@e@eeee © @ Oe @ i MID-RANGE, TIER 2 & 3 SERIES POWER UNIT OPERATIONS & MAINTENANCE MANUAL SUPPLEMENTMID — RANGE SERIES POWER UNITS OPERATIONS & MAINTENANCE MANUAL SUPPLEMENT TABLE OF CONTENTS INTRODUCTION. TO THE OWNER AND OPERATOR, SAFETY PRECAUTIONS AND WARNINGS. APPLICATION AND INSTALLATION GUIDELINES. PRE-HEAT INSTRUCTIONS. COOLANT CAPACITIES. LIFTING GUIDELINES, WIRING SCHEMATIC ~ A-SERIES. 2a ap oewH a 9-10 11-13 WIRING SCHEMATIC - B3.3, Tier 2 WIRING SCHEMATIC - B3.3NA, Tier 3. WIRING SCHEMATIC - B3.3T AA, Tier 3 WIRING SCHEMATIC - QSB3.3, Tier 3 WIRING SCHEMATIC 4BTAA/6BTAA/ /B3.9/B4.5/B5.9/6CTAA. WIRING SCHEMATIC - B3.3NA/B3.3T AA Panel WIRING SCHEMATIC - QSB/QSC/QSL Panel WIRING SCHEMATIC ~ QSB/QSC/QSL Engine, Tier2 WIRING SCHEMATIC ~ QSB/QSC/QSL Engine, Tier3 WIRING SCHEMATIC - B3.3NA, Tier 3, WIRNG SCHEMATIC ~ 12 VOLT/GRID HEATER. WIRNG SCHEMATIC - 24 VOLT/GRID HEATER. WIRNG SCHEMATIC - HIGH CURRENT WITH STARTER GROUND. POWER UNIT OPERATION PRACTICES. 14 15 16 47 18-21 22 23 24-25 26-27 28 29-31 32-34 35-39 40 POWER UNIT PRE-START CHECKLIST & OPERATING PROCEDURES. 41 OPERATIONS AND MAINTENANCE SUPPLEMENTAL MANUAL P/N 99000083 REV. 04/12INTRODUCTION This manual provides operating instructions for Cummins Power Units. The following manual points out areas of potential problems and explains some of the major factors that can cause a decrease in engine life. Engine life can be influenced by many factors. Proper maintenance practices can reduce repair costs and down time. The full benefit of design changes made to improve engine life cannot be obtained unless all factors, which shorten engine life, are controlled. Be aware that various options or accessories installed on the engine may have some effect on the engine assembly procedures. WARNING: This symbol appears when a potentially hazardous safety condition exists that could cause personal injury or death. These hazards are not always apparent to a trained mechanic. Review the safety precautions at the beginning of this manual. Read and familiarize yourself with this manual and the procedures involved before assembling the power unit. Note any additional parts that may be needed so that they can be purchased. Check tool availability and verify that they are the proper size and in good working order before starting assembly. Make sure your work area is clean and safe. Parts Manuals are available for Power Units. Each parts list contains part numbers, quantities and descriptions of each part in the subassembly. For assembly and replacement purposes, use the parts list for proper identification. For service and service parts requirements, contact your local Cummins Distributor or Dealer. Parts can also be found online at either http://epp.cummins.com or http//cumminspowerproducts.com . THIS MANUAL SHOULD BE KEPT NEAR THE POWER UNIT FOR FUTURE, REFERENCE. FOR GENERAL OPERATING INSTRUCTIONS, SERVICING REQUIREMENTS, AND RECOMMENDATIONS refer to the manual(s) and literature provided by Cummins, Inc. included with the engine for proper operation of the engine.To the Owner and Operator Preventative maintenance is the easiest and least expensive type of maintenance, Follow the maintenance schedule recommendations outlined in the Maintenance Guidelines provided to you by Cummins, Ine. Keep records of regularly scheduled maintenance. Use the correct fuel, oil, and coolant in your engine as specified in your Operation and Maintenance Manual. 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 Engine Operations Manual supplied by Cummins or refer to this Operations and Maintenance Manual supplement included with the engine. Each unit is shipped with the appropriate operation and warning decals. They are shipped loose to accommodate various paint schemes that can be applied. It is your responsibility to properly install all the decals supplied with the power unit. Safety is built into every power unit; however, like any other mechanical device, it can present a serious threat to life and limb if improperly operated and maintained. Remember that the best safe guards against accidents are to keep fully alert to the potential dangers and