Registered Office Cummins Ltd. 49 - 51 Gresham Road, Staines, Middlesex TW18 2BD, England Registration 573951 England Cummins Customer Assistance Center 1-800-DIESELSTM (1-800-343-7357) APPLICABLE ONLY IN U.S.A. AND CANADA Copyright© 2014 Cummins Inc. Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine Cummins Inc. Box 3005 Columbus, Indiana, U.S.A., 47202 Operation and Maintenance Manual QSB4.5 and QSB6.
Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine Copyright© 2014 Cummins Inc.
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. 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.
Table of Contents Section Introduction ........................................................................................................................................................ i Engine and System Identification .................................................................................................................... E Operating Instructions ......................................................................................................................................
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.
QSB4.5 and QSB6.7 Section i - Introduction Page i-a Section i - Introduction Section Contents Page About the Manual .........................................................................................................................................................i-2 General Information.....................................................................................................................................................i-2 Acronyms and Abbreviations ......................................
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QSB4.5 and QSB6.7 Section i - Introduction To the Owner and Operator Page i-1 To the Owner and Operator General Information Preventive 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, lubricating oil, and coolant in your engine as specified in Maintenance Specifications (Section V).
About the Manual Page i-2 QSB4.5 and QSB6.7 Section i - Introduction About the Manual General Information This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Inc. 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.
QSB4.5 and QSB6.7 Section i - Introduction How to Use the Manual Page i-3 How to Use the Manual General Information This manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenance schedule, that states the required intervals and maintenance checks, is located in Maintenance Guidelines (Section 2). Locate the interval at which you are performing maintenance; then follow the steps given in that section for all the procedures to be performed.
Symbols Page i-4 QSB4.5 and QSB6.7 Section i - Introduction Symbols General Information The following symbols have been used in this manual to help communicate the intent of the instructions.
QSB4.5 and QSB6.7 Section i - Introduction Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.
General Safety Instructions Page i-6 QSB4.5 and QSB6.7 Section i - Introduction General Safety Instructions Important Safety Notice WARNING Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death. 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.
QSB4.5 and QSB6.7 Section i - Introduction General Safety Instructions Page i-7 • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. • Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can cause electrical damage to the ignition or governor.
General Repair Instructions Page i-8 QSB4.5 and QSB6.7 Section i - Introduction General Repair Instructions General Information This engine or system incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards. WARNING Cummins Inc. does not recommend or authorize any modifications or repairs to components except for those detailed in Cummins Service Information.
QSB4.5 and QSB6.7 Section i - Introduction General Repair Instructions Page i-9 • 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 ReCon® service parts and assemblies - The assembly instructions have been written to use again as many components and assemblies as possible.
General Cleaning Instructions Page i-10 QSB4.5 and QSB6.7 Section i - Introduction General Cleaning Instructions Definition of Clean Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to appear as new. Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface.
QSB4.5 and QSB6.7 Section i - Introduction General Cleaning Instructions Page i-11 abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication. Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine as much as possible.
General Cleaning Instructions Page i-12 QSB4.5 and QSB6.7 Section i - Introduction pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer. Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the capscrew holes and the oil drillings.
QSB4.5 and QSB6.7 Section i - Introduction General Cleaning Instructions Page i-13 2 Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break. 3 Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning. Rinse with hot water. Dry with compressed air. CAUTION The bead blasting operation must not disturb the metal surface.
General Cleaning Instructions Page i-14 QSB4.5 and QSB6.7 Section i - Introduction is 76 microns [0.003 in] in diameter. One micron measures 0.001 mm [0.00004 in.]. The contaminants being filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope. The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel system parts, tools that are coated with oil or fuel attract airborne contaminants.
QSB4.5 and QSB6.7 Section i - Introduction Acronyms and Abbreviations Page i-15 Acronyms and Abbreviations General Information The following list contains some of the acronyms and abbreviations used in this manual. ANSI API ASTM ATDC BTU BTDC °C CAN CO CCA CARB C.I.B. C.I.D.
Acronyms and Abbreviations Page i-16 NOx NG O2 OBD OEM OSHA PID ppm psi PTO REPTO RGT rpm SAE SCA SCR STC SID TDC VDC VGT VS VSS QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Page E-a Section E - Engine and System Identification Section Contents Page Cummins® Service Engine Model Product Identification ....................................................................................E-15 General Information..................................................................................................................................................E-15 Engine Diagrams ...........................................
Page E-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Identification Page E-1 Engine Identification Engine Dataplate The engine dataplate provides important information about the engine. The engine serial number (ESN) and control part list (CPL) provide information for service and for ordering parts. The engine dataplate must not be changed unless approved by Cummins Inc. Have the following engine data available when communicating with a Cummins® Authorized Repair Location.
Engine Identification Page E-2 QSB4.5 and QSB6.7 Section E - Engine and System Identification 1 Engine serial number 2 Engine model information 3 Horsepower and rpm rating 4 Valve lash (overhead) setting. NOTE: Depending on the manufacturing plant, calibration data may also be found on the engine dataplate. NOTE: If the engine dataplate (1) is not legible, the engine serial number (2) can be found on the engine block, on top of the lubricating oil cooler housing.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Fuel Injection Pump Dataplate The Bosch™ fuel injection pump dataplate is located on the fuel pump. The dataplate contains the following information to assist in servicing or replacement: • Pump serial number • Cummins® part number • Factory code • Bosch™ part number • Date code. ECM Dataplate The electronic control module (ECM) dataplate shows information about the ECM and how the ECM was programmed.
Engine Diagrams Page E-4 QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Engine Views The following illustrations show the locations of the major external engine components, filters, and other service and maintenance points. Some external components will be at different locations for different engine models. NOTE: The illustrations are only a reference to show a typical engine.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Page E-5 Engine Diagrams Engine Views QSB 6.7 Engine - Front View 1 Air inlet 2 Fan drive 3 Electronic control module 4 Engine speed sensor (crankshaft) 5 Dipstick 6 Fuel filter 7 Vibration damper 8 Water pump 9 Starter 10 Belt tensioner 11 Alternator 12 Coolant outlet 13 Coolant temperature sensor 14 Turbocharger air outlet.
Engine Diagrams Page E-6 QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Engine Views QSB 6.7 Engine - Left Side View 1 Fuel rail 2 Intake pressure and temperature sensor 3 Bosch™ fuel pump 4 Flywheel housing 5 Oil pressure switch 6 Fuel filter 7 Oil pan drain plug 8 Barometric pressure sensor 9 Engine speed sensor (crankshaft) 10 Electronic control module 11 Engine position sensor (camshaft) 12 Air intake inlet 13 Rail pressure sensor 14 Dipstick.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Page E-7 Engine Diagrams Engine Views QSB 6.7 Engine - Rear View 1 Rear engine lifting bracket 2 Turbocharger exhaust outlet 3 Clutch mounting holes 4 Flywheel housing 5 Flywheel/flexplate 6 Crankcase breather tube 7 Injector drain line.
Engine Diagrams Page E-8 QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Engine Views QSB 6.7 Engine - Right Side View 1 Coolant outlet 2 Alternator 3 Coolant inlet 4 Lubricating oil cooler 5 Oil filter 6 Oil pan drain plug 7 Turbocharger exhaust outlet 8 Starter 9 Flywheel housing 10 Turbocharger compressor inlet.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Page E-9 Engine Diagrams Engine Views QSB 6.7 Engine - Top View 1 Turbocharger wastegate 2 Crankcase breather 3 Barometric pressure/temperature sensor 4 Fuel rail pressure sensor 5 Fuel rail 6 High-pressure fuel lines 7 Oil fill cap 8 Tone wheel 9 Vibration damper 10 Coolant temperature sensor 11 Coolant outlet 12 Alternator 13 Exhaust manifold 14 Rail pressure relief valve.
Engine Diagrams Page E-10 QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Engine Views QSB 4.5 Engine - Front View 1 Air inlet 2 Electronic control module 3 Engine speed sensor (camshaft) 4 Engine speed sensor (crankshaft) 5 Fuel filter 6 Vibration damper (Optional) 7 Fan or PTO drive flange mounting 8 Starter mounting location 9 Coolant inlet 10 Water pump 11 Belt tensioner 12 Alternator 13 Coolant outlet 14 Coolant temperature sensor.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Page E-11 Engine Diagrams Engine Views QSB 4.
Engine Diagrams Page E-12 QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Engine Views QSB4.5 Engine - Rear View 1 Coolant connection for air compressor 2 Air outlet from turbocharger 3 Air inlet to turbocharger 4 Flywheel 5 Flywheel housing 6 Crankcase breather tube 7 Fuel return line 8 Engine lifting brackets.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Page E-13 Engine Diagrams Engine Views QSB4.5 Engine - Right Side View 1 Coolant outlet 2 Alternator 3 Oil cooler 4 Coolant inlet 5 Oil filter 6 Oil pan drain plug 7 Turbocharger exhaust outlet 8 Starter 9 Flywheel housing 10 Turbocharger compressor inlet.
Engine Diagrams Page E-14 QSB4.5 and QSB6.7 Section E - Engine and System Identification Engine Diagrams Engine Views QSB4.
QSB4.5 and QSB6.7 Section E - Engine and System Identification Cummins® Service Engine Product Identification Cummins® Service Engine Model Product Identification Page E-15 Model General Information The Cummins® Service Engine Model Nomenclature procedure describes how engines are identified within Cummins service organization. This method was introduced for models after and including manufacture year 2007.
Cummins® Service Engine Model Product Identification Page E-16 QSB4.5 and QSB6.7 Section E - Engine and System Identification The control system is identified with the letters "CM" followed by the control system model number. The technology identifier after the control system designates the prevailing technology used with the engine. (See table in this procedure for letter designations.
QSB4.5 and QSB6.
Cummins® Service Engine Model Product Identification Page E-18 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 1 - Operating Instructions Page 1-a Section 1 - Operating Instructions Section Contents Page Cold Weather Starting ................................................................................................................................................1-4 General Information....................................................................................................................................................1-4 Using Starting Aids...............................
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QSB4.5 and QSB6.7 Section 1 - Operating Instructions Operating Instructions - Overview Page 1-1 Operating Instructions - Overview General Information Correct care of your engine will result in longer life, better performance, and more economical operation. Follow the daily maintenance checks Maintenance Guidelines (Section 2). listed in The new Cummins® engine associated with this manual does not require a "break-in" procedure.
Normal Starting Procedure Page 1-2 QSB4.5 and QSB6.7 Section 1 - Operating Instructions WARNING Do not operate a diesel engine where there are or can BE COMBUSTIBLE vapors. These vapors can be sucked through the air intake system and cause engine acceleration and over speeding that can result in a fire, an explosion, and extensive property damage.
QSB4.5 and QSB6.7 Section 1 - Operating Instructions CAUTION The engine must have adequate oil pressure within 15 seconds after starting. If the WARNING lamp indicating low oil pressure has not gone out or there is no oil pressure indicated on a gauge within 15 seconds, shut off the engine immediately to avoid engine damage. The low oil pressure troubleshooting procedure is located in Troubleshooting Symptoms(Section TS). Idle the engine 3 to 5 minutes before operating with a load.
Cold Weather Starting Page 1-4 QSB4.5 and QSB6.7 Section 1 - Operating Instructions Jump Starting WARNING Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative(-) battery cable last. CAUTION When using jumper cables to start the engine, make sure to connect the cables in parallel: Positive (+) to positive (+) and negative(-) to negative (-).
