CUMMINS B4.5 Series, B3.9 Series, B5.9 Series Installation Manual, Operation And Maintenance Manual

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Operation and Maintenance Manual Industrial B3.9, B4.5, and B5.9 Series Engines

Cummins Customer Assistance Center 1-800-DIESELS APPLICABLE ONLY IN U.S.A. AND CANADA

(1-800-343-7357)

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Operation and Maintenance Manual Industrial B3.9, B4.5, and B5.9 Series Engines

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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. If the equipment is traded or sold, give the manual to the new owner.

The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada.

The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.

NOTE: Note: Warranty information is located in Section W. Make sure you are familiar with the warranty or warranties applicable to your engine.

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Table of Contents

Section

Introduction ........................................................................................................................................................ i

Engine and System Identification .................................................................................................................... E

Operating Instructions ...................................................................................................................................... 1

Maintenance Guidelines .................................................................................................................................... 2

Maintenance Procedures at Daily Interval ...................................................................................................... 3

Maintenance Procedures at 250 Hours or 3 Months ...................................................................................... 4

Maintenance Procedures at 500 Hours or 6 Months ...................................................................................... 5

Maintenance Procedures at 1000 Hours or 1 Year ......................................................................................... 6

Maintenance Procedures at 2000 Hours or 2 Years ....................................................................................... 7

Adjustment, Repair, and Replacement ............................................................................................................ A

System Diagrams .............................................................................................................................................. D

Service Literature .............................................................................................................................................. L

Service Assistance ............................................................................................................................................ S

Troubleshooting Symptoms ............................................................................................................................. TS

Maintenance Specifications .............................................................................................................................. V

Warranty ............................................................................................................................................................. W

Back .................................................................................................................................................................... back

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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.

Name Number Number

Engine Model

Engine Serial Number (ESN)

Control Parts List (CPL)

Fuel Pump Part Number

Electronic Control Module (ECM)

Electronic Control Module Serial Numbers (ECM)

Filter Part Numbers:

• Air Cleaner Element

• Lubricating Oil

• Fuel

• Fuel-Water Separator

• Coolant

• Crankcase Ventilation

• Cummins Particulate Filter

Governor Control Module (GCM) (if applicable)

Belt Part Numbers:

•

Clutch or Marine Gear (if applicable):

• Model

• Serial Number

• Part Number

• Oil Type

• Sea Water Pump

- Model

- Part Number

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B3.9, B4.5, B5.9 Industrial Section i - Introduction Page i-a

Section i - Introduction

Section Contents

Page

About the Manual .........................................................................................................................................................i-2

General Information.....................................................................................................................................................i-2

Acronyms and Abbreviations ...................................................................................................................................i-15

General Information...................................................................................................................................................i-15

General Cleaning Instructions ..................................................................................................................................i-10

Abrasive Pads and Abrasive Paper...........................................................................................................................i-10

Definition of Clean......................................................................................................................................................i-10

Fuel System...............................................................................................................................................................i-13

Gasket Surfaces........................................................................................................................................................ i-11

Plastic Bead Cleaning................................................................................................................................................i-12

Solvent and Acid Cleaning.........................................................................................................................................i-11

Steam Cleaning......................................................................................................................................................... i-12

General Repair Instructions ........................................................................................................................................i-8

General Information.....................................................................................................................................................i-8

Welding on a Vehicle with an Electronic Controlled Fuel System................................................................................i-9

General Safety Instructions ........................................................................................................................................i-6

Important Safety Notice...............................................................................................................................................i-6

How to Use the Manual ................................................................................................................................................i-3

General Information.....................................................................................................................................................i-3

Illustrations ...................................................................................................................................................................i-5

General Information.....................................................................................................................................................i-5

Symbols ........................................................................................................................................................................i-4

General Information.....................................................................................................................................................i-4

To the Owner and Operator .........................................................................................................................................i-1

General Information.....................................................................................................................................................i-1

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B3.9, B4.5, B5.9 Industrial

Page i-b Section i - Introduction

This Page Left Intentionally Blank

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B3.9, B4.5, B5.9 Industrial To the Owner and Operator Section i - Introduction 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). Blending engine oil with fuel is prohibited for engines with an aftertreatment system.

Cummins Inc. uses the latest technology and the highest quality components to produce its engines. Cummins Inc. recommends using genuine Cummins new parts and ReCon® exchange parts.

Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. If you have a problem that can not be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the Service Assistance (Section S).

Product coverage, warranty limitations and owner responsibilities are available in Warranty (Section W).

CAUTION Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine mounted components is not recommended.

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About the Manual B3.9, B4.5, B5.9 Industrial Page i-2 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.

Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets.

Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to Symbols in this section for a complete listing of symbols and their definitions.

Each section of the manual is preceded by a Section Contents to aid in locating information.

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B3.9, B4.5, B5.9 Industrial How to Use the Manual Section i - Introduction 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.

Keep a record of all the checks and inspections made. A maintenance record form is located in Maintenance Guidelines (Section 2).

Engine troubleshooting procedures for your engine are located in Troubleshooting Symptoms (Section TS).

Specifications for your engine are located in Maintenance Specifications (Section V).

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Symbols B3.9, B4.5, B5.9 Industrial Page i-4 Section i - Introduction

Symbols

General Information

The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below:

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B3.9, B4.5, B5.9 Industrial Illustrations Section i - Introduction Page i-5

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.

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General Safety Instructions B3.9, B4.5, B5.9 Industrial Page i-6 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. Special safety precautions are included in the procedures when they apply.

• Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition

sources and hazardous substances. Be aware of hazardous conditions that can exist.

• Always wear protective glasses and protective shoes when working.

• Rotating parts can cause cuts, mutilation or strangulation.

• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.

• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.

Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's compartment or on the controls.

• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the

crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure.

• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler

cap to relieve the pressure from the cooling system.

• Always use blocks or proper stands to support the product before performing any service work. Do not work on

anything that is supported ONLY by lifting jacks or a hoist.

• Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed

or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid

refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant.

• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg

[50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded.

• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes.

Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the

manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.

• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas

flow, and hot fluids in lines, tubes, and compartments.

• Always use tools that are in good condition. Make sure you understand how to use the tools before performing any

service work. Use ONLY genuine Cummins® or Cummins ReCon® replacement parts.

• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of

lesser quality if replacements are necessary.

• When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts

should only be carried out be a trained technician. Before removing any guards the engine must be turned off and any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.

• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

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B3.9, B4.5, B5.9 Industrial General Safety Instructions Section i - Introduction 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.

• Always torque fasteners and fuel connections to the required specifications. Overtightening or undertightening can allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.

• Always test for fuel leaks as instructed, as odorant can fade.

• Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.

• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

• The catalyst reagent contains urea. Do not get the substance in your eyes. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent is ingested, contact a physician immediately.

• The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly. Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water.

• The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local regulations.

• 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.

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General Repair Instructions B3.9, B4.5, B5.9 Industrial Page i-8 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. In particular, unauthorized repair to safety-related components can cause personal injury or death. Below is a partial listing of components classified as safety-related:

1 Air Compressor

2 Air Controls

3 Air Shutoff Assemblies

4 Balance Weights

5 Cooling Fan

6 Fan Hub Assembly

7 Fan Mounting Bracket(s)

8 Fan Mounting Capscrews

9 Fan Hub Spindle

10 Flywheel

11 Flywheel Crankshaft Adapter

12 Flywheel Mounting Capscrews

13 Fuel Shutoff Assemblies

14 Fuel Supply Tubes

15 Lifting Brackets

16 Throttle Controls

17 Turbocharger Compressor Casing

18 Turbocharger Oil Drain Line(s)

19 Turbocharger Oil Supply Line(s)

20 Turbocharger Turbine Casing

21 Vibration Damper Mounting Capscrews

22 Manual Service Disconnect

23 High Voltage Interlock Loop

24 High Voltage Connectors/Connections and Harnesses

25 High Voltage Battery System

26 Power Inverter

27 Generator Motor

28 Clutch Pressure Plate

• Follow all safety instructions noted in the procedures

• Follow the manufacturer's recommendations for cleaning solvents and other substances used during repairs. Some

solvents have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety practices with tools and equipment

• Provide a clean environment and follow the cleaning instructions specified in the procedures

• The engine or system and its components must be kept clean during any repair. Contamination of the engine,

system or components will cause premature wear.

• All components must be kept clean during any repair. Contamination of the components will cause premature

wear.

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B3.9, B4.5, B5.9 Industrial General Repair Instructions Section i - Introduction 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. When it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or Cummins ReCon® components. All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations.

• Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components

Complete rebuild instructions are available in the service manual which can be ordered or purchased from a Cummins Authorized Repair Location. Refer to Section L — Service Literature for ordering instructions.