to always use good common sense. In the interest of safety, some general precautions have been presented, Remember that Cummins has no way of knowing the use you have for your engine. ‘THE EQUIPMENT OWNER AND OPERATOR ARE RESPONSIBLE FOR THE SAFE OPERATION IN A HOSTILE ENVIRONMENT. CONSULT REGIONAL DISTRIBUTORS, DEALERS, OR CUMMINS FOR FURTHER INFORMATION.SAFETY PRECAUTIONS AND WARNINGS NOTE: Read and understand all of the safety precautions and warnings before assembling or performing any repair. This list contains general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. / WARNING: Carbon Monoxide Gas can be FATAL!!! ‘Carbon Monoxide gas is a colorless, odorless gas that is generated whenever internal combustion engines are operating. Prolonged inhalation of air contaminated with only a small percentage of carbon monoxide gas may cause injury or death. A DO NOT operate an internal combustion engine in a confined area without first providing adequate ventilation. v BE ALERT at all times during engine operation for evidence of exhaust system leaks. If Pp exhaust odors are present, take immediate action to provide ventilation. Repair the exhaust leaks prior to restarting the engine. / WARNING: Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starter, if equipped, to prevent accidental engine starting. Put a “Do Not Operate” tag on engine controls. WARNING: Use ONLY the correct engine barring techniques for manually rotating the crankshaft. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can damage the fan blade(s), causing premature failure, resulting in property damage or serious personal injury. / WARNING: If'an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system. W WARNING: Do not work on anything that is supported ONLY by jack lifts or a hoist. ‘Always use blocks or correct stands to support the product before performing any service work. WARNING: To avoid bums, be alert for hot component parts, hot fluids in lines, tubes, and compartments just after the engine has been shut off. / WARNING: Relieve all pressure in the air, oil, and cooling system 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. WARNING: To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant lines in a well-ventilated area with proper recovery equipment. 4/ WARNING: Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL APHYSICIAN. KEEP OUT OF REACH OF CHILDREN. WARNING: Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. WARNING: Always use the same fastener part number (or equivalent) when replacins et eq replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. / WARNING: Never use gasoline or other flammable materials to clean parts. Always use approved cleaning solvents. / WARNING: Avoid prolonged and repeated skin contact with used engine oils. Such " gin prolonged and repeated contact can cause serious skin disorders or other serious bodily injury. - AVOID EXCESSIVE CONTACT: WASH THOROUGHLY AFTER CONTACT. - KEEP OUT OF REACH OF CHILDREN. WARNING: Do not operate with guards, panels, or covers removed. / 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, which can result in a fire, an explosion, and extensive property damage. A fuel spill or gas leak may create a combustible environment in which an engine might operate and over-speeding may result. Numerous safety devices such as air intake shutoff are available to minimize the risk of over-speeding. WARNING: Always install safety signs on engine, equipment, and work areas that follow 8.A.E. Recommended Practice guidelines. Maintain and replace the signs as necessary. Check for: = Good Color - Letter and pictorial legibility - Proper placementAPPLICATION AND INSTALLATION GUIDELINES: Please Note: The relevant Installation Guidelines published by Cummins, Inc. shall apply to power units and kits manufactured and/or marketed by Cummins Power Products. The cooling system has been engineered and tested for proper cooling and is in compliance with the recommendations published by Cummins, Inc. It is the responsibility of the Customer/Operator to routinely clean any debris or dirt from the fins of the radiator core. Modifications