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www.changlin.com.cn Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins Authorized Repair Locations and component manufacturers. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
www.changlin.com.cn Table of Contents Section 1‐lntroduction ..................................................................................................................................... 10 To The Owner and Operator ....................................................................................................................... 11 About the Manual........................................................................................................................................
www.changlin.com.cn Fuel‐Water Separator .................................................................................................................................. 34 Oil Level ....................................................................................................................................................... 34 Coolant Level ...............................................................................................................................................
www.changlin.com.cn Coolant draining ...................................................................................................................................... 58 Cooling System Flushing .......................................................................................................................... 60 Coolant System Filling ............................................................................................................................. 61 Vibration Damper (Rubber) ........
www.changlin.com.cn Coolant Temperature Above Normal ...................................................................................................... 79 Coolant Temperature Above Normal (Continued) .................................................................................. 79 Coolant Loss............................................................................................................................................. 80 Coolant Temperature Below Normal ...............................
www.changlin.com.cn Fuel Filter Head Adapter‐Replacement ................................................................................................... 99 Lift Pump‐Replacement Preparatory Steps: .......................................................................................... 100 High Pressure Fuel Lines‐Replacement Preparatory Steps: .................................................................. 101 Fuel Drain Manifold‐Replacement ........................................................
www.changlin.com.cn Electrical System Repair ............................................................................................................................ 150 Starting Motor‐Replacement................................................................................................................. 150 Alternator‐Replacement ........................................................................................................................ 151 Section 12‐Specifications and Torque Values..
www.changlin.com.cn Important Reference Numbers Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required.
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www.changlin.com.cn To The Owner and Operator Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations Outlined in Maintenance Guidelines (Section 2). Keep records of regularly scheduled maintenance. Use the correct fuel, oil and coolant in your engine as specified in Engine Specifications (Section V).
www.changlin.com.cn Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears the meaning defined below: WARNING-Serious personal injury or extensive property damage can result if the warning instructions are not followed. PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly.
www.changlin.com.cn General Safety Instructions Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. NOTE: It is not possible for Cummins Engine Company, Inc.to anticipate every possible circumstance that can involve a potential hazard.
www.changlin.com.cn Warning: Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. Warning: Never use gasoline or other flammable materials to clean parts. Always use approved cleaning Solvents. Warning: Avoid prolonged and repeated skin contact with used engine oils Such prolonged and repeated contact may cause serious skin disorders or other serious bodily injury. --- Avoid excessive contact.
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www.changlin.com.cn Batteries (Specific Gravity) Specific Gravity at 27℃ [80°F] State of Charge 1.260-1.280 100% 1.230-1.250 75% 1.200-1.220 50% 1.170-1.190 25% 1.110-1.
www.changlin.com.cn External Engine Components The illustrations which follow show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models.
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www.changlin.com.cn General Information Correct care of your engine will result in longer life, better performance, and more economical operation. •Follow the daily maintenance checks listed in Maintenance Guidelines,Section 2. •Check the oil pressure indicators,temperature indicators,warning lightsand other gauges daily to make sure they are operational. Warning: DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE OR CAN BE COMBUSTIBLE VAPORS.
www.changlin.com.cn Starting Procedure Matrix Idle Throttle Full Throttle Automotive All pumps-above 16°C [60°F] …………………………………………. x All pumps-below 16°C [60°F] …………………………………………………………………………..x Industrial/Marine All pumps-above 0°C [32°F] …………………………………………...x All except Bosch VE-below 0°C [32° F] …………………………… x Bosch VE-below 0°C [32°F] ……………………………………………………………………….
www.changlin.com.cn Cold Weather Operation Starting Aid Requirements Use the following chart as a reference for required cold weather starting aids: Operation in ambient temperatures below 0°C [32°F] can require special consideration be given to engine starting. At temperatures below 0°C [32°F], operate the engine at moderate speeds for 5 minutes before full loads are applied.
www.changlin.com.cn Cold Weather Starting Using Starting Fluid With Mechanical or Electrical Metering Equipment • • • • • Set the throttle at half speed. Disengage the driven unit,or if equipped,put the transmission in neutral. Activate the switch to open the fuel pump shut-off valve. While cranking the engine,inject metered amounts of starting fluid. Engine oil pressure must be indicated on the gauge within 30 seconds after starting.
www.changlin.com.cn Operating the Engine Do not operate engine at full throttle below peak torque engine speed (1100 to 1600 RPM.dependent on engine rating) for extended periods (more than 1 minute) of time. Allow the engine to idle 3 to 5 minutes before shutting it off after a full load operation. Monitor the oil pressure and coolant temperature gauges frequently.Refer to Lubricating Oil System or Cooling System,Section v,for recommended operating pressures and temperatures.
www.changlin.com.cn descending a steep grade, use a combination of transmission gears and engine or service brakes to control the vehicle and enginespeed. Engine Shut‐down Allow the engine to idle 3 to 5 minutes after a full load operation before shutting it off.This allows the engine to cool gradually and uniformly. Turn the ignition key switch to the OFF position.
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www.changlin.com.cn General Information Cummins Engine Company, Inc. recommends that the engine be maintained according to the Maintenance Schedule in this section. If the engine is operating in ambient temperatures consistently below-18°C [0°F] orabove38°C [100°F], perform maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a dusty environment or if frequent stops are made. See your Cummins Authorized Repair Location for recommended intervals.
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www.changlin.com.cn Maintenance Record From Maintenance Record Engine Serial No.
