Service Manual QSB6.7 CM2350 B105 . Volume 2 Copyrights 2013 Bulletin 4392778, Gurwmins ne Printed 08-OCTORER-2013, Allighis eservedForeword This manual provides instructions for troubleshooting and repaitng this engine in the chassis. Component and assembly rebuild procedures are provided inthe engine shop manual Refer to Secton | Inroduction for structions fn how use this manual Read and follow al safety instructions. Rfer to the WARNING in the General Safety Instructions In Section | - Introduction. ‘The manual is organized to guide a service technician through the logical steps of Kentfying and corecting problems ‘elated tothe engine. This marusal does not cover vehicle or equipment problems. Consult the vehicle or equipment ‘manufacturer for repair procedures. ‘A saries of specific service manuals for example: Shop, Specifations, and Altemative Repait) are avalabe and can be ordered by Contacing yout local area Cummins Regional ofice. A Cummins Regional ofc listing Is located in Service Literature (Section U), ‘The repair procedures used in this manual ar recommended by Cummins Ine. Some service procedures require the se of special service tools. Use the corect ool as described, ‘Cummins ine. encourages the usor of his manval fo repot error, omissions, and recommendations fo improvement. Please use the postage paid, preaddressod Lisrature Survey Form Inthe back of Uus manual for communicating your comments ‘The specications and rebuild information inthis manual are based on the information in affect at the timo of printing. ‘Cummins in. reserves the right fo make any changes a any time without obligation. If dferences are found between Your engine andthe information inthis manual, contact a Cummins Authorized Repair Location or call -200-DIESELS ('300°843-7357) tol ree inthe U.S. and Canada, ‘The latest technology and the highest qualiy components are used to manufacture Cummins engines. When «replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parsTable of Contents Section Introduction Cooling System - Group 08, Drive Units - Group 09 Ar intake Systom - Group 10 Exhaust Systom - Group 14 Compressed Air System - Group 12 Electrical Equipment - Group 13. Engine Testing - Group 14. Mounting Adaptations - Group 16 Miscollanoous- Group 17 Electronic Controls - Group 19 Service Literatu Specifications Back 10 " 2 8 “‘98087 cuzss0 8105 Stetion tntrdtion Section i - Introduction Section Contents About the Manual ‘General information, ‘Acronyms and Abbreviations ‘General information. General Cleaning instructions ‘Abrasive Pads and Abrasive Paper Defnon of Clan, Fuel Systom, Gasket Suraces. Piasle Bead Gearing. Solvent and Acid Cleaning. Steam Cleaning, General Repair Insinictions ‘Gonaal information. Wielding ona Vehicle wi an Elaczonic Carraied Fuel Syeiom, General Safety instructions. Timpotant Satety Notice. How to Use the Manual ‘General information. ystrations (General formation. ‘symbols ‘General infomation Pages.9586,7 cw2360 6105 Paget Section | ineducton This Page Left Intentionally Blank.9586,7 cw2350 B108 About the Manust ‘Section |-intoduetion Paget About the Manual General Information ‘This Service Manual is intended to ald In determining the cause of engine related problems and to provide recommenced repat procedures. Addtonaly the manual is Ifonded to ald mechanics in elsassembly,inapecting Parts for reuse, rebuilding and assembly of components ‘The manual is divided into sections. Each section is equivalent to a group used in Cummins’ fmcard systam, Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, Spectications, cagrams, and service tools where applicable. Procedure numbers are used t enty and reference peat repair procedures for correcting he problem and describe spect rebuild procedures. “This manual does not contain fut systems electronic troubleshooting. Use the troubleshooting trees inthis manual, f ‘here are no electron faut codes, “This manual is designed so the troubleshooting trees aro used to locate the cause of an engine problem. The ‘waubleshooting trees then direc the user to the corec repair procedure. The ropalr procedures witun a section are In numerical order, However, tie repair stops wihin @ given procedure are organized in the order the repair must be Derlomed regarcess ofthe numerical ocder of the sleps. The User mut use the contents pages or the index at the back of te manval to locate speci topics when not using the woubleshooting treesHow to Use te Manus 886, cm2ss0 B10 02 Section | =inteduetion How to Use the Manual General Information “This manual fs divided into the same group eystem used for previous manuals and the Curmins'flmeard system. Section 00 is organized ino a logical soquence of engine disassemtlelassomblo, al her secions are In numerical Sequence. Refer to the Table of Canfents atthe front of the book to determine the secton that details the desived informaten. ‘The dsassemblelassemble sections of his manval is dvded into the same group system used for previous manuals and the Cummins flmeard system, Section 00 Is organized into a logical sequence of engine disassomblalassomble, all otier sections are In numerical sequence, Rofr to the Table of Contents atthe font of the book to determine the sechon that deals the desired information, Each saction contains the folowing in sequen: + Table of Contents + Rogured Service Too Listings + General Information containing the basic service, maintenance, design and revision information necessary to assist Inthe rebuild ofan engine or a component + Procedure instructions forthe sieassembly, inspection, maintenance, and assem thet can be required to rebuild ‘an engine, addional procedures that are nat necessary during every rebula, bul can be necessary, are included ‘Thess precedures depend onthe length of time an engine has been it service and the canaltans o the parts ‘Al the procedures ar Identfed with a name and a number. Each digit inthe procedure number has a specie mesning ‘The fst roe gts ofthe number refer to the specie section thatthe procedure can be found within the manual. In this example, “001” represents Secon O1 - Gyn Blok. This rmbr wil range rom 00 to 022 ‘Tha second tree dita of the number ae unique and refer to a specie subject. this example, “028” rapes Glin Liner Tis number wil ange rom 001 to 98, Refer to Section V for specications recommended by Cummins Engine Company, Inc. for your engine. Spacfications ‘and torque values foreach engine system are aven i hat section, NOTE: Discharge of oor cly water nto or ypon the water sa direct violation of todays laws, Violators are subject to 2 penalty of varlous monetafy charges, Dispose of these subelaneas fh acoordanes Wath standards set By the focal utromental governing agency.