Welding on a Vehicle with an Electronic Controlled Fuel System

CAUTION Disconnect both the positive (+) and negative (-) battery cables from the low voltage battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground clamp of the welder to any of the sensors, wiring harness, electronic control units or the components. Direct welding of any electronic components must not be attempted. Sensors, wiring harness, and electronic control unit should be removed if nearby welding will expose these components to temperatures beyond normal operation. Additionally, all electronic control unit connectors must be disconnected

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General Cleaning Instructions B3.9, B4.5, B5.9 Industrial Page i-10 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. Gaskets are designed to fill small voids in the specified surface finish.

Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the parts are better removed with a blunt-edged scraper on the spots rather than spending time polishing the whole surface with an air sander or disc.

For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to prevent sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in place a long time, has been overheated or the purpose of the release agent has been defeated by the application of some sealant. The object however is just to remove the gasket without damaging the surfaces of the mating parts without contaminating the engine (don't let the little bits fall where they can not be removed).

Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon build-up above the top ring and in the ring grooves. There is more information on bead blasting and piston cleaning later in this document.

Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out) will be destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and there will be less damage. Yes, one must look carefully for broken wires after the piston is removed but the wires are more visible and can be attracted by a magnet.

Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible, leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before installation. Make sure parts are lubricated with clean oil before installation. They do not need to be oiled all over but do need oil between moving parts (or a good lube system priming process conducted before cranking the engine).

Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again so all that needs happen is remove any loose paint.

Abrasive Pads and Abrasive Paper

The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are all supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.

WARNING Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material in oil passages can cause bearing and bushing failures that can progress to major component damage beyond reuse. This is particularly true of main and rod bearings.

Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or counterbores.

Great care must be taken when using abrasive products to clean engine parts, particularly on partially assembled engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles, silicon carbide, or sand or some other similar hard material. These particles are harder than most of the parts in the engine. Since they are harder, if they are pressed against softer material they will either damage the material or become embedded in it. These materials fall off the holding media as the product is used. If the products are used with power equipment the particles are thrown about the engine. If the particles fall between two moving parts, damage to the moving parts is likely.

If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger than the running clearance then damage will occur when the parts move relative to each other (engine started). While the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass between the parts without damage and be trapped in the oil filter. However, particles larger than the bearing clearance will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will

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B3.9, B4.5, B5.9 Industrial General Cleaning Instructions Section i - Introduction 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. This is particularly true of lubricating oil ports and oil drilling holes, especially those located downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles and debris with compressed air because the debris is often simply blown further into the oil drilling.

All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel). What little sealing material that can adhere is best removed with a blunt-edged scraper or putty knife. Cleaning gasket surfaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time.

WARNING Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which can cause early cylinder wear-out or piston ring failures.

Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really necessary because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and clean as much of the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination of the drilling. Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use compressed air to blow the debris out of oil drilling on an assembled engine! More likely than not, the debris can be blown further into the drilling. Using compressed air is fine if both ends of the drilling are open but that is rarely the case when dealing with an assembled engine.

Gasket Surfaces

The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.

Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used, check the directions to make sure the material being cleaned will not be harmed.

Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part of the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air powered gasket scrapers on parts made of soft materials takes skill and care to prevent damage.

Do not scrape or brush across the gasket surface if at all possible.

Solvent and Acid Cleaning

Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90° to 95° Celsius (180° to 200° Fahrenheit). Kerosene emulsion based cleaners have different temperature specifications, see below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions. Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank.

WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners should not be heated to temperature in excess of 77°C (170°F). The solution begins to break down at temperatures in excess of 82°C (180°F) and will be less effective.

Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components. They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly.

Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline solutions.

Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away from the neutral 7.0, the chemicals become highly alkaline or highly acidic.

Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high

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General Cleaning Instructions B3.9, B4.5, B5.9 Industrial Page i-12 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.

If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust proofing compound must be removed from the parts before assembly or installation on the engine.

Steam Cleaning

Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method for cleaning the oil drillings and coolant passages

WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

Do not steam clean the following components:

• Electrical Components

• Wiring Harnesses

• Belts and Hoses

• Bearings (ball or taper roller)

• Electronic Control Module (ECM)

• ECM Connectors

• Capacitive Coil Driver Module (CCD)

• Ignition Coils and Leads

• NOx Sensor

• Fuel Control Valve

• Throttle Driver and Actuator.

Plastic Bead Cleaning

Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part. Cummins Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the media manufacturer's recommendations can cause excess dust and can embed in engine parts that can result in premature failure of components through abrasive wear.

Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is controlled by the use of plastic beads, the operating pressure and cleaning time.

CAUTION Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.

CAUTION Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads. Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear.

Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any bead blasting media on piston pin bores or aluminum skirts.

Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part and cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to manufacturer's instructions:

1 Bead size: U.S. size Number 16 — 20 for piston cleaning with plastic bead media, Part Number 3822735

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B3.9, B4.5, B5.9 Industrial General Cleaning Instructions Section i - Introduction 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. If the metal surface is disturbed the engine can be damaged due to increased parts clearance or inadequate surface finish on parts that move against other parts.

When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure is too high or the blast is being held on one spot too long. The blast operation must not disturb the metal surface.

Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is increased above media manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to clean engine parts due to the risk media embedment and subsequent contamination of the engine.

Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats easily in the air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water) is used to blow the media after it is removed from the blasting cabinet (blowing the part off inside the cabinet may remove large accumulations but never removes all the media).

Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher pressure washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the pistons first then use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of damaging the surface finish of the groove with a wire wheel or end of a broken piston ring. Make sure the parts are dry and oil free before bead blasting to prevent clogging the return on the blasting machine.

Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under the unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at one-place too long causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or carbon. If the machining marks on the piston groove or rim have been disturbed then there has not been enough movement of the nozzle and/or the air pressure is too high.

Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across the seat surface and radius rather than straight at them. The object is to remove any carbon build up and continuing to blast to remove the stain is a waste of time.

Fuel System

When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas are not cleaned, dirt or contaminants can be introduced into the fuel system.

The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. Some fuel injection systems can operate at very high pressures. High pressure fuel can convert simple particles of dirt and rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors.

Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather than compressed air, to wash dirt and debris away from fuel system fittings. Diesel fuel on exposed fuel system parts attracts airborne contaminants.

Choose lint free towels for fuel system work.

Cap and plug fuel lines, fittings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the fuel system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.

When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/chips that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are removed.

Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter. The micron rating is the size of the smallest particles that will be captured by the filter media. As a reference, a human hair

Page 21

General Cleaning Instructions B3.9, B4.5, B5.9 Industrial Page i-14 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. Remember the following points regarding your fuel system tools:

• Fuel system tools are to be kept as clean as possible.

• Clean and dry the tools before returning them to the tool box.

• If possible, store fuel system tools in sealed containers.

• Make sure fuel system tools are clean before use.

Page 22

B3.9, B4.5, B5.9 Industrial Acronyms and Abbreviations Section i - Introduction Page i-15

Acronyms and Abbreviations

General Information

The following list contains some of the acronyms and abbreviations used in this manual.

ANSI American National Standards Institute

API American Petroleum Institute ASTM American Society of Testing and Materials ATDC After Top Dead Center

BTU British Thermal Unit

BTDC Before Top Dead Center

°C Celsius

CAN Controller Area Network

CO Carbon Monoxide

CCA Cold Cranking Amperes

CARB California Air Resources Board

C.I.B. Customer Interface Box C.I.D. Cubic Inch Displacement

CNG Compressed Natural Gas

CPL Control Parts List

cSt Centistokes

DEF Diesel Exhaust Fluid

DOC Diesel Oxidation Catalyst

DPF Diesel Particulate Filter

ECM Engine Control Module

EFC Electronic Fuel Control

EGR Exhaust Gas Recirculation

EPA Environmental Protection Agency

°F Fahrenheit

ft-lb Foot-Pound Force

FMI Failure Mode Indentifier

GVW Gross Vehicle Weight

Hg Mercury hp Horsepower

H2O Water

inHg Inches of Mercury

in H20 Inches of Water

ICM Ignition Control Module

IEC International Electrotechnical Commission

km/l Kilometers per Liter

kPa Kilopascal

LNG Liquid Natural Gas

LPG Liquified Petroleum Gas LTA Low Temperature Aftercooling

MCRS Modular Common Rail System

MIL Malfunction Indicator Lamp

MPa Megapascal mph Miles Per Hour mpq Miles Per Quart

N•m Newton-meter

Page 23

Acronyms and Abbreviations B3.9, B4.5, B5.9 Industrial Page i-16 Section i - Introduction

NOx Mono-Nitrogen Oxides

NG Natural Gas

O2 Oxygen

OBD On-Board Diagnostics

OEM Original Equipment Manufacturer

OSHA Occupational Safety and Health Administration

PID Parameter Identification Descriptions

ppm Parts Per Million

psi Pounds Per Square Inch

PTO Power Takeoff

REPTO Rear Power Take Off

RGT Rear Gear Train

rpm Revolutions Per Minute

SAE Society of Automotive Engineers SCA Supplemental Coolant Additive SCR Selective Catalytic Reduction

STC Step Timing Control

SID Subsystem Identification Descriptions

TDC Top Dead Center VDC Volts of Direct Current

VGT Variable Geometry Turbocharger

VS Variable Speed

VSS Vehicle Speed Sensor

Page 24

B3.9, B4.5, B5.9 Industrial 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-25

General Information..................................................................................................................................................E-25

Engine Diagrams ........................................................................................................................................................E-4

Engine Views..............................................................................................................................................................E-4

Engine Identification ..................................................................................................................................................E-1

Cummins® Engine Nomenclature..............................................................................................................................E-2

Engine Dataplate........................................................................................................................................................E-1

B3.9, B5.9, and B4.5 Engines.................................................................................................................................E-1

B4.5 RGT Engines..................................................................................................................................................E-1

Fuel Injection Pump Dataplate...................................................................................................................................E-3

Bosch® Rotary........................................................................................................................................................E-3

Delphi Rotary...........................................................................................................................................................E-3

Page 25

B3.9, B4.5, B5.9 Industrial

Page E-b Section E - Engine and System Identification

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Page 26

B3.9, B4.5, B5.9 Industrial Engine Identification Section E - Engine and System Identification Page E-1

Engine Identification

Engine Dataplate

B3.9, B5.9, and B4.5 Engines

The engine dataplate shows specific facts about your engine. The engine serial number and Control Parts List provide information for ordering parts and for service. The engine dataplate must not be changed unless approved by Cummins Inc.