QSB4.5 and QSB6.7 Section 1 - Operating Instructions Using Starting Aids WARNING Do not use starting fluids with this engine. This engine is equipped with an intake air heater; use of starting fluid can cause an explosion, fire, personal injury, severe damage to the engine, and property damage. Cold weather starting aids are available for this engine. Contact a Cummins® Authorized Repair Location for more information.
Engine Operating Range Page 1-6 QSB4.5 and QSB6.7 Section 1 - Operating Instructions Winterfronts and Shutters Winterfronts and shutters can be used on a vehicle or equipment to reduce air flow through the radiator core into the engine compartment. This can reduce the time required to warm the engine and help maintain the engine coolant temperature. The engine coolant temperature specifications are in the Maintenance Specification (Section V).
QSB4.5 and QSB6.7 Section 1 - Operating Instructions Engine Shutdown General Information Allow the engine to idle 3 to 5 minutes before shutting it off after a full-load operation. This allows adequate cool down of pistons, cylinders, bearings, and turbocharger components. NOTE: For engines equipped with an electronic control module (ECM) ensure the keyswitch is turned off for a minimum of 70 seconds prior to disconnecting the continuous (unswitched) battery power supply.
Electronic Controlled Fuel System Page 1-8 QSB4.5 and QSB6.7 Section 1 - Operating Instructions The ECM communicates with service tools and some other vehicle controllers such as transmissions, antilock brake system, and antislip reduction through an SAE J1939 data link. Some vehicles and equipment will have J1939 networks on them that link many of the "smart" controllers together.
QSB4.5 and QSB6.7 Section 1 - Operating Instructions Engine Protection System The engines are equipped with an engine protection system. The system monitors critical engine temperatures and pressures and will log diagnostic faults when an over or under normal operation condition occurs. If an out-ofrange condition exists and engine derate action is to be initiated, the operator will be alerted by an in-cab WARNING lamp. The WARNING lamp will blink or flash when out-of-range conditions continue to worsen.
Electronic Controlled Fuel System Page 1-10 QSB4.5 and QSB6.7 Section 1 - Operating Instructions Diagnostic Fault Codes The control system can show and record operation anomalies that present themselves as fault codes. These codes will make troubleshooting easier. The fault codes are recorded in the ECM. They can be read using the fault lamps in the dash or with INSITE™ electronic service tool. NOTE: Not all engine or control system anomalies are shown as fault codes.
QSB4.5 and QSB6.7 Section 1 - Operating Instructions Some vehicles will also have a WAIT-TO-START lamp and a WATER-IN-FUEL lamp. The WAIT-TO-START lamp is illuminated during the preheating time that takes place at keyswitch ON during cold-weather starting. To minimize cranking time during cold-weather starting, the engine should not be cranked until the WAIT-TO-START lamp has been extinguished.
Electronic Controlled Fuel System Page 1-12 QSB4.5 and QSB6.7 Section 1 - Operating Instructions The fault code will flash in the following sequence: • First, a WARNING (yellow) lamp will flash. • Then there will be a short 1- or 2-second pause, after which the number of the recorded fault code will flash in STOP (red) lamp. There will be a 1- or 2-second pause between each number. • When the number has finished flashing in red, a yellow lamp will appear again.
QSB4.5 and QSB6.7 Section 1 - Operating Instructions Electromagnetic Interference (EMI) Page 1-13 Fault Code Snapshot Data Use INSITE™ electronic service tool to obtain the additional fault cod date information. The snapshot data records the value or state of the control system sensors and switches at the time a fault occurrs. This data is stored for the first occurrence of the fault, since it was last cleared, and for the most recent occurrence.
Electromagnetic Interference (EMI) Page 1-14 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines Page 2-a Section 2 - Maintenance Guidelines Section Contents Page Maintenance Guidelines - Overview .........................................................................................................................2-1 General Information....................................................................................................................................................2-1 Maintenance Record Form .....................................
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QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines Maintenance Guidelines - Overview Page 2-1 Maintenance Guidelines - Overview General Information Cummins Inc. recommends that the system be maintained according to the Maintenance Schedule in this section. If the system is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], perform maintenance at shorter intervals.
Tool Requirements Page 2-2 QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines Tool Requirements General Information Most of the maintenance operations described in this manual can be performed with common hand tools (metric and S.A.E. wrenches, sockets, and screwdrivers).
QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines Maintenance Schedule Page 2-3 Maintenance Schedule General Information For your convenience, listed below are the section numbers that contain specific instructions for performing the maintenance checks. Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance. Maintenance Procedures at Daily Interval3 ...................................
Maintenance Schedule Page 2-4 QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines 3 Follow the manufacturer's recommended maintenance procedures for the starter, alternator, generator, batteries, electrical components, exhaust brake, charge-air cooler, radiator, air compressor, air cleaner, refrigerant compressor, and fan clutch. 4 This cooling system requirement to Flush at this scheduled maintenance includes: Drain, Flush, and Fill.
QSB4.5 and QSB6.7 Section 2 - Maintenance Guidelines Maintenance Record Form Page 2-5 Maintenance Record Form Maintenance Data Maintenance Record Engine Model: Equipment Name/Number: Engine Serial No.
Maintenance Record Form Page 2-6 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 3 - Maintenance Procedures at Daily Interval Page 3-a Section 3 - Maintenance Procedures at Daily Interval Section Contents Page Air Tanks and Reservoirs ..........................................................................................................................................3-2 Drain...........................................................................................................................................................................
Page 3-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 3 - Maintenance Procedures at Daily Interval Daily Maintenance Procedures - Overview Page 3-1 Daily Maintenance Procedures - Overview General Information Preventative maintenance begins with day-to-day awareness of the system. Before starting the system, check the appropriate fluid levels. Look for: • Leaks • Loose or damaged parts • Worn or damaged belts • Worn or damage low and high voltage harnesses • Any change in system appearance.
Crankcase Breather Tube Page 3-2 QSB4.5 and QSB6.7 Section 3 - Maintenance Procedures at Daily Interval Air Tanks and Reservoirs Drain If automatic purging or spitter valves are used, confirm the valves are operating correctly. If a manual drain valve is used on the wet tank, open the draincock on the wet tank to drain any moisture accumulated in the air system. If oil is present, the air compressor system must be checked. Contact your Cummins Authorized Repair Location.
QSB4.5 and QSB6.7 Section 3 - Maintenance Procedures at Daily Interval Fuel-Water Separator Drain WARNING Drain the water-fuel separator into a container and dispose of in accordance with local environmental regulations. Cummins Inc. requires a fuel-water separator or fuel filter be 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 the drain tube.
Drive Belts Page 3-4 QSB4.5 and QSB6.7 Section 3 - Maintenance Procedures at Daily Interval Lubricating Oil Level Maintenance Check CAUTION Never operate the engine with oil level below the L (low) mark or above the H (high) mark. Poor engine performance or engine damage can occur. The engine must be level when checking the oil level to make sure the measurement is correct. Shut off the engine for an accurate reading. Wait at least 15 minutes after shutting off the engine to check the oil level.
QSB4.5 and QSB6.7 Section 3 - Maintenance Procedures at Daily Interval Cogged Belt Inspect the belts daily. Replace the belts if they are cracked, frayed, or have chunks of material missing. Small cracks are acceptable. Adjust the belts that have a glazed or shiny surface, which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear. Refer to Section A for belt adjustment and replacement procedures.
Drive Belts Page 3-6 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 4 - Maintenance Procedures at 250 Hours or 3 Months Page 4-a Section 4 - Maintenance Procedures at 250 Hours or 3 Months Section Contents Page Air Cleaner Restriction ...............................................................................................................................................4-1 Maintenance Check....................................................................................................................................................
Page 4-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 4 - Maintenance Procedures at 250 Hours or 3 Months Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Air Cleaner Restriction Maintenance Check Mechanical Indicator CAUTION Never operate the engine without an air cleaner.
Charge-Air Cooler Page 4-2 QSB4.5 and QSB6.7 Section 4 - Maintenance Procedures at 250 Hours or 3 Months Industrial Gas Mechanical Indicator A mechanical restriction indicator is available to indicate excessive air restriction through a dry-type air cleaner. This instrument is mounted in the air cleaner outlet. The red flag (1) in the window gradually rises as the cartridge loads with dirt. When air restriction is indicated the air filter must be replaced.
QSB4.5 and QSB6.7 Section 4 - Maintenance Procedures at 250 Hours or 3 Months Charge-Air Piping Maintenance Check Inspect the charge-air piping and hoses for leaks, holes, cracks, or loose connections. Tighten the hose clamps if necessary. Refer to the vehicle or equipment manufacturer's specifications for the correct torque value. Radiator Hoses Maintenance Check Check all hoses for cracks, cuts, or collapsing.
Coolant Level Page 4-4 QSB4.5 and QSB6.7 Section 4 - Maintenance Procedures at 250 Hours or 3 Months 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. Tighten the capscrews, if necessary. WARNING Do not straighten a bent fan blade or continue to use a damaged fan. A bent or damaged fan blade can fail during operation and cause personal injury or property damage.
QSB4.5 and QSB6.7 Section 4 - Maintenance Procedures at 250 Hours or 3 Months CAUTION Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to below 50°C [120°F] before adding coolant. Coolant added to the engine must be mixed with the correct proportions of antifreeze, supplemental coolant additive, and water to avoid engine damage.
Coolant Level Page 4-6 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Page 5-a Section 5 - Maintenance Procedures at 500 Hours or 6 Months Section Contents Page Cooling System ...........................................................................................................................................................5-1 Drain..................................................................................................................................................................
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QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Cooling System General Information WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap.
Cooling System Page 5-2 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill or recovery/expansion tank. NOTE: Some radiators have two fill necks, both of which must be filled when the cooling system is drained. Maintenance Check CAUTION Over-concentration of antifreeze or use of high silicate antifreeze can cause damage to the engine. Check the antifreeze concentration.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Drain WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Position the vehicle or equipment on a level surface. Isolate the engine from the vehicle cooling system by closing coolant flow valves to the equipment heating systems before initiating repair.
Cooling System Page 5-4 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Flush CAUTION The system must be filled properly to prevent air locks or serious engine damage can result. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months WARNING Coolant is toxic. Keep away from children and pets. Dispose of in accordance with local environmental regulations. WARNING Do not stand near surge tank or radiator while operating engine with pressure cap off. If the vehicle is equipped with a fill door on side of surge tank, keep it closed due to coolant expansion. CAUTION Do not operate engine with the pressure cap off at temperatures above 200 degrees F.
Cooling System Page 5-6 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months WARNING Do not stand near the surge tank or radiator while operating the engine with the pressure cap off. If the vehicle is equipped with a fill door on side of the surge tank, keep it closed due to coolant expansion. CAUTION Do not operate the engine with the pressure cap off a temperatures above 93°C [200°F].
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Shut the engine OFF, allow the cooling system to cool to 50°C [122°F]. Drain the cooling system. NOTE: If the water being drained is still dirty, the system must be flushed again until the water is clean. Fill CAUTION The system must be filled properly to prevent air locks or serious engine damage can result. During filling, air must be vented from the engine coolant passages.
Cooling System Page 5-8 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. WARNING Do not stand near the surge tank or radiator while operating the engine with the pressure cap off.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Cooling System Page 5-9 Figure 1: Sequence of Events for Coolant Fill and Deaeration. NOTE: If all coolant drained from the system was collected, the same volume or more must go back into the system. If any drained coolant remains after filling, this is an indication of an air pocket which must be purged before returning the vehicle to service.
