 SPRING, GASK 22202063 1 GRILL, FRONT END 22068373 2 SEAL,DOORL 22207930 2 BRACE, END PANEL 36895746 NUTSERTM 22197487 1 PANEL, REAR END 35279025 SCREW,8MMN 22300644 2 COVER, END PANEL 36797652 SCREW,6MMP 22208318 PANEL, FRONT TOP 54413117 2 DECAL, GALVANEAL0 22237557 1 PANEL, TOP MIDDLE A5 22312599 1 PLUGR 22199038 1 PANEL, TOP REAR A6 95934873 2 SCREW, SHOULDER
95935029 2 WASHER95931564 2 NUT
A7 35278720 PINN»I.W_ ~ - DRAWING t.V DATE I REV
22330252 34A 11103 A-~--------- ~~~------
ENCLOSURE BAFFLESIIIIIIIIIIIIIIIIII
---- I
/-0
FRONT
ITEM CPN
A 22301089B 22301097C 54718184
54519202D 22301048E 22301105F 22301717G 22301113
368957463527902536797652
H 22336184
t.IANUA.l P«<). - ORAW1t-Kl NO [)ATE I REV
22330252 35 11!OJ A
OTY OTY DESCRIPTIONDESCRIPTION CPN
1 BAFFLE, FRONT AIR INTAKE1 BAFFLE, LEFT FRONT AIR INTAKE15 STRAP, FOAM RETENTION (DOORS AND ROOF)15 SCREW
BAFFLE, RIGHT FRONT AIR INTAKE2 BAFFLE, EXHAUST2 PLATE, BAFFLE
FOAM, FRONT X 22306096 FOAM. BAFFLEFOAM. FRONT Y 22306104 1 FOAM, BAFFLEFOAM, FRONT Z 22306088 2 FOAM. BAFFLEFOAM, FRONT A1 22252225 1 FOAM. TOPFOAM, FRONT A2 22252217 1 FOAM. TOPFOAM, BAFFLE A3 22252241 1 FOAM, TOPFOAM, FRONT A4 22252233 1 FOAM, TOPFOAM, FRONT A5 22252258 2 FOAM. TOPFOAM, INST. PANEL A6 22252399 FOAM. RIGHT SIDEFOAM, DOOR A7 22252209 1 FOAM. RIGHT DOORFOAM, LEFT DOOR A8 22252381 FOAM, RIGHT SIDE
ITEM ePN OTY. DESCRIPTIONA 54413177 1 GALVANEAL DECAL (GALVANEAL OPTION)B 54640024 GENUINE PARTS DECALC 22298343 FALL OFF UNIT DECALD 54568761 HOT PRESSURIZED FLUID DECALE 22383319 OIL LEVEL DECALF 54604970 OIL FILL PLUG DECALG 54568795 HIGH PRESSURE AIR DECALH 54640164 AIR END WARRANTY DECAL
,-----------WI01 RED_16---------------.- A_ FI B II ~ ISA
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III COMPR 1 ATI
TEMP ~_SENDER ); U
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II
22330252MM'UALNO.-DfUWlNONO. OATE,fUiV.
39 '1/03 A
ENGINE 1 AT1TEMP ~_
SENDER > U
rn
ENGINEOILPRESS
SENDER
LO<n<D I
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u:: IT: rr- aQOO 0=
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STARTERRELAY
A 1
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B 2
,5]IT
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STARTERMOTOR81
.----.__L__L__~--POSr-r-:-: __ \-".c-_,'GND
W156 BRN_12-
za:cc
t-------t-WI29 BLU_16--------+-----+---,
'"ro
K7
BYPASSRELAY
El1 fn
,za:a
8a:
r
S7 DISCHAIRPRESSURESWITCH
I~~-----'l Iw u,
i"1 fr\.CRANKLATCHRElAY
I~,'"m
K3
SiARTIRUNLATCHRELAY
K2
SIS
ENGINEOILPRESSSW
,-W181 ORN-'61
,----"---'---,K6
I ,'"co
,~
ALTERNATORINDICATORRELAY
I
HAl~ REGULATOR
HEATER
,--'
ilL3
STA~T!RUNVALVESOLENOID
za:=
12V
I
> t22 UNLOADER
VALVESOLENOID
~
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