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4-35
4.6 Removal and installation of engine as

4.5.2 Installation of fan
Structural drawing of engine mounting assembly (version 40C5782000)
S/N Parts name Quantity S/N Parts name Quantity

1 Bracket 1 6 Hard washer 4
2 Diesel engine 1 7 Cap 4
3 Shock absorber 2 8 Bolt 8
4 Locknut 2 9 Bracket 1
5 Bolt 2 10 Engine fan 1
1. Regularly measure with eyes engine mounting (including engine mounting support and shock
absorber). Tighten the bolts if the looseness occurs. If safety seat of engine cracks, replace it. If the
4-36
4.6.1 Removal and installation of engine mounting
shock absorber is cracked, damaged or rotted, replace it.

Tool list
Name Specifications
Open-end spanner 16mm, 30mm
Torque spanner 120±6N.m, 1020±6N.m
Plastic sealing membrane
Travelling crane above 2t
Wire rope with hooks Weight load over 840Kg
Tool for measuring the clearance between shroud and fan
Steel ruler
Remarks:
1. In view of large M20 bolts during the removal and installation of engine mounting, it is recommended using
a blower gun and a socket for easy removal and installation, as well as using an open-end spanner for
auxiliary holding.
2. Re-measurement of fan clearances is needed after shock absorber is replaced. If possible, it is
recommended using LiuGong shroud-fan clearance measuring tool; otherwise, a steel ruler can also be used
for measurement.
4-37
The removal of engine mounting:
Picture Removal objects Tool
1. Turn off the negative

electrode switch, and
hang on a "No
operation" warning
board.
2. Remove the engine
hood top cover
according to removal
and installation
requirements and steps
of engine hood in
Section 12.3.
3. Remove exhaust pipe,
air pre-filter and
connecting pipe
thereof, and use plastic
sealing film to seal
each end as required,
Plastic sealing
and installation
membrane
of intake and exhaust
Note system described in
Section 4.4.
No Operation
hood according to
removal and
installation
of engine hood in
Section 12.3.
5. Loosen captive bolts of
transmission according
to removal and
installation
of transmission
described in Section
5.1.1.
4-38
6. Hold captive nut 4 of

engine with an open-
end spanner, and
remove captive bolt 5
of engine from under
engine mounting Tool:
support with a blower Open-end spanner
gun, a rod and a 30#
socket. And take down
the shock absorber and
its cover from the
engine mounting
support.
7. Operate wire rope on

Lifting hole
travelling crane for
lifting hook to pass
hook through lifting
hole at fan side of
engine, and lift engine Travelling crane
as slowly as possible.
Wire rope with
Lifting height should
hooks
allow no interference
between fan and
shroud of engine. It is
Warranty recommended lifting
clearance
height is not larger than
5 mm.
4-39
8. Take out shock

absorber 3 and cover 7
under the mounting
support of the engine.
9. Loosen captive bolt 8

of engine mounting
support and take it out
with an open-end Tool:
spanner or a blower
Open-end spanner
gun (ratchet spanner),
16#
a rod and a socket, and
then take down engine
mounting support 9 and
1.
4-40
The installation of engine mounting:
Installation
Picture Tool
objects
1. Turn off the

negative electrode
switch, and hang on
a "No operation"
warning board.
CAUTION
No Operation
4-41
Installation
Picture Tool
objects
2. Install engine
mounting support
on engine with
captive bolt for
engine mounting
support, and pre-
tighten captive bolt
Tool:
with an open-end
Open-end spanner
spanner or a blower
16#,
gun (ratchet
spanner), a rod and 120±6N.m torque
a socket. spanner
3. Tighten mounting
support captive bolt
of engine with a
torque spanner to
torque of 120 ±50
N.m.
4. Place shock
absorber and cover
at upper and lower
sides of engine
mounting support
respectively, and
adjust shock
absorber so that it is
installed into hole of
mounting support.
5. Assemble shock
absorber, cover and
engine mounting
support together by
passing engine
fasteners such as
captive bolt and nut
through them.
4-42
Installation
Picture Tool
objects
Lifting hole
6. Lay down the

engine slowly when
maneuvering the
vehicle and loose
the lifting hook.
7. Hold nut with an

