Service Manual Manual

Section 8B Cummins Engine
Model 6036/6036T S/N 9B0500 thru 14833
8B-1
SECTION 8B
ENGINE, CUMMINS 4B3.9 AND 4BT3.9
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TABLE OF CONTENTS
SAFETY CONSIDERATIONS ...... 8B-2
8B.1 DISCLAIMER AND SCOPE ......... 8B-3
8B.2 STANDARD PRACTICES ............ 8B-3
8B.3 ENGINE MAINTENANCE ............ 8B-3
8B.3.1 Left and Right Sides of Engine ............ 8B-3
8B.3.2 Maintenance Intervals .......................... 8B-3
8B.4 ENGINE MAINTENANCE
DAILY BEFORE OPERATING
ENGINE ....................................... 8B-3
8B.4.1 Inspect the Engine ............................... 8B-3
8B.4.2 Check Engine Coolant Level ................ 8B-3
8B.4.3 Check Engine Oil Level ........................ 8B-4
8B.4.4 Fill Fuel Tank ....................................... 8B-4
8B.4.5 Check Air Cleaner
Restriction Indicator ............................. 8B-4
8B.4.6 Check Air Cleaner Vacuator Valve ...... 8B-5
8B.4.7 Clean or Replace Primary Element as
Required by Restriction Indicator ......... 8B-5
8B.4.8 Install a New Safety Element with Every
Third Primary Element ......................... 8B-5
8B.5 ENGINE MAINTENANCE
EVERY 250 HOURS OR
3 MONTHS ................................... 8B-6
8B.5.1 Inspect Air Intake System .................... 8B-6
8B.5.2 Change Engine Oil and Filter ............... 8B-6
8B.5.3 Drain Fuel-Water Separator ................. 8B-7
8B.6 ENGINE MAINTENANCE
EVERY 500 HOURS OR
6 MONTHS ................................... 8B-8
8B.6.1 Replace Fuel Filter Elements ............... 8B-8
8B.6.2 How to Bleed the Fuel System ............. 8B-8
8B.7 ENGINE MAINTENANCE
EVERY 1,000 HOURS
OR ANNUALLY .......................... 8B-10
8B.7.1 Drive Belt Inspection .......................... 8B-10
8B.7.2 Tensioner Bearing .............................. 8B-11
8B.7.3 Fan Hub ............................................. 8B.11
8B.7.4 Check Valve Stem to
Rocker Arm Gap ................................ 8B-11
8B.7.5 Drain Cooling System ........................ 8B-12
8B.7.6 Cleaning the Cooling System ............. 8B-13
8B.7.7 Filling the Cooling System ................. 8B-13
8B.7.8 Replace Air Filter Primary Element .... 8B-13
8B.8 ENGINE OIL
SPECIFICATIONS ..................... 8B-14
8B.9 ENGINE COOLING SYSTEM .... 8B-14
8B.9.1 Coolant Requirements ....................... 8B-14
8B.9.2 Radiator Pressure Cap ...................... 8B-15
8B.9.3 How to Replace Thermostat .............. 8B-15
8B.10 ENGINE ELECTRICAL
SYSTEM .................................... 8B-16
8B.11 ENGINE FUEL SYSTEM ............ 8B-16
8B.11.1 Type of Diesel Fuel to Use ................. 8B-16
8B.11.2 Fuel Tank ........................................... 8B-18
8B.11.3 Fuel Level Sender and Gauge ........... 8B-19
8B.11.4 Fuel Lift Pump Testing ....................... 8B-19
8B.11.5 Dual Head Fuel Filter ......................... 8B-19
8B.11.6 How to Bleed the Fuel System ........... 8B-19
8B.11.7 Fuel Injectors ..................................... 8B-19
8B.12 ENGINE EXHAUST SYSTEM .... 8B-21
8B.13 HOW TO REMOVE
ENGINE FROM FORKLIFT ........ 8B-23
8B.14 HOW TO OVERHAUL
THE ENGINE ............................. 8B-24
8B.15 HOW TO INSTALL THE
ENGINE IN FORKLIFT ............... 8B-24
8B.16 ENGINE STORAGE ................... 8B-27
8B.17 TROUBLESHOOTING ............... 8B-29
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