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www.changlin.com.cn General Information Preventative maintenance begins with day-to-day awareness of the condition of the engine and its systems. 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 Fuel‐Water Separator Draining Draing the water and sediment from the separator daily. Shut off the engine. Use your hand to open the drain valve.
www.changlin.com.cn Coolant Level Check Warning: Do not remove the radiator cap from a hot engine. Wait until the temperature is below 50 °C [120 ° F]. Before removing the pressure cap. Failure to do so can result in personal injury from heated coolant spray or steam. Remove the filler cap slowly to relieve coolant system pressure. NOTE: Never use a sealing additive to stop leaks in the coolant system. This can result in coolant system plugging and inadequate coolant flow causing the engine to overheat.
www.changlin.com.cn Drive Belt Inspection Visually inspect the belt. Check the blet for intersecting cracks. Transverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing. Refer to Adjustment and Replacement (Section A). Cooling Fan Inspection Warning: Personal injury can result from a fan blade failure. Never pull or pry on the fan.
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www.changlin.com.cn General Information All checks or inspections listed under daily or previous maintenance intervals must also be performed at this time in addition to those listed under this maintenance interval. Lubricating Oil and Filter Change Interval Refer to the following flow chart to determine the maximum recommended oil and filter change intervals in kilometers, milse, hours or months; whichever comes first.
www.changlin.com.cn 17mm Caution: Hot oil can cause personal injury Operate the engine until the water temperature reaches 60°C[140°F].Shut the engine off. Remove the oil drain plug. NOTE: Use a container that can hold at least 20 liters [15 U.S. qts.] of oil. 90 to 95 mm Filter Wrench Clean the area around the lubricating oil filter head. Remove the filter. Clean the gasket surface of the filter head. NOTE: The o-ring can stick on the filter head. Make sure it is removed before installing the new filter.
www.changlin.com.cn NOTE: Fill the filters with clean lubricating oil before installation. Apply a light film of lubricating oil to the gasket sealing sur- face before installing the filters. Caution: Mechanical over-tightening can distort the threads or damage the filter element seal. Install the filter as specified by the filter manufacturer. 17 mm Check and clean the oil drain plug threads and sealing surface. Install the oil drain plug.
www.changlin.com.cn Fill the engine with clean oil to the proper level. Four Cylinder Six Cylinder Pan Capacity 9-5 Liters [10U.S. Qts] 14.2 Liters [15U.S. Qts] Total System 10.9 Liters 16.3 Liters Capacity [11.5 U.S. Qts] [17.2 U.S. Qts] NOTE: Capacities assume standard pan. Total system assumes standard pan plus filter. Some 6B applications use a reduced capacity pan 10.4 Liters [11 U.S. Qts] and some have increased capacity of 16 liters [17 U.S. Qts].
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www.changlin.com.cn Air Intake System Inspection Inspect the intake piping for cracked hoses, loose clamps, or punctures which can allow dirt and debris to enter the engine. Tighten or replace parts as necessary to make sure the air intake system does not leak. Charge Air Cooler Inspection If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the CAC, the CAC must be cleaned. Remove the CAC from the vehicle. Refer to the vehicle manufacturer's instructions.
www.changlin.com.cn Cleaning Flush the CAC internally with solvent in the opposite direction of normal air flow Shake the CAC and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Continue flushing until all debris or oil is removed. Caution: Do not use caustic cleaners to clean the CAC. Damage to the CAC will result. After the CAC has been thoroughly cleaned of all oil and debris with solvent, wash the CAC internally with hot soapy water to remove the remaining solvent.
www.changlin.com.cn Air Cleaner Restriction Check Maximum intake air restriction is 635 mm [25.0 in.] of water for turbocharged engines. Naturally aspirated engines have a maximum restriction of 510 mm [20.0 in.] of water. Turbocharged engines must be operated at rated RPM and full load to check maximum intake air restriction. Replace the air cleaner element when the restriction reaches the maximum allowable limit or clean according to the manufacturer's recommendations.
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www.changlin.com.cn General Information All checks or inspections listed under daily or previous maintenance intervals must also be performed at this time in addition to those listed under this maintenance interval. Fuel Filter Replacement 75-80 mm and 90-95 mm Clean the area around the fuel filter head. Remove the filters. Clean the gasket surface of the filter head. Replace the o-ring. Fill the new filter (s) with clean fuel and lubricate the o- ring seal with clean lubricating oil.
www.changlin.com.cn Fuel System Bleeding Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically, if the fuel filter is changed in accordance with the instructions. No manual bleeding of fuel lines is required. NOTE: Manual bleeding is required if: •The fuel filter is not filled prior to installation. •Injection pump is replaced.
www.changlin.com.cn Venting 8 mm Bleed the Lucas CAV pump at the location shown in the illustration. Air/fuel can be pumped from this location with the hand lever on the lift pump if the fuel solenoid valve is energized. Air can be vented from both pumps through the fuel drain manifold line by operating the starting motor. Caution: When using the starting motor to vent the system, do not engage it for more than 30 seconds at a time: Wait 2 minutes between engagements.
www.changlin.com.cn High Pressure Lines (Rotary and‐ In‐line Pumps) Venting 17 mm, 19 mm Warning: The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious bodily harm. Venting is accomplished by loosening one or more fittings at the injectors and cranking the engine to allow entrapped Re-Tighten Line Fittings Torque Value: 30 N*m 122 ft-Ib] Warnig: Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire.
www.changlin.com.cn Section 6‐Maintenance Procedures at 38,000 Kilometers [24,000 Mi.
