Operation and maintenance manual

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 ............................................................................L-1
General Information..........................................................................................L-1
Air Cleaner Restriction ......................................................................................4-1
Maintenance Check..........................................................................................4-1
Air Compressor ..................................................................................................4-2
Maintenance Check..........................................................................................4-2
Air Compressor Air Pressure Rises Slowly ...................................................TS-3
Air Compressor Cycles Frequently.................................................................TS-4
Air Compressor Discharge Lines .....................................................................7-1
General Information..........................................................................................7-1
Maintenance Check..........................................................................................7-1
Air Compressor Noise is Excessive...............................................................TS-5
Air Compressor Pumping Excess Lubricating Oil into the Air System ..........TS-6
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping
Continuously)......................................................................................................TS-7
Air Compressor Will Not Stop Pumping.........................................................TS-8
Air Intake Piping .................................................................................................4-3
Maintenance Check..........................................................................................4-3
Air Intake System ...............................................................................................V-5
Specifications...................................................................................................V-5
Air Tanks and Reservoirs ..................................................................................3-2
Drain.................................................................................................................3-2
Alternator ............................................................................................................A-1
Finishing Steps.................................................................................................A-9
General Information..........................................................................................A-1
Initial Check......................................................................................................A-4
Install................................................................................................................A-7
Preparatory Steps.............................................................................................A-6
Remove............................................................................................................A-6
Test...................................................................................................................A-4
Alternator Not Charging or Insufficient Charging............................................TS-9
Alternator Overcharging...............................................................................TS-10
California Emission Control System Warranty, Off-Highway .......................W-6
Owner's Warranty Responsibilities .................................................................W-9
Capscrew Markings and Torque Values ........................................................V-18
Capscrew Markings and Torque Values - Metric............................................V-18
Capscrew Markings and Torque Values - U.S. Customary............................V-19
General Information........................................................................................V-18
Charge-Air Cooler ..............................................................................................4-2
Maintenance Check..........................................................................................4-2
Charge-Air Cooler ..............................................................................................A-9
Maintenance Check..........................................................................................A-9
Charge-Air Piping ...............................................................................................4-3
Maintenance Check..........................................................................................4-3
Cold Weather Starting ........................................................................................1-4
General Information..........................................................................................1-4
Using Starting Aids...........................................................................................1-5
Coolant Contamination.................................................................................TS-11
Coolant Level ......................................................................................................4-4
Maintenance Check..........................................................................................4-4
Coolant Loss - External................................................................................TS-12
Coolant Recommendations and Specifications ............................................V-13
Cooling System Sealing Additives..................................................................V-14
Cooling System Soluble Oils..........................................................................V-15
Fully Formulated Coolant/Antifreeze..............................................................V-13
Coolant Temperature Above Normal - Gradual Overheat............................TS-13
Coolant Temperature Above Normal - Sudden Overheat............................TS-15
Coolant Temperature Below Normal............................................................TS-17
Coolant Thermostat ...........................................................................................A-9
Clean and Inspect for Reuse..........................................................................A-10
General Information..........................................................................................A-9
Install..............................................................................................................A-12
Measure..........................................................................................................A-11
Remove..........................................................................................................A-10
Cooling Fan Belt Tensioner ...............................................................................6-1
Maintenance Check..........................................................................................6-1
Cooling Fan Belt Tensioner ............................................................................A-12
Maintenance Check........................................................................................A-12
Cooling System ..................................................................................................5-1
Drain.................................................................................................................5-3
Fill.....................................................................................................................5-7
Flush.................................................................................................................5-4
General Information..........................................................................................5-1
Maintenance Check..........................................................................................5-2
Cooling System ..................................................................................................7-2
Drain.................................................................................................................7-3
Fill.....................................................................................................................7-6
Flush.................................................................................................................7-4
General Information..........................................................................................7-2
Cooling System ..................................................................................................V-4
Specifications...................................................................................................V-4
.............................................................................................................................W-7
Crankcase Breather Tube ..................................................................................3-2
Maintenance Check
..........................................................................................3-2