(9806, cw2s60 6108 Section introduction ‘Symbols General Information ‘symbots Paget The fllowing symbols have been used in ths manual to help communicate the intent ofthe instuctons. When one of the symbols appears Il conveys the meaning dafned below: A .WABWANG -Sercus orsnal nur oF ‘utnsie propery arog can recut ‘Bowamiy waructons so ot ‘Blows {CAUTION - Minor perona ry can Feauttr a para ecamoly rte on ‘Sa canbe damaged fe Cauton ir Sune ee not towed Incest « REMOVAL or DISASSEMBLY. step. BLY step. i INSPECTION is roguied ‘CLEAN to par or assombly. ® § onHE PERFORM a macranca or me MEASUNEMENT, LWBRICATE no par or assombly. (nests that & WRENCH oF TOOL SIZE ‘napa gon TIGHTEN 02 sect rau ‘PERFORM an eacca! MEASUREMENT, ft orcas ton ni mania ‘Stomatare ‘To componant waighe 23 010 or ‘mere To als poorly uso @ ‘lt oF ot aninaon th emgMustations Paget ‘as96,7 cunaso 8106 Sections Introduction lustrations General Information Some of the ilustratons throughout this manual are {generic and will not look exact lke the engine or pats {Sed In your application. The tlustrations can contain Symbols to deato an action required and an acceptable {tot acceptabie condton ‘The iustatons ae_inlended to show repair or feplacement procedures. The procedure wil be the Sarie {oral applications, although tho ustaton can der.‘9886.7 cmz360 5105 General Safety Instructions Section |= Introdoetion Pagers General Safety Instructions Important Safety Notice dAwarninc A Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or ‘other personal injury or death. Read and understand ail ofthe safety precautions and wamings before performing any repalr. This lst contains the {general safety precautions that must be folowed to provide porsonal safety. Special safety precautions are included inthe procedures when they apply. ‘+ Workin an area surrounding the product thats dey, well it, ventilated, free from clutter, loose tools, parts, inion 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, mutation or strangulation + Do not wear loose-fting orton clothing. Remove al jewelry when working, Disconnect the baer (negative [cable frst) and discharge any capactors before beginning any rept work. Disconnect the air staring motor i equlpped to prevent acclental engine staring. Put 8 D9 Not Operste” tag In the operata’s compartment or on the conls. + Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attompt to rotate the crankshaft by puling r prying onthe fan. This practice can ease sarious pereonal injury, propecy damage, oF ‘damage to the fan blade(s) causing premature fan flue. Ian engine nas been operating and the coolant is hot, allow the engine to cool before slowly loosening the filer ‘ap to relive the pressure rom the coding sytem, ‘Always use biocks or proper stands to suppor the product befoe pecorming any service work, Do not work on ‘anything thats supported ONLY by iting jacks ora holst olive al proceure in thea fal and eacling aystoma before any ine, fing, o elated Rem ere removed fr disconnected. Be alert for possible pressure vinen disconnecting any deves ftom a system that utizes pressure. Do not check for pressure leaks wth your hand, High pressure oor fuel can cause personal nj. + To reduce the possiblity of eutfecaon and frostbite, wear protacive clathing and ONLY disconnect quid retigerant (Freon) ines in 8 well vertated area. To protect the envionment, qua ekigerant systems must be bropery empled and filed using equipment that prevents the release of retigerant 8 Ruorocarbons) info the ‘tmosphere, Federal aw requires capturing and recycling rligerant + To reduce the possibilty of personal injury, use a hoist ox get assistance when fing components that weigh 23 kg [0b] or mare. Make sure al tng deviocs such a chains, hooks, or slings are In good candtion and ae ofthe Correct capacity. Mako cure hooks are postion correctly. Always use a Spreader bar when necassary. The Ig hooks must not be sdevoaded. CCorosion inhibitor, a component of SCA and lubricating cl, contains alka. Do not get the substance in eyes. ‘Avoid prolonged or repeated contact with skin. Do not swaiow inlomally In case of contact, immediately wash skin with soap and water. In case of contact, immediatly ood eyes wih frye amounts of water fr a minimum of ‘Sminutes. MMEDIATELY CALL A PHYSICIAN. KEEP QUT OF REACH OF CHILDREN. + Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used vith caution. Fotiow the manufacture’ instuctons to provide complete safely whan using these materials. KEEP OUT OF REACH OF CHILDREN, + To reduce the possibilty of bums, be alr for hot pats on products that have just been tumed off, exhaust gas flow, and hat fds in nes, tides, and compartment + Always use to's that are in good conlton. Make sure you understand how to use the tools before performing any ‘service work. Use ONLY genuine Cummins® or Cummins ReCon® replacement pats ‘Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quay i replacements are necessary, \Wmnen novessary, the removal and replacement of any guards covering rotating components, dives, andlor belts should ony be cared out be a tained tecnician. Before removing any guards the engine must be turned of an any staring mechanisms must be isolated. Al fasieners must be replaced on reiting the guards ‘+ Domot peronm any repair when fatigued or after consuming alcohol or drugs that can Impal your functioningGenera Safety Instruct 8867 cmzss0 B105 Page 6 Section = Infoduction “+ Some state and federal agencies in the United States of America have determined that used engine oll can be ‘carcnogenic and can cause reproductive toll. Avol inhalation of vapors, Ingestion, and prolonged contact with Used engine ol ‘Do not connect the jumper starting or battery charging cables to any ignition or governor control wring. This can cause elecical damage to the gti or governor. Always torque fasteners and fuel connections to the required specticalons, Overtghtening or undertghening can allow leakage. This is ertical othe natural gas and iquetied petcleum gas fuel and ar systoms. Always tes for uel leaks as instructed, as odorant can fade + Close the manual uel valves prior to performing maintenance and repairs, and when storing the vehicle inside, + Coolants toxic. 