Fuel Filter (Spin-On Type) Page 5-10 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Fuel Filter (Spin-On Type) Remove Remove the spin-on fuel filter with fuel filter wrench, Part Number 3398231. Install NOTE: Do not pre-fill an on-engine fuel filter. CAUTION Do not pre-fill an on-engine fuel filter with fuel. The system must be primed after the fuel filter is installed.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Prime WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. To prime the engine use the OEM installed priming device. Typically, a priming pump is installed at or near the pre-filter.
Lubricating Oil and Filters Page 5-12 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Remove Clean the area around the lubricating oil filter head. Use the oil filter wrench, Part Number 3400158, to remove the filter. Clean the gasket surface of the filter head. NOTE: The o-ring can stick on the filter head. Be sure it is removed before installing the new filter. Install Use the correct oil filter.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Fill Clean and check the lubricating oil drain plug threads and sealing surface. Use a new sealing washer, if damaged. Install the lubricating oil pan drain plug. Automotive and Industrial Applications: Steel Oil Pan Drain Plug Torque N•m M18 60 MIN M22 80 MIN ft-lb 44 59 Cast Aluminum Oil Pan Drain Plug Torque N•m ft-lb M22 60 MIN 44 NOTE: Use lubricating oil, equivalent, in lubricating oil Section V.
Radiator Pressure Cap Page 5-14 QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Idle the engine to inspect for leaks at the drain plug and, if replaced, the oil filter seal. NOTE: Engine oil pressure must be indicated on the gauge within 15 seconds after starting. If oil pressure is not registered within 15 seconds, shut off the engine immediately to avoid engine damage. Confirm that the correct oil level is in the oil pan. Shut off the engine.
QSB4.5 and QSB6.7 Section 5 - Maintenance Procedures at 500 Hours or 6 Months Pressure-test the radiator cap. Refer to the OEM service manual for radiator cap test procedures. The pressure cap must seal within 14 kPa [2 psi] of the value stated on the cap, or it must be replaced. An incorrect or malfunctioning cap can result in the loss of coolant and the engine running hot.
Radiator Pressure Cap Page 5-16 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 6 - Maintenance Procedures at 1000 Hours or 1 Year Page 6-a Section 6 - Maintenance Procedures at 1000 Hours or 1 Year Section Contents Page Cooling Fan Belt Tensioner .......................................................................................................................................6-1 Maintenance Check....................................................................................................................................................
Page 6-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 6 - Maintenance Procedures at 1000 Hours or 1 Year Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Cooling Fan Belt Tensioner Maintenance Check With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced.
Fan Hub, Belt Driven Page 6-2 QSB4.5 and QSB6.7 Section 6 - Maintenance Procedures at 1000 Hours or 1 Year Check the location of the drive belt on the belt tensioner pulley. The belt should be centered on, or close to the middle of, the pulley. Misaligned belts, either too far forward or backward, can cause belt wear, belt roll-offs, or increase uneven tensioner bushing wear. Remove the drive belt. Refer to Procedure 008-002 in Section A.
QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Page 7-a Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Section Contents Page Air Compressor Discharge Lines ..............................................................................................................................7-1 General Information....................................................................................................................................................
Page 7-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Air Compressor Discharge Lines General Information All air compressors have a small amount of lubricating oil carryover that lubricates the piston rings and moving parts.
Cooling System Page 7-2 QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Measure the total carbon deposit thickness inside the air discharge line as shown. If the total carbon deposit (X + X) exceeds 2 mm [1/16 in], clean and inspect the cylinder head, the valve assembly, and the discharge line. Replace if necessary. Contact the Cummins Authorized Repair Location for procedures.
QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years CAUTION Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool below 50°C [120°F] before adding coolant. On applications that use a coolant recovery system, check to make sure the coolant is at the appropriate level on the coolant recovery tank, for the engine temperature.
Cooling System Page 7-4 QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Check for damaged hoses and loose or damaged hose clamps. Replace as required. Check the radiator for leaks, damage, and buildup of dirt. Clean and replace as required. Flush CAUTION The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top.
QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years CAUTION Do not install the radiator cap. The engine is to be operated without the cap for this process. Fill the system with a mixture of sodium carbonate and water (or a commercially available equivalent). NOTE: Adequate venting is provided for a fill rate of 19 liters [5 gal.] per minute. WARNING Coolant is toxic. Keep away from children and pets. Dispose of in accordance with local environmental regulations.
Cooling System Page 7-6 QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Fill CAUTION The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. To be sure air is vented during the fill process: • The thermostat has check balls that allow air to vent through the thermostat when the thermostat is closed.
QSB4.5 and QSB6.7 Section 7 - Maintenance Procedures at 2000 Hours or 2 Years Vibration Damper, Rubber Inspect Check the index lines (A) in the vibration damper hub (B) and the inertia member (C). If the lines are more than 1.59 mm [1/16 in] out of alignment, replace the vibration damper. Inspect the rubber member for deterioration. If pieces of rubber are missing or if the elastic member is more than 3.18 mm [1/8 in] below the metal surface, replace the damper.
Vibration Damper, Viscous Page 7-8 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years Page 8-a Section 8 - Maintenance Procedures at 5000 Hours or 4 Years Section Contents Page Maintenance Procedures - Overview ........................................................................................................................8-1 General Information....................................................................................................................................................
Page 8-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Overhead Set Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
Overhead Set Page 8-2 QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years Disconnect the breather tube connection at the back of the rocker lever cover. In general, two types of breather tube connections are used at the rocker lever cover: • A clamping plate and capscrew hold the breather tube connection to the rocker lever cover. Remove the capscrew and clamping plate to disconnect the breather tube connection from the rocker lever cover.
QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years NOTE: Check the gasket while it is installed in the valve cover. Once the gasket is removed from the cover it must be replaced. Check the gasket for cracks on the sealing surface. Replace the gasket if damage is present. Replace the gasket if it is removed from the groove in the rocker lever cover. Inspect the rubber isolators for cracks. Replace if cracked or broken.
Overhead Set Page 8-4 QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years Align the vibration damper/crankshaft speed indicator ring so the TDC indicator is at the 12 o'clock position. If both number 1 cylinder rocker levers are loose, move to the following steps. If both number 1 cylinder rocker levers are not loose, rotate the crankshaft 360 degrees.
QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years NOTE: The clearance is correct when some resistance is “felt” when the feeler gauge is slipped between the crosshead and the rocker lever socket. Measure lash by inserting a feeler gauge between the crosshead and the rocker lever socket. If the lash measurement is out of specification, loosen the locknut, and adjust the lash to nominal specifications. Lash Specifications mm Intake 0.254 Exhaust 0.508 in 0.010 0.
Overhead Set Page 8-6 QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years If equipped, at the rear of the rocker lever cover, install the banjo bolt and sealing washers connecting the breather oil drain line to the rocker lever cover. Torque Value: 12 N•m [ 106 in-lb ] Not all engines with an internal mounted crankcase breather are equipped with an external breather oil drain line. On some engines the breather oil drain line is internal to the breather connection tube (1).
QSB4.5 and QSB6.7 Section 8 - Maintenance Procedures at 5000 Hours or 4 Years Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Connect the batteries. Refer to the OEM service manual. • Operate the engine and check for leaks.
Overhead Set Page 8-8 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Page A-a Section A - Adjustment, Repair, and Replacement Section Contents Page Alternator ....................................................................................................................................................................A-1 Finishing Steps...........................................................................................................................................................
Page A-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Alternator Page A-1 Alternator General Information Due to the number of different alternator brands and configurations, the following procedure has been generalized to cover the most common configurations. Consult the alternator manufacturer for any information that is not covered in this procedure.
Alternator Page A-2 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement One Wire System, Typical Alternator (Delco-Remy™ One Wire System, Typical Alternator (Delco-Remy™) 3 GRD* 4 R* 5 6 BAT I* Ground Charge indicator, automatic lockout system, tachometer** Battery Indicator light *Not all alternators have this feature. **Provides voltage pulses at about one-half system voltage at a frequency of one-tenth of alternator rpm.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Alternator Page A-3 Three Wire System, Typical Alternator (Delco-Remy™) Key Terminal 1 Blade number 1* 2 Blade number 2 3 GRD* 4 R* 5 6 BAT I* Connected To Indicator light Voltage sense Ground Charge indicator, automatic lockout system, tachometer** Battery Indicator light *Not all alternators have this feature. **Provides voltage pulses at about one-half system voltage at a frequency of one-tenth of alternator rpm.
Alternator Page A-4 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Initial Check Check the drive belt and alternator pulley to be sure the alternator is rotating properly. If any problems exist, check the following: • If the drive belt is slipping on the alternator pulley. Refer to Procedure 008-002 in Section A. • Use the following procedure to inspect the belt tensioner. Refer to Procedure 008-087 in Section A . • Remove the drive belt. Refer to Procedure 008-002 in Section A.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Connect a carbon-pile load (battery/alternator tester) across the batteries in one of the battery boxes. Clamp an induction pickup-type ampere-hour meter around the battery cable; or use the digital multimeter, Part Number 3164488 or 3164489, with the clamp-on current probe, Part Number 3164490. WARNING Batteries can emit explosive gases.
Alternator Page A-6 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Acid is extremely dangerous and can damage the machinery and can also cause serious burns.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Pad Mount • Remove the alternator mounting capscrews. • Remove the alternator. Hinge Mount • Remove the alternator link capscrew. Remove the alternator mounting capscrew. Remove the alternator. Install Spool Mount • Install the alternator and the bottom alternator mounting capscrew and nut. • Tighten the capscrews.
Alternator Page A-8 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Pad Mount • Install the alternator. • Install and tighten the alternator mounting capscrews. Torque Value: M10 Capscrew Step 1 36 N•m [ 27 ft-lb ] Torque Value: M12 Capscrew Step 1 64 N•m [ 47 ft-lb ] Hinge Mount • Install the alternator. • Install and tighten the alternator mounting capscrew. Torque Value: 40 N•m [ 30 ft-lb ] Install the alternator link capscrew.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Acid is extremely dangerous and can damage the machinery and can also cause serious burns.
Coolant Thermostat Page A-10 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement CAUTION Never operate the engine without a thermostat. Without a thermostat, the path of least resistance for the coolant is through the bypass to the water pump inlet. This can cause the engine to overheat. CAUTION A missing check ball can cause the engine to run cold, resulting in engine damage. The thermostat contains two check balls to vent air past the thermostat when it is closed.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Coolant Thermostat Page A-11 Inspect the thermostat for external damage. Also inspect for cracks, embedded debris, missing check balls, damaged seat, and other damage. Replace the thermostat if any damage is found. Measure If the thermostat is suspected to be malfunctioning, the opening temperature of the thermostat should be measured to determine if the thermostat is functioning properly.
Cooling Fan Belt Tensioner Page A-12 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Install CAUTION Always use the correct thermostat and do not operate the engine without a thermostat installed. The engine can overheat if operated without a thermostat because the path of least resistance for the coolant is through the bypass to the pump inlet. An incorrect thermostat can cause the engine to overheat or run too cold.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement With the belt removed, verify that the tensioner arm stop is in contact with the spring case stop. If these two are not touching, the tensioner must be replaced. After replacing the belt, if the tensioner arm stop is still in contact with the spring case stop, the tensioner MUST be replaced. Check the location of the drive belt on the belt tensioner pulley. The belt should be centered on, or close to the middle of, the pulley.