www.changlin.com.cn General Information All checks or inspections listed under daily or previous maintenance intervals must also be performed at this time in addition to those listed under this maintenance interval. The procedures given in this section for valve lash adjustment are to be performed at the initial 38,000 km [24,000 mi] adjustment. Subsequent adjustments are to be performed at 77,000 km [48,000 mi] intervals. Valves Adjustment 15 mm Remove the valve cover.
www.changlin.com.cn Caution: To prevent damage to the engine or pin, be sure do disengage the pin after locating TDC. Feeler Gauge Intake Clearance: 0.254 mm [0.010 IN] Exhaust Clearance: 0.508 mm [0.020 IN ] Check/set valves with engine cold-below 60°C [140°F]. NOTE: The clearance is correct when some resistance i “felt” when the feeler gauge is slipped between the valvi stem and the rocker lever.
www.changlin.com.cn Mark the pulley and rotate the crankshaft 360 degrees. Caution: To prevent engine or pin damage, be sure timing is disengaged. 14 mm, Flat blade Screwdriver Adjust the valves as indicated in the illustration. Tighten the lock nut and measure the valve lash again. Torque Value: 24 N*m [18 ft-lb] Six‐Cylinder Engine Adjustment 14 mm, Flat blade Screwdriver Locate Top Dead Center (TDC) for Cylinder Number 1.
www.changlin.com.cn Adjust the valves as indicated in the illustration. Tighten the lock nut and measure the valve lash again. Torque Value: 24 N*m [18 ft-lb] 15 mm Install the valve covers and tighten capscrews. Torque Value: 24 N*m [18 ft-lb] Drive Belt Tension Check Measure the belt deflection at the longest span of the belt. Maximum Deflection: 9.5 to 12.7 mm [3/8 to 1/2 inch] NOTE: The Cummins belt tension gauge, Part No. ST-1293 can be used.
www.changlin.com.cn Drive Belt Inspection Inspection 3/8 Inch Square Drive, 13 mm Remove the drive belt. Lift the tensioner to remove and install the belt. NOTE: After the tensioner has been raised to remove/in- stall the belt, check the torque of the tensioner cap screw. Torque Value: 43 N*m [32 ft-lb] Inspect the belt for damage. Transverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with Transverse cracks are not acceptable.
www.changlin.com.cn Section8‐Maintenance Procedures at 77,000 Kilometers [48,000 Mi.
www.changlin.com.cn General Information All checks or inspections listed under daily or previous maintenance intervals must also be performed at this time in addition to those listed under this maintenance interval. Cooling System Maintenance Coolant draining Caution: Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeated contact can cause skin disorders or other bodily Injury. •Avoid excessive contact-wash thoroughly after contact. •Keep out of reach of children.
www.changlin.com.cn Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet. A drain pan with a capacity of 20 liters [5 U.S. gallons] will be adequate in most applications. Check for damaged hoses and loose or damaged hose clamps. Replace as required. Check the radiator for leaks, damage and build up of dirt. Clean and repair as required.
www.changlin.com.cn Cooling System Flushing Caution: During filling, air must be vented from the engine coolant passages. Open the engine venting pet- cock and the petcock on the aftercooler for aftercooled engines. The system must be filled slowly to prevent air locks. Wait 2 to 3 minutes to allow air to be vented, then add mixture to bring the level to the top. Fill the system with a mixture of sodium carbonate and water (or a commercially available equivalent). NOTE: Use 0.5 kilogram [1.
www.changlin.com.cn Operate the engine for 5 minutes with the coolant temperature above 80°C [176°F], Shut the engine off and drain the cooling system. NOTE: If the water being drained is still dirty, the system must be flushed again until the water is clean. Coolant System Filling The system has a maximum fill rate of 14 liters per minute [3.5 U.S. Gallons per minute]. Do not exceed this fill rate. Caution: The system must be filled slowly to prevent air locks.
www.changlin.com.cn Intall the pressure cap. Operate the engine until it reaches a temperature of 80°C [180°F], and check for coolant leaks. Check the coolant level again to make sure the system is full of coolant, or that the coolant level has risen to the hot level in the recovery bottle on the system, if so equipped. Warning: Before removing the pressure cap, wait until the coolant temperature is below 50 °C [120°F]. Failure to do so can cause personal injury from heated coolant spray.
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www.changlin.com.cn General Information The following drawings show the flow through the engine systems. Although parts can change between different applications and installation, the flow remains the same. The systems shown are: • Fuel System • Lubricating Oil System • Coolant System • Intake Air System • Exhaust System Knowledge Of the engine systems can help you in troubleshooting, service and general maintenance of your engine.
www.changlin.com.cn Hydraulic Cold Start Injection Advance (Rotary Automotive Pumps Only) A hydraulic cold start injection advance (KSB) device is used on 1988 and later certified engines for white smoke control during cold starting. When the engine is cold, the KSB cauese the injection timing mechanism to be fully advanced at low speeds. When the engine reaches normal operating temperature, the KSB is deactivated and injection timing is then advanced proportionally to increased engine speed.
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www.changlin.com.cn Troubleshooting Procedures and Techniques This guide describes some typical engine operating problems, their causes, and some acceptalbe corrections to those problems. Unless notes otherwise, the problems listed are those which an operator can diagnose and repair See a Cummins Authorized Repair Location for diagnosis and repair of problems not listed. Follow the suggestions below to develop good troubleshooting procedures: • Study the problem thoroughly before acting.