1 nat reused, clspose of in accordance with local environmental regulations. ‘The catalyst reagent contains urea. Do not get the substance in your eyes. In ease of contact, immediatly flood {yee ith large amounts of water for a'minmum of 6 minutos, Avold prolonged contact wiih skin. In case of Contact, immediately wash skin wih soap and water. Do not swaliow Intra. nthe event the catalyst reagent is Ingested, contact a physician immediatly. + The catalyst eubstate containe Vanadium Pentoxide. Vanadium Pentaxde has been determined by the State of CCalroria to cause cancer. Aways woar protective gloves ana eye protecton when Randing the catalyst assembly Do not got tho catalyst matarial in your eyes. In Caso of contact, immodiatoly flood ayes wih large amounts of Water fr a minimum of 15 minutes. Avold prolonged contact wth skin. In case of contac, immediately wash skin ‘with Soap and water. +The Catalyst substrate contains Vanadium Pentoxde. Vanacium Pentoxide has been determined by the State of CCalforia fo cause cancer. In the ovent the catalyst Is boing replaced, dispose of in accordance wih local regulations. + Calforia Propositon 65 Warning - Diesel engine exhaust and some of its consuents are known tothe State of (Calfomia to cause cancer, btn defects, and oer reproaucive harm.(9806.7 cmasso 8105 General Repair instructions Section |= tntodvtion Pager? General Repair Instructions General Information ‘This system incorporates te latest technology a the time it was manufactured: ye, it Is designed to be repaired using normal repair prices performed to quality standards, Awarninc A ‘Cummins inc. doos not recommend or authorize any modifications oF repairs to components except for those detailed in Cummins Service Information. In particular unauthorized repair to safety elated components can ‘ause personal injury oF death. Below ie partial listing of components Classified as safety-related: ‘Air Compressor Ar Controls Air Shuto Assemblies Balance Weights Coating Fan Fan Hub Assembly Fan Mounting Bracket(s) Fan Mounting Capscrews 9 Fan Hub Spindle 10 Flywheel 1 Flywheel Crankshaft Adapter 12 Flywheo! Mounting Capecrave 13 Fuel Shuto Assembles 14 Fuel Supply Tubes 15 Ling Brackets 16 Throtle Controls 17 Turbocharger Compressor Casing 18 Turbocharger Ol Drain Lines) 19 Turbocharger Ol Supply Lins) 20 Turbocharger Turbine Casing 21 Vibration Damper Mounting Capserews 22 Manual Service Disconnect 23 High Voltage Interiock Loop 24 High Votage ConnectorsConnesions and Hamesses, 25 High Voltage Battery System 26 Power Inverter 27 Generator Mote 28 Clutch Pressure Pate + Follow al safety instructions noted inthe procedures + Follow the manufacturers recommendations fr cleaning colvents and other substances used during repairs. Some solvents have been identified by government agencies as toxic of carcnagenic. Avod excestive. breathing, ingestion and contact wih such substances. Always Use good safety pracioes with cols and equipment + Provide a lean environment and folow the cleaning instructions specie in the procedures + All components must be kept clean during any repair. Contamination af the components wil cause premature + Perform the inspections specified Inthe procedures Replace all components or assembles which are damaged or worn beyond the specications‘General Repair nstructons as86,7 cuaa60 2105 Pagers Section | invoduction + Use genuine Cummins new or ReCon® service parts and assembles ~The assembly instructions have been written fo use again as many components and assemblies a6 possible. \wmon tis necessary to replace a component or assembly, the procedure is based on the use of new Cummins or ‘Cumming ReCon® components Al ofthe repair services described inthis manual are availabe fom all Cummins Distroutors and most Dealer locations. Follow the specified disassembly and assembly procedures to reduce the possibilty of damage othe components ‘Welding on a Vehicle with an Electronic Controlled Fuel System AcautionA Disconnect both the positive (+) and nagative () battory cables from the battery before welding on the vehicle. [Attach the welder ground cable no more than 0.61 metors [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 oF the ‘components. Direct welding of any eloctzonie components must not be attompted. Sensors, wiring harness, land electronic. control unit should ‘be removed it nearby welding will expose these components 0 temperatures ‘beyond normal operation. Additionally, all electronic contral unit connectors must be disconnected(9806: cmzss0 8105 (Genera Cleaning instructions Section = ntodtion Pages General Cleaning Instructions Definition of Clean Parts must be free of debris that can contaminate any engine system. This does net necessarly mean they have to appear as new. ‘Sanding gasket surfaces unt the factory machining marks ae disturbed adds no value and is oten harm to forming 2 Seal It's important to maintain surface fi and flatness tolerances to form a quality sealing suraca. Gaskets are ‘esigned to fi small vids in the spaced surface Mish. ‘Sanding gasket surtaces where edge-molded gaskels are used is most often unnecessary. Edge-molded gaskets are ‘those moll carirs with ceaing material bonded to the edges ofthe gasket to soal while the metal portion forms ‘etal to meta joint for stability. Ary of tho small amounts of sealing Material that can stick to the parta are betior Femoved wih a blunt-edged seraper on the spots rather than spending time potshing the whole surface wih an ait Sandor or so For those gaskots that do not have the edge melding, neat all have @ material that contains release agents to prevent sucking. Certainly this is not to say that som gaskets are not dificult to remove because the gasket has been in place @ long time, has been overheated or the purpose of the ralease gant has been defeated by the pplication of some sealan. The object however Is Just to remove the gasket without damaging the suriacas ofthe ‘mating parts without contaminating the engine (dr lt the Ite bs fall where tey can not be removed), ‘oad blasting piston crowns unt the dark sain is removed ls unnecessary. il tha is required isto remeave the carbon Duld-up above the top ring and inthe rng grooves. There is moe information on bead Blasting and piston cleaning Tater inthis document ‘Cummins ine. does not recommend sanding or grinding the carbon ring atthe top of cylinder ners unt clean metal Vise. Tha liner wil be raned and any signs of problem at the top ing reversal point (ike a cust) wal be ‘estroyed. It is necessary lo remove tha carbon rng fo provide for easier removal ofthe piston assembly. A medium bist high quality, ste! wire whee! that i rated above the rpm ofthe power tool being used wil be just as quick and ‘here wil bo loss damage. Yes, ne must ook careful Tor broken wires ater the piston Ie removed but the wes are ‘ore visible and canbe atracted by a magnet. ‘oon parts that have boon removed from the angine wil tract dit inthe ai. The dt wil adhere tothe ol. posite, leave the old ol onthe pat unt its ready tobe cleaned, inspected and insted, and then clean tof along with any alracted drt the pars cleaned thon let exposed it can have tobe cleaned again before installation, Make ure Parts are lubricated with clean ol before instalation. They do not need tobe old all over But do need oll Between ‘roving pats (or 8 good le system priming process conducted before cranking te engine). ‘Bead blasting pats to remove exterior paint i also usualy unnecessary. The part will most IMely be painted agaln so althat needs happen s remove any loase paint Abrasive Pads and Abrasive Paper ‘Te keyword here is “abrasive”. There is no part of an engine designed to withstand abrasion, That is they ave ail supposed fo lock together or side across each other. Abrasives and dirt paras wil degrade both functions, Awarninc A Abrasive matorial must be kept out of or removed from oll passages and parts wear points. Abrasive material in ll passages can cause bearing and bushing fallures that can progress to major component damage boyond reuse. This Is particularly true of main and rod bearings Cummins ine. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or ‘omparent Including but not limited to removing the carbon rage from cyinder ners orto clean Block decks oF ‘Sounterbores. ‘Groat care must be taken when using abrasive products to clean engine paris, particulary on partally assembled engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxde parts, ‘siicon carbide, or sand or some other simiar hard materia. These partclos are harder than most of the pais the fngine. Sinco they are harder, i they are pressed against softer matoral they wil ether damage the materal ‘become embedded in. These matorls fall othe icing mea as te products used. ithe products are used with power equipment the parles are town about the engine, I the paricies fall between two maving pare, damage to the moving part is key It particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger than the unaing clearance then damage wil occur when the parts move rave to each oer (engine stated). While the engine Is running and tere is ol pressure, partes thal sre smaller than the bearing Gearance are ikely to pass bbatwoen the parts without damage and be rapped in the ol fit, However, parties larger than the baering ceersnce will emove material fom one part and can bebame embedded In one ofthe parts. Once embedded in one part & Wil‘General Cleaning Instructions 9586, cwass0 B105 Page 9 ection | Intreducton brade the other part uni contact eno longer being made between the two parts. If the damage suficiely degrades theo fim, the two parts vil come into contact resulting in early wear-out or falas from lack of elective lication. ‘Abrasive particles can fy about ducing clearing it is very impertant to block these particles rom entering the engine as ‘much ae possible. This Is parioulary tue of Mbreatng ol pers and oll dillng holes, especaly those located Sovmstream ofthe lubricating ol ters, Plug the holes instead of ying to blow the abrasive particles and debris with {compressed ar bocause the debi is oten simply blown further into the ol ring. Al old gasket material must te removed from the parts gasket surfaces. However, iis not necessary to clean and polish the gasket surface unt tho machining marke are erased. Excesaive sanding or buffing can damage the gasket Surface Many newer gaskets are of the edge molded typo (a steal carrier with a sealing member bonded tothe steal). ‘What ile seating material that can adhere 's best remved with a blun-edged scraper or putty knife. Cleaning gasket ‘surfaces where an edge-molded gasket used with abrasive pads ar paper is usualy a waste of time. Awarnnc A, Excessive sanding or grinding the carbon ring fom the top of the cylinder liners can damage tho liner beyond reuse. The surface finish wil be damaged and abrasive particles can be forced into the liner material which ‘can cause early cylinder wear-out or piston ring failures. “Tape of or plug all openings to any component itarir before using abrasive pads or wire brushes. If ely necessary because of me to Use 2 power lool with abrasive pads, tape the ol dings closed or use plug and clean as much of the surface as possible wth the too! but clean around thei holelopaning by hand so ae to prevent contamination of the dling, Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use Compressed ar to blon the debris out of ol dling on an assembled engin More Thal than not, the debris can De Blown futher info the ding. Using compressed airs fine bath ends of the ring are open but hats rarely the ‘ase whon dealing wih an assembled engine Gasket Surfaces ‘The object of leaning gasket surfaces isto remove any gasket malarial not refnsh the gasket surface ofthe pat. ‘Cummins Inc. does not recommend any specific brand of fiuid gasket remover. fa quid gasket remover is used, GAoSTie drectoneformake sure ha maiota being loaned wil etbeharmed [Ar powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part ofthe Scraper must be ageinet the gasket surface to prevent the blade ftom digging ino the sutace. Using a powered {gasket scrapers on parts made of sot materials takes aki and care to prevent damage. Do net srape or brush across the gasket surface I at all possible, Solvent and Acid Cleaning ‘Several solvent and acid-ype cleaners can be used to clean the disassembled engine parts (other than pions. See Below) Expartenes has show that te best reslls can be oblaled using a cleaner that can be heated to 80" to 85" Cass (180° to 200" Falvenne). Kerosene emulsion based cleaners ave diferent temperature specifeations, see below A cleaning tank that provide a constant mong and iterng of te cleaning sluton wil give the best results Gummins Ine. does not recommend any spectie cleaners. Always folow the cleaner manulacurers Instructions. Remove all te gasket material. e-rings, and the depoate of sudge, carbon, et, witha wire brush or scraper