B4.5 RGT Engines

Have the following engine data available when communicating with a Cummins Authorized Repair Location. The information on the dataplate is mandatory when sourcing service parts.

1. Control parts list (CPL)

2. Model

3. Engine serial number

4. Emissions certification

5. Horsepower and rpm rating.

Page 27

Engine Identification B3.9, B4.5, B5.9 Industrial Page E-2 Section E - Engine and System Identification

NOTE: If the engine dataplate (1) is not readable, the

engine serial number (2) can be identified on the engine block above the oil cooler.

Cummins® Engine Nomenclature

B5.9

The model name provides the following engine data:

B = Engine series

5.9 = Displacement in liters.

B3.9

The model name provides the following engine data:

B = Engine series

3.9 = Displacement in liters.

The Cummins engine nomenclature provides the data as illustrated in the graphic.

Page 28

B3.9, B4.5, B5.9 Industrial Engine Identification Section E - Engine and System Identification Page E-3

The model name for engines in industrial applications provides the data shown below For example:

4BTAA-3.9

4 = Number of cylinders B = Engine series T = Turbocharged AA = Charge air cooled

3.9 = Displacement in liters.

NOTE: The suffix RGT refers to “Rear Gear Train” engines.

Fuel Injection Pump Dataplate

Bosch® Rotary

The injection pump dataplate for the Bosch® VE pump is located on the side of the injection pump. The dataplate provides information for fuel pump calibration.

Delphi Rotary

The injection pump dataplate for the Delphi DP pump is located on the side of the injection pump. The dataplate provides information for fuel pump calibration.

Page 29

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-4 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.

Page 30

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-5

Engine Views

Engine Diagrams

1. Turbocharger air outlet

2. Lubricating oil fill

3. Engine air inlet

4. Fuel pump drive cover

5. Front gear cover

6. Accessory drive cover (optional)

7. Fan drive belt

8. Front Pulley

9. Water pump

10. Automatic belt tensioner

11. Water inlet

12. Alternator

13. Fan pulley

14. Turbocharger air inlet.

Front View - B3.9 Industrial

Page 31

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-6 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Engine air inlet

2. Fuel filter/water separator

3. Fuel inlet connection

4. Magnetic pickup location (3/4-16 UNF)

5. Fuel lift pump

6. Crankcase breather tube

7. Lubricating oil dipstick

8. Fuel drain connection

9. Front engine mounting bracket

10. Engine dataplate

11. High pressure fuel lines

12. Fuel injection pump

13. Intake air preheater (optional).

Left Side View - B3.9 Industrial

Page 32

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-7

Engine Views

Engine Diagrams

1. Rear engine lifting bracket

2. Turbocharger exhaust outlet

3. Flexplate mounting holes

4. Flywheel housing

5. Flywheel/flexplate.

Rear View - B3.9 Industrial

Page 33

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-8 Section E - Engine and System Identification

Engine Views

Engine Diagrams

Right Side View - B3.9 Industrial

1. Fuel injection nozzles

2. Turbocharger wastegate actuator

3. Lubricating oil fill

4. Front engine lifting bracket

5. Water outlet

6. Lubricating oil filter

7. Water inlet

8. Lubricating oil cooler

9. Lubricating oil drain

10. Provision for lubricating oil immersion heater

11. Starter motor and solenoid

12. Provision for coolant heater.

Page 34

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-9

Engine Views

Engine Diagrams

1. Water outlet

2. Turbocharger

3. Exhaust manifold

4. Magnetic pickup location (3/4-16 UNF)

5. Engine air inlet.

Top View - B3.9 Industrial

Page 35

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-10 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Turbocharger air outlet

2. Lubricating oil fill

3. Engine air inlet

4. Fuel pump drive cover

5. Front gear cover

6. Accessory drive cover (optional)

7. Fan drive belt

8. Front Pulley

9. Water pump

10. Automatic belt tensioner

11. Water inlet

12. Alternator

13. Fan pulley

14. Turbocharger air inlet.

Front View - B4.5 Industrial

Page 36

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-11

Engine Views

Engine Diagrams

1. Engine air inlet

2. Fuel filter/water separator

3. Fuel inlet connection

4. Magnetic pickup location (3/4-16 UNF)

5. Fuel lift pump

6. Crankcase breather tube

7. Lubricating oil dipstick

8. Fuel drain connection

9. Front engine mounting bracket

10. Engine dataplate

11. High pressure fuel lines

12. Fuel injection pump

13. Intake air preheater (optional).

Left Side View - B4.5 Industrial

Page 37

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-12 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Rear engine lifting bracket

2. Turbocharger exhaust outlet

3. Flexplate mounting holes

4. Flywheel housing

5. Flywheel/flexplate.

Rear View - B4.5 Industrial

Page 38

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-13

Engine Views

Engine Diagrams

Right Side View - B4.5 Industrial

1. Fuel injection nozzles

2. Turbocharger wastegate actuator

3. Lubricating oil fill

4. Front engine lifting bracket

5. Water outlet

6. Lubricating oil filter

7. Water inlet

8. Lubricating oil cooler

9. Lubricating oil drain

10. Provision for lubricating oil immersion heater

11. Starter motor and solenoid

12. Provision for coolant heater.

Page 39

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-14 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Water outlet

2. Turbocharger

3. Exhaust manifold

4. Magnetic pickup location (3/4-16 UNF)

5. Engine air inlet.

Top View - B4.5 Industrial

Page 40

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-15

Engine Views

Engine Diagrams

1. Engine air inlet

2. Lubricating oil dipstick

3. Fan drive belt

4. Front pulley

5. Water pump

6. Automatic belt tensioner

7. Alternator

8. Fan pulley

9. Lubricating oil fill.

Front View - B4.5 RGT

Page 41

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-16 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Lubricating oil dipstick

2. High pressure fuel lines

3. Rear engine mounting bracket

4. Fuel return line and fuel drain connection

5. Inlet fuel filter

6. Crankcase breather tube

7. Fuel injection pump

8. Engine dataplate

9. Provision for lubricating oil immersion heater

10. Fuel lift pump

11. Magnetic pickup location (3/4-16 UNF)

12. Fuel filter/water separator

13. Intake air preheater (optional)

14. Engine air inlet.

Left Side View - B4.5 RGT

Page 42

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-17

Engine Views

Engine Diagrams

1. Rear engine lifting bracket

2. Fuel return and fuel drain connection

3. Inline fuel filter

4. Fuel Inlet connection

5. Exhaust outlet

6. Flexplate mounting holes

7. Flywheel/flexplate

8. Flywheel housing

9. Rear gear train housing

10. Crankcase breather tube.

Rear View - B4.5 RGT

Page 43

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-18 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Lubricating oil fill

2. Front engine lifting bracket

3. Water outlet

4. Lubricating oil filter

5. Water inlet

6. Lubricating oil cooler

7. Lubricating oil drain

8. Starter motor and solenoid

9. Provision for coolant heater.

Right Side View - B4.5 RGT

Page 44

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-19

Engine Views

Engine Diagrams

1. Exhaust manifold

2. Engine air inlet

3. Magnetic pickup location (3/4-16 UNF).

4. Water outlet

Top View - B4.5 RGT

Page 45

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-20 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Turbocharger air outlet