Drive Belt, Cooling Fan Page A-14 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Drive Belt, Cooling Fan General Information Due to the number of drive belt arrangements, this procedure does not cover all available cooling fan drive belt routing. To make sure the cooling fan drive belt is routed correctly upon installation, make a diagram of the cooling fan belt routing prior to removing the belt as shown in the illustration.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement CAUTION Applying excessive force in the opposite direction of windup or after the tensioner has been wound up to the positive stop can cause the tensioner arm to break. NOTE: Make a diagram of the belt arrangement prior to removing the drive belt. This aids in installation and proper routing of the cooling fan drive belt. NOTE: The location of the belt tensioner can vary, depending on the front engine accessory arrangement.
Drive Belt, Cooling Fan Page A-16 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Inspect all system pulleys for embedded debris: • Rocks, stones • Metal • Belt material. Remove the debris from the grooves of the pulley. If the pulley has been deformed as a result of foreign material embedment, the pulley MUST be replaced. Install CAUTION The belt tensioner is spring-loaded and must be pivoted away from the drive belt.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Fan Spacer and Pulley Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. NOTE: Prior to removing the drive belt, loosen the fan pulley and cooling fan (if equipped) mounting capscrews.
Fan Spacer and Pulley Page A-18 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. Clean the fan pulley and spacer with solvent and dry with compressed air. Inspect the fan pulley for cracks near the bolt holes and for damage at the drive belt contact surface.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement NOTE: Some applications do not have a cooling fan or the cooling fan is located elsewhere on the application. For engines equipped with an engine driven cooling fan, the fan holds the fan pulley and spacer in place. Install the fan pulley and spacer. If removed, install the cooling fan. Refer to the OEM service manual for instructions.
Starting Motor Page A-20 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement If the crankshaft does not rotate or requires more than the normal effort to bar, check for an internal malfunction or a problem with the drive unit and/or accessories. If the engine cranking speed is too slow/will not crank at all, and the engine rotates freely: Make sure the wiring connections are clean, tight, and not damaged. Check the battery voltage. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing.
Starting Motor Page A-22 QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Inspect the starter motor pinion gear and/or flywheel ring gear for chipping or uneven wear. NOTE: If the starter motor pinion gear and/or flywheel ring gear teeth are damaged, they must be replaced. Install For engines with wet flywheel housings, apply a 1.5 to 2.0 mm [0.06 to 0.09 in] wide bead of sealant, Part Number 3164067, to the flywheel housing starting motor mounting flange.
QSB4.5 and QSB6.7 Section A - Adjustment, Repair, and Replacement Cummins® Branded Starters WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. CAUTION Do not overtighten the electrical connections. Starter damage can result.
Starting Motor Page A-24 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section D - System Diagrams Page D-a Section D - System Diagrams Section Contents Page Flow Diagram, Air Intake System ........................................................................................................................... D-10 Flow Diagram...........................................................................................................................................................D-10 Flow Diagram, Compressed Air System ....................................
QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section D - System Diagrams System Diagrams - Overview Page D-1 System Diagrams - Overview General Information The following drawings show the flow through the engine systems. Although parts can change between different applications 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.
Flow Diagram, Fuel System Page D-2 QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Fuel System Flow Diagram © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc.
QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Fuel System Page D-3 With Electric Lift Pump(s) © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc.
Flow Diagram, Lubricating Oil System Page D-4 QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Lubricating Oil System Flow Diagram © Cummins Inc. 8 7 11 © Cummins 13 Inc. 11 14 14 9 13 © Cummins Inc. 14 3 4 2 5 6 © Cummins Inc. © Cummins Inc.
QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Lubricating Oil System Page D-5 Flow Diagram, Lubricating Oil System Flow Diagram 1 © Cummins Inc. © Cummins Inc. © Cummins Inc. 2 © Cummins Inc. © Cummins Inc. 07d00074 Lubrication for the Turbocharger 1 Turbocharger lubricating oil supply 2 Turbocharger lubricating oil drain.
Flow Diagram, Lubricating Oil System Page D-6 QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Lubricating Oil System Flow Diagram 10 3 © Cummins Inc. 4 4 2 © 5Cummins Inc.6 6 © Cummins Inc. 7 © Cummins Inc. 9 © Cummins Inc.
QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Lubricating Oil System Page D-7 Flow Diagram, Lubricating Oil System Flow Diagram 6 © Cummins Inc. © Cummins Inc. 4 © Cummins Inc. 5 2 © Cummins Inc. © Cummins Inc. 1 3 07900025 Lubrication for the Overhead Components 1 Main lubricating oil rifle 2 Rocker lever support 3 Transfer slot 4 Rocker lever shaft 5 Rocker lever bore 6 Rocker lever.
Flow Diagram, Lubricating Oil System Page D-8 QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Lubricating Oil System Flow Diagram © Cummins Inc. © Cummins Inc. 1 2 © Cummins Inc. © Cummins Inc. © Cummins Inc. 07d00212 Lubrication for the Accessory Drive 1 Oil supply to accessory drive 2 Oil feed from block.
QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Cooling System Page D-9 Flow Diagram, Cooling System Flow Diagram 4 6 9 5 © Cummins Inc. 7 5 © Cummins Inc. 8 6 4 © Cummins Inc. 2 © Cummins Inc. 3 7 10 11 12 7 © Cummins Inc.
Flow Diagram, Air Intake System Page D-10 QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Air Intake System Flow Diagram 1 2 © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc. 4 5 © Cummins Inc. 3 10d00022 1 Intake air inlet to turbocharger 2 Turbocharger air to charge air cooler 3 Charge-air cooler 4 Intake manifold (integral part of the cylinder head) 5 Intake valve.
QSB4.5 and QSB6.
Flow Diagram, Exhaust System Page D-12 QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Exhaust System Flow Diagram Without EGR 1 © Cummins Inc. 2 © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc. 3 4 1 Exhaust valve 2 Exhaust manifold 3 Turbocharger 4 Turbocharger exhaust outlet.
QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Exhaust System Page D-13 With EGR 5 7 8 © Cummins Inc. 6 © Cummins Inc. © Cummins Inc. 3 2 © Cummins Inc. 1 © Cummins Inc. 4 11d00077 1 Exhaust gas to manifold 2 Exhaust manifold 3 Exhaust gas to turbocharger 4 Exhaust gas to exhaust gas recirculation (EGR) valve 5 EGR valve 6 Exhaust gas from EGR valve to EGR cooler connection 7 EGR cooler 8 Cooled exhaust gas to EGR connection tube and EGR mixer.
Flow Diagram, Exhaust System Page D-14 QSB4.5 and QSB6.7 Section D - System Diagrams Marine Applications 3 2 © Cummins Inc. 1 © Cummins Inc. © Cummins Inc. 4 © Cummins Inc. © Cummins Inc. 11d00095 1 Exhaust valve 2 Exhaust manifold (wet) 3 Turbocharger (water cooled) 4 Exhaust outlet.
QSB4.5 and QSB6.7 Section D - System Diagrams Flow Diagram, Compressed Air System Page D-15 Flow Diagram, Compressed Air System Flow Diagram 1 © Cummins Inc. © Cummins Inc. © Cummins Inc. © Cummins Inc. 6 1 Air in 2 Air out 3 Coolant in 4 Coolant out 5 Lubricating oil in (internal to the gear housing) 6 Lubricating oil out (internal to the gear housing). 3 2 4 © Cummins Inc.
Flow Diagram, Compressed Air System Page D-16 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section L - Service Literature Page L-a Section L - Service Literature Section Contents Page Additional Service Literature .....................................................................................................................................L-1 General Information....................................................................................................................................................L-1 Cummins Customized Parts Catalog ............................
QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section L - Service Literature Additional Service Literature Page L-1 Additional Service Literature General Information The following publications can be purchased: 4021271 4021578 4021597 4022188 4022254 4021416 4021570 4021524 4022225 4021532 4021572 4021625 4021670 4022230 4021531 4021546 4021602 4021619 4021680 4022189 4022263 4021601 4021620 4021681 4022220 4022262 3379000 3379001 3379009 3666132 3387266-R 3810340 Additional Service Literature ISB, ISBe, ISBe4, QSB4.5, QSB5.
Additional Service Literature Page L-2 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section L - Service Literature Service Literature Ordering Location Page L-3 Service Literature Ordering Location Contact Information Region United States and Canada All Other Countries Ordering Location Cummins Distributors or Credit Cards at https:// store.cummins.
Cummins Customized Parts Catalog Page L-4 QSB4.5 and QSB6.7 Section L - Service Literature Cummins Customized Parts Catalog General Information Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contain only the new factory parts that were used to build your engine. The catalog cover, as well as the content, is customized with you in mind.
QSB4.5 and QSB6.7 Section S - Service Assistance Page S-a Section S - Service Assistance Section Contents Page Distributors - International ...................................................................................................................................... S-33 Locations..................................................................................................................................................................S-33 Distributors and Branches ............................
QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section S - Service Assistance Problem Solving Page S-1 Routine Service and Parts General Information Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your system. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained to provide sound advice, expert service, and complete parts support.
Problem Solving Page S-2 • Telephone: +1 812-377-3000 (International) QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section S - Service Assistance Division and Regional Offices Page S-3 Division and Regional Offices - Locations Australia Regional Office (This office also serves New Zealand) Cummins Engine Company Pty. Ltd., 2 Caribbean Drive Scoresby, Victoria, 3179, Australia, Telephone: (61-3) 9765-3222, Fax: (61-3) 9763-0079 Cummins Americas Regional Office (This office serves Puerto Rico and South America excluding Brazil) Cummins Americas Inc.
Distributors and Branches Page S-4 QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches - United States Alabama Birmingham Cummins Mid-South, LLC 2200 Pinson Highway P.O. Box 1147 Birmingham, AL 35217 Telephone: (205) 841-0421 FAX: (205) 849-5926 Alabama Mobile Cummins Mid-South, LLC 1924 N. Beltline Hwy. Mobile, AL 36617 Telephone: (334) 456-2236 FAX: (334) 452-6419 Alaska Anchorage Cummins Northwest, Inc.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-5 California Redding Cummins West, Inc. 20247 Charlanne Drive Redding, CA 96002 Telephone: (530) 222-4070 FAX: (530) 224-4075 California Stockton Cummins West, Inc. 5250 Claremont Ave Suite 204 Stockton, California 95207, USA Telephone: (209) 472-3460 FAX: (209) 472-3450 California West Sacramento Cummins West, Inc.
Distributors and Branches Page S-6 QSB4.5 and QSB6.7 Section S - Service Assistance Connecticut Rocky Hill Cummins Metropower, Inc. 914 Cromwell Ave. Rocky Hill, CT 06067 Telephone: (860) 529-7474 FAX: (860) 529-7524 Florida Ft. Myers Cummins Power South, LLC 2671 Edison Avenue Ft. Myers, FL 33916 Telephone: (941) 337-1211 FAX: (941) 337-5374 Florida Jacksonville Cummins Power South 755 Pickettville Rd.
QSB4.5 and QSB6.7 Section S - Service Assistance Georgia Atlanta Georgia Distributors and Branches Page S-7 Cummins South, Inc. 100 University Ave. S.W. Atlanta, Georgia 30315-2202 Telephone: (404) 527-7800 FAX: (404) 527-7832 Cummins South, Inc. 5125 Georgia Highway 85 College Park, GA 30349 Telephone: (404) 763-0151 FAX: (404) 766-2132 Georgia Albany Cummins South, Inc. 1915 W. Oakridge Drive Albany, GA 31707-4938 Telephone: (912) 888-6210 FAX: (912) 883-1670 Georgia Augusta Cummins South, Inc.