before pling the parts na Gearing tank. Be careful not o damage any gasket surfaces. When possible, steam clean the ars Before puting them in he Searing tank Awarninc A When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations for "use, Wear goggles and protective clothing to reduce the possibilly of personal injury. Experience has shown that Kerosene emulsion based cleaners perform the best fo clean pistons. These cleaners ‘should not be heated to temperature in excess of 77°C (170°F) The slution begins to break Gown at lemperatures in ‘0088 82°C (20°F) and wil be loss atfoctve. Do not use solutons composed mainly of chlorinated hydrocarbons with resol, phenols andlor eesyic components. ‘Thay often do nat do @ good job of removing deposits from the ng groove and are costo cscse of property. Solutons with a pH above approximately 9.5 will cause aluminum to tum black: therefore do not use high alkaline solutions Chemicals with a pH above 7.0 are considered abaline and those below 7.0 ae acidic. As you move further away {tom the neutral 7.0, the chemicals become highly alkaline ox highly ace Remove all the gasket materia, ings, and the deposits of studge, carbon, et, witha wie brush or soraper before putting the pate n'a cleaning fark, Be careful fo not damage ary gaskst suaces. When possible uso hol high‘ase67 cwnss0 e105, ‘Gonoral Cleaning Instructions Section troduction Paget pressure water of steam clean the parts bofoe puting them inthe cleaning tank. Removing the heaviest dit before pacing in the tank wl alow the cleaner fo work more efectvely and the leaning agent wil last longer Ringe al the parts in hot wale ater cleaning. Dry completely with compressed ar, Blow the rinse water ftom al the capseraw halos and the ol ailngs Hf the pars are not to be used immediatly after cleaning, dip them in a suitable rust proofing compound. The ust rooting compound must be removed Irom the parts bore assembly or installation on ne engine Steam Cleaning ‘Stam clearing can be used to remove all types of dt that can contaminate the cleaning tank. Its a good method for ‘leaning the of dings and coolant passages, Awarnnc A When using a steam cleaner, wear safety glasses or a face shiold, as well as protective clothing. Hot steam can cause serious personal injury. ‘Do not steam clean the following components + Electrical Components + Wing Hamesses + Bots and Hoses + Bearings (bao taper rele) + Electronic Control Module (ECM) + ECM Connectors + Capactive Goll Driver Module (CCD) + lantion Cos and Leads + NOx Sensor + Fuel Gontol Valve + Tote Diver and Actuator. Plastic Bead Cleaning Cummins inc. does not recomment the use of glass bead blast or wainut shell media on any engine part, Cummins Inc. recommonds using only plastic baad madia, Pant Number 3822735 or equivalent on any engine part. Never use sand 3s a blast media to clean engine parts. Glass. and walnut shell media When not used {0 the media Manufacturers recommendations can cause excess dst and can embed in engine pats that can result in premature {allure of components tough 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 leaning tine, AcautionA. 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 tho modia will embed inthe aluminum or other soft metal and result in premature wear ofthe cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shaft, eto, can also be damaged. Follow the cleaning directions listed Inthe procedures. AcautionA Do not contaminate wash tanks and tank type solvent cloaners with the foreign material and plastic beads. Remove the foreign material and plastic beads with compressed al, hot high pressure wator or steam before placing thom in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any ther engine parts cleaned inthe tank. Contaminated parts may eause failures from abrasive Wear. Plastic bead blasting media, Part Numbor 3822736, can be used to clean al piston ring grooves, Do not sure any ead blasting median piston pin bores or aluminum skits Follow the equipment manufacture’ clearing instructions. Make sure to adjust the alr pressure in the blasting rmactina tothe baad manufacturers recommendations. Tuming Up the pressure can move material onthe part and ause the plastic bead madia to wear out more quickly. ‘The folowing guidelines can be uted to adapt to ‘rufecturers instructons 1. Bead size: U.S. sizo Numbor 18 —20 for piston leaning wih plastic bead media, Part Number 3822735‘Genera Cleaning Instructions .9586,7 cuaaso B105 Pageri2 Section | sinoduetion 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 ofthe foreign material and plastic beads ater cleaning nse wit hot water. Ory th compressed at AcautionA “The bead blasting operation must not disturb the metal surface. Ifthe metal surface is disturbed the engine an be damaged due to Increased parts clearance or inadequate surtace finish on parts that move against other parts. \When cleaning pistons, its not necessary to remove all the dark stain from the piston Al that is nacessary isto Temove the carbon on the rm and In te rng grooves. Ths fs best done by directing tho blast across the part as ‘opposed to straight atthe pa ifthe machiung marks are dlsturbed by the Basting proces, then the pressure Is 0 high ore bast is being held on one spot too lng, The blast operation must not str the metal surface. Want shell bead blast material is sometimes used to clean ferrous meals (fon and ste!) Wat shal blasting produces a great amount of dust parloulary when tho pressure Ifthe ait pressure on the Biasting machine is ‘Moreased above media manufactuers recommendation. Cummins Ine. recommends not using walnut shell media to ‘Sean engine part due to tha risk media embedment and subsequent comtamination of he enna. ‘Cummins Ine. now recommends glass bead media NOT used to clean any engine pats, Gass media is too easly ‘mbedded into the material parieuarly in soll maletais and when at pressures greater than madia manufacturer's fecommand are used. The glass Is an abrasive co when iis in a moving pat, that part Is abrading all the parts in ‘contact with When higher pressures aro used the media Is broken and forms @ dust of very small size that floats yin tha ar. This dusts vory hard to contol the shop, pareulary i only compressed alr (and not Hot wate) is tied to Diow the med after is remaved from the Basing cabinet dlowing the par off side the cabinet ay remove large accumulations but neve removes all the medi). Bead basting is best used on stubborn diriearbon build-up