2. Lubricating oil fill

3. Engine air inlet

4. Fuel pump drive cover

5. Front gear cover

6. Accessory drive cover (optional)

7. Fan drive belt

8. Vibration damper

9. Water pump

10. Automatic belt tensioner

11. Water inlet

12. Alternator

13. Fan pulley

14. Turbocharger air inlet.

Front View - B5.9 Industrial

Page 46

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-21

Engine Views

Engine Diagrams

1. Engine air inlet

2. Fuel filter/water separator

3. Fuel inlet connection

4. Magnetic pickup location (3/4-16 UNF)

5. Fuel lift pump

6. Crankcase breather tube

7. Lubricating oil dipstick

8. Fuel drain connection

9. Front engine mounting bracket

10. Engine dataplate

11. High pressure fuel lines

12. Fuel injection pump

13. Intake air preheater (optional).

Left Side View - B5.9 Industrial

Page 47

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-22 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Rear engine lifting bracket

2. Turbocharger exhaust outlet

3. Flexplate mounting holes

4. Flywheel housing

5. Flywheel/flexplate.

Rear View - B5.9 Industrial

Page 48

B3.9, B4.5, B5.9 Industrial Engine Diagrams Section E - Engine and System Identification Page E-23

Engine Views

Engine Diagrams

Right Side View - B5.9 Industrial

1. Fuel injection nozzles

2. Turbocharger wastegate actuator

3. Lubricating oil fill

4. Front engine lifting bracket

5. Water outlet

6. Lubricating oil filter

7. Water inlet

8. Lubricating oil cooler

9. Provision for coolant heater

10. Lubricating oil drain

11. Provision for lubricating oil immersion heater

12. Starter motor and solenoid.

Page 49

Engine Diagrams B3.9, B4.5, B5.9 Industrial Page E-24 Section E - Engine and System Identification

Engine Views

Engine Diagrams

1. Water outlet

2. Turbocharger

3. Exhaust manifold

4. Magnetic pickup location (3/4-16 UNF)

5. Engine air inlet.

Top View - B5.9 Industrial

Page 50

B3.9, B4.5, B5.9 Industrial Cummins® Service Engine Model Product Identification Section E - Engine and System Identification Page E-25

Cummins® Service Engine Model Product Identification

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.

Electronic engines are identified by the first two letters, either an "IS" for On-Highway automotive or "QS" for OffHighway industrial market applications.

The third letter is the engine platform designation followed by the engine liter size.

If the engine operates on a fuel type other than diesel, the type will be identified after the liter size.

Page 51

Cummins® Service Engine Model Product Identification B3.9, B4.5, B5.9 Industrial Page E-26 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.)

Example:

1 On-Highway automotive "X" 15 liter engine

2 Control system number 871

3 Technology supported; Electric EGR and Diesel

Particulate Filter

Page 52

B3.9, B4.5, B5.9 Industrial Cummins® Service Engine Model Product Identification Section E - Engine and System Identification Page E-27

Technology Name Suffix

Exhaust Gas Recirculation Not used None

Pneumatic P

Electric E

Diesel Particulate Filter (DPF) Not used None

Full Flow DPF F

Partial Flow DPF F2

Diesel Oxidation Catalyst Not used None

DOC C

3-Way Oxidation Catalytic Converter Not used None

3-Way Catalyst J

Selective Catalytic Reduction System Not used None

Air Driven S

Airless A

Nox Sensor Not used None

Nox Sensor N

Modular Common Rail System Used only on QSK19, 38, 50 , 60

MCRS

HHP Engines

Integrated Dosing Control Unit Not Used None

Integrated I

Page 53

Cummins® Service Engine Model Product Identification B3.9, B4.5, B5.9 Industrial Page E-28 Section E - Engine and System Identification

Notes

Page 54

B3.9, B4.5, B5.9 Industrial Section 1 - Operating Instructions Page 1-a

Section 1 - Operating Instructions

Section Contents

Page

Cold Weather Starting ................................................................................................................................................1-5

Ether Starting Aids......................................................................................................................................................1-6

Industrial Applications..............................................................................................................................................1-6

Grid Heater.................................................................................................................................................................1-5

Industrial Applications..............................................................................................................................................1-5

With Flame Start System............................................................................................................................................1-5

Electromagnetic Interference (EMI) ..........................................................................................................................1-9

General Information....................................................................................................................................................1-9

System EMI Radiation Levels.....................................................................................................................................1-9

System EMI Susceptibility..........................................................................................................................................1-9

Engine Operating Range ............................................................................................................................................1-8

General Information....................................................................................................................................................1-8

Engine Shutdown ........................................................................................................................................................1-9

General Information....................................................................................................................................................1-9

Normal Starting Procedure ........................................................................................................................................1-2

General Information....................................................................................................................................................1-2

Jump Starting..............................................................................................................................................................1-4

Operating Instructions - Overview ............................................................................................................................1-1

General Information....................................................................................................................................................1-1

Operating the Engine ..................................................................................................................................................1-7

Normal........................................................................................................................................................................1-7

Winterfronts and Shutters...........................................................................................................................................1-8

Starting Procedure After Extended Shutdown or Oil Change ................................................................................1-7

General Information....................................................................................................................................................1-7

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Page 56

B3.9, B4.5, B5.9 Industrial Operating Instructions - Overview Section 1 - Operating Instructions 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 listed in Maintenance Guidelines (Section 2).

The new Cummins® engine associated with this manual does not require a "break-in" procedure. This section of the manual provides all of the necessary information required for proper engine operation.

U.S. legislation requires that stationary compression ignition internal combustion engines designated for emergency use are limited to emergency operations and required maintenance and testing.

Check the oil pressure indicators, temperature indicators, warning lights, and other gauges daily to make sure they are operational.

Check the oil pressure, coolant temperatures DEF level, and other engine parameters daily via the OEM front panel to make sure they are operational. Check the panel regularly for any alarm messages. Take appropriate action to rectify the alarm condition or contact your nearest Authorized Cummins® Distributor.

Page 57

Normal Starting Procedure B3.9, B4.5, B5.9 Industrial Page 1-2 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. Numerous safety devices are available, such as air intake shutoff devices, to minimize the risk of over speeding where an engine, due to its application, is operating in a combustible environment, such as due to a fuel spill or gas leak. Remember, Cummins Inc. has no way of knowing the use you have for your engine. The equipment owner and operator ARE responsible for safe operation in a hostile environment. Consult A Cummins® Authorized Repair Location for further information.

CAUTION Do not expose the engine to corrosive chemicals. Corrosive chemicals can damage the engine.

Cummins recommends the installation of an air intake shutoff device or a similar safety device to minimize the risk of overspeeding when an engine is operating in a combustible environment, such as due to a fuel spill or gas leak.

Normal Starting Procedure

General Information

WARNING Do not depress the accelerator pedal or move the accelerator lever from the idle position while cranking the engine. This can result in engine overspeed and severe damage to the engine.

CAUTION To prevent damage to the starting motor, do not engage the starting motor for more than 30 seconds. Wait 2 minutes between each attempt to start (electrical starting motors only).

NOTE: Engines equipped with air starting motors require

a minimum of 480 kPa [70 psi].

• Disengage the driven unit, or if equipped, put the

transmission in neutral.

• With the accelerator pedal or lever in the idle position,

turn the key switch to the ON position, and wait for the WAIT-TO-START lamp to go out; then, turn the key to the START position.

• If the engine does not start after three attempts, check

the fuel supply system. Absence of blue or white exhaust smoke during cranking indicates no fuel is being delivered.

Page 58

B3.9, B4.5, B5.9 Industrial Normal Starting Procedure Section 1 - Operating Instructions Page 1-3

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.

After starting a cold engine, increase the engine speed (rpm) slowly to provide adequate lubrication to the bearings and to allow the oil pressure to stabilize.

CAUTION Do not operate engine at low idle for long periods with engine coolant temperature below the minimum specification in Maintenance Specifications (Section V). This can result in the following:

• Fuel Dilution of the lubricating oil

• Carbon build up in the cylinder

• Cylinder head valve sticking

• Reduced performance.

Page 59

Normal Starting Procedure B3.9, B4.5, B5.9 Industrial Page 1-4 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 (-). When using an external electrical source to start the engine, turn the disconnect switch to the OFF position. Remove the key before attaching the jumper cables.

CAUTION To avoid damage to engine parts, do not connect jumper starting or battery charging cable to any fuel system or electronic component.

This illustration shows a typical parallel battery connection. This arrangement doubles the cranking amperage.

NOTE: Always reference the relevant OEM literature for jump starting procedures. Failure to follow correct procedures can result in damage to the ECM and other electrical equipment.

This illustration shows a typical series battery connection. This arrangement, positive (+) to negative (-), doubles the voltage.

NOTE: Always reference the relevant OEM literature for jump starting procedures. Failure to follow correct procedures can result in damage to the ECM and other electrical equipment.

Page 60

B3.9, B4.5, B5.9 Industrial Cold Weather Starting Section 1 - Operating Instructions Page 1-5

Cold Weather Starting

With Flame Start System

WARNING Do not use starting fluids with this engine. This engine is equipped with a flame start system; use of starting fluid can cause an explosion, fire, personal injury, severe damage to the engine and property damage.

The only recommended cold weather starting aids for industrial applications with grid a flame start system, are engine coolant preheaters and oil pan immersion heaters. Contact a Cummins® Authorized Repair Location for more information

Cold weather starting aids are available for your engine. Contact a Cummins® Authorized Repair Location for more information.