Distributors and Branches Page S-8 QSB4.5 and QSB6.7 Section S - Service Assistance Illinois Madison Cummins MId-South, LLC 222 SR-203 Madison, Illinois 62060 Telephone: (618) 798-9512 FAX: (618) 798-9521 Illinois Rock Island Cummins Central Power, LLC 7820 - 42nd Street West Rock Island, IL 61201 Telephone: (309) 787-4300 FAX: (309) 787-4397 Indiana Indianapolis Cummins Mid-States Power, Inc. P.O.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-9 Iowa Des Moines Cummins Central Power, LLC 1680 N.E.
Distributors and Branches Page S-10 QSB4.5 and QSB6.7 Section S - Service Assistance Maryland Baltimore Cummins Power Systems, Inc. 1907 Park 100 Drive MD 21061 Telephone: (410) 590-8700 FAX: (410) 590-8731 Massachusetts Boston Cummins Northeast, Inc. 100 Allied Drive Dedham, MA 02026 Telephone: (781) 329-1750 FAX: (781) 329-4428 Massachusetts Springfield Cummins Northeast, Inc.
QSB4.5 and QSB6.
Distributors and Branches Page S-12 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-13 New York Syracuse Cummins Northeast, Inc. 6193 Eastern Avenue Syracuse, NY 13211 Telephone: (315) 437-2751 FAX: (315) 437-8141 North Carolina Charlotte Cummins Atlantic, Inc. 11101 Nations Ford Road Charlotte, NC 28273 Telephone: (704) 588-1240 FAX: (704) 587-4870 North Carolina Charlotte Cummins Atlantic, Inc.
Distributors and Branches Page S-14 QSB4.5 and QSB6.7 Section S - Service Assistance Ohio Toledo Cummins Bridgeway, LLC 801 Illinois Avenue Maumee , OH 43537 Telephone: (419) 893-8711 FAX: (419) 893-5362 Ohio Youngstown Cummins Bridgeway, LLC 7145 Masury Road Hubbard (Youngstown), OH 44425 Telephone: (216) 534-1935 FAX: (216) 534-5606 Oklahoma Oklahoma City Cummins Southern Plains ,Ltd.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-15 Pennsylvania Pittsburgh Cummins Power Systems, Inc. 3 Alpha Drive Pittsburgh, PA 15138-2901 Telephone: (412) 820-8300 FAX: (412) 820-8308 Pennsylvania Harrisburg Cummins Power Systems, Inc. 4499 Lewis Road Harrisburg, PA 17111-2541 Telephone: (717) 564-1344 FAX: (717) 558-8217 Puerto Rico Cummins de Puerto Rico, Inc. Calle 1 G1 Urb.
Distributors and Branches Page S-16 QSB4.5 and QSB6.7 Section S - Service Assistance Tennessee Nashville Cummins Cumberland, Inc. 706 Spence Lane Nashville, TN 37217 Telephone: (615) 366-4341 FAX: (615) 366-5693 Texas Arlington Cummins Southern Plains, Ltd. 600 N Watson Road Arlington, TX 76004-76011 Telephone: (817) 640-6801 FAX: (817) 640-6852 Texas Amarillo Cummins Southern Plains, Ltd.
QSB4.5 and QSB6.7 Section S - Service Assistance Utah Distributors and Branches Page S-17 Salt Lake City Cummins Rocky Mountain, LLC 1030 South 300 West Salt Lake City, UT 84101 Telephone: (801) 524-1321 FAX: (801) 524-1351 Virginia Richmond Cummins Atlantic, Inc. 3900 Deepwater Terminal Road Richmond, VA 23234 Telephone: (804) 232-7891 FAX: (804) 232-7428 Virginia Tidewater Cummins Atlantic, Inc. 3729 Holland Blvd.
Distributors and Branches Page S-18 QSB4.5 and QSB6.7 Section S - Service Assistance West Virginia Fairmont Cummins Cumberland, Inc. Rt 73 So.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-19 Distributors and Branches - Canada Alberta Edmonton Alberta Cummins Western Canada 11751 - 181 Street Edmonton, AB T5S 2K5 Telephone: (780) 455-2151 FAX: (780) 454-9512 Cummins Western Canada 4887 - 35th Street S.E.
Distributors and Branches Page S-20 QSB4.5 and QSB6.7 Section S - Service Assistance Newfoundland Wabush Cummins Eastern Canada, LP Wabush Industrial Park Wabush, Newfoundland A0R 1B0 Telephone: (709) 282-3626 FAX: (709) 282-3108 Nova Scotia Halifax Cummins Eastern Canada, LP 50 Simmonds Drive Dartmouth, Nova Scotia B3B 1R3 Telephone: (902) 468-7938 FAX: (902) 468-5177 Ontario Kenora Cummins Mid-Canada Ltd. Highway 17 East P.O.
QSB4.5 and QSB6.
Distributors and Branches Page S-22 QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches - China, People's Republic Beijing Cummins Engine (Beijing) Co., Ltd. No. 8, Wan Yuan Street, Beijing Economic and Technology Development Zone, Beijing, 100176, People's Republic of China. Telephone: (86-10) 67882258 Fax: (86-10) 67882285 Shenyang Cummins Engine (China) Investment Co., Ltd. ShenYang Workshop & Branch Office. No.
QSB4.5 and QSB6.7 Section S - Service Assistance Shenzhen Distributors and Branches Page S-23 Shenzhen Chongfa Cummins Engine Company Ltd. Tian An Che Gong Miao Industrial Estate,Unit F2.6 2D, Shenzhen Shennan Da Dao, Shenzhen, Guangdong 518040, China.
Distributors and Branches Page S-24 QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches - Australia Branches: Gepps Cross Cummins Engine Company, Pty. Ltd. P.O. Box 108 Blair Athol, 5084 South Australia, Australia Location: 45-49 Cavan Road Gepps Cross, 5094 Telephone: (61-8) 8262-5211 Branches: Dosra Cummins Engine Company, Pty. Ltd. P.O.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-25 Branches: Devonport Cummins Engine Company, Pty. Ltd. P.O. Box 72E Tasmania, Australia Location: 2 Matthews Way Devonport, 7310 Telephone: (61-3) 6424-8800 Branches: Emerald Cummins Engine Company, Pty. Ltd. P.O. Box 668 Emerald, 4720 Queensland, Australia Location: Capricorn Highway Emerald, 4720 Telephone: (61-7) 4982-4022 Branches: Grafton Cummins Engine Company, Pty. Ltd. P.O.
Distributors and Branches Page S-26 QSB4.5 and QSB6.7 Section S - Service Assistance Branches: Leeton Cummins Engine Company, Pty. Ltd. P.O. Box 775 Leeton, NSW 2705 Australia Location: 29 Brady Way Leeton, NSW 2705 Australia Telephone: (61-2) 6953-3077 FAX: (61-2) 6953-3109 Branches: Mackay Cummins Engine Company, Pty. Ltd. P.O. Box 842 Mackay, 4740 Queensland, Australia Location: 4 Presto Avenue Mackay, 4746 Telephone: (61-7) 4955-1222 Branches: Mount Gambier Cummins Engine Company, Pty. Ltd. P.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches Page S-27 Branches: Swan Hill Cummins Engine Company, Pty. Ltd. P.O. Box 1264 Swan Hill, 3585 Victoria, Australia Location: 5 McAllister Road Swan Hill, 3585 Telephone: (61-3) 5032-1511 Branches: Tamworth Cummins Engine Company, Pty. Ltd. P.O. Box 677 Tamworth, 2320 New South Wales, Australia Location: Lot 65 Gunnedah Road Tamworth, 2340 Telephone: (61-2) 6765-5455 Branches: Townsville Cummins Engine Company, Pty. Ltd. P.O.
Distributors and Branches Page S-28 QSB4.5 and QSB6.7 Section S - Service Assistance Distributors and Branches - New Zealand Auckland Cummins Engine Company, Pty. Ltd. Private Bag 92804 Penrose, Auckland, New Zealand Location: 440 Church Street Penrose Telephone: (64-9) 579-0085 Branches: Auckland Cummins Engine Company, Pty. Ltd. Private Bag 92804 Penrose, Auckland, New Zealand Location: 440 Church Street Penrose Telephone: (64-9) 579-0085 Branches: Christchurch Cummins Engine Company, Pty. Ltd.
QSB4.5 and QSB6.7 Section S - Service Assistance Regional Offices - International Page S-29 Regional Offices - International - Locations Regional Office - Daventry Cummins Engine Co.
Regional Offices - International Page S-30 QSB4.5 and QSB6.7 Section S - Service Assistance Beijing Regional Office - China Cummins Corporation Bejing Branch (CCBJ) 28, Tower A, Gateway, 18, Xiaguangli North Road, East Third Ring Chaoyang District Beijing 100027 People's Republic of China Telephone: (86-10) 84548888 Fax: (86-10) 6462-0226 Countries Covered: China Hong Kong S.A.R Mongolia Taiwan Gross-Gerau Regional Office - Germany Cummins Diesel Deutschland GmbH Odenwaldstr.
QSB4.5 and QSB6.7 Section S - Service Assistance Regional Offices - International Page S-31 Seoul Regional Office - Korea Cummins Korea Ltd. 25th floor, ASEM tower 159-1, Samsung-Dong Kangnam-ku, Seou ZIP / Postal Code: 135-798 South Korea Telephone: (82-2) 3420-0901 Fax: (82-2) 3452-4113 / 539-6569 Country Covered: South Korea Col. Polanco Regional Office - Mexico Cummins, S. de R.L. de C.V. Arquimedes No. 209 Col.
Regional Offices - International Page S-32 QSB4.5 and QSB6.7 Section S - Service Assistance Southeast Asia Regional Office - Singapore Singapore Cummins Diesel Sales Corporation 8 Tanjong Penjuru ZIP / Postal Code: 609019 Singapore Telephone: (65) 265-0155 Fax - Parts/MIS/Shipping: (65) 6264-0664 Countries Covered: Bangladesh Brunei Cambodia Indonesia Laos Malaysia Philippines Singapore Sri Lanka Thailand Vietnam Latin America Regional Office - Miramar (U.S.A.) Cummins Americas, Inc.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors - International Page S-33 Distributors - International - Locations Cummins Middle East FZE Cummins Middle East FZE P.O. Box No 17636, Units ZF 05 & 06Jebel Ali Free Zone, DubaiUnited Arab EmiratesTelephone: 00 9714 8838998Fax: 00 9714 8838997, United Arab Emirates Cummins Emirates Sales & Service LLC P.O.
Distributors - International Page S-34 QSB4.5 and QSB6.
QSB4.5 and QSB6.
Distributors - International Page S-36 QSB4.5 and QSB6.7 Section S - Service Assistance BENIN TOGOMAT s.a. Zone Industrielle CNPPMELomeTogoTelephone: (228) 2272395Fax: (228) 2270310, BERMUDA Bronx (Office in U.S.A.) Cummins Metropower, Inc.
QSB4.5 and QSB6.7 Section S - Service Assistance BRITISH VIRGIN ISLANDS BRITISH VIRGIN ISLANDS - See Puerto Rico , Cummins de Puerto Rico, Inc. BRUNEI BRUNEI Calle 1 G1Urb.