that has not been removed by fst stoamhighor pressure ‘washing then washing in a heated wash tank Thess partoulry tue of pistons. Steam and soak the pistons frst then Use the paste bead method to safely remove the carton cemaining the grooves (instead of running the risk of fdamaging the surface fis of he groove wih awe wheel or ond ofa broken piston rng. Make sure the pars are dry fd a fa befor head blasting to prevent clogalng the retum on the blasting machine “Always direct the bead blaster nozzle "across" rather than directly atthe par. This allows the bead to get under the Uinvarted material. Keep the nozale moving rater than hold on one place. Keeping he nazzie rected at one-laoe to long causes the metal fo heat up and be moved around. Remember thatthe spray is not just iting the at oF Carbon. if the machining marks on the piston groove off have been disturbed then there has not been enough ‘movement of the nozzle andlor the a pressure ft high, Never bead blast vale stems. Tape or uso a sloove to protect the stems during besd basting. Direc the nozzle ‘croes the seat surface and radi rather than straight af them. The object fs to remove any carbon build up and Continuing to bast fo remove the stain isa wast af ime. Fuel System \Wnen servicing any fue system components, which can be exposed to potential contaminants, prior to disassembiy, "lean the tings, mounting hardware, andthe area around the component to be removed. ithe susrouncng areas as not cleaned, air or contaminants canbe introduced into the fel system, ‘The internal dings of some injectors are extremely small and susceptible to plugging rom contamination, Some fuel Injection systems ean operate at very high pressures. High pressure fual can convert simple parties ofc nd rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors. Etecrcal contact casner can be used i steam clearing tools are not avalabl. Use eleccal contact cleaner rather than compressed air lo wash dt and debris avay from ful system fitings, Diesel uel on exposed fuel systom parts atractsarborne contaminants (Choose lint fee towels fr fuel system work. Cap and plug fue ines, fitings, and ports whenever the uel system is opened. Rust, dt, and pat ‘system whenever a fuel ine oF other component fs loosened or removes from the eigis. In many i pattie fot ooeen a line or iting to Break the rust and pain loose, and then cesn of the loosened materia When removing fue nes or itings from a new or nawy-paintod engine, make sue to remove loose paint flakesIchips that can be created when a wrench contacts painted ine nuls oF fings, or when quck disconnect fitngs are removed. Fuel fters are rated in microns. The word micron isthe abbreviation for a micrometer, or one millonth of ameter. The ‘meron rating is te sizeof the smallest pariles that wil be captured by tne iter media. As a reference, a human har(9586.7 cmasso 510s ‘Goneral Cleaning instructions ‘Seetion | lnvodietion Pages is 76 microns [0003 in] in lamer. One micron measures 0.001 mm [0.00004 in], The contaminants being teed ‘ut aro smaller than can Be sean wth he human eye, a magaiying gass, oF 8 low powered microscope. “The tools used for fuel system troubleshooting and rapair are tobe cleaned regularly fo avoid contamination, Like fuel system parts, tools that are costed wth ll oF fuel alract arbome contaminants, Remember the folowing points regarding your fuel system toc: + Fuel sytem tools are tobe kept as clean a possible (Clean and ery the tols before returning them tothe tol box. + possible, store fuel system tools in sealed containers. ‘Make sure fuel sysom tools are clean before use.‘Acronyms and Abbreviations 9506,7 cw2360 B105 Pagers section induction Acronyms and Abbreviations General Information ‘The folowing Ist contains some of the acronyms and abbreviations used inthis manual "ANSI Fimarcan National Standards Insite API “American Petroleum Insitute ‘ASTHN ‘Arran Society af Testing and Matar ‘ATOC ‘ter Top Dead Certer BTU ah Thermal Unit ‘roe Before Top Dead Contor =o ‘colius TaN Cantor Area Waiver co Garton Monoxide Con, oid Cranking Ampere CARE’ Calfomia Ar Resources Board CAB. Customer interface Box CAD. ‘Subic Displacement ‘ENG. ‘Gompressed Natural Gas CPL. ‘Goniroi Paris Uist est Centos DEF Diasel Sxraust Fad DOG. Diesel Oxidation Catayat DPF Diesel Particulate Fit EC Engine Conor Modu EFC Elecronic Fuel Cont EGR Exhaust Gas Recruation EPA Environmental Pretacton Agony °F Fahrenhot Te Foot Pound Fats FM Failure Mode indenter cw ‘Gross Vehicle Wah Hg Merny hp. Torsepower 70. ‘Water ci Tries of Marcu in Hes Tnches of Water Tew Tghiion Convel Module TE Trlematonal Electrotechnical Commission Tei Telometers per Ltr Wa ‘lopascal LNG Tiauid Natural Gas 16 Tiguited Petoleum Gas LTA. Taw Temperature Afercooing CRS. ‘Modular Common Rail Syster a Mafunation Indicator Lamp MPa ‘Megapascal mph Wiles Per Hour ‘ma Ties Per Quart Wem ‘Newion-meter‘98067 cmz3s0 e105, Section Introduction ‘Acronyms and Abbreviations Paget Nox Teno Noga Owes NG. Tatural Gas 02 ‘Gxygen ‘O80. CrrBoard Diagrostes ‘OE ‘riginal Equipment Manufacturer ‘OSHA ‘Decupatonal Safety and Heath Adminisaon PID. Parameter denicaton Descristons Pom Paris Per hilion si Pounds Per Square ch PTO Power Takeo REPTO Teer Power Take OF RGT Rear Gear Train pm Revolutions Per Winute SAE Basel of Automotive ENgineSe ‘SCA, ‘Supplemental Coolant Adaive ‘SCR Selective Gaalyic Reduction STC. ‘Step Timing Control ‘SID ‘Subsystem ientiicaton Deserpons ToC! “Top Dead Center VOC Vat of Direct Curent ver Vafable Geomety Turbocharger ve Variable Speed vss ‘Vehicle Speed Sensor‘Acronyms and Abbreviations Pages Notes(988627 cmzss0 6105 Section 8 -Cooing System - Group 08 Page ta Section 8 - Cooling System - Group 08 Section Contents Page Coolant Heater 87 ‘lean and inspec for Reuse 88 Finishing Stops ‘a0 General informaian a7 Inet, re Preparatory Stops 88 Remove. 88 Coolant Piumiing ‘sea ‘lean and inspec for Reuse 870 Fishing Stops. B71 General information 309 instal ari Proparaiory Stops 270 Remove 870 Coolant Thermostat 5-10 Clean and inspect or suse 12 Finishing Stops. B14 ‘Genera Informacion 10 Instat 13 sake Tat ett Measure 13 Proparatory Sisps B12 Remove 12 Coolant Vent Lines Bota ‘Giean and Inspect fo cs, B16 Finishing Stops ‘Genera Information Install, Preparaiory Sepa. Remove, Cooling Fan Bei Tensioner Ba ‘ean and inspect for Reuse ‘B84 Fishing Steps. 866 Ina Check 8.62 Inst B85 Preparaiory Sicps. 64 Romove. 