In cold weather, the WAIT-TO-START lamp will stay on longer.

If ambient temperature is below 16° C [60° F], fully depress the throttle after engaging the stater. Full throttle on the VE pump makes sure there is sufficient start fuel delivery and helps keep the engine operating once started. The in-line pumps with RQV and RQV-K governors require full throttle position and hold the rack in the start fuel position. The throttle must be depressed after engaging the starter to allow the shutoff lever to move to the run position before moving the throttle.

Grid Heater

Industrial Applications

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.

The only recommended cold weather starting aids for marine or industrial applications with grid a heater or air intake heater, are engine coolant preheaters and oil pan immersion heaters. Contact a Cummins® Authorized Repair Location for more information

Cold weather starting aids are available for your engine. Contact a Cummins® Authorized Repair Location for more information.

Page 61

Cold Weather Starting B3.9, B4.5, B5.9 Industrial Page 1-6 Section 1 - Operating Instructions

In cold weather, the WAIT-TO-START lamp will stay on longer.

Ether Starting Aids

Industrial Applications

WARNING Because of the potential for an explosion, do not use volatile cold starting aids in underground mine or tunnel operations. Ask the local U.S. Bureau of Mines inspector for instructions.

WARNING Starting fluid is highly flammable and explosive. Keep flames, sparks, and arcing switches away from starting fluid.

WARNING To reduce the possibility of personal injury, avoid inhalation of starting fluid vapors.

CAUTION Do not use excessive amounts of starting fluid when starting an engine. The use of too much starting fluid will cause damage to the engine.

Spray starting fluid into the air cleaner intake while another person cranks the engine.

Page 62

B3.9, B4.5, B5.9 Industrial Operating the Engine Section 1 - Operating Instructions Page 1-7

Starting Procedure After Extended Shutdown or Oil Change

General Information

Complete the following steps after each oil change, or after the engine has been shut down for more than 30 days to make sure the engine receives the correct oil flow through the lubricating oil system.

1. Disconnect the electrical wire from the fuel pump solenoid.

2. Rotate the crankshaft, using the starting motor, until oil pressure appears on the gauge or the warning lamp goes out.

3. Connect the electrical wire to the fuel pump solenoid valve.

4. Start the engine. Refer to 101-014 (Normal Starting Procedure).

Operating the Engine

Normal

If equipped, monitor the oil pressure and coolant temperature gauges frequently. Refer to Lubricating Oil System specifications and Cooling System specifications, in Maintenance Specifications (Section V) for recommended operating pressures and temperatures. Shut off the engine if any pressure or temperature does not meet the specifications.

Continuous operation with engine coolant temperature above or below the engine coolant temperature specifications listed in Maintenance Specifications (Section V) can damage the engine.

If an overheating condition starts to occur, reduce the power output of the engine by releasing the accelerator pedal or lever or shifting the transmission to a lower gear, or both, until the temperature returns to the normal operating range. If the engine temperature does not return to normal, shut off the engine, and refer to Troubleshooting Symptoms (Section TS), or contact a Cummins® Authorized Repair Location.

Page 63

Engine Operating Range B3.9, B4.5, B5.9 Industrial Page 1-8 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).

Engine Operating Range

General Information

CAUTION Do not operate the engine at full throttle below peak torque rpm (refer to engine dataplate for peak torque rpm) for more than 30 seconds. Operating the engine at full throttle below peak torque will shorten engine life to overhaul, can cause serious engine damage, and is considered engine abuse.

Cummins® engines are designed to operate successfully at full throttle under transient conditions down to peak torque engine speed. This is consistent with recommended operating practices.

CAUTION Do not operate the engine beyond the maximum engine speed. Operating the engine beyond the maximum engine speed can cause severe engine damage. Use proper operating techniques for the vehicle, vessel, or equipment to prevent engine overspeed. The maximum engine speed specification is listed in Maintenance Specifications (Section V).

CAUTION Do not idle the engine for excessively long periods. Long periods of idling, more than 10 minutes, can cause poor engine performance.

Page 64

B3.9, B4.5, B5.9 Industrial Electromagnetic Interference (EMI) Section 1 - Operating Instructions Page 1-9

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. If the unswitched battery power supply is disconnected in less than 70 seconds after the keyswitch is turned off active fault codes and incorrect ECM information can occur.

Turn the ignition switch to the OFF position. If the engine does not shut down, refer to Troubleshooting Symptom (Section TS) in appropriate Operation and Maintenance manual.

CAUTION Failure to follow the correct shutdown procedure may result in damage to the turbocharger and shorten the turbocharger life.

Electromagnetic Interference (EMI)

General Information

Some applications utilize accessories such as (CB radios, mobile transmitters, etc.) if not installed and used correctly the radio frequency energy generated by these accessories can cause electromagnetic interference (EMI) conditions to exist between the accessory and the Cummins electronically controlled systems. Cummins is not liable for any performance problems with either the electronically controlled systems or the accessory due to EMI. EMI is not considered by Cummins to be a system failure and therefore is not warrantable.

System EMI Susceptibility

Your Cummins product has been designed and tested for minimum sensitivity to incoming electromagnetic energy. Testing has shown that there is no performance degradation at relatively high energy levels; however, if very high energy levels are encountered, then some noncritical diagnostic fault code logging can occur. The electronically controlled systems EMI susceptibility level will protect your systems from most, if not all, electromagnetic energyemitting devices that meet the legal requirements.

System EMI Radiation Levels

Your Cummins product has been designed to emit minimum electromagnetic energy. Electronic components are required to pass various Cummins and industry EMI specifications. Testing has shown that when the systems are properly installed, they will not interfere with onboard communication equipment or with the vehicle's, equipment's, or vessel's ability to meet any applicable EMI standards and regulated specifications.

If an interference condition is observed, follow the suggestions below to reduce the amount of interference:

1 Locate the transmitting antenna as far away from the electronically controlled systems and as high as possible.

2 Locate the transmitting antenna as far away as possible from all metal obstructions (e.g., exhaust stacks)

3 Consult a representative of the accessory supplier in your area to:

- Accurately calibrate the device for proper frequency, power output, and sensitivity (both base and remote site

devices must be properly calibrated)

- Obtain antenna reflective energy data measurements to determine the optimum antenna location

- Obtain optimum antenna type and mounting arrangement for your application

- Make sure your accessory equipment model is built for maximum filtering to reject incoming electromagnetic noise.

Page 65

Electromagnetic Interference (EMI) B3.9, B4.5, B5.9 Industrial Page 1-10 Section 1 - Operating Instructions

Notes

Page 66

B3.9, B4.5, B5.9 Industrial 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 .........................................................................................................................................2-5

Maintenance Data.......................................................................................................................................................2-5

Maintenance Schedule ...............................................................................................................................................2-3

General Information....................................................................................................................................................2-3

Oil Drain Intervals.......................................................................................................................................................2-4

Tool Requirements .....................................................................................................................................................2-2

General Information....................................................................................................................................................2-2

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B3.9, B4.5, B5.9 Industrial

Page 2-b Section 2 - Maintenance Guidelines

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Page 68

B3.9, B4.5, B5.9 Industrial Maintenance Guidelines - Overview Section 2 - Maintenance Guidelines 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. Shorter maintenance intervals are also required if the system is operated in a dusty environment or if frequent stops are made. For gas fueled generator sets, shorter maintenance intervals are also required, if operating at loads below 70% for prolonged periods. Contact your local Cummins® Authorized Repair Location for recommended maintenance intervals.

Some of these maintenance procedures require special tools or must be completed by qualified personnel. Contact your local Cummins® Authorized Repair Location for detailed information.

If your system is equipped with a component or accessory not manufactured or supplied by Cummins Inc., refer to the component manufacturer's maintenance recommendations.

OEM supplied equipment and components can impact on the performance and reliability of the engine if they are not correctly maintained.

Use the chart provided in this section as a convenient way to record maintenance performed.

Page 69

Tool Requirements B3.9, B4.5, B5.9 Industrial Page 2-2 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).

The following is a list of special service tools required for some maintenance operations:

Tool Part Number Description

ST-1273 Pressure gauge 3375045 Torque wrench (0 to 175 ft-lb) 3375049 Oil filter wrench 3376807 Engine coolant and fuel filter wrench 3824556 Charge air cooler (CAC) pressure kit 3824591 Engine barring gear 3824783 Torque wrench (0 to 300 in-lb) CC-2800 Refractometer CC-2802 Coolant test kit 3824842 M10 Compucheck® fitting 3377161 Digital multimeter 3164488 Digital multimeter

Contact your nearest Cummins® Authorized Repair Location for the required service tools.

