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Chapter 6 - Engine: Service Manual
Chapter 6 - Engine: Service Manual
Chapter 6 - Engine
Engine ................................................................................................................................................................ 6-3
1 Technical data .................................................................................................................................. 6-3
2 Cooling system ................................................................................................................................ 6-5
2.1 Cooling schematic .................................................................................................................. 6-5
2.2 Function.................................................................................................................................. 6-7
2.3 Coolant capacity ..................................................................................................................... 6-7
2.4 Cleaning system and changing antifreeze.............................................................................. 6-8
2.5 Antifreeze and corrosion protection of coolant ....................................................................... 6-12
3 Fuel system ...................................................................................................................................... 6-14
3.1 Fuel schematic ....................................................................................................................... 6-14
3.2 Fuel capacity .......................................................................................................................... 6-14
3.3 To drain condensation ............................................................................................................ 6-14
3.4 Fuel filter change .................................................................................................................... 6-17
3.5 Bleeding procedure ................................................................................................................ 6-18
LFR/en/version: 08 / 2007
LFR/en/version: 08 / 2007
6 Engine
LFR/en/version: 08 / 2007
2a Make up line for the principal circuit 6b Bypass for LTA circuit
2b Make up line for the LTA circuit 7a Coolant return to principal radiator
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6.2.2 Function
For a detailed description of the engine cooling system flow, see Cummins Operation and Maintenance Ma-
nual.
6.2.3Coolant capacity
R 9250
Cooling capacity
Caution!
Do not use caustic cleaners in the cooling system. Aluminium components will be damaged.
Warning!
Wait until the temperature is below 50°C (120°F) before removing the coolant system pressure cap.
At or near operating temperature, the engine coolant system is hot and under pressure.
Avoid contact with coolant and components containing coolant, since it could cause severe burns.
Check the coolant level only after the cap 6 is cool enough to touch. When cold, the coolant level should not
drop below the bottom end of the filler neck under the cap 6 of the expansion tank 7.
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Push the lever 1 all the way backward to open the heater water supply.
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Open the coolant shut off valves 5 for the cab heater on the Diesel engine.
The radiators are fitted with a drain valve 9 situated at the bottom.
To drain the coolant, first remove teh cap of the drain valve and screw the drain hose delivered with the ma-
chine onto the drain valve and drain the coolant in a suitable container (remove the coolant pressure cap).
Remove the drain hose and reinstall the cap of the drain valve.
Do not allow the cooling system to dry out.
Do not remove the coolant filter.
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Caution!
Fleetguard RESTORE contains antifreeze. Do not allow the cooling system to freeze during the
cleaning operation.
Be sure that the coolant shut off valves 5 are open and that the lever 2 is pushed all the way backward to open
the heater water supply. The blower does not have to be on.
Run the engine at high idle and add water until the coolant level will no longer drop.
Operate the engine at normal operating temperatures (at least 85°C (185°F)) for 1 to 1,5 hours.
Shut the engine off, and drain the cooling system.
Fill the cooling system with clean water to flush the cooling system.
Operate the engine at high idle for 5 minutes with the coolant temperature above 85°C (185°F).
Shut the engine off, and drain the cooling system.
Note!
If the water being drained is still dirty, the system must be flushed again until the water is clean.
Fill the cooling circuit with a new heavy-duty coolant and SCA (see Cummins Operation and Maintenance Ma-
nual page V-17).
Open the cap on the surge tank on top of the powerpack.
Add the coolant until it reaches the middle range of the indicator.
Run the engine at high idle and add coolant until the coolant level will no longer drop. It should reach the middle
range of the indicator.
Note!
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If the heater will not run normally after the coolant change, it is possible that air is collected in the
heat exchanger. In this case the heater exchanger must be vented :
– run the engine and be sure that the coolant shut off valves for the cab heater on the Diesel engine
are open and that the lever is pushed all the way backward.
– Unscrew the vent screw 10 on the heat exchanger under the cab until coolant comes out, than
retighten the screw.
Caution!
Under-concentration of coolant additives can result in liner pitting and system corrosion. Over-con-
centration can result in water pump leakage.
The recommended concentration level of supplemental coolant additives is 1,5 units per US gallon of coolant.
The additive level must never drop below 1,2 units or exceed 3 units per gallon of coolant.
See Cummins Operation and Maintenance Manual for details.
• Turn the valve 1 on the filter head to the OFF position to prevent water loss.
• Unscrew and remove the filter elements.
• Clean the area around the filter head and the gasket surface on the filter head.
• Lightly oil the seal rings on the new filter element.
• Screw on the new elements until the seal ring touches the filter housing, and then turn it by hand ½ - ¾
turns (do not use any tools to tighten the filters).
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3 Fuel filters
The maximum capacity of the fuel tank is 5220 liters (1380 US gallon).
The fuel filters must be changed at regular intervals (see Cummins Operation and Maintenance Manual).
• Close the fuel shut off valve 2 near the fuel tank 1.
• Clean the area around the fuel filter head.
• Use a filter wrench to remove the fuel filter (see chapter 5 : tooling).
• Use a clean, lint-free towell and clean the filter head gasket surface.
• Use the correct filters.
• Apply a light film of clean engine oil to the filter gasket surface.
• Fill the filter with clean fuel.
• Install the filter on the filter head. Tighten the filter until the gasket contacts the filter head surface.
• Tighten the filter per the filter manufacturer’s instructions.
• Open the fuel shut off valve 2 near the fuel tank 1.
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• Fill the fuel tank with appropriate fuel (see Cummins Operation and Maintenance Manual) at is maximum
level.
• On the fuel pump, drain at the bottom point until clear fuel drains off.
• Try to start the engine.
• If the engine does not start, drain at the top point during cranking.
• Stop to drain when clear fuel drains off.
LFR/en/version: 08 / 2007
LFR/en/version: 08 / 2007