open-end spanner,
and pre-tighten
captive bolt of
engine from under
engine mounting
support with a
blower gun, a rod
and a socket.
8. Tighten captive bolt
of engine with a Tool:
torque spanner to
Open-end spanner 16#
torque of 1,020 ±6
1,020±6N.m Torque
N.m.
spanner
9. Re-tighten captive
bolt of transmission
with a torque
spanner according
to removal and
installation
requirements and
steps of
transmission
5.1.2.
4-43
Installation
Picture Tool
objects
10.Measure clearances
between fan and
shroud, protection
Clearance between fan and shroud>10mm
shield. Clearance
between fan and Tool for measuring the
shroud should be clearance of fan (steel
larger than 10 mm, ruler)
while that between
Edge of the fan
fan and protection
shield should be
larger than 20 mm.
Inner edge of the

protection shield
11. Install hood

according to
removal and
installation
requirements and
steps of hood
12.3.
4-44
4.6.2 Removal and installation of engine
Installation
Picture Tool
objects
12. Install exhaust
pipe, air pre-filter
and connecting pipe
thereof according to
removal and
installation
requirements and
steps of intake and
exhaust system
4.4.
13. Install engine hood
according to
removal and
installation
requirements and
steps of engine
hood hereinafter.
14. Close the engine
hood and take off
the warning board
"No operation".

Tool list
Name Specifications
Travelling crane Above 2t
Wire rope with hooks
Plastic sealing membrane
Oil collecting basin
Remarks:
1. In view of large M20 bolts during the removal and installation of engine mounting, it is recommended using
a blower gun and a socket for easy removal and installation, as well as using an open-end spanner for
auxiliary holding.
2. Re-measurement of fan clearances is needed after fan is removed and installed. If possible, it is
recommended using LiuGong shroud-fan clearance measuring tool; otherwise, a steel ruler can also be
used for measurement.
4-45
1. Turn off the negative

electrode switch, and
hang on a "No
operation" warning
board.
hood according to
removal and
installation
requirements and
steps of engine hood
in Section 12.3.
3. Remove air filter,
muffler and their
connecting pipes
and installation
requirements and
steps of intake and
exhaust system
4.4; seal every
terminal with plastic
CAUTION seal membrane as per
the requirements.
No Operation Whether to remove
and install muffler
bracket depends on
specific conditions of
an engine position
under repair.
4. Remove feed and
drain hoses and pipe,
empty coolant into oil
collecting basin for
treatment together,
and use plastic sealing
film to seal each end
as required, according
to removal and
installation
requirements and
steps of cooler lines
4.10.2.
4-46
5. Remove protection
shield according to
removal and
installation
requirements in
Section 4.10.3.
6. Remove engine fan
and support thereof
and installation
requirements and
steps of fan described
in Section 4.5.
7. Remove electrical
connector and wiring
on engine according to
removal and
installation
requirements and
steps of electrical
system described in
Section 7.
8. Remove A/C pipe and Plastic sealing
warm air hose on membrane
engine, and use Oil collecting basin
plastic sealing film to
seal each end as
required, according to
removal and
installation
requirements and
steps of air
conditioning system
8.2.
9. Remove fuel hose and
flexible throttle shaft
on engine, and use
plastic sealing film to
seal each end as
required, according to
removal and
installation
requirements and
steps of fuel lines and
throttle control system
described in Sections
4.7 and 4.8.
4-47
Lifting eye Lifting eye
10. Slowly operate

travelling crane, hang
lifting eye on engine Travelling crane
with hook on wire
Wire rope with hooks
rope, and tauten wire
rope without lifting
engine.
11. Remove captive bolt

in connecting surface
of engine and torque
converter according to
removal and
installation
requirements and
steps of transmission
& torque converter as
described hereinafter.
12. Remove captive bolt
of engine according to
removal and
installation
requirements and
steps of engine
mounting described
hereinbefore.
4-48
4.6.3 Turbocharger
13. Slowly operate

travelling crane and
hold both sides of
engine in order to
ensure that engine is
slowly and steadily
lifted out of complete
Buttress Buttress machine and will not
collide with other parts
of complete machine.
Installation of engine
Installation is in the reverse order of removal.
4.6.3 Turbocharger
Turbocharger is mainly used to increase intake pressure and improve intake quantity (intake density), and
finally improve engine power and economy.
Installation location and its diagram of turbocharger
4-49
4.6.3 Turbocharger
S/N Description S/N Description