64 cooling Sysiom 18 Drain B19 Fil B24 Push 8.20 ‘Gone informaion ete Cooling System Diagnostics 827 ‘nalyzng the Daa, B42 ‘General information 27 Inital Check 8.33 Pressure Test 835 Test “38 workshest a2 Drive Belt, Cooling Fan re Clean and Inspect or Reuse. 35. Finishing Stops 87 ‘General Information 83 Insta BT Maintenance Check 33 Preparatory Stops. ‘Bs Remove. 85Page se Fan Clutch, Electric ‘ean and inspect or Reuse. Fishing Steps. (General tnormaion Install Proparaiory Sips. Remove, Fan Hub, Beit Briven ‘Giean and Inspect for Fuss, Finishing Steps. Insta Preparatory Steps. Remove. Fan Spacer and Pulley ‘Clean and Inspect for Reuss, Finishing Stops. Insta Preparatory Stops Remove. Pulley, Fan iio ‘assemble, Clean and inspect for Reuse, Disassemble. Finshing Steps. General information, Inst Propariny Sips. ‘service Toois ‘Toraiie Converter Cosier ‘Assombi.. : Clean and inspect for Reuse Disacsombl, Fishing Steps. (Gener information, Install Propariory Sips. Romave. Water inlet Connection ‘ean and inspect for Reuse. Finishing Steps (Gener inormaion Insta Proparaiory Sips. Remove. Water Pump ‘ean and inspect or Rouse. Fishing Stops (Genera tntormaisn, InilalChece Inet Preparatory Sips, Remove. ase67 cmzss0 6105 Section 8 Cooling System = Group 08(9887 cmzsa0 9105, Section 8 Cooling System - Group 08 Service Tools Cooling System Service Toole Page e ‘Te following special tots are recommended to perform procedures inthis secon. The use ofthese 1018 is shown in the appropriate procedure. These tools can Be purchased from local Cummins® Aushorzed pair Location, Too! No. ‘Too! Deseription ‘Too! tustration ‘Combustion Gas Leak Tester Used to test for combustion gasses inthe cooling system, 3822985 0 femmatoana Bone oni mens ust er rice Wi ant sou [SRST vce Used menare ta erty ears ot, restene| =) hf 3464488 oF | (ohms), and current (amperes). 3164488 - Standard meter. s164480| (J) Sita | oseteNtaowte ae setae | | 9 Vngnio uns an Fo tee eer eae a surrm | Seeed SERS, Bl Taba KF Vent cnet can ne congo sus02 7 te Rega cfntoncer het wk be ere cn asea cmzss0 8105 Page82 Section & Cooling System = Group 08 Tool No. ‘Too! Description Tool ilustration ‘Coolant DamvPressure Tester Used with shop air pressure, the coolant dam creates a vacuum, ‘sez4at9 | balding the coolant in vith ite oF no cookant loss Back Light Lamp (125VDG) Used with fuoresoent tracer to locate coolant andor oll leaks. Lamp s1eaase | operates of vice battery or portabe rechargeable batery included Ik. OW tracer Pan Number 8376801, coolant tracer, Part Number ‘Serra.(98867 ctz3s0 2105, Section 8 = Cooing System - Group 08 Drive Belt, Cooling Fan (008-002) General Information Due to the number of drive belt arrangements, this procedure does not cover al avaiable eoaing fan ave Bal routing, ‘To make sure th cooling fan dive bets routed correctly Upon installation, make a giagram of the cooling fan batt ‘our per fe removing the bot a8 shown In the stration, ‘Tho cooling fan belt routing typcally consists of the folloning components, but may net include al of them: 1 Crankshaf puleyivbration damper Fan pulley Wate pump pulley Retigerant compressor pulley ‘Aternatr pulley 6 Tensioner ler pully. NOTE: Some engine driven belts are instaled/supplied by the vehicles orginal equipment manufacturer (OEM). Seo the OEM serve manual for removal and instalation instuctone ‘Maintenance Check Poly-Vee Bett Inspect the bets daily. Check the belt for Intrsecting cracks. Traverse (across. the bet with) cracks are ‘ceptable. Longitudinal (recon of belt length) cracks that intersect wih traneverse cracks are not acceptable, Replace the belt If it's frayed or has pieces of material missing. See. Secion A’ for\ bell adjustment and replacement procedures. Bolt damage can be caused by: + Income tension Incorect size or length + Pulley misalignment Incoect installation + Severe operating environment + Oller grease on the side of the bets. ® page 83rive Bot, Cooting Fan Page st ‘as96.7 cwn3s0 8105 Section 8 Cooting System = Group 08 Cogged Bett Inspect the belts daly. Replace the belts if they are cracked, frayed, of have chunks of material missing ‘Smal cracks are acceptable, ‘Aju the belts that have a glazed or shiny surface, which indicates vet slippage. Cored installed ana teneioned belts wil show oven pulley and belt wear, See Section A forbelt adjustment and replacement procedures. Belt damage can be caused by + Incoreet tension + Incorect size or length + Pulley misatignment + Incorect instalation + Severe operating envoament + Oller grease on the the bets Measure the bal tension inthe center span of he pulleys. ‘See the Belt Tension Chart in Section V for tho correct (gauge and tension value for he belt width used. {An altemate method (defection method) can be used to ‘heck. belt tension by. applying’ 110.N [25 Ib] force Between the pulleys on vibalts F the defection is more ‘han ane belt thickness pe fot of pully center distance, the bat tension must be austed. For cogged bolts, make sure that the belt tension gauge Is posiloned so that the canter tensioning leg ts placed ‘recty over the high point (hump) of a009, ‘Other posttoning wil resultn ncorect measurement.‘9806.7 cmz360 8105 Section 8 Cooing System - Group 08 Preparatory Steps. dAwarninc A Battorios can emit explosive gases. To reduce the possibilty of personal injury, always ventilate the Compartment before servicing the. batteries, To Feduce the possibilty of arcing, remove the negative (battery ‘able first and attach the negative (-) Battery eable last. + Disconnect the batioy cables. Refer to the OEM ‘sence manual. AcautionA ‘The belt tensioner Is springoaded and must be pivoted away from the drive belt Pivoting in. the wrong direction ‘can result In damage to the belt tensioner. ‘The bal tensioner winds in the drecton thatthe sping fang is bent over the tensioner body. To loosen the tension onthe Belt, rotate the tensioner to wind the spring tighter AcautionA Applying excessive force in the opposite direction of windup or after the tensioner has been wound up 10 the positive stop can cause the tonsionor arm to break NOTE: Make a dlagram of the belt arrangement prior to removing the ‘ive bat. This aids In ltallaion and proper routing ofthe cooing fan dive bet NOTE: The locaton of the belt tensioner can vary, ‘depending onthe font engine accossory arrangement. Pivot the tensioner inthe direction of the spring tang to remove the bel Remove the bet. Clean and Inspect for Reuse Inspect the rive belt for damage. “Transverse (across the bet cracks are