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www.changlin.com.cn Repair Tools Required Sockets 10 mm 12 mm 13 mm 15 mm 17 mm 18 mm 19 mm 22 mm 27 mm Wrenches Other 8 mm 10 mm 13 mm 15 mm 17 mm (open end) 19 mm 22 mm 24 mm Allen Wrench (8 mm) Breaker Bar (1/2 in. Sq. Drive) Flat Screwdriver Ratchet (3/8 in. Sq. Drive) Ratchet (1/2 in. Sq.
www.changlin.com.cn Cooling System Repair Drive Belt‐Replacement 3/8 Inch Square Drive Lift the tensioner arm and pulley to remove and install the belt. The belt tensioner winds in the direction that the spring tang is bent over the tensioner body. To lossen ten tensior on the belt, rotate the tensioner to wind the spring tighter. Applying excessive force in the opposite direction of windup or after the tensioner has been wound-up to the positive step can cause the tensioner arm to break.
www.changlin.com.cn 13 mm Install the belt tensioner. Torque Value: 43 N*m [32 ft-lb] Fan Pulley‐Replacement Preparatory Steps: • Remove the drive blet. NOTE: Loosen the capscrews before removing the belt and torque the capscrews after the belt is installed. 10 mm and 13 mm Remove the four capscrews, fan and spacer. Replace the fan pulley. Torque Values: 8 mm Capscrews-24 N • m [18 ft-lb] 10 mm Capscrews-43 N • m [32 ft-lb] Water Pump‐Replacement Preparatory Steps: •Drain the coolant.
www.changlin.com.cn 10 mm Remove the water pump. Clean the sealing surface on the cylinder block. Install a new o-ring into the groove in the water pump. 10 mm Install the water pump.
www.changlin.com.cn Lift the tensioner arm and pulley to install the drive belt. Caution: The system must be filled slowly to prevant air locks. During filling, air must be vented from the engine coolant passages. Be sure to open the petcock on the aftercooler for aftercooled engines. The system has a maximum fill rate of 14 liters per minute [3.5 U.S. gallons per minute]. Do not exceed this fill rate. Wait 2 to 3 minutes to allow air to be vented. Then add coolant to bring the level to the top.
www.changlin.com.cn Thermostat‐Replacement Preparatory Steps: • Disconnect the negative battery cable. • Drain 2 liters (2.1 U.S. Quarts) of coolant. • Remove the radiator hose from the outlet connection. • Remove the drive belt. 14 mm, 16 mm Loosen the lower alternator link cap screw. Remove the upper alternator mounting cap screw. Lower the alternator. 10 mm Remove the thermostat housing, lifting bracket, thermostat and thermostat seal. Clean the gasket surfaces.
www.changlin.com.cn Clean the gasket surfaces. NOTE: Do not let any debris fall into the thermostat cavity when cleaning gasket surface. Caution: Always use the correct thermostat and never operate the engine without a thermostat. An incorrect thermostat can cause the engine to overheat or run too cold. The engine will overheat if operated without a thermostat because the coolant flows back to the inlet of the water pump instead of through the radiator for cooling.
www.changlin.com.cn 14 mm, 16 mm Position the alternator and install the mounting capscrew. Torque Value: (A) 24 N • m [18 ft-lb] (B) 43 N• m [32 ft-lb] 13 mm Install the drive belt. NOTE: After the tensioner has been raised to remove/in- stall the belt, check the torque of the tensioner cap screw. Torque Value: 43 N• m [32 ft-lb] Fill the cooling system. Operate the engine and check for leaks.
www.changlin.com.cn Fuel System Repair Summary Component To Be Replaced Lift Pump High Pressure Lines Injector Fuel Drain Manifold Injectors Tools 13,14 and 17 mm Wrenches Clean debris. 13 mm Socket, 14,17, and 19mm Open End Wrenches and a Torque Wrench Clean debris. 10 mm and 19 mm Open End Wrenches, 10 Manifold mm and 13 mm Sockets, and a Torque Wrench.
www.changlin.com.cn Low Pressure Fuel Line‐Replacement Preparatory Step: • Clean all debris from around the fittings. 14 mm, 17 mm Disconnect the fuel line from the lift pump and filter head. Use two wrenches to disconnect the line from the lift pump. 14, 17 mm Install the fuel line to the lift pump and filter head. Use two wrenches to tighten the connection to the lift pump. NOTE: Do not over tighten the connection. Fuel leaks can result from over tightening.
www.changlin.com.cn Lift Pump‐Replacement Preparatory Steps: • Clean debris from around the lift pump. 14 mm, 17 mm Disconnect the fuel lines. 10 mm Remove the lift pump and clean the mounting surface the cylinder block. 10 mm Install the lift pump and a new gasket. Connect the fuel lines.
www.changlin.com.cn High Pressure Fuel Lines‐Replacement Preparatory Steps: • Clean all debris from around the fittings. 17 mm NOTE: If individual lines are to be replaced, remove the support clamp from the let of lines containing the line to be replaced. 17 mm Disconnect the line (s) from the fuel pump. Install protective covers to the injectors and delivery valves to prevent the entry of dirt into the system.
www.changlin.com.cn Fuel Drain Manifold‐Replacement Preparatory Steps: • Clean debris. 10 mm Remove the cap screw from the hold-down clamp. 10 mm Remove the banjo fitting screws and washers. 17 mm Disconnect the drain line fitting from the injection pump.
www.changlin.com.cn NOTE: Use new seals and sealing washers. Assemble the drain line and fuel drain manifold in the reverse order of removal. Torque Value: (Banjo fitting screw) (Banjo fitting) (Clamp screw) 15 N• m [11 ft-lb] 9 N• m [7 ft-lb] 24N• m [18 ft-lb] Injection Pump Supply Line‐Replacement 17 mm Remove the bleed screw banjo fitting. 14 mm, 16 mm, 17 mm Remove the supply line (Bosch Injection Pump). Replace the seals (1) in the fittings if the line is disassembled.