Page 70

B3.9, B4.5, B5.9 Industrial Maintenance Schedule Section 2 - Maintenance Guidelines 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 Interval

• Air Intake Piping - Inspect

• Air Tank and Reservoirs - Drain

• Cooling Fan - Check

• Crankcase Breather Tube - Inspect

• Drive Belts - Check

• Engine Coolant Level - Check

• Engine Lubricating Oil Level - Check

• Fuel-Water Separator - Drain

Maintenance Procedures at 250 Hours or 3 Months

• Air Cleaner Restriction - Check

• Air Compressor Mounting Hardware - Check

• Charge Air Cooler - Check

• Charge Air Piping - Check

• Fuel Injection Pump Mounting Hardware - Check

• Lubricating Oil and Filters - Change

• Radiator Hoses - Check

• Radiator Pressure Cap - Check

Maintenance Procedures at 500 Hours or 6 Months

• Engine Coolant - Check

• Fuel Filter, Canister Type - Change

• Fuel Filter, Spin-On Type - Change

• Lubricating Oil and Filters - Change

Maintenance Procedures at 1000 Hours or 1 Year

• Cooling Fan Belt Tensioner - Check

• Fan Hub, Belt-Driven - Check

• Overhead Set - Adjust

Maintenance Procedures at 2000 Hours or 2 Years

• Air Compressor Discharge Line - Check

•

Cooling System - Flush

• Vibration Damper, Rubber - Check

• Vibration Damper, Viscous - Check

1 The lubricating oil and lubricating oil filter interval can be adjusted based on application, fuel consumption, gross

vehicle weight, and idle time. For engines whose aspiration is jacket water-cooled, turbocharged only, or natural, refer to Table 1 in the Oil Drain Intervals section.

2 The lubricating oil and lubricating oil filter interval can be adjusted based on application, fuel consumption, gross

vehicle weight, and idle time. For engines whose aspiration is charge air cooled, refer to Table 2 in the Oil Drain Intervals section.

(4)

.................................................................................................Section 3

(1, 4)

..............................................................................Section 4

(2, 3, 4)

...........................................................................Section 5

(4)

....................................................................................Section 6

(3, 4)

...............................................................................Section 7

Page 71

Maintenance Schedule B3.9, B4.5, B5.9 Industrial Page 2-4 Section 2 - Maintenance Guidelines

3 Antifreeze check interval is every oil change or 500 hours or 6 months, whichever occurs first. The operator must

use a heavy-duty year-round antifreeze that meets the chemical composition of ASTM D6210. The antifreeze change interval is 2 years, 2000 hours, or whichever occurs first. Antifreeze is essential for freeze, overheat, and corrosion protection.

4 Follow the manufacturer's recommended maintenance procedures for the starter, alternator, generator, batteries,

electrical components, charge air cooler, radiator, air compressor, air cleaner, refrigerant compressor, and fan clutch.

5 The cooling system requirement to Flush at this scheduled maintenance includes: Drain, Flush. and Fill.

Oil Drain Intervals

Refer to Table 1 or Table 2 to determine the maximum recommended oil change and filter change intervals engine operating in hours or months, whichever comes first.

Table 1: Jacket Water Cooled, Turbocharged Only, or Naturally Aspirated Engines

Cummins® Engine

Standard Classification

(CES) (API)

CES-20078, CES-20077, CES-20076, CES-20072,

CES-20071 CES-20075 API CF-4/SG ACEA E-3, ACEA E-2, JAMA

American Petroleum

Institute Classification

API CI-4/SK, API CI-4, API

CH-4, API CH-4/SJ

API CG-4/SH, API CD, API

International

All Engine Ratings

Classifications

ACEA E-5, Global DHD-1 250 Hours or 3 Months

150 Hours or 6 Weeks

DH-1

ACEA E-1 Obsolete. Do not use.

Table 2: Charge Air Cooled Engines

Cummins® Engine

Standard Classification

American Petroleum

Institute Classification

(CES) (API)

CES-20078, CES-20077, CES-20076, CES-20072,

API CI-4/SK, API CI-4, API

CH-4, API CH-4/SJ

CES-20071 CES-20075 API CF-4/SG ACEA E-3, ACEA E-2, JAMA

Months API CG-4/SH, API CD, API

International

All Engine Ratings

Classifications

ACEA E-5, Global DHD-1 500 Hours or 6 Months

250 Hours or 3 Months

DH-1

ACEA E-1 Obsolete. Do not use.

Page 72

B3.9, B4.5, B5.9 Industrial Maintenance Record Form Section 2 - Maintenance Guidelines Page 2-5

Maintenance Record Form

Maintenance Data

Maintenance Record Engine Serial No.: Engine Model: Owner's Name: Equipment Name/Number:

Key to table headings:

A = Date

B = km [Miles], Hours or Time Interval

C = Actual km [Miles] or Hours

D = Maintenance Check Performed

E = Check Performed By

F = Comments

A B C D E F

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Maintenance Record Form B3.9, B4.5, B5.9 Industrial Page 2-6 Section 2 - Maintenance Guidelines

Notes

Page 74

B3.9, B4.5, B5.9 Industrial Section 3 - Maintenance Procedures at Daily Interval Page 3-a

Section 3 - Maintenance Procedures at Daily Interval

Section Contents

Page

Air Intake Piping ..........................................................................................................................................................3-2

Maintenance Check....................................................................................................................................................3-2

Air Tanks and Reservoirs ..........................................................................................................................................3-2

Drain...........................................................................................................................................................................3-2

Coolant Level ..............................................................................................................................................................3-4

Maintenance Check....................................................................................................................................................3-4

Crankcase Breather Tube ..........................................................................................................................................3-3

Maintenance Check....................................................................................................................................................3-3

Daily Maintenance Procedures - Overview ..............................................................................................................3-1

General Information....................................................................................................................................................3-1

System Operation Report...........................................................................................................................................3-1

Unusual System Noise...............................................................................................................................................3-1

Drive Belts ...................................................................................................................................................................3-5

Maintenance Check....................................................................................................................................................3-5

Fan, Cooling ................................................................................................................................................................3-2

Inspect for Reuse........................................................................................................................................................3-2

Fuel-Water Separator ..................................................................................................................................................3-6

Drain...........................................................................................................................................................................3-6

Canister Type..........................................................................................................................................................3-6

Spin-on Type...........................................................................................................................................................3-7

Lubricating Oil Level ..................................................................................................................................................3-7

Maintenance Check....................................................................................................................................................3-7

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Page 76

B3.9, B4.5, B5.9 Industrial Daily Maintenance Procedures - Overview Section 3 - Maintenance Procedures at Daily Interval 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.

• Odor of fuel

• Odor of electronic devices

System Operation Report

The system must be maintained in top mechanical and electronic condition if the operator is to get optimum satisfaction from its use. The maintenance department needs daily running reports from the operator to make necessary adjustments in the time allocated. The daily running report also helps to make provisions for more extensive maintenance work as the reports indicate the necessity.

Comparison and intelligent interpretation of the daily report, along with a practical follow-up action, will eliminate most failures and emergency repairs.

Report to the maintenance department any of the following conditions that may apply:

• Low lubricating oil pressure

• Low power

• Power increases or engine surge

• Erratic or no accelerator control or response

• Any warning lights flashing or staying on

• Abnormal water or oil temperature

• Unusual system noise

• Excessive smoke

• Excessive use of coolant, fuel, or lubricating oil

• Any fuel, coolant, or lubricating oil leaks

• Loose or damaged parts

• Worn or damaged belts

• Worn or damaged low or high voltage harnesses

Unusual System Noise

During daily maintenance checks, listen for any unusual system noise(s) that can indicate that service is required.

Page 77

Fan, Cooling B3.9, B4.5, B5.9 Industrial Page 3-2 Section 3 - Maintenance Procedures at Daily Interval

Air Intake Piping

Maintenance Check

Inspect the intake piping daily for wear points and damage to piping, loose clamps, and punctures that can damage the engine.

Replace damaged pipes and tighten loose clamps, as necessary, to prevent the air system from leaking.

Torque Value: 8 N•m [ 71 in-lb ]

Check for corrosion under the clamps and hoses of the intake system piping. Corrosion can allow corrosive products and dirt to enter the intake system. Disassemble and clean, as required.

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.

Fan, Cooling

Inspect for Reuse

WARNING Do not rotate the engine by pulling or prying on the fan. The fan blade(s) can be damaged and cause the fan to fail and cause personal injury or property damage. Use the accessory drive shaft or the crankshaft barring tool to rotate the crankshaft.

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.

Page 78

B3.9, B4.5, B5.9 Industrial Crankcase Breather Tube Section 3 - Maintenance Procedures at Daily Interval Page 3-3

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.

Replace original equipment fan that is damaged with a fan of the identical part number. Cummins Inc. must approve any other fan changes to be covered under warranty.

Refer to the vehicle or equipment manufacturer's specifications for capscrew torque.

Crankcase Breather Tube

Maintenance Check

Inspect the breather tube for sludge, debris, or ice in the tube.

Inspect the tube more frequently in icy conditions.

If sludge, debris, or ice is found clean the tube with detergent and warm water or a solvent. Dry the tube with compressed air.