Cummins Customized Parts Catalog ...............................................................L-4
General Information..........................................................................................L-4
Ordering the Customized Parts Catalog...........................................................L-4
Cummins® Service Engine Model Product Identification ............................E-15
General Information........................................................................................E-15
Cummins®/Fleetguard® Filter Specifications .................................................V-8
General Information..........................................................................................V-8
Daily Maintenance Procedures - Overview ......................................................3-1
General Information..........................................................................................3-1
System Operation Report.................................................................................3-1
Unusual System Noise......................................................................................3-1
Distributors - International ..............................................................................S-33
Locations........................................................................................................S-33
Distributors and Branches ................................................................................S-4
Australia..........................................................................................................S-24
Canada...........................................................................................................S-19
China, People's Republic................................................................................S-22
New Zealand..................................................................................................S-28
United States....................................................................................................S-4
Division and Regional Offices ..........................................................................S-3
Locations..........................................................................................................S-3
Drive Belt Tension ...........................................................................................V-16
Tension Chart.................................................................................................V-16
Drive Belt, Cooling Fan ...................................................................................A-14
Clean and Inspect for Reuse..........................................................................A-15
Finishing Steps...............................................................................................A-16
General Information........................................................................................A-14
Install..............................................................................................................A-16
Preparatory Steps...........................................................................................A-14
Remove..........................................................................................................A-14
Drive Belts ...........................................................................................................3-4
Maintenance Check..........................................................................................3-4
Electrical System ...............................................................................................V-7
Batteries (Specific Gravity)...............................................................................V-7
Specifications...................................................................................................V-7
Electromagnetic Interference (EMI) ................................................................1-13
General Information........................................................................................1-13
System EMI Radiation Levels.........................................................................1-13
System EMI Susceptibility...............................................................................1-13
Electronic Controlled Fuel System ...................................................................1-7
Diagnostic Fault Codes...................................................................................1-10
Engine Protection System.................................................................................1-9
Fault Code Snapshot Data..............................................................................1-13
General Information..........................................................................................1-7
Emergency and Technical Service ...................................................................S-1
General Information..........................................................................................S-1
Engine Acceleration or Response Poor.......................................................TS-18
Engine Diagrams ................................................................................................E-4
Engine Views....................................................................................................E-4
Engine Difficult to Start or Will Not Start (Exhaust Smoke)..........................TS-20
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)....................TS-22
Engine Identification ..........................................................................................E-1
Air Compressor.................................................................................................E-3
Cummins® Engine Nomenclature....................................................................E-2
ECM Dataplate.................................................................................................E-3
Engine Dataplate..............................................................................................E-1
Fuel Injection Pump Dataplate.........................................................................E-3
Engine Noise Excessive...............................................................................TS-24
Engine Noise Excessive — Combustion Knocks.........................................TS-26
Engine Operating Range ...................................................................................1-6
General Information..........................................................................................1-6
Engine Power Output Low............................................................................TS-27
Engine Runs Rough at Idle..........................................................................TS-29
Engine Runs Rough or Misfires....................................................................TS-30
Engine Shutdown ...............................................................................................1-7
General Information..........................................................................................1-7
Engine Shuts Off Unexpectedly or Dies During Deceleration......................TS-32
Engine Speed Surges at Low or High Idle...................................................TS-33
Engine Speed Surges in PTO or Cruise Control..........................................TS-36
Engine Speed Surges Under Load or in Operating Range..........................TS-34
Engine Starts But Will Not Keep Running....................................................TS-37
Engine Vibration Excessive..........................................................................TS-38
Engine Will Not Crank or Cranks Slowly (Air Starter)...................................TS-39
Engine Will Not Crank or Cranks Slowly (Electric Starter)...........................TS-41
Engine Will Not Reach Rated Speed (RPM)................................................TS-42
Exhaust System .................................................................................................V-6
Specifications...................................................................................................V-6
Fan Hub, Belt Driven ..........................................................................................6-2
Maintenance Check..........................................................................................6-2
Fan Spacer and Pulley .....................................................................................A-17
Clean and Inspect for Reuse..........................................................................A-18
Finishing Steps...............................................................................................A-19
Install..............................................................................................................A-18
Preparatory Steps...........................................................................................A-17
Remove..........................................................................................................A-17
Fan, Cooling ........................................................................................................4-3