Distributors - International Page S-38 QSB4.5 and QSB6.7 Section S - Service Assistance CHILE Santiago Distribuidora Cummins Chile, S.A. Avda. Americo Vespucio # 0631Santiago, QuilicuraZIP / Postal Code: 873-0596Chile Telephone: (56-2) 655-7253 / 7245Fax: (56-2) 655-7216 / 7436, CHINA, PEOPLE'S REPUBLIC Beijing Cummins Engine (Beijing) Co., Ltd.No.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors - International Page S-39 COLOMBIA Bucaramanga Cummins API Ltda. Kilómetro 7 Vía a Girón - Zona Industrial A.A. 1821Bucaramanga, Colombia Bucaramanga, Santander ColombiaTelephone: (57-76) 468060 / 469262 / 469263Fax: (57-76) 468065, COLOMBIA Cali Tecnodiesel LimitadaApartado Aereo No. 6398 Carrera 8, No.
Distributors - International Page S-40 DOMINICAN REPUBLIC QSB4.5 and QSB6.7 Section S - Service Assistance Santo Domingo Argico C. por A.Calle Jose A. Soler No.3Esq. Lope de Vega Santo Domingo, Distrito NacionalDominican RepublicTelephone: (809) 562-6281Fax: (809) 562-4233 , DUBAI - See United Arab Emirates , DUBAI Cummins Middle East FZEP.O.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors - International Page S-41 FIJI - See Cummins New Zealand, FIJI Cummins9 Langley RoadManukau City Centre, Auckland 1702New ZealandTelephone: (64-3) 277 1000Fax: (64-3) 277 1001, FINLAND Helsinki Machinery OyAnsatie 5VantaaZIP / Postal Code: FIN-01741FinlandTelephone: (358-9) 89551, FRANCE Lyon CUMMINS DIESEL S.A.
Distributors - International Page S-42 GUINEA QSB4.5 and QSB6.7 Section S - Service Assistance Mechelen (Office in Belgium) GUINEA BISSAU Cummins Belgium N.V./S.A.Egide Walschaertsstraat, 2Industriepark ZuidMechelen 2800BelgiumTelephone: (32-15) 479 100Fax: (32-15) 275 686, - See North/West/East and Central Africa Regional Office - DaventryCummins Engine Company LtdRoyal Oak Way SouthDaventry, Northants NN11 5NUUnited KingdomTelephone: (44-1327) 886000Fax: (44-1327) 886106, GUYANA Miami (Office in U.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors - International Page S-43 INDIA Ranchi Cummins Diesel Sales & Service (India) Ltd.`Shanti Kunj' C-202, Vidyalaya Marg Road No. 01, Ashok Nagar,Ranchi, Jharkhand 834002India Telephone: (91-651) 2241948 / 2241521Fax: (91-651) 2242815, INDONESIA Jakarta P.T. Alltrak 1978 J1. R.S.C. Veteran No.
Distributors - International Page S-44 KUWAIT QSB4.5 and QSB6.7 Section S - Service Assistance Kuwait LAOS General Transportation & Equipment Co. (GTE)(Sales Department) Safat 13011KuwaitTelephone: (965) 483 3380/1/2Fax: (965) 481 2860, Diethelm & Co. LtdBan Phonsinouan, Unit 18,New Road Sisattanak District,VientianeLaos P.D.R.
QSB4.5 and QSB6.7 Section S - Service Assistance MALTA Valletta MARTINIQUE Distributors - International Page S-45 International Machinery LtdRegency House254 Republic Street Valletta, MaltaMaltaTelephone: (356-21) 232620 / 233343Fax: (356-21) 235484 / 247571, Cummins Power South, LLC9900 N.W. 77 Ave.Hialeah Gardens, FL 33016 Telephone: (305) 821-4200Fax: (305) 557-2992, MEXICO Guadalajara Distribuidora Megamak de OccidenteMetalurgia No. 2980 Fracc.
Distributors - International Page S-46 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors - International Page S-47 PERU Lima Mitsui Maquinarias Peru, S.A.Av. Nicolas Ayllon 2648Parcela Rustica Sta. Angelica AteLima ZIP / Postal Code: 03PeruTelephone: (51-1) 326-4957Fax: (51-1) 326-4954, PHILIPPINES EDSA Cummins Sales & Service Philippines, Inc.
Distributors - International Page S-48 QSB4.5 and QSB6.7 Section S - Service Assistance SAUDI ARABIA Al-Khobar General Contracting Company - OLAYANP.O.
QSB4.5 and QSB6.7 Section S - Service Assistance Distributors - International Page S-49 SPANISH GUINEA - See Spain Cummins Ventas y Servico S. A.
Distributors - International Page S-50 QSB4.5 and QSB6.7 Section S - Service Assistance TURKEY Istanbul Hamamcioglu Muesseseleri Ticaret T.A.S. Okul Cad. No. 1334956 Orhanli - P.K. 62 TuzlaIstanbulTurkey Telephone: (90-216) 394 3210Fax: (90-216) 394 3208 / 9, UKRAINE - See Moscow Regional Office - Moscow Cummins Engine Company, Inc.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Page TS-a Section TS - Troubleshooting Symptoms Section Contents Page Troubleshooting Procedures and Techniques ......................................................................................................TS-1 General Information.................................................................................................................................................TS-1 Troubleshooting Symptoms Charts ..................................
Page TS-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page TS-1 Troubleshooting Procedures and Techniques General Information This guide describes some typical operating problems, their causes, and some acceptable corrections to those problems. Unless noted otherwise, the problems listed are those which an operator can diagnose and repair.
Troubleshooting Symptoms Charts Page TS-2 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts General Information Use the charts on the following pages of this section to aid in diagnosing specific symptoms. Read each row of blocks from top to bottom. Follow through the chart to identify the corrective action. WARNING Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be performed by trained, experienced technicians.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-3 Air Compressor Air Pressure Rises Slowly Cause STEP 1 Air intake system restriction to air compressor is excessive Correction Replace the air compressor air cleaner (if installed). Check the air intake piping. Check ............. engine air intake restriction if the air compressor inlet is plumbed to the vehicle or equipment intake system. Refer to Section 3 and Section 4.
Troubleshooting Symptoms Charts Page TS-4 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Air Compressor Cycles Frequently STEP 1 Air system leaks Correction Block the vehicle wheels and check the air system for leaks with spring brakes applied and released. ............. Check for leaks from the air compressor gaskets and the air system hoses, fittings, tanks, and valves. Refer to the OEM service manuals.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-5 Air Compressor Noise is Excessive STEP 1 Carbon buildup is excessive in the air discharge line, downstream air valves, or cylinder head Correction Check for carbon buildup. Replace the air ............. compressor discharge line and cylinder head assembly if necessary. Refer to Section 7. OK Go To Next Step STEP 2 Air compressor is sending air pulses into the air tanks .............
Troubleshooting Symptoms Charts Page TS-6 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Air Compressor Pumping Excess Lubricating Oil into the Air System Cause STEP 1 Lubricating oil drain interval is excessive Correction ............. Verify the correct lubricating oil drain interval. Refer to Section 2. OK Go To Next Step STEP 2 Air intake system restriction to air compressor is excessive Replace the air compressor air cleaner (if installed). Check the air intake piping. Check ........
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-7 Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) Cause STEP 1 Air system leaks OK Go To Next Step STEP 2 Contact a Cummins® Authorized Repair Facility Correction Block the vehicle wheels and check the air system for leaks with spring brakes applied and released. .............
Troubleshooting Symptoms Charts Page TS-8 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Air Compressor Will Not Stop Pumping STEP 1 Air system leaks OK Go To Next Step STEP 2 Contact a Cummins® Authorized Repair Facility Correction Block the vehicle wheels and check the air system for leaks with spring brakes applied and released. ............. Check for leaks from the air compressor gaskets and the air system hoses, fittings, tanks, and valves. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-9 Alternator Not Charging or Insufficient Charging Cause STEP 1 Alternator pulley is loose on the shaft Correction ............. Tighten the pulley. Refer to OEM service manual. OK Go To Next Step STEP 2 Batteries have malfunctioned Check the condition of the batteries. Replace the ............. batteries, if necessary. Refer to OEM service manual.
Troubleshooting Symptoms Charts Page TS-10 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Alternator Overcharging STEP 1 Batteries have failed Correction Check the condition of the batteries. Replace the ............. batteries, if necessary. Refer to the OEM service manual. OK Go To Next Step STEP 2 Voltage regulator is malfunctioning OK Go To Next Step STEP 3 Contact a Cummins® Authorized Repair Facility Check the voltage regulator. Replace the voltage .............
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-11 Coolant Contamination STEP 1 Coolant is rusty and has debris ............. Correction Drain and flush the cooling system. Fill with correct mixture of antifreeze and water. Refer to Section 7. OK Go To Next Step STEP 2 Transmission oil cooler or torque converter cooler is leaking Check the transmission oil cooler and torque ............. converter cooler for coolant leaks.
Troubleshooting Symptoms Charts Page TS-12 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Coolant Loss - External STEP 1 Coolant level is below specification Correction Inspect the engine and cooling system for external ............. coolant leaks. Repair if necessary. Add coolant. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-13 Coolant Temperature Above Normal - Gradual Overheat Cause STEP 1 Charge air cooler fins, radiator fins, or air conditioner condenser fins are damaged or obstructed with debris Correction Inspect the charge air cooler, air conditioner ............. condenser, and radiator fins. Clean, if necessary. Refer to Section 4 and the OEM service manual.
Troubleshooting Symptoms Charts Page TS-14 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Coolant Temperature Above Normal - Gradual Overheat Cause STEP 10 Coolant temperature gauge is malfunctioning Correction ............. Test the temperature gauge. Repair or replace the gauge, if necessary. OK Go To Next Step STEP 11 Fan drive belt is loose, tight, or not in alignment ............. Check the fan drive belt. Refer to Section 4.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-15 Coolant Temperature Above Normal - Sudden Overheat Cause STEP 1 Coolant level is below specification Correction Inspect the engine and cooling system for external ............. coolant leaks. Repair if necessary. Add coolant. Refer to Section 3. OK Go To Next Step STEP 2 Electronic fault codes are active For instructions on how to read active fault codes, ............. refer to Section 1.
Troubleshooting Symptoms Charts Page TS-16 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-17 Coolant Temperature Below Normal STEP 1 Coolant temperature gauge or sensor is malfunctioning ............. Correction Test the gauge and the sensor. Repair or replace, if necessary. Refer to OEM service manual. OK Go To Next Step STEP 2 Electronic fault codes are active For instructions on how to read active fault codes, ............. refer to Section 1.
Troubleshooting Symptoms Charts Page TS-18 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Acceleration or Response Poor STEP 1 Operator technique is not correct Correction ............. Refer to Section 1, Operating Instructions. OK Go To Next Step STEP 2 Fuel level is low in the tank ............. Fill the supply tank. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-19 Engine Acceleration or Response Poor STEP 10 Air in the fuel system Correction Check for air in the fuel system. Tighten or replace ............. the fuel connections, fuel lines, fuel tank standpipe, and fuel filters as necessary. OK Go To Next Step STEP 11 Air intake or exhaust leaks Check for loose or damaged piping connections and missing pipe plugs. Check the turbocharger .............
Troubleshooting Symptoms Charts Page TS-20 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Difficult to Start or Will Not Start (Exhaust Smoke) Cause STEP 1 Starting procedure is not correct Correction ............. Verify the correct starting procedure. Refer to Section 1. ............. Fill the supply tank. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-21 Engine Difficult to Start or Will Not Start (Exhaust Smoke) Cause STEP 10 Vehicle parasitics are excessive Correction Check the vehicle for brakes dragging, transmission malfunction, cooling fan operation ............. cycle time, and engine-driven units. Refer to the OEM service manual. OK Go To Next Step STEP 11 Fuel leak Check the fuel lines, fuel connections, and fuel .............