www.changlin.com.cn 17 mm Engines rated at 2500 RPM and above require additional fuel line support. Install as illustrated. Torque Value: 24 N• m [18 ft-lb] Injectors‐Replacement Preparatory Steps: • • • Thoroughly clean around the injectors. Disconnect the high pressure fuel lines. Disconnect the fuel drain manifold. 16 mm, 24 mm Box Wrench Caution: The injector must not rotate in the bore of the cylinder head. This will damage the cylinder head. Remove the injectors.
www.changlin.com.cn Remove the injector hold-down nut and apply a coat of anti-seize compound to injector surface (A). Avoid getting anti-seize compound in the fuel drain hole (B). Install the hold-down nut on the injector body. Install a new o-ring into the recessed groove on the top of the hold-down nut. Make sure the o-ring is not cut or wisted when installing (BOSCH and Stanadyne). CAV injectors retain the o-ring inside the hold-down nut.
www.changlin.com.cn Assemble the injector and new copper washer. Use only one copper washer. Service Tip: A light coat of clean 15W40 engine oil between the washer and injector can help to keep the washer from falling during installation. 24 mm Install the Injectors The protrusion on the side of the nozzle fits into a notch in the head to orient the injector. Tighten the injector nozzle nuts. Torque Value: 60 N-m [44 ft-lb] 10 mm Install the fuel drain manifold.
www.changlin.com.cn Fuel Shut Off Solenoid‐Replacement Preparatory Steps: • Label and disconnect the wiring. Bosch and CAV 22 mm-CAV 24 mm-Bosch Clean around the valve. WHEN REMOVING THE VALVE, BE CAREFUL NOT TO DROP THE PISTON AND SPRING. Replace the valve and connect the electrical wire. Stanadyne DB4 • Remove the electrical wiring. • Remove the fuel drain line. • Remove the throttle shutoff linkage. • Remove the fuel injection pump top cover. • Disassemble the fuel injection pump top cover.
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www.changlin.com.cn 5/16 Inch Install the cover and gasket onto the fuel injection pump. NOTE: Extreme care must be taken in assembling the cover to a fuel injection pump to make sure the shutoff arm is in proper with the linkage hook tab. Install the cover to pump at a downward angle from the drive shaft end of the fuel injection pump, then slide the cover horizontally into position. Torque Value: 4.6 N*m [41 in-lb] KSB Replacement T30 TORX, 12 mm Disconnect the wiring harness from the KSB solenoid (1).
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www.changlin.com.cn NOTE: A diesel engine cannot tolerate dirt or water in the fuel system. A tiny piece of dirt or a few drops of water in the injection system may stop your unit. Clean all external surfaces of the injection pump, including all line connections and fittings that are to be disconnected. Clean the area around the injection pump gear cover to prevent dirt from entering the crankcase. Removing the Fuel Pump Locate TDC for cylinder number 1.
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www.changlin.com.cn 10 mm The special washer on the Bosch injection pump must be removed so the lockscrew can be tightened against the drive shaft. Torque Value: 30 N*m [22 ft-lb] 22 mm Remove the gear cover access cap. Remove the nut and washer from the fuel pump shaft. 75 mm T-Bar Puller Pull the fuel pump drive gear loose from the shaft. Caution: Do not remove the control lever. The lever is indexed to shaft during pump calibration.
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www.changlin.com.cn 13 mm NOTE: Do not drop drive gear key when removing pump. Remove the three mounting nuts. Remove the fuel pump. Installing the Fuel Pump Make sure the engine has cylinder number 1 at TDC. The keyway in the shaft of new and reconditioned pumps will be locked in a position corresponding to the keyway in the drive gear when cylinder number 1 is at TDC on the compression stroke. After verifying that Cylinder Number 1 if at TDC, install the pump.
www.changlin.com.cn 13 mm If reinstalling the removed pump, install the pump onto the engine. Rotate the pump to align the scribe marks. Tighten the three mounting nuts. Caution: The pump shaft must be unlocked after installation to prevent pump damage. Torque Value: 24 N • m [18 ft-lb] 13 mm If installing a new or rebuilt pump without scribe marks,take up gear lash by rotating the pump against the direction of drive rotation. Tighten pump retaining nuts.
www.changlin.com.cn 3/8 Inch Loosen the Stanadyne DB4 fuel injection pump lock screw and position the special washer behind the lock screw head. Tighten the lock screw. 10 mm NOTE: On the Bosch pump, the special washer is wired to the pump and must be installed under the lockscrew. Tighten the pump lockscrew. Torque value: 13 N • m [10 ft-lb] NOTE: Be sure to disengage the timing pin. 10 mm Install the injection pump support bracket. Finger tighten all cap screws before final tightening.
www.changlin.com.cn Torque Value: 24 N • m [18 ft-lb] 22 mm Tighten the drive gear mounting nut. Install the access cap. Torque Value: Bosch 60 N•m Stanadyne 65N• m [48 ft-lb] [48 ft-lb] 8 mm Install the solenoid wiring and all fuel lines. NOTE: When connecting the cable/rod to the control lever, adjust the length so the lever has stop-to-stop movement.
www.changlin.com.cn NOTE: Similarly adjust the length of the cable/rod to the mechanical shut down lever so there is a stop-to -stop movement. Bleed all air from the fuel system. If necessary, adjust the idle speed. Fuel System Repair‐In‐Line Pump Fuel system Components‐£leaning Thoroughly clean all fittings and components before removal. Make sure that the debris, water, steam or cleaning solution does not reach the inside of the fuel system.