to the cooling system are the responsibility of the modifier. ‘The engine-cooling fan provided has been correctly sized and tested for the specified power unit. DO NOT substitute any other brands or sized fans. Additions to the cooling system may create fan vibration and failures. Modifications become the responsibility of the modifier. The electrical and instrument panel system has been engineered and tested for proper communication and wire sizing. It is in compliance with the recommendations published by Cummins, Inc. Its the responsibility of the Customer/Operator to connect battery power, Modifications become the responsibility of the modifier. Only air cleaner options for 25 gram per cfin are available. In a dusty/dirty environment, the air cleaner will need more frequent servicing. An air restriction indicator is available and should be installed and used for determination of proper air cleaner maintenance. Refer to the Operation and Maintenance manual(s) provided by Cummins, Inc. with the engine for proper operation of the air cleaner servicing instructions. Modifications become the responsibility of the modifier. Lift your power unit in a safe manor. DO NOT use the engine lifting hooks to lift the complete power unit. Care must be exercised to avoid systematic torsional vibration problems, which could seriously damage the engine, ancillary equipment, or both. The selling Cummins distributorship is responsible for the collection and the analysis of the proposed torsional ystem, The data shall include values of all elements of the powertrain so that a representative torsional model can be constructed and analyzed. (Reference ISO 3046 Part V-1978) When initially setting up the power unit, ensure that the unit is level within 5 degrees in any direction. Ifa drive shaft is used, indicate the shaft runout with a dial indicator, and keep the runout within plus or minus 0.002 inches. Disconnect the battery and ECM before welding. Drive train configurations, mounting, vibration control, and electrical interfacing are all responsibilities of the first purchaser and or the installer. 6PRE —- HEAT INSTRUCTIONS: DO NOT USE ETHER! Turn Ignition to ’ON’ Position. Press Pre-Heat Button for: © 30 seconds If Temp <-2 F © 20 seconds If Temp < 17 F © 10 seconds If Temp < 46F . Release Pre-Heat Button and Start Engine. If Engine Fails to Start In 10 seconds, repeat Steps 1 through 3COOLANT CAPACITIES The quantity of coolant required for the radiator and engine is: A1400/A1700 ] 8.04 Liters 8.5 US qt. ‘A2000/A2300 9.94 Liters 10.5 US qt. B33 12.73 Liters | 13.45 US qt. B3.3-TAA 11.52 Liters | 12.17 US qt. QSB3.3 11.52Liters | 12.17USqt. B45 27.05 Liters 28.58 US qt. BAST 27.05 Liters 28.58 US at. QSB4.5-30-T 25.5 Liters 27.0 US qt. B3.9TAA 20.8 Liters 22.0 US qt. QSB3.9-30-TAA 20.8 Liters 22.0 US qt. QsB4.s-T3 208 Liters 22.0 US qt. QSB5.9-30-T 27.4 Liters 29.0 US qt. BSOTAA 28.01 Liters 29.6 US at. QSB5.9-30-TAA 28.01 Liters 29.6 US qt. QSB5.9-44 HD 37.8 Liters 40.0 US qt. QSB5.9-44 STD. 37.8 Liters 40.0 US qt. | QSB6.7-T3 25.3 Liters 26.75 US at C83TAA 38.0 Liters 40.5 US at. QSC8.3 -T2 37.0 Liters | 39.5 US qt. QSL9-T2 37.0 Liters 39.5 US qt. QSC8.3-T3 32.2 Liters 34.0 US gt QSL9-13 32.2 Liters 34.0 US atLIFTING GUIDELINES & INSTRUCTIONS: ‘The most common ways to lift the unit are described below Lifting Brackets at the comers of the enclosure (2 points). A spreader bar is ideal for lifting the unit via these points. A chain may be used providing the angle from horizontal is greater than 30 degrees. Use the below table to estimate the minimum length of chain needed. Distance between | Chain Length Lifting points (inch) (Inch) 26 3312 | 39 44 4/2 56 2. Baserail & Crossmember pockets. Use these areas to lift the unit via a forklift. Also, a pair of bars may be inserted through the pockets to allow lifting of the power unit via overhead chains.LIFTING GUIDELINES & INSTRUCTIONS: NOTE: The following are NOT acceptable ways to lift a CPP Power Unit: DO NOT lift the unit by using the door openings to wrap a strap around the top of the enclosure. iL 2. DO NOT use the engine-mounted lifting brackets