Troubleshooting Symptoms Charts Page TS-22 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Difficult to Start or Will Not Start (No Exhaust Smoke) Cause STEP 1 Starting procedure is not correct Correction ............. Verify the correct starting procedure. Refer to Section 1. ............. Fill the supply tank. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-23 Engine Difficult to Start or Will Not Start (No Exhaust Smoke) Cause STEP 10 Air in the fuel system Correction Check for air in the fuel system. Tighten or replace ............. the fuel connections, fuel lines, fuel tank standpipe, and fuel filters as necessary. OK Go To Next Step STEP 11 Electronic control module (ECM) is locked up ............. Disconnect the battery cables for 30 seconds.
Troubleshooting Symptoms Charts Page TS-24 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Noise Excessive STEP 1 Fan drive belt is loose, tight, or not in alignment Correction ............. Check the fan drive belt. Refer to Section 3 . OK Go To Next Step STEP 2 Lubricating oil is thin or diluted Refer to the Lubricating Oil Specifications in Section V. If the oil pressure is low, refer to the .............
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-25 Engine Noise Excessive Correction STEP 10 Fan is loose, damaged, or has excessive hub bearing end clearance OK Go To Next Step STEP 11 Contact a Cummins® Authorized Repair Facility ............. Check the fan. Refer to Section 3.
Troubleshooting Symptoms Charts Page TS-26 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Noise Excessive — Combustion Knocks Cause STEP 1 Engine is operating at low ambient temperature Correction Check the winterfront, shutters, and under-thehood air. Use under-the-hood intake air in cold ............. weather. Refer to Cold Weather Operation, see Bulletin 3387266, and Section 1. OK Go To Next Step STEP 2 Ether starting aid is malfunctioning .............
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-27 Engine Power Output Low STEP 1 Electronic fault codes are active Correction For instructions on how to read active fault codes, ............. refer to Section 1. If fault codes are active, contact a Cummins Authorized Repair Facility. OK Go To Next Step STEP 2 Fuel grade is not correct for the application or the fuel quality is poor Operate the engine from a tank of high-quality fuel. .........
Troubleshooting Symptoms Charts Page TS-28 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Power Output Low STEP 9 Charge air cooler is restricted or leaking ............. Correction Inspect the charge air cooler for air restrictions or leaks. Refer to Section 4. OK Go To Next Step STEP 10 Fuel leak Check the fuel lines, fuel connections, and fuel ............. filters for leaks. Check the fuel lines to the supply tanks. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-29 Engine Runs Rough at Idle STEP 1 Engine is cold Correction Allow the engine to warm to operating temperature. If the engine will not reach operating ............. temperature, refer to the Coolant Temperature Below Normal symptom tree. OK Go To Next Step STEP 2 Electronic fault codes are active For instructions on how to read active fault codes, ............. refer to Section 1.
Troubleshooting Symptoms Charts Page TS-30 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Runs Rough or Misfires STEP 1 Engine is cold Correction Allow the engine to warm to operating temperature. If the engine will not reach operating ............. temperature, refer to the Coolant Temperature Below Normal symptom tree. OK Go To Next Step STEP 2 Electronic fault codes are active For instructions on how to read active fault codes, ............. refer to Section 1.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-31 Engine Runs Rough or Misfires STEP 10 Moisture in the wiring harness connectors OK Go To Next Step STEP 11 Contact a Cummins® Authorized Repair Facility ............. Correction Dry the connectors with Cummins electronic cleaner, Part Number 3824510.
Troubleshooting Symptoms Charts Page TS-32 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Shuts Off Unexpectedly or Dies During Deceleration Cause STEP 1 Engine will not restart Correction ............. Refer to the Engine Difficult to Start or Will Not Start symptom tree. ............. Fill the supply tank. Refer to the OEM service manual.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-33 Engine Speed Surges at Low or High Idle Cause STEP 1 Fuel level is low in the tank Correction ............. Fill the supply tank. Refer to the OEM service manual. ............. Adjust the idle speed. Refer to an Authorized Cummins Repair Facility.
Troubleshooting Symptoms Charts Page TS-34 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Speed Surges Under Load or in Operating Range Cause STEP 1 Fuel level is low in the tank Correction ............. Fill the supply tank. Refer to the OEM service manual. OK Go To Next Step STEP 2 Electronic fault codes are active For instructions on how to read active fault codes, ............. refer to Section 1. If fault codes are active, contact a Cummins Authorized Repair Facility.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-35 Engine Speed Surges Under Load or in Operating Range Cause STEP 10 Fuel grade is not correct for the application or the fuel quality is poor OK Go To Next Step STEP 11 Contact a Cummins® Authorized Repair Facility Correction Operate the engine from a tank of high-quality fuel. ............. Refer to Fuel Recommendations and Specifications in Section V.
Troubleshooting Symptoms Charts Page TS-36 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Speed Surges in PTO or Cruise Control Cause STEP 1 Engine speed also surges at idle Correction ............. Refer to the Engine Speed Surges at Low or High Idle symptom tree. OK Go To Next Step STEP 2 Refer to the Engine Speed Surges Under Load or Engine speed surges while in the normal operating ............. in Operating Range symptom tree.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-37 Engine Starts But Will Not Keep Running Cause STEP 1 Fuel level is low in the tank Correction ............. Fill the supply tank. Refer to the OEM service manual. ............. Check the battery connections. Refer to the OEM service manual.
Troubleshooting Symptoms Charts Page TS-38 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Vibration Excessive STEP 1 Belt-driven accessories are malfunctioning Correction Check the fan hub, alternator, refrigerant compressor, and hydraulic pump for interference. ............. Isolate belt-driven accessories and check for vibration. Refer to Section 3 and Section 4. OK Go To Next Step STEP 2 Air compressor pumping time is excessive .............
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-39 Engine Will Not Crank or Cranks Slowly (Air Starter) Cause STEP 1 Air pressure is low in the air tanks Correction ............. Increase air pressure with an external air source. Refer to the OEM service manual. ............. Disengage engine-driven units. Refer to the OEM Service Manual.
Troubleshooting Symptoms Charts Page TS-40 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-41 Engine Will Not Crank or Cranks Slowly (Electric Starter) Cause STEP 1 Batteries are cold Correction ............. Check the battery heater. Refer to the manufacturer's instructions. OK Go To Next Step STEP 2 Battery cables or connections are loose, broken, or ............. Check the battery cables and connections.
Troubleshooting Symptoms Charts Page TS-42 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Engine Will Not Reach Rated Speed (RPM) Cause STEP 1 Electronic fault codes are active Correction For instructions on how to read active fault codes, ............. refer to Section 1. If fault codes are active, contact a Cummins Authorized Repair Facility. OK Go To Next Step STEP 2 Vehicle speed is too low for adequate cooling with high engine load ............. Reduce the engine load.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-43 Engine Will Not Reach Rated Speed (RPM) Cause STEP 9 Vehicle parasitics are excessive Correction Check the vehicle brakes for dragging, transmission malfunction, cooling fan operation ............. cycle time, and engine-driven units. Refer to the OEM service manual. OK Go To Next Step STEP 10 Engine power output is low OK Go To Next Step STEP 11 Contact a Cummins® Authorized Repair Facility ........
Troubleshooting Symptoms Charts Page TS-44 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Fault Code Warning Lamps Stay On (No Apparent Reason) Cause STEP 1 Diagnostic shorting plug is installed Correction ............. Remove the diagnostic shorting plug. OK Go To Next Step STEP 2 Diagnostic switch is in the ON position ............. Turn off the diagnostic switch.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS-45 Fault Code Warning Lamps Do Not Illuminate Cause STEP 1 Keyswitch is in the OFF position Correction ............. Turn the keyswitch to the ON position. OK Go To Next Step STEP 2 Battery voltage supply to the electronic control module (ECM) is low, interrupted, or open Check the battery connections, the fuses, and the ............. unswitched battery supply circuit. Refer to the OEM service manual.
Troubleshooting Symptoms Charts Page TS-46 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Fuel Consumption Excessive STEP 1 Operator technique is not correct Correction ............. Refer to Section 1, Operating Instructions. OK Go To Next Step STEP 2 Electronic fault codes are active For instructions on how to read active fault codes, ............. refer to Section 1. If fault codes are active, contact a Cummins Authorized Repair Facility.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-47 Fuel Consumption Excessive STEP 9 Lubricating oil level above specification OK Go To Next Step STEP 10 Contact a Cummins® Authorized Repair Facility Correction Check the oil level. Verify the oil pan capacity. Fill ............. the system to the specified level. Refer to Section V.
Troubleshooting Symptoms Charts Page TS-48 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Fuel in Coolant STEP 1 Bulk coolant supply is contaminated OK Go To Next Step STEP 2 Contact a Cummins® Authorized Repair Facility Correction Check the bulk coolant supply. Drain the coolant ............. and replace with noncontaminated coolant. Replace the coolant filters. Refer to Section 5.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-49 Fuel in the Lubricating Oil STEP 1 Engine idle time is excessive Correction Low oil and coolant temperatures can be caused by long idle time (greater than 10 minutes). Shut ............. off the engine rather than idle for long periods. If idle time is necessary, raise the idle speed.
Troubleshooting Symptoms Charts Page TS-50 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Intake Manifold Air Temperature Above Specification Cause STEP 1 Charge air cooler fins, radiator fins, or air conditioner condenser fins are damaged or obstructed with debris Correction Inspect the charge air cooler, air conditioner ............. condenser, and radiator fins. Clean, if necessary. Refer to Section 4 and the OEM service manual.
QSB4.5 and QSB6.
Troubleshooting Symptoms Charts Page TS-52 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Intake Manifold Pressure (Boost) is Below Normal Cause STEP 1 Air intake or exhaust leaks Correction Check for loose or damaged piping connections and missing pipe plugs. Check the turbocharger ............. and exhaust manifold mounting. Refer to Section 4. OK Go To Next Step STEP 2 Air intake system restriction is above specification Check the air intake system for restriction. Clean .............
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-53 Lubricating Oil Consumption Excessive STEP 1 Crankcase ventilation system is plugged Correction ............. Check and clean the crankcase breather and vent tube. Refer to Section 3. ............. Change the oil and filters. Refer to Section 5. Use the oil recommended in Section V. ............. Verify the correct lubricating oil drain interval. Refer to Section 2.
Troubleshooting Symptoms Charts Page TS-54 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Lubricating Oil Contaminated STEP 1 Lubricating oil sludge is excessive Correction Change the oil and filters. Refer to the Lubricating ............. Oil Sludge in the Crankcase Excessive symptom tree. OK Go To Next Step STEP 2 Lubricating oil is contaminated with coolant or fuel ............. Change the oil and filters. Refer to Section 5. Use the oil recommended in Section V.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-55 Lubricating Oil Loss STEP 1 Lubricating oil leak (external) Correction Inspect the engine for external oil leaks. Tighten the capscrews, pipe plugs, and fittings. Replace ............. gaskets, if necessary. Refer to the OEM service manual. OK Go To Next Step STEP 2 Lubricating oil level is below specification Check the oil level. Verify the dipstick calibration .............