www.changlin.com.cn Low Pressure Fuel Line‐Replacement Preparatory Step: • Clean debris from fittings 14 mm, 17 mm, 20 mm Disconnect the fuel line from the lift pump and filter head. Use two wrenches to disconnect the line from the lift pump. 14 mm, 17 mm, 20 mm Install the fuel line to the lift pump and filter head. Use two wrenches to tighten the connection to the lift pump. Torque Value: 24 N*m [18 ft-lb] Fuel Filter Head Adapter‐Replacement Preparatory Steps • Clean debris. • Remove fuel filters.
www.changlin.com.cn 24 mm Remove the retaining nut, filter head adapter and sealing washers. Install in the reverse order of removal. Torque Value: 32 N*m [24 ft-lb] Lift Pump-Replacement Preparatory Steps: • Clean debris • Disconnect the fuel lines. 10 mm Remove the lift pump. Clean the mounting surface on the cylinder block.
www.changlin.com.cn 10 mm Caution: Alternately tighten the mounting capscrews. As the capscrews are tightened, the fuel transfer pump plunger is pushed into the pump. Failure to tighten the capscrews in an even manner can result in the plunger being bent or broken. Install the pump. Torque Value: 24 N • m [18 ft-lb] High Pressure Fuel Lines‐Replacement Preparatory Steps: Clean debris.
www.changlin.com.cn Fuel Drain Manifold‐Replacement Preparatory Steps: • Clean debris. 10 mm Remove the drain line banjo capscrew from the fuel filter head. Remove the capscrew from the bracket on the intake cover. Remove the banjo capscrews from the injectors. NOTE: Use new seals and sealing washers. Assemble the drain line and fuel drain manifold in the reverse order of removal.
www.changlin.com.cn Injectors-Replacement Preparatory Steps: • Thoroughly clean around the injectors. • Remove the high pressure fuel lines. •Remove the fuel drain manifold. 24 mm Remove the injectors. Injector Bore Brush Clean the injector nozzle bore, using Service Tool No. 3822509. Lubricate the sealing lips of the sleeve with anti-seize compound. Package the injector, sealing sleeve, a new copper sealing washer and the hold down clamp.
www.changlin.com.cn Install the injector package into the injector bore. The injector leak off connection must be away from the valve cover. 24 mm Tighten the injector nozzle nut. The protrusion on the side of the nozzle fits into a notch in the head to orient the injector. . Torque Value: 60 N •m [44 ft-lb] 10 mm Install the fuel drain manifold. Torque Value: 9 N •m [7 ft-lb] 17 mm, 19mm Install the high pressure fuel lines.
www.changlin.com.cn Fuel Shutoff Solenoid‐Replacement Preparatory Steps: • Label and disconnect the wiring. RQVK Governor Shutoff Solenoid 10 mm Remove the hitch pin clip, mounting capscrews and the fuel shutoff solenoid. Install the new solenoid in reverse order of removal and connect the wires. Torque Value: 10 N*m [89 in-lb] 10 mm, 16 mm Adjust the solenoid linkage as necessary so that the plunger is magnetically held in with the shutoff lever in the absolute full run position.
www.changlin.com.cn NOTE: A diesel engine can not tolerate dirt or water in the fuel system. A tiny piece of dirt or a few drops of water in the injection system may stop your units. Clean all external surfaces of the injection pump, including all line connections and fittings that are to be disconnected. Clean the area around the injection pump gear cover to prevent dirt from entering the crankcase. Injection Pump-Removal 3377371 Engine Barring Gear Locate TDC for cylinder No. 1.
www.changlin.com.cn 75 mm T-Bar Puller Pull the fuel pump drive gear loose from the shaft. 15 mm Remove the four mounting nuts. Remove the fuel pump. Injection Pump-Installation 3377371 Engine Barring Gear Make sure the engine has cylinder No. 1 at TDC. Injection Pump-Timing The injection pump also has a timing pin, located in the governor housing, to position the pump shaft to correspond with TDC for cylinder No. 1.
www.changlin.com.cn 24 mm Remove the access plug. Remove the timing pin. If the timing tooth is not aligned with the timing pin hole, rotate the pump shaft until the timing tooth aligns. Reverse the position of the pin so the slot of the pin will fit over the timing tooth in the pump. Install and secure the pin with the access plug.
www.changlin.com.cn Lubricate the mounting flange of the fuel injection pump with clean engine oil. Caution: The fuel pump drive gear inside diameter and the shaft outside diameter must be clean and dry before installing the shaft into the gear. NOTE: The P7100fuel injection pump driveshaft has a provision for a Woodruff key, however, it is not required. Timing mark alignment is not required for the P7100 drive gear.
www.changlin.com.cn Disengage the engine timing pin. 24 mm Remove the fuel pump timing pin plug. Reverse the position of the pin and install the pin, plug, and sealing washer. Torque Value: 15 N • m [11 ft-lb] 22 mm or 27 mm Tighten the fuel pump drive nut. Torque Value: P7100 Pump, 165 N>m [122 ft-lb] Install the gear cover access cap hand tight. 10 mm Install the fuel pump mounting bracket capscrews finger tight. To make sure the alignment is correct, tighten the support mounting capscrews.
www.changlin.com.cn 10 mm Hex Drive Caution: If a replacement or repaired pump was installed, be sure to fill the governor housing with engine oil before starting the engine. Failure to do so will result in damage to the governor fly weights. Remove the access plug. Oil Capacity RQVK Governor 750 ML [0.71 Qt] Install the access plug.
www.changlin.com.cn Air System Repair Summary Air System Repair Air Crossover Tube‐Replacement 8 mm or Screwdriver Lossen the hose clamps and position the hose so the crossover tube can be removed. 8 mm or Screwdriver Use new hose and clamps as required to install the crossover tube.