1 Exhaust pipe 6 Bearing
2 Nozzle ring 7 Diffuser
3 Turbine 8 Compressor impeller
4 Turbine housing 9 Compressor housing
5 Rotor shaft 10 Intake pipe
Maintenance
Turbocharger is a precision machine running at a high speed, and thus random removal is forbidden. If
severe wear or damage is found during a check, corresponding parts must be adjusted, repaired or
replaced. If turbocharger is damaged or improperly adjusted, it cannot function sufficiently, that is, it cannot
deliver sufficient air to engine. If malfunctions, go to Cummins maintenance center for repair.
Proper operation:
1. Before lubricant pressure of engine is built, keep engine idle.
2. Before engine is stopped, gradually lower its temperature and revolutions from maximum values (for
approximately 5 minutes).
3. Lubricate the turbocharger first. After replacement of lubricant or any services (including draining
lubricant), pre-lubrication is required for turbocharger. Move crankshaft disc several times before
engine starts. After engine starts and before it begins to run at a high speed, keep engine idling for a
period so pressure of whole lubricant circulation can be built.
4-50
4.6.3 Turbocharger
4. Be cautious when start the engine at low temperature. When ambient temperature is too low or vehicle
is idle for a long period, engine’s ability to build proper lubricant pressure and flow will be affected. In
that case, engine cannot but idle for several minutes after starting in order to work properly.
5. Avoid running the engine idle for a long time. In addition, whenever lubricant is replaced, oil filter is
washed or engine is rest for a long period (approximately more than a week), loosen oil inlet joint of
turbocharger and inject clean lubricant so turbocharger lubrication system is filled with lubricant.
6. For other maintenance information on turbocharger, see engine operation and service manual attached
to machine.
Faults
Fault mode: air intake system blockage;
Troubleshooting: check lines between air filter and air compressor, lines between air compressor outlet and
intake pipe and intake pipe, and keep those positions clean and clear.
Fault mode: leakage in air intaking;
Troubleshooting: check lines between air filter and air compressor, lines between air compressor outlet and
intake pipe, and joint between intake pipe and engine to see whether any part having a leak, a captive bolt
able to be tightened, a gasket needing replacement, etc. exists.
Fault mode: air exhaust system blockage;
Troubleshooting: maintain or replace the related parts.
Fault mode: leakage in air exhausting;
Troubleshooting: check joints between exhaust pipe and engine, between turbine inlet and exhaust pipe,
between turbine housing and middle housing as well as between turbine outlet and exhaust pipe. If any
leak exists, defective sealing gasket can be replaced to tighten corresponding captive bolt.
Fault mode: air compressor rotor collides with air compressor housing, and turbine collides with turbine
housing;
Troubleshooting: replace the assembly.
Replace assembly: oil inlet or return pipe leakage;
Troubleshooting: replace relevant parts.
Removal and installation
For the removal and installation of turbocharger, see Cummins Engine Service Manual.
4-51
4.7 Fuel system
4.7.1 Function and working principle of fuel system
4.7 Fuel system

4.7.1 Function and working principle of fuel system
Fuel inlet
Fuel return
Working principle of fuel system

1.Fuel tank 2. Fuel-water separator 3. Fuel transfer pump
4. Fuel filter 5. Fuel injection pump 6. Injector
Fuel system acts to provide engine with clean and sufficient fuel, which thus ensures proper operation of
engine. Its working principle is shown above: when engine works, fuel transfer pump 3 sucks fuel from fuel
tank 1, then fuel-water separator 2 eliminates water from fuel, next fuel filter 4 eliminates impurities from
fuel, and finally fuel enters fuel injection pump 5. After fuel is pressurized and metered in fuel injection
pump, it is supplied into injector 6, and finally is injected into combustion chamber by injector. Return fuel
from top of injector returns to fuel injection pump inlet, while spare fuel supplied by fuel transfer pump
returns to fuel tank.
4-52
4.7 Fuel system
4.7.2 Removal and installation of fuel lines

Fuel lines comprise fuel inlet pipe, fuel return pipe, fuel-water separator, etc. See
below diagram and list for details:
Part No. Name Quantity Part No. Name Quantity

1 Fuel hose 1 12 Washer 4
2 Fuel hose 1 13 Bolt 3
3 Turbine worm clamp 6 14 Fuel hose 1
4 Support 1 15 Connector 1
5 Washer 6 16 Washer 10
4-53
4.7 Fuel system

6 Washer 6 17 Connector 1
7 Bolt 6 18 Screw 5
8 Drain hose 1 19 Bolt 1
9 Fuel-water separator 1 20 Nut 1
10 Hose clamp 4 21 Connector 4
11 Washer 4 22 Pipe clamp 1
Tool list
Name Specifications
Open-end spanner 7#, 16#, 18#, 19#
Waste oil tank
Plastic sealing bag
Remark: removed standard parts should be placed with relevant material together to avoid confusion.
Removal of fuel lines
Picture Steps Tool
1. Remove fuel returnpipe 2

