Service Manual User Manual

Cummins Engine
8B-21
18. For priming purposes, pour hydraulic oil into the main
hydraulic pump. Connect the hydraulic system inlet
and outlet hoses at the main hydraulic pump. If
necessary, connect the inlet hose to the hydraulic
reservoir. Refer to
Section 9 Hydraulic System
as
required.
19. Connect the transmission hoses (Fig. 8B–5) to the
radiator.
20. Connect the engine coolant temperature switch lead
(Fig. 8B–17) and oil pressure switch lead (refer to
Section 10 Electrical System
for detailed views of
harness leads).
21. Connect the hydraulic oil pressure and temperature
wiring harness leads (Fig. 8B–11 and Fig. 8B–15).
22. Connect the alternator wire leads (Fig. 8B–14), then
connect the positive (+) battery cable to the starter,
then to the battery. DO NOT connect the negative (-)
lead at this time.
23. Connect the exhaust pipe (Fig. 8B–10) to the exhaust
bellows. Secure with a heavy-duty T-bolt band clamp.
For turbocharged engines, connect the turbocharger
outlet to the exhaust. Secure with a stainless steel V-
band clamp.
24. Secure the air cleaner mount band assembly (Fig.
8B–13) and mount plate to the engine with two 3/8-
16 x 1-1/4 Grade 5 hex-head capscrews and two 3/8"
lockwashers.
25. Install the air cleaner assembly (Fig. 8B–13) in its
entirety. Install the air cleaner hose to the
turbocharger intake port. Secure the air cleaner hose
with a heavy-duty T-bolt clamp.
26. Install the air intake hose (Fig. 8B–13) at the engine
panel. Tighten the SAE Type F clamp to secure the
air intake hose to the engine panel.
27. Attach the upper and lower radiator hoses (Fig. 8B–
4) to the engine water pump (and to the radiator, if
necessary) and secure with hose clamps.
28. Open the radiator cap (Fig. 8B–4) and fill the radiator
with a 50/50 mixture of water and ethylene glycol.
More coolant will need to be added later. Replace
and tighten the radiator cap.
29. Install the hood with the help of at least one assistant
(refer to
Section 4 Cab, Covers and Mirrors
).
30. Connect the positive (+) battery cable at the starter,
then at the battery.
31. Connect the negative (-) battery ground cable lead to
the starter mounting bolt. Connect the negative (-)
battery cable at the starter, and the negative frame
ground cable to the frame stud (Fig. 8B–16).
32. Check that all hydraulic system, electrical system,
cooling system, fuel system, and exhaust system
connections are correctly and tightly connected.
33. From within the cab, lightly depress the throttle pedal
(Fig. 8B–24) to full-throttle position. As needed,
adjust the limit-stop screw until it touches the pedal.
Tighten the locknut to 120 to 125 lb/in (13,6 to 14,1
Nm).
Figure 8B–24. Adjust the throttle limit-stop screw.
34. Have an assistant stand by with a Class B fire
extinguisher. Start and idle the engine.
35. Check for leaks from the engine, main hydraulic
pump and lines, transmission, hydraulic reservoir and
fuel tank. Check the levels of all fluids and lubricants.
Fill as required.
IMPORTANT:
During the full throttle check:
• DO NOT operate any hydraulic function;
• DO NOT steer or apply any pressure to
the steering wheel;
• Keep the transmission in NEUTRAL (N).
36. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle. If
the rpm is not 2600 to 2800 rpm, readjust the throttle
limit-stop screw at the throttle pedal within the cab.
37. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
38. Check for proper operation of all components.
39. Turn the engine OFF.
MA0191
Limit-stop
screw
Locknut
Throttle
pedal
Cab
floor
Model 3606 • Origin 10/99