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www.changlin.com.cn Intake Manifold Cover and Gasket-Replacement Preparatory Steps: • Remove the high pressure fuel lines. • Disconnect the cold starting aid,if used. • Remove the air crossover tube(lndustrial). 10 mm Remove the manifold cover and gasket. Clean the sealing surface. NOTE: Keep the gasket material and any other material out of the air intake. NOTE: The holes shown in the illustration are drilled through and must be sealed by applying liquid teflon sealant to the capscrews.
www.changlin.com.cn 10 mm Install the cover and a new gasket. Torque Value: 24 N*m [18 ft-lbl Assemble the intake piping and connect the cold starting aid if used. Install and bleed the high pressure fuel lines. Jacket‐Water Aftercooler and Gasket‐ Replacement Preparatory Steps: • Disconnect the cold starting aid , if used. • Remove the air crossover tube. • Remove high pressure fuel lines. • Drain 2 liters (2.1 U.S. Quarts) of coolant.
www.changlin.com.cn Remove the coolant supply tube (1) and the coolant return tube (2). Remove the high pressure fuel lines 10 mm Remove the aftercooler housing and gasket. Clean the sealing surface. NOTE: Keep the gasket material and any other material out of the air intake.
www.changlin.com.cn 10 mm NOTE: The holes shown in the illustration are drilled through. Apply liquid teflon sealant to the capscrews. Install the aftercooler housing and a new gasket. Torque Value: 24 N*m [18 ft-lb] 8 mm Install the coolant supply tube (1) and coolant return tube (2). Install the air crossover tube (3). Reinstall and bleed the high pressure fuel lines. Torque Value: 8 N*m [6 ft-lb] Caution: The system must be filled slowly to prevent air locks.
www.changlin.com.cn Intake Manifold Pressure‐Check Install pressure gauge, Part No. ST-1273, to the fitting in the turbocharger outlet. Install another pressure gauge, Part No. ST-1273, in the intake manifold. Operate the engine at rated RPM and load. Record the readings on the two gauges. If the differential pressure is greater than 21 kPa [3 psi], check the charge air cooler for plugging. Clean or replace if necessary Intake Manifold Temperature-Check Install a temperature gauge in the intake manifold.
www.changlin.com.cn Apply 276 kPa [40 psi] of air pressure to the cooler. If the pressure drop is 35 kPa [5 psi] or less in 15 seconds, the cooler is okay. If the pressure drop is greater than 35 kPa [5 psi] in 15 seconds, the charge air cooler must be repaired or replaced. Refer to the CAC manufacturer for repair instructions. NOTE: A leak tank can be used to locate the air leak. Turbocharger‐Replacement Preparatory Steps: • Remove the air crossover tube. • Disconnect the intake and exhaust piping.
www.changlin.com.cn If equipped with a wastegate turbocharger, remove the intake manifold pressure supply line from the boost capsule. 15 mm and 11 mm Remove the exhaust clamp, turbocharger, and gasket. Clean the sealing surface. Inspect the sealing surface and mounting studs for damage. NOTE: If the turbocharger is not be immediately replaced, cover the opening to prevent any material from falling into the manifold.
www.changlin.com.cn Install a new gasket and apply anti-seize compound to the mounting studs. 15 mm Install the turbocharger and a new gasket. Torque Value: 32 N • m [24 ft-lb] 13 mm If required, bend the lockplates back and loosen the turbine housing capscrews and position the bearing housing to install the turbocharger drain tube. 13 mm Install the hose and clamps on the turbocharger drain tube loosely. Install the drain tube and gasket on the turbocharger.
www.changlin.com.cn Position the turbocharger drain hose to connect the drain tubes; tighten the clamps. 13 mm. Punch, Hammer If loosened, tighten the turbine housing capscrews. Bend the lockplates onto the flats to prevent loosening. Torque Value: 11.3 N • m [8 ft-lb] 10 mm If required, loosen the compressor housing and position the housing to align with the crossover tube. Torque Value: 5.7 N*m [50 in-lb] 11 mm, plastic Hammer Tighten the band clamp to 5.7 N • m [50 in-lb].
www.changlin.com.cn Caution: To prevent bearing damage newtubochargers must be prelubricated before start-up. Pour 50 to 60 [2 to 3 ounces] of clean engine oil into the oil supply fitting. Rotate the turbine wheel to allow the oil to enter the bearing housing. Install the exhaust oulet connection. Do not tighten the two mounting capscrews until the band clamp has been tightened. Torque Value: Band Clamp-8 N * m [6 ft-lb] Capscrews - 43 N*m [32 ft-lb] 16 mm Install the oil supply line.
www.changlin.com.cn Install the air crossover tube, inlet and exhaust piping. Operate the engine and check for leaks. Exhaust Manifold and Gaskets ‐Replacement Preparatory Steps: • Remove the air crossover tube. • Disconnect the air intake and exhaust piping. • Remove the turbocharger, if used. 15mm Remove the exhaust manifold and gaskets. Clean the sealing surfaces.