(line from fuel tank to fuel Tool:
return joint of engine) Open-end spanner
a. Remove the hose clamp 16#
10 fixing the fuel hose.
4-54
4.7 Fuel system
b. Unscrew turbine worm

clamp 3 connecting fuel
hose and engine fuel
return port, take down fuel
Tool:
hose here and recover fuel
flowing out of line and Open-end spanner
engine fuel return port 7#, 19#, waste oil
through waste fuel drum. drum
c. Block the engine return oil
port with clean plastic
bags.
d. Remove screw 18
connecting fuel hose and
fuel tank end, take down Tool:
fuel hose, and install Open-end spanner
screw back on fuel return 7#, 19#, waste oil
port of fuel tank. Block the drum
fuel hose with clean plastic
bag.
4-55
4.7 Fuel system
2. Remove fuel inlet pipe 14

(fuel-water separator to
fuel hose of oil transfer
pump):
a. Disassemble the hose
clamp 10 fixing the fuel
hose.
b. Remove screw 18 of fuel
hose at oil transfer pump
end, take down fuel hose, Tool:
recover fuel in line
Open-end spanner
through waste fuel drum
16#, 19#, waste oil
and install screw back on
barrel
fuel inlet of oil transfer
pump.
c. Remove screw 18 of fuel
hose at fuel-water
separator end, install
screw back on fuel-water
separator after taking
down fuel hose, and mask
fuel hose with clean
plastic bag.
3. Remove fuel inlet pipe 1
(fuel tank to fuel-water
separator fuel hose)
a. Remove the fixed fuel
hose clamp 10.
b. Remove screw 18 of fuel
hose at fuel-water
separator end, take down
fuel hose, and recover Tool:
fuel in line through waste Open-end spanner
fuel drum. Then put bolt 16#, 19#, waste oil
back onto fuel-water barrel
separator.
c. Remove screw 18 of fuel
hose at fuel tank end,
install screw back on fuel
tank after taking down
fuel hose, and mask fuel
hose with clean plastic
bag.
4-56
4.7 Fuel system
4. Remove fuel-water
separator 9:
Remove 4 bolts 7 on fuel- Tool:
water separator mounting Open-end spanner
bracket, take down fuel- 18#
water separator and bracket,
and put them away properly.
Installation of fuel lines

Installation is in the reverse order of removal.
4-57
4.8 Throttle control system
4.8.1 Throttle control system

4.8.1 Throttle control system
1 Throttle control system 1 2 Flexible shaft 1
Tool list
Name Specifications
Open-end spanner 10#, 13#, 16#, 22#
4-58
4.8.2 Removal of throttle control system
4.8.2 Removal of throttle control system
Picture Steps Tool
1. Remove the flexible shaft:

Remove captive nuts on Tool:
mounting bolts at both ends
Open-end spanner
of flexible shaft, loosen fixing
10#, 22#
cap of jacket, and take
flexible shaft down.
2. Remove the throttle

control system:
Tool:
Lift up floor mat, remove 4
Open-end spanner
captive bolts on throttle
16#
control system, and take
down throttle control system.
4-59
4.8.3 Installation of throttle control system
4.8.3 Installation of throttle control system

Picture Steps Tool
1. Install the throttle control

system Tool:
Screw the 4 captive bolts Open-end
on the throttle control spanner 16#
system.
2. Accelerator flexible
shaft installation
(installation between
flexible shaft and
accelerator pedal joint)
a. Fix end of accelerator
flexible shaft to Tool:
mounting hole
Open-end
corresponding to
spanner 10#, 22#
accelerator pedal, and
tighten mounting nut.
b. Adjust the positions of
two nuts fixing flexible
shaft, then fix them on
the bracket and fasten
them.
4-60
4.8.4 Adjustment of throttle control system
Picture Steps Tool
3. Accelerator flexible
shaft installation
(installation between
flexible shaft and engine
joint)
a. Fix end of accelerator
flexible shaft to
mounting hole Tool:
corresponding to Open-end
accelerator linkage of spanner 10#, 22#
engine, and tighten
mounting nut.
b. Adjust the positions of
two nuts fixing flexible
shaft, then fix them on
the bracket and fasten
them.
4.8.4 Adjustment of throttle control system

After accelerator flexible shaft is installed, under normal circumstances: accelerator pedal is free, and
engine can be idling; accelerator pedal can be operated smoothly and freely, and when it is at the lowest
point, engine is in maximum working conditions; Release the accelerator pedal, and the pedal can return
automatically. If any exceptional conditions occur, that is, engine cannot idle, accelerator pedal operations
are obviously tough, accelerator cannot reach maximum accelerator position, or accelerator cannot return,
carry out mutual coordination and adjustment through installation steps 2b and 3b of throttle control
system, until operation is normal.
4-61
4.9 Removal and installation of fuel tank as
4.9.1 Fuel tank as