Page 79

Coolant Level B3.9, B4.5, B5.9 Industrial Page 3-4 Section 3 - Maintenance Procedures at Daily Interval

Visually inspect the tube for cracks or damage. If damage is found, replace the crankcase breather tube. Contact your Cummins Authorized Repair Location.

Coolant Level

Maintenance Check

WARNING Do not remove a pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

CAUTION Never use a sealing additive to stop leaks in the cooling system. This can result in cooling system plugging and inadequate coolant flow, causing the engine to overheat.

The coolant level must be checked daily.

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 recommendations and specification details on correct mixing of coolant can be found in Maintenance Specifications (Section V).

Fill the cooling system with coolant. Refer to the markings on the radiator or expansion tank for coolant levels or refer to the OEM manual.

NOTE: Some radiators have two fill necks, both of which must be filled when the cooling system is drained.

Page 80

B3.9, B4.5, B5.9 Industrial Drive Belts Section 3 - Maintenance Procedures at Daily Interval Page 3-5

Drive Belts

Maintenance Check

Poly-Vee Belt

CAUTION Make sure that the engine is switched off and any starting mechanisms are isolated before any inspections are made. Daily belt inspections can be carried out through an appropriate aperture. Do not remove any guards.

Inspect the belts daily. Check the belt for intersecting cracks. Traverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing. Refer to Section A for belt adjustment and replacement procedures.

Belt damage can be caused by:

• Incorrect tension

• Incorrect size or length

• Pulley misalignment

• Incorrect installation

• Severe operating environment

• Oil or grease on the side of belts.

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.

Belt damage can be caused by:

• Incorrect tension

• Incorrect size or length

• Pulley misalignment

• Incorrect installation

• Severe operating environment

• Oil or grease on the belts

Page 81

Fuel-Water Separator B3.9, B4.5, B5.9 Industrial Page 3-6 Section 3 - Maintenance Procedures at Daily Interval

Measure the belt tension in the center span of the pulleys.

Refer to the Belt Tension Chart in Section V for the correct gauge and tension value for the belt width used.

An alternate method (deflection method) can be used to check belt tension by applying 110 N [25 lbf] force between the pulleys on v-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjusted.

Refer to Section A for adjustment procedures.

For cogged belts, make sure that the belt tension gauge is positioned so that the center tensioning leg is placed directly over the high point (hump) of a cog. Other positioning will result in incorrect measurement.

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. Drain the filter sump until clear fuel is visible.

Push up on the drain valve until fluid drains out of the drain tube.

Page 82

B3.9, B4.5, B5.9 Industrial Lubricating Oil Level Section 3 - Maintenance Procedures at Daily Interval Page 3-7

Spin-on Type

Shut off the engine.

Use your hand to open the drain valve. Turn the valve counterclockwise approximately 3½ turns until the valve drops down 25.4mm [1 in] and draining occurs.

Drain the filter sump until clear fuel is visible.

CAUTION When closing the drain valve, do not overtighten the valve. Overtightening can damage the threads.

To close the valve, lift the valve and turn clockwise until it is hand-tight.

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. This allows time for the oil to drain into the oil pan.

For additional lubricating oil recommendations and oil pan capacity information, refer to Maintenance Specifications (Section V).

Page 83

Lubricating Oil Level B3.9, B4.5, B5.9 Industrial Page 3-8 Section 3 - Maintenance Procedures at Daily Interval

Notes

Page 84

B3.9, B4.5, B5.9 Industrial 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....................................................................................................................................................4-1

Air Compressor ...........................................................................................................................................................4-2

Maintenance Check....................................................................................................................................................4-2

Charge-Air Cooler .......................................................................................................................................................4-2

Maintenance Check....................................................................................................................................................4-2

Charge-Air Piping .......................................................................................................................................................4-3

Maintenance Check....................................................................................................................................................4-3

Closed Crankcase Ventilation Hoses .......................................................................................................................4-3

Maintenance Check....................................................................................................................................................4-3

Fuel Pump ....................................................................................................................................................................4-3

Maintenance Check....................................................................................................................................................4-3

Maintenance Procedures - Overview ........................................................................................................................4-1

General Information....................................................................................................................................................4-1

Radiator Hoses ...........................................................................................................................................................4-3

Maintenance Check....................................................................................................................................................4-3

Radiator Pressure Cap ...............................................................................................................................................4-4

General Information....................................................................................................................................................4-4

Inspect for Reuse........................................................................................................................................................4-5

Pressure Test.............................................................................................................................................................4-5

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Page 86

B3.9, B4.5, B5.9 Industrial Air Cleaner Restriction Section 4 - Maintenance Procedures at 250 Hours or 3 Months Page 4-1

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. Intake air must be filtered to prevent dirt and debris from entering the engine and causing premature wear.

NOTE: Do not remove the felt washer from the indicator.

The felt washer absorbs moisture.

A mechanical restriction indicator is available to indicate excessive air restriction through a dry-type air cleaner. This instrument can be mounted in the air cleaner outlet or on the instrument panel. The red flag (1) in the window gradually rises as the cartridge loads with dirt. After changing or replacing the cartridge, reset the indicator by pushing the reset button (2).

Restriction or vacuum indicators need to be installed as close as possible to the turbocharger air inlet in order to obtain a true indication of restrictions.

Vacuum Indicator

Vacuum switches actuate a warning light on the instrument panel when the air restriction becomes excessive.

Page 87

Charge-Air Cooler B3.9, B4.5, B5.9 Industrial Page 4-2 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. After changing or replacing the cartridge, reset the indicator by pushing the reset button (2)

Air Compressor

Maintenance Check

NOTE: Depending on the application, it is possible

engines will not be equipped with an air compressor.

Inspect the compressor housing for cracks and damage.

Inspect the hydraulic pump couplings for cracks, wear, or other damage, if equipped.

Inspect the air plumbing for splits or cracks.

Inspect the air compressor mounting nuts, including support bracket, for loose or damaged hardware.

Operate the engine and check for correct compressor operation.

Check for air, oil, and coolant leaks.

Torque Value:

Mounting 18 mm Step 1 77 N•m [ 57 ft-lb ]

Torque Value:

Bracket 10 mm Step 1 45 N•m [ 33 ft-lb ]

Charge-Air Cooler

Maintenance Check

Inspect the charge-air cooler (CAC) for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, refer to the vehicle, vessel, or equipment manufacturer.

Page 88

B3.9, B4.5, B5.9 Industrial Closed Crankcase Ventilation Hoses Section 4 - Maintenance Procedures at 250 Hours or 3 Months Page 4-3

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.

Fuel Pump

Maintenance Check

Inspect the fuel injection pump mounting nuts, including the tail support bracket, for loose or damaged hardware.

Radiator Hoses

Maintenance Check

Check all hoses for cracks, cuts, or collapsing. NOTE: The silicone engine coolant hose will exhibit

swelling due to the elasticity of the hose.

If damage is found, replace damaged hoses. Contact your local Cummins Authorized Repair Location.

Closed Crankcase Ventilation Hoses

Maintenance Check

Inspect the closed-crankcase ventilation piping and hoses for leaks, holes, cracks, or loose connections. Tighten the hose clamps, if necessary to proper torque. Refer to Section V for torque specification. The illustration shown is one of two options available for the closed-crankcase ventilation system.

Page 89

Radiator Pressure Cap B3.9, B4.5, B5.9 Industrial Page 4-4 Section 4 - Maintenance Procedures at 250 Hours or 3 Months

The illustration shown is the second of two options available for the closed-crankcase ventilation system.

Radiator Pressure Cap

General Information

Pressure Caps

The system is designed to use a pressure cap to prevent boiling of the coolant.

Different caps are specified for the two recommended systems:

Radiator Cap Pressure Test

System Cap

A (Normal-Duty) 104°C [219°F] 103 KPa [15 psi] B (Light-Duty) 99°C [210°F] 48 KPa [7 psi]

NOTE: An incorrect or malfunctioning cap can result in the loss of coolant and the engine running hot.

An incorrect or malfunctioning cap can result in loss of coolant and the engine running hot.

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B3.9, B4.5, B5.9 Industrial Radiator Pressure Cap Section 4 - Maintenance Procedures at 250 Hours or 3 Months Page 4-5

Air in the coolant can result in loss of coolant from the overflow when the aerated coolant is hot. The heated air expands, increasing the pressure in the system, causing the cap to open.

Similarly, coolant can be displaced through the overflow if the head gasket leaks compression gases to the coolant system.

The operating pressure of the coolant system and the lubricating system can result in the mixing of the fluids if there is a leak between the systems, such as the head gasket or oil cooler (refer to Procedure 007-037 Lubricating Oil System in Section 7).

NOTE: Transmission fluid can also leak into the coolant through radiator bottom tank transmission oil coolers. Refer to the OEM service manual.

Inspect for Reuse

Be sure the correct radiator cap is being used. Refer to (Cooling System) in Section V - Specifications.

Inspect the rubber seal of the pressure cap for damage.

Inspect the radiator fill neck for cracks or other damage.