acceptable. Longitudinal (erection of belt ribs) cracks that intersect ‘wih Wanaverea cracks are not acceptable, Ifthe bet is frayed, punctured, or mater is missing, the bal is unacooprabe for reuse and must be repiaced, B = @ vs page 8SDrive Bat, Cooting Fan Page 8 .086,7 cw2360 8105 Section 8 -Cootng System - Group 08 Inspec the bel grooves for + Embedded debris + Unevenfoxcessve lo wear + Exposed bet cords Inspec the backside ofthe bal fo: + Glazing (igh heat) + Embedded debris + Exposed batt cons. I any of the above conditions are present, the bet is unacceptable for rouse and must be replaced, Inspect theo an erive pulleys for wear or eracks Plastic pulleys often have a build-up of road det and bet ‘material tals not to be confused with woot. The dit can be removed with a suitable tol to check for Clean, check, and reuse all puileys in the front end accoséory ative I not damaged, rather than replacing. Pulleys damaged ‘rom embedded “debris! must be replaced, Inspect the tensioner. Refer to Procedure 008.087 in Seton 6 Inspec al system ples for embedded debris: + Rocks, stones + Metal + Belt materia Remove the debris fom the grooves ofthe pulley. f the puley has boen deformed ao 9 result of forign material ‘omedment, the pulley must be replaced.(98067 cuzas0 0105 Section 8 Cooling System - Group 08 Install AcaurionA ‘The belt tensioner is springloaded and must bo pivoted away from the drive belt. Pvoting In the ‘erong direction can result in damage. to the belt tensioner. Route the dive belt on the engine using the bet diagram created in the Remeave seston, Do not instal the belt over the water pump pulley at tis time. Pvt the tensioner inthe direction of the spring tang an inal the drive bet, sipping the bet over the water pump pulley last Siowly release the tensioner to apply tension tothe dive belt CChock the alignment ofthe belt wit the tensioner and the Fest of the tant ond ooaseory drive, Finishing Steps Awarninc A Battries can emit explosive gases. To reduce the possibilty of personal injury, always ventilate the Compartment before. servicing. tho. batteries, To Feduce the possibilty of arcing, remove the negative (0 battery cable first and attach the negative (.) Battery eable last + Connect the battery cables. Refer tothe OEM service manval Operate the engine and check for bolt squeal Exoossive belt squsal indicate belt slippage I belt squeal is present, check the routing of tho belt to ‘maka sire thatthe bet fs Installed comecty on each pally. Coolant Heater (008-011) General Information Some heaters wil operate continuously when plugged into the corect voltage electrical socket. Operate them only when the anion! temperature Is below O°C [32°F] & oy fapBs (08867 cMass0 Systm = Group Section 8- Coot Proparatory Steps Awarninc A Batteries can emit explosive gases. To reduce the possibilty of personal injury, always ventilate the Compartment before servicing. the batteries. To ‘educe the possibilty of arcing, remove the negative (G) battery ‘cable first and attach the negative () Dattory cable ast. Awanniic A Coolant is toxle. Keop away from children and pets. f ‘ot reused, dispose of In accordance ‘with local ‘environmental regulations. + Disconnect the batioy cables. Refer to the original equipment manufacturer (OEM) service manta + Drain at least 19 tors (5 gall rom the cooing system. Rotor to Procedce 008-078 In Seaton 8 Remove ‘The threaded coolant heater is located adjacent to the lubeeating ol” cooler. Disconnect the block. hoalar lectnical cor. ‘Unscrew the coolant neate from the block Remove the coolant heater from th block(98867 cmasso 2108 Section 8 = Cooling System - Group 08 Clean and Inspect for Reuse Clean the coolant heater por thoroughly with a clean rag Make suce thee are no burs, metal shavings, or sharp edges that can cul the ong. CGean the coolant heater thoroughly with a clean rag Make. sure the heating elements tree of debris and Dullup and the seating area i lean (Check the coolant heater fr cracks on the element. Awarninc A To reduce the possibilty of personal injury, due to lectical ‘shock, do not touch the electrical supply Wires or component while the testing procedure fe ia etion. Measure the coolant heater resistance. The resistance ‘must read between 18.2 and 21-1 ohms, & [Coolant Heater Resiatance (Ohms) [aon MAX ie it Install ‘Apply pipe sealant, Part Number 3375066, tothe threads ‘ofthe Gaolant heater. Install the coolent heater into the cylinder block and tighten. Torque $5 Nem 41 Rb] Insert the power cod nto the socket. Be careful to align the pins withthe sockets of the power cord. Tighen the retaining nut by hand, NOTE: Do not apply power to the element unt the ‘cooing system is flac, and the engine has run long fnough forthe thermosiat to open and allow the ar to ‘cape.Ccootent Thermostat Page 8-10 ‘as96:7 cwaaso a10s Section 8 -Cooing Systom = Group 08 Finishing Steps Awarninc A Coolant is tox. Keep away from children and pets. If ot roused, dispose of in accordance with local ‘environmental regulations. dwarninc A Batteries can emit explosive gases. To reduce the Possibility of personal injury, always ventilate the Compartment before servicing. the batteries. To Feduce the possibilty of arcing, remove the negative (G) battery cable frst and atach the negative () Battery cable ast. Fil the engine cooling system. Refer to Procedure (008-078 n Secon 8 Connect the battery cables. Refer tothe OEM service smanval + Operate the engine to check for leaks. + Connect power to the heating element to check for proper operation. Coolant Thermostat (008-013) General Information ‘Tho thermostat controls the engine coolant temperature, \Wiron'tho.eoolant omperature fa below the operating ‘ange, engine coolant Is bypassed back tothe it ofthe water’ pump. When the engine coolant temperature Teaches the operating range, tne thermostat opons, seals ‘of the bypass, and forces engine coolant to flow to the Fadlator or the hen excnanger. NOTE: Some applications use an ofginal equipment manufacturer’ (OEM). supplied " remote, mourted thormosta Rete tothe OEM service manus for oeaion, Refer to the OEM sonice manual for remota mourted thormestat removal and nsalaton Instructions, ‘An incorrect or malfunctioning thermostal can cause the engine orn too hot orto co AcautionA. Never operate the engine without a. thermostat. Without a thermostat, the path of least resistance for the coolant is through the bypass to the water pump Inlet. This can cause the engine fo overheat.