Troubleshooting Symptoms Charts Page TS-56 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Lubricating Oil Loss STEP 9 Turbocharger oil seal is leaking OK Go To Next Step STEP 10 Contact a Cummins® Authorized Repair Facility Correction Check the turbocharger for oil seals and for leaks. ............. Refer to the Turbocharger Leaks Engine Oil or Fuel symptom tree.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-57 Lubricating Oil Pressure High STEP 1 Coolant temperature is above specification Correction ............. Refer to the Coolant Temperature Below Normal symptom tree. ............. Change the oil and filters. Refer to Section 5. Use the oil recommended in Section V.
Troubleshooting Symptoms Charts Page TS-58 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Lubricating Oil Pressure Low Correction STEP 1 Engine angularity during operation exceeds specification ............. Refer to the Engine Data Sheet. OK Go To Next Step STEP 2 Lubricating oil does not meet specifications for operating conditions ............. Change the oil and filters. Refer to Section 5. Use the oil recommended in Section V.
QSB4.5 and QSB6.
Troubleshooting Symptoms Charts Page TS-60 QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Lubricating Oil Sludge in the Crankcase Excessive Cause STEP 1 Bulk oil supply is contaminated Correction Check the bulk oil supply. Drain the oil and replace with noncontaminated oil. Replace the oil filter(s). ............. Refer to Section 5. Use the oil recommended in Section V. OK Go To Next Step STEP 2 Coolant temperature is below specification .............
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-61 Smoke, Black — Excessive STEP 1 Electronic fault codes are active Correction For instructions on how to read active fault codes, ............. refer to Section 1. If fault codes are active, contact a Cummins Authorized Repair Facility. OK Go To Next Step STEP 2 Air intake system restriction is above specification Check the air intake system for restriction. Clean .............
Troubleshooting Symptoms Charts Page TS-62 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Smoke, White — Excessive STEP 1 Starting procedure is not correct ............. Correction Verify the correct starting procedure. Refer to Section 1. OK Go To Next Step STEP 2 Engine is cold Allow the engine to warm to operating temperature. If the engine will not reach operating ............. temperature, refer to the Coolant Temperature Below Normal symptom tree.
QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Cause Troubleshooting Symptoms Charts Page TS-63 Smoke, White — Excessive STEP 9 Air intake system restriction is above specification Correction Check the air intake system for restriction. Clean ............. or replace the air filter and inlet piping as necessary. Refer to Section 3. OK Go To Next Step STEP 10 Charge air cooler is restricted or leaking OK Go To Next Step STEP 11 Contact a Cummins® Authorized Repair Facility .............
Troubleshooting Symptoms Charts Page TS-64 Cause QSB4.5 and QSB6.7 Section TS - Troubleshooting Symptoms Turbocharger Leaks Engine Oil or Fuel Correction STEP 1 Engine is operating for extended periods under light or no-load conditions (slobbering) ............. Review the engine operating instructions. Refer to Section 1. ............. Remove the intake and exhaust piping, and check for oil or fuel. Refer to Section 3.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Page V-a Section V - Maintenance Specifications Section Contents Page Air Intake System .......................................................................................................................................................V-5 Specifications.............................................................................................................................................................
Page V-b QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications General Engine Page V-1 General Engine Specifications Listed below are the general specifications for this engine. Bore and Stroke.........................................................................................................107 mm [4.21 in] x 124 mm [4.88 in] Horsepower................................................................................................................................
Fuel System Page V-2 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Fuel System Specifications For performance and fuel rate values, refer to the Engine Data Sheet. Maximum Fuel Inlet Restriction - With gear pump only (no engine mounted electric fuel lift pump) (at gear pump inlet) ................................................................................................................................................................50.7 kPa [7.3 psi] Rail Pressure - 4.5 liters [275 C.I.D.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Lubricating Oil System Page V-3 Lubricating Oil System Specifications Oil Pressure Low idle (minimum allowed)..................................................................................................................69 kPa [10 psi] At rated (minimum allowed).................................................................................................................207 kPa [30 psi] Oil-regulating valve-opening pressure range...............
Cooling System Page V-4 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Cooling System Specifications Coolant Capacity (four-cylinder engine only)..........................................................................................8.5 liters [2.2 gal] Coolant Capacity (six-cylinder engine only).............................................................................................10 liters [2.6 gal] Standard Modulating Thermostat - Range - Industrial Applications........................
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Air Intake System Page V-5 Air Intake System Specifications Maximum Intake Restriction (clean air filter element)..............................................................254 mm H2O [10.0 in H2O] Maximum Intake Restriction (dirty air filter element)................................................................635 mm H2O [25.
Exhaust System Page V-6 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Exhaust System Specifications Maximum Back Pressure measured at the turbocharger outlet (exhaust manifold outlet for naturally aspirated engines): Without Aftertreatment SCR Catalyst...................................................................................................10 kPa [1.5 psi] With Aftertreatment SCR Catalyst...................................................................................................
QSB4.5 and QSB6.
Cummins®/Fleetguard® Filter Specifications Page V-8 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Cummins®/Fleetguard® Filter Specifications General Information Fleetguard®/Nelson® is a subsidiary of Cummins Inc. Fleetguard®/Nelson® filters are developed through joint testing at Cummins® and Fleetguard®/Nelson®. Fleetguard®/Nelson® filters are standard on new Cummins® engines. Cummins Inc. recommends their use.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Fuel Recommendations and Specifications Page V-9 Fuel Recommendations and Specifications Fuel Recommendations WARNING Do not mix gasoline, alcohol, or gasohol 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.
Lubricating Oil Recommendations and Specifications Page V-10 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Lubricating Oil Recommendations and Specifications General Information CAUTION The fuel sulphur content should not exceed 0.5 mass percent sulphur. If the fuel sulphur content is greater than 0.5 mass percent sulphur, seek advice from your local Cummins® Distributor. For recommendations of fuel for Cummins® engines, refer to Fuel for Cummins® Engines, Bulletin 3379001.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications CAUTION An SAE 10W-30 designation on a product is a viscosity designation only. This designation alone does not imply that the product meets Cummins Inc. requirements. Only 10W30 oils with diesel performance credentials listed in table above can be used in Cummins® engines if the reduced ambient temperature indicated in chart above is observed. The primary Cummins Inc.
Lubricating Oil Recommendations and Specifications Page V-12 QSB4.5 and QSB6.7 Section V - Maintenance Specifications As the engine oil becomes contaminated, essential oil additives are depleted. Lubricating oils protect the engine as long as these additives are functioning properly. Progressive contamination of the oil between oil and filter change intervals is normal.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Coolant Recommendations Specifications Coolant Recommendations and Specifications Page V-13 and Fully Formulated Coolant/Antifreeze Cummins Inc. recommends the use of fully formulated antifreeze/coolant meeting Cummins Engineering Standards (C.E.S.) 14603. For further details and discussion of coolant for Cummins® engines, refer to Coolant Requirements and Maintenance, Bulletin 3666132.
Coolant Recommendations and Specifications Page V-14 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Fully formulated antifreeze must be mixed with goodquality water at a 50/50 ratio (40- to 60-percent working range). A 50/50 mixture of antifreeze and water gives a -36°C [-33°F] freezing point and a 108°C [226°F] boiling point, which is adequate for locations in North America. The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Cooling System Soluble Oils Do not use soluble oils in the cooling system. The use of soluble oils will: • Corrode brass and copper • Damage heat transfer surfaces • Damage seals and hoses.
Drive Belt Tension Page V-16 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Drive Belt Tension Tension Chart SAE Belt Size Belt Tension Gauge Part No. Click-type Burroughs 0.380 in 3822524 0.
QSB4.5 and QSB6.7 Section V - Maintenance Specifications Sealants Page V-17 Sealants General Information Use the sealants listed below or sealants containing equivalent properties.
Capscrew Markings and Torque Values Page V-18 QSB4.5 and QSB6.7 Section V - Maintenance Specifications Capscrew Markings and Torque Values General Information CAUTION When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being 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 surface of the nuts. U.S.
QSB4.5 and QSB6.
Capscrew Markings and Torque Values Page V-20 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section W - Warranty Page W-a Section W - Warranty Section Contents Page California Emission Control System Warranty, Off-Highway ................................................................................W-6 Owner's Warranty Responsibilities .........................................................................................................................W-9 .......................................................................................................................
QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section W - Warranty All Engines United States And Canada Industrial (Off-Hi [...
All Engines United States And Canada Industrial (Off-Hi [...] Page W-2 QSB4.5 and QSB6.7 Section W - Warranty Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items replaced during repair of a Warrantable Failure. During The Base Engine And Extended Major Components Warranties Owner is responsible for the operation and maintenance of the Engine as specified in the applicable Cummins Operation and Maintenance Manual.
QSB4.5 and QSB6.7 Section W - Warranty All Engines United States And Canada Industrial (Off-Hi [...] Page W-3 This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Emission Warranty Products Warranted This Emission Warranty applies to new Engines marketed by Cummins that are used in the United States* and Canada in vehicles designed for Industrial Off-Highway use.
All Engines International Industrial (Off-Highway) Page W-4 QSB4.5 and QSB6.7 Section W - Warranty All Engines International Industrial (Off-Highway) Coverage Products Warranted This Warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, that are used in Industrial (Off-Highway) applications anywhere in the world where Cummins approved service is available, except the United States and Canada.
QSB4.5 and QSB6.7 Section W - Warranty All Engines International Industrial (Off-Highway) Page W-5 Before the expiration of the applicable Warranty, Owner must notify a Cummins distributor, authorized dealer or other repair location approved by Cummins of any Warrantable Failure and make the product available for repair by such facility. Service locations are listed in the Cummins Worldwide Service Locator at cummins.com.
California Emission Control System Warranty, Off-Highwa [...] Page W-6 QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section W - Warranty Page W-7 Coverage This emission control system warranty applies only to the following A series, B3.3, B3.9, B4.5s, B5.9, B6.7s, QSB3.9-30, QSB4.5-30, QSB5.9-30, QSB5.9-44, C8.3, QSC8.3, QSF2.8, QSF3.
QSB4.5 and QSB6.
QSB4.5 and QSB6.7 Section W - Warranty Page W-9 Owner's Warranty Responsibilities As the off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in your Cummins Operation and Maintenance Manual. Cummins recommends that you retain all receipts covering maintenance on your off-road diesel engine, but Cummins cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
Page W-10 QSB4.5 and QSB6.7 Section W - Warranty 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 any warranted part. Cummins is not responsible for failures resulting from improper repair or the use of parts which are not genuine Cummins or Cummins approved parts.
Index Page X-1 About the Manual ................................................................................................i-2 General Information...........................................................................................i-2 Acronyms and Abbreviations ...........................................................................i-15 General Information.........................................................................................i-15 Additional Service Literature ................
Index Page X-2 Inspect for Reuse..............................................................................................4-3 Fault Code Warning Lamps Do Not Illuminate.............................................TS-45 Fault Code Warning Lamps Stay On (No Apparent Reason).......................TS-44 Flow Diagram, Air Intake System ...................................................................D-10 Flow Diagram...........................................................................................
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CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Registered Office Cummins Ltd. 49 - 51 Gresham Road, Staines, Middlesex TW18 2BD, England Registration 573951 England Cummins Customer Assistance Center 1-800-DIESELSTM (1-800-343-7357) APPLICABLE ONLY IN U.S.A. AND CANADA Copyright© 2014 Cummins Inc. Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine Cummins Inc. Box 3005 Columbus, Indiana, U.S.A., 47202 Operation and Maintenance Manual QSB4.5 and QSB6.