4.9.1 Fuel tank as

1 Fuel tank 1 13 Filler tube 1
2 Drain plug 1 14 Strainer 1
3 O-ring 1 15 Tank cover as 1
4 Hard washer 8 16 Retainer 1
5 Locknut 4 17 Adjustable connector 1
6 Bolt 4 18 Turbine worm clamp 2
4-62
4.9.2 Removal of fuel tank
7 Washer 4 19 Fuel hose 1

8 Shock absorber cushion 4 20 Adjustable connector 1
9 Rubber washer 1 21 Suction flange 2
10 Washer 3 22 O-ring 2
11 Washer 3 23 Bolt 12
12 Bolt 3 24 Washer 12
Tool list
Name Specifications
Open-end spanner 7#, 16#, 18#, 19#, 20#, 24#, 30#
Socket spanner, socket Socket spanner, 24# socket
Clean oil basin, towel
Plastic sealing bag
Forklift
Diagram Removal objects Tool
1. Drain diesel oil:

Clean drain hole of fuel tank,
place a clean oil container
under the fuel tank, and Tool:
unscrew drain plug 2. After fuel
24# socket,
is drained, fix drain plug back
socket spanner
to fuel tank. Drained fuel
should be strictly sealed for
preservation to prevent
pollution to fuel.
4-63
2. Remove the clamp: Tool:

Remove the clamp bolt on the Open-end
fuel tank, and take off the hose spanner 16#,
clamp. 18#
Hose clamp
3. Remove the fuel lines of

suction and return port:
After fuel is drained, remove
screw 23 of fuel hose at fuel Tool:
tank end, take down fuel hose Open-end
of that end, and fix the screw spanner 19#
back to fuel return hole. Block
the fuel hose with clean plastic
bag.
4-64
4. Remove the fuel sensor

wire harness:
Remove the harness connector
of fuel tank sensor.
5. Remove fuel-water
separator:
a. Remove assembly joint
screws of fuel hose at both
ends of fuel-water
separator, take down fuel Tool:
hose close to fuel tank, and Open-end
screen fuel hose with a spanner 19#,
clean plastic bag. 18#
b. Remove 4 bolts from
mounting bracket of fuel-
water separator, and take
down fuel-water separator
and its bracket.

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4-35

4.6 Removal and installation of engine as

Structural drawing of engine mounting assembly (version 40C5782000)

S/N Parts name Quantity S/N Parts name Quantity

shock absorber is cracked, damaged or rotted, replace it.

The removal of engine mounting:

Picture Removal objects Tool

1. Turn off the negative

Picture Removal objects Tool

6. Hold captive nut 4 of

7. Operate wire rope on

Picture Removal objects Tool

8. Take out shock

9. Loosen captive bolt 8

The installation of engine mounting:

1. Turn off the

6. Lay down the

7. Hold nut with an

Inner edge of the

11. Install hood

4.6.2 Removal and installation of engine

Picture Removal objects Tool

1. Turn off the negative

Picture Removal objects Tool

Picture Removal objects Tool

Lifting eye Lifting eye

10. Slowly operate

11. Remove captive bolt

Picture Removal objects Tool

13. Slowly operate

S/N Description S/N Description

4.7 Fuel system

Working principle of fuel system

4.7.2 Removal and installation of fuel lines

Part No. Name Quantity Part No. Name Quantity

Part No. Name Quantity Part No. Name Quantity

Removal of fuel lines

Picture Steps Tool

1. Remove fuel returnpipe 2

b. Unscrew turbine worm

2. Remove fuel inlet pipe 14

Installation of fuel lines

4.8 Throttle control system

Part No. Name Quantity Part No. Name Quantity

1 Throttle control system 1 2 Flexible shaft 1

4.8.2 Removal of throttle control system

Picture Steps Tool

1. Remove the flexible shaft:

2. Remove the throttle

4.8.3 Installation of throttle control system

1. Install the throttle control

Picture Steps Tool

4.8.4 Adjustment of throttle control system

4.9 Removal and installation of fuel tank as

Part No. Name Quantity Part No. Name Quantity

7 Washer 4 19 Fuel hose 1

4.9.2 Removal of fuel tank

Diagram Removal objects Tool

1. Drain diesel oil:

Diagram Removal objects Tool

2. Remove the clamp: Tool:

3. Remove the fuel lines of

Diagram Removal objects Tool