Refer to the radiator manufacturer for instructions if the fill neck is damaged.

Pressure Test

The system is designed to use the pressure cap to prevent boiling of the coolant.

Different caps are specified for the two recommended systems:

System Cap

A-Normal-Duty 104°C [219°F] 103 kPa [15 psi] B-Light-Duty 99°C [210°F] 48 kPa [7 psi]

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Radiator Pressure Cap B3.9, B4.5, B5.9 Industrial Page 4-6 Section 4 - Maintenance Procedures at 250 Hours or 3 Months

Pressure-test the radiator cap.

The pressure cap must seal within the value stated on the cap, or it must be replaced.

NOTE: An incorrect or malfunctioning cap can result in loss of coolant and the engine running hot.

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B3.9, B4.5, B5.9 Industrial 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

Engine Coolant Antifreeze .........................................................................................................................................5-1

Maintenance Check....................................................................................................................................................5-1

Fuel Filter (Canister Type) ..........................................................................................................................................5-1

Install..........................................................................................................................................................................5-2

Preparatory Steps.......................................................................................................................................................5-1

Prime..........................................................................................................................................................................5-2

Remove......................................................................................................................................................................5-2

Fuel Filter (Spin-On Type) ..........................................................................................................................................5-4

Drain...........................................................................................................................................................................5-4

Finishing Steps...........................................................................................................................................................5-7

Install..........................................................................................................................................................................5-5

Preparatory Steps.......................................................................................................................................................5-4

Prime..........................................................................................................................................................................5-6

General Information.................................................................................................................................................5-6

Remove......................................................................................................................................................................5-4

Lubricating Oil and Filters .........................................................................................................................................5-8

Drain...........................................................................................................................................................................5-8

Fill.............................................................................................................................................................................5-10

Install..........................................................................................................................................................................5-9

Remove......................................................................................................................................................................5-8

Maintenance Procedures - Overview ........................................................................................................................5-1

General Information....................................................................................................................................................5-1

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Page 5-b Section 5 - Maintenance Procedures at 500 Hours or 6 Months

This Page Left Intentionally Blank

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B3.9, B4.5, B5.9 Industrial Fuel Filter (Canister Type) Section 5 - Maintenance Procedures at 500 Hours or 6 Months Page 5-1

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.

Engine Coolant Antifreeze

Maintenance Check

CAUTION Overconcentration of antifreeze or use of high silicate antifreeze can cause damage to the engine.

Check the antifreeze concentration. Use a mixture of 50percent water and 50-percent ethylene glycol or propylene glycol-base antifreeze to protect the engine to -32°C [-25°F] year-around.

The Fleetguard® refractometer, Part Number C2800, provides a reliable, easy to read, and accurate measurement of freezing point protection and glycol (antifreeze) concentration.

Antifreeze is essential in every climate.

It broadens the operating temperature by lowering the coolant freezing point and by raising its boiling point.

The corrosion inhibitors also protect the cooling system components from corrosion and provides longer component life.

Fuel Filter (Canister Type)

Preparatory Steps

WARNING Drain the fuel-water separator into a container, and dispose of contents in accordance with local environmental regulations.

Lift up on the filter drain lever to drain fuel out of the filter for approximately 5 seconds. This will eliminate fuel from running over the top of the filter upon removal.

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Fuel Filter (Canister Type) B3.9, B4.5, B5.9 Industrial Page 5-2 Section 5 - Maintenance Procedures at 500 Hours or 6 Months

Remove

Clean all debris from around the canister lid.

Remove the filter lid and filter element. A crescent wrench can be used if the lid can not be removed by hand.

NOTE: Remove the filter element by twisting the element sideways from the filter lid.

Install

Install the new element in the canister lid, and place back in the canister by twisting clockwise.

Refer to Procedure 018-024 (Cummins/Fleetguard® Filter Specifications) in Section V.

NOTE: The replacement filter element comes with a new o-ring for the canister lid. The o-ring must be replaced with the filter element.

Lubricate the o-ring with clean engine oil.

Hand-tighten the canister lid.

Prime

Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically if the fuel filter is changed in accordance with the instructions.

However, manual bleeding will be required if one of the following conditions exists:

•

The fuel filter is not filled prior to installation

•

The fuel injection pump is replaced

•

The high-pressure fuel line connections are loosened or the lines are replaced

•

It is an initial engine start-up or start-up after an extended period of no engine operation.

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B3.9, B4.5, B5.9 Industrial Fuel Filter (Canister Type) Section 5 - Maintenance Procedures at 500 Hours or 6 Months Page 5-3

Open the bleed screw.

Operate the hand lever until the fuel flowing from the fitting is free of air.

Tighten the bleed screw.

Torque Value: 9 N•m [ 80 in-lb ]

Air and fuel can be vented from the illustrated vent locations on the Bosch® VE fuel injection pumps.

Loosen the vent screw and operate the priming lever on the fuel transfer pump until the fuel injection pump is primed.

Tighten the vent screw.

Torque Value: 9 N•m [ 80 in-lb ]

CAUTION It is necessary to turn the keyswitch to the ON position. Because the engine can start, be sure to follow all safety precautions. Use the normal engine starting procedure.

CAUTION When using the starting motor to vent the system, do not engage it for more than 30 seconds, or starter damage will occur. Wait 2 minutes before starting the engine again.

Air can also be vented through the fuel drain manifold line by operating the starting motor.

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Fuel Filter (Spin-On Type) B3.9, B4.5, B5.9 Industrial Page 5-4 Section 5 - Maintenance Procedures at 500 Hours or 6 Months

Fuel Filter (Spin-On Type)

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.

•

Disconnect the batteries.

Drain

WARNING Drain the fuel-water separator into a container, and dispose of contents in accordance with local environmental regulations.

If equipped, use the filter drain valve to drain fuel out of the filter for approximately 5 seconds. This will eliminate fuel from running over the top of the filter upon removal.

Remove

Clean the area around the fuel filter head.

WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

Remove the fuel filter.

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B3.9, B4.5, B5.9 Industrial Fuel Filter (Spin-On Type) Section 5 - Maintenance Procedures at 500 Hours or 6 Months Page 5-5

Install

CAUTION When pre-filling the filter do not pour fuel down the center (clean side) of the filter. Pour clean fuel into the outer openings (dirty side) of the filter. Use a clean side block off plug, if available, to prevent fuel from entering the clean side of the filter. Pre-filling on the clean side of the filter can result in debris entering the fuel system and damaging fuel system components.

Fill the new filter(s) with clean diesel fuel.

Lubricate the seal with clean lubricating engine oil.

CAUTION Mechanical overtightening can distort the threads as well as damage the filter element seal or filter can.

Install the fuel filter on the fuel filter head. Turn the filter until the gasket contacts the filter head surface.

Tighten the fuel filter an additional ½ to ¾ of a turn after the gasket contacts the fuel filter head surface, or as specified by the fuel filter manufacturer.

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Fuel Filter (Spin-On Type) B3.9, B4.5, B5.9 Industrial Page 5-6 Section 5 - Maintenance Procedures at 500 Hours or 6 Months

Connect the batteries.

Prime

General Information

However, manual bleeding will be required if one of the following conditions exists:

•

The fuel filter is not filled prior to installation

•

The fuel injection pump is replaced

•

The high-pressure fuel line connections are loosened, or the lines are replaced

•

It is an initial engine start-up or start-up after an extended period of no engine operation.

Refer to Procedure 006-015 (Fuel Filter (Spin-On)) in Section 6 for proper venting of the low pressure side of the fuel system.

Refer to the Procedure 005-012 (Fuel Injection Pumps, InLine) in Section 5 to determine if venting the fuel pump is necessary. Or, refer to Procedure 005-014 (Fuel Injection Pumps, Rotary) in Section 5 to determine if venting the fuel pump is necessary.

Refer to Procedure 006-051 Injector Supply Lines (High Pressure) in Section 6 for venting of the high pressure side of the fuel system.

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B3.9, B4.5, B5.9 Industrial Fuel Filter (Spin-On Type) Section 5 - Maintenance Procedures at 500 Hours or 6 Months Page 5-7

CAUTION It is necessary to turn the keyswitch to the ON position. Because the engine can start, be sure to follow all safety precautions. Use the normal engine starting procedure.

CAUTION When using the starting motor to vent the system, do not engage the starter for more than 30 seconds, or starter damage will occur. Wait 2 minutes before starting the engine again.

Air can also be vented through the fuel drain manifold line by operating the starting motor.

Low Pressure Fuel Line(s) NOTE: For engines equipped with Distributor type pumps

equipped with bleed screws.

Open the bleed screw. NOTE: If the engine is not equipped with a bleed screw,

loosen the fitting on the low pressure supply line to the injection pump. Once priming has been completed, tighten the fitting to the specified torque.

Operate the hand lever until the fuel flowing from the fitting is free of air.

Tighten the bleed screw.

Torque Value: 9 N•m [ 80 in-lb ]

Finishing Steps

•

Operate the engine and check for leaks.