www.changlin.com.cn 15 mm Install the exhaust manifold and new gaskets. Torque Value: 43 N*m [32 ft-lb] Follow the tightening sequence shown in the illustration Then, follow the same sequence and tighten the capscrews again to the same torque values. Install the parts previously removed. Operate the engine and check for leaks.
www.changlin.com.cn 22 mm Remove the plug and regulator valve. 22 mm Clean and inspect the bore and regulator valve before assembly. Caution: In order to regulate the oil pressure, the valve must move freely in the bore. Install the regulator and spring. Torque Value: 80 N*m [60 ft-lb] Oil Cooler Element and Gasket‐Replacement Preparatory Steps: • • Drain The coolant. Remove the oil filter. Clean all debris from around the oil cooler.
www.changlin.com.cn 16mm Remove the turbocharger oil supply line from the oil filter head. 10 mm Remove the oil cooler cover, element and gaskets. Clean the sealing surfaces. Pressurize the element to 690 kPa [100 psi] to check it for leaks.
www.changlin.com.cn 10 mm Assemble the oil cooler gasket, element, cooler cover gasket and cooler cover to the cylinder block. NOTE: Be sure to remove the shipping plugs (A) from the new cooler element. Torque Value: 24 N*m [18ft-lb] 16 mm Connect the turbocharger oil supply line. Torque Value: 15 N*m [11 ft-lb] Install a new oil filter. Follow the manufacturer's instructions for tightening. Caution: The system must be filled slowly to prevent air locks.
www.changlin.com.cn Electrical System Repair Electrical System Repair Summary , , and Torque Wrench . Component To Be Replaced Tools Ratchet, 17 mm Socket, 14 mm Wrench Alternator Preparatory steps Disconnect battery ground cable to Ratchet, 8 mm, 14 mm and 16 mm Disconnect ground cable to Socket and torque Wrench, 1/2 battery and remove drive belt inch Square Drive Breaker Bar Starting Motor‐Replacement Disconnect the ground cable from the battery.
www.changlin.com.cn 10 mm Remove the starting motor. Install the starting motor in the reverse order or removal. Torque Value: 43 N*m [32 ft-lb] Alternator‐Replacement Disconnect the ground cable from the battery terminal, identify each electrical wire with a tag indicating location. Remove the drive belt. 14 mm Remove the capscrew from the alternator link. 16 mm Remove the alternator mounting capscrews. Remove the alternator.
www.changlin.com.cn Position the alternator on the bracket and secure it with the mounting capscrews. Do not tighten at this time. Connect the alternator link to the alternator. Finger tighten. NOTE: Make sure the alternator link is properly positioned for correct belt alignment. 14,16 mm Tighten the alternator mounting capscrew.
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www.changlin.com.cn Fuel Recommendations / Specifications Warning: Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. Caution: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzles.
www.changlin.com.cn Acceptable Alternate Fuels-Component Wear/Durability Fuel Bosch Nippondenso Stanadyne Lucas CAV A P7100 VE Ep-9 DB-4 DPA DPS NO. 1-D Diesel OK OK OK OK OK OK OK NO. 2 Fuel Oil OK OK OK OK OK OK OK NO. 1-K Kerosene OK OK OK * * * NO.
www.changlin.com.cn Oil Viscosity Recommendations The use of multi-viscosity lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures. While 15W-40 oil is recommended for most climates, refer to the accompanying table for oil viscosity recommendations for extreme climates.
www.changlin.com.cn Oil Consumption In addition to the information that follows, a service publication entitled Technical Overview of Oil Consumption is available, Bulletin 3379214-00. Cummins defines “Acceptable Oil Usage” as outlined in the following table: ACCEPTABLE OIL USAGE ANY TIME DURING COVERAGE PERIOD HOURS PER MILES HRS HRS ENGINE PER PER IMPERIAL FAMILY QT LITER 4B 10.0 10.6 12.0 400 425 475 650 675 775 6B 10.0 10.6 12.0 400 425 475 650 675 775 6C 10.0 10.6 12.
www.changlin.com.cn Coolant Recommendations / Specifications Heavy duty diesel engines require a balanced coolant mixture of water and antifreeze. Drain and replace the mixture every 2 years. 320, 000 KM [200,000 miles] or 6, 000 hours of operation (whichever occurs first) to eliminate build up of harmful chemicals. •Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point.
www.changlin.com.cn Filter Selection Oil Filters A = LF 3345 Standard Four Cylinder Applications B = LF 3349 Standard Six Cylinder Applications Fuel Filters A = Standard Filter used as secondary filter in fuel filter applications. B = Fuel Water Separator Primary filter for fuel filter applications. C = Fuel Water Separator used in single filter applications.
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www.changlin.com.cn Sealants Use the sealants listed below or sealants containing equivalent properties. Description 1. Pipe Plugs 2. Cup Plugs 3. O-Rings 4. Rear Camshaft Expansion Plug 5. Fuel Pump Studs 6. Turbo Drain in Block 7. Front Seal in Gear Cover 8. Rear Seal in Rear Cover 9. Oil Pan at T-Joint Sealing Method Precoated teflon or pipe sealer. Loctite 277 or 11,264 No sealant required. Precoated or Loctite 59,241 liquid teflon. Loctite 609. Loctite 277 or 11,264 Loctite 277 or 11,264 No sealant.
www.changlin.com.cn Capscrew Markings and Torque Values Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using incorrect capscrews can result in engine damage. Most of the capscrews used on the B Series engine are metric. Some components, such as the air compressor and fuel pump, are installed using U. S. Customary capscrews.
www.changlin.com.cn Capscrew Markings and Torque Values‐Metric Capscrew Markings and Torque Values ‐ U.S.