to lift the Power Unit, These brackets are to be used to lift the base engine only. 10WIRING SCHEMATIC — A-SERIES Revo Grid Heat Control WIRING SCHEMATIC A-Series w/Instruments ke nue Start ight car 508 B G_ Swi swe NC > i TILETALE RELAY, ROTARY FUE PUMP. 99000132 WWWIRING SCHEMATIC — A-SERIES Rev o WIRING SCHEMATIC A-Se: ries No Instruments PRE HEAT Terperature ‘Switch B G_ Swi Sv2_ NC TATILETALE RELAY GRID HEATER or pine [ROTARY FUE! PUMP. 9000140 12WIRING SCHEMATIC — A-SERIES WIRING SCHEMATIC BG Swi sve NC TATILETALE RELAY pink [ROTARY FUEW = PUMP, GRID HEATER 99000141 13WIRING SCHEMATIC — B3.3 REV. 0 WIRING SCHEMATIC B3,3 POWER UNIT TACH PINK & HOUR | yetuay [————TTACH PICK _UF| fr GAUGE § Bu {TEMP SENDER] DIL SENDER RED FUSE [ G B_ Swi Swe NC TATTLETALE RELAY pink [ROTARY FUEL PUMP. 99000026 14WIRING SCHEMATIC - B3.3NA, Tier 3 ‘95000352 a a fers —“ ae =o Soares em a ac t t + Fuel Pump + rt feet contraiter | 7 Grid Heat, soar Relays + La > & ‘Ground STARTER Alternator [CUMMINS POWER PRODUCTS New Hudson, Mi TET (zara ——] RAR) ncices | atecsee ))))2) 2) 152 WIRING SCHEMATIC - B3.3TAA, Tier 3 oo os aa yo tes w/e Po 4 Ko oe/ Ground STARTER Alternator si ng ra won Gace oe eee amos Cee PROBS Mea a) muse EE wed Heater Trer [33000402 16f f € € WIRING SCHEMATIC — QSB3.3, Tier 3 4. Pin to CH 60 Pin Connector _-_To Engine ECM =») [BBR = 9 RaeA™"S2 a BBR SSS Om BT Lh Ic 2|z By} ER iE E lg i 8 pottery [eee oe 33 is al ¢ E a EF ag Ha 2] ¢ Ht F og ee 3 5 a: a i ele "E i Ele] ar zs eeu BSR Eee] [TR i Kh "HP Erghe tarneas to Panel Harness Gomector ECWIRING SCHEMATIC — INSTRUMENT PANEL 4BTAA/6BTAA/B3.3/B4.5/B5.9/6CTAA Fi B eee Saas ci — feel a sire Green TATILETALE, +e See RELAY BG Swi Sw2_NC PA a Optional 91 19 2 t 4 Zl 8 | eo [Yeon - : Tie l 2 2 2 ee s| ls 1 Vs Ht | seat + 6 s 5 2 Us. Jt | <2 9 oes ‘sonteae For 12V Syston 90000889 For 24V Systens Tachoneter @& Gaara aes ne vaseneter Coolant Terperature ret vernon ww FE —WIRING SCHEMATIC — INSTRUMENT PANEL 4BTAA/6BTAA/B3.3/B4.5/B5.9/6CTAA TATTLETALE RELAY BG Swi swe Hourneter (CUMMINS POWER PRODUCTS Wow messon. HI Panet Harrwas w/ eurneser nly fee ord | 19WIRING SCHEMATIC — ENGINE HARNESS 4BTAA/6BTAA/B3.3/B4.5/B5.9 Rotary Grid Heater Fuel Pump Option ow Pressure age veo Coolant ee Temperature — Optional = Magnetic Pickup Bosch Exciter Option cea ory STARTER = Alternator [cumans POvER PRODUCTS Wes Hosen Crone Harness feta] stray ran hoe [~BBCC0126 20WIRING SCHEMATIC — ENGINE HARNESS 6CTAA cor Grid Heater Option Optionet Magnetic Pickup Option Bosch Exciter Intine Fuel Purp c Ol Press Sensor Coolant Temperature ‘Setten Fumi Solana ‘eg Setter POW GND, STARTER Alternator (CUMMINS POWER PRODUCTS New Watson. ML Sera = Bee fear rT] Troe Harness (ERE wine For Pe |" onze 2WIRING SCHEMATIC — PANEL SCHEMATIC B3.3NA/B3.3TAA 31 Pin Connector ayaui0n eungueduey u0Ie09 aT oe . I rg r iy Acs i + g Gee r E if R| 2 fe ? OF Th | & g ie ia 5 iF i : 5 i 1 as WSs aT We ag a 1H wos BAN SONOS BIAOd SNINAND| wg tag ene rz ‘a Gs aN Sn SN Sgtto00T Nd aWITBIL ddd 22WIRING SCHEMATIC — PANEL SCHEMATIC QSB/QSC/QSL 33000297] Fe = & 25] V wimeccrece= | | ster |S Not Uses ace Lo. 1 Pi Engine Herness to Panel Harness Connector 3 5 , =, : _ aN | eS cor ‘Resistor : = neg Thmorsie ‘Bpelone Linear Throttle Resistor Pack Connection | (Standard) SEO »)>)))D..D >) 7D »)>)))D))D DD 23WIRING SCHEMATIC — ENGINE HARNESS QSB/QSC/QSL Tier2 Lf i ‘ . ili Hi i i F Hl Tee ! ie 24€ € € €of € { € € € € WIRING SCHEMATIC — ENGINE HARNESS QSB/QSC/QSL Tier2 ccd 22 Pin Connector to ECM 30 Pn Connecter _~ To Engine ECM EES SSS SEE ee aS Bees] PETE co = : seit ai MTP it k E id ve] fk me ell 4 |] i's {tt vi] ee eel H rr igi ly eee af en Hl i fet een ae rie 25WIRING SCHEMATIC — ENGINE HARNESS QSB/QSC/QSL Tier3 1 Woeen| AN SIONOORd MNOd SNIMAND| vmuwe SS | ETT RRIHY a L RYT] eg 5 + q f FYEEEE || A os He EF lz REGED a Ih swe | Ed Fe fl oy : i ¢ 8 2 ye 6 sesr " BRBRES* "Re oe Ti Pin Engine Harness to Panel Herness Conector 26Pe iar baer tame mo * oo i. ne =f} 3) oe ee as —- <= = a : ‘ Fie! Jecrenent. io] Q as ui 2 : all Z i el § e i: ale is : an §* "I = Slo ee sen ‘Ve Be | fp - | Za | 4s TAF] moet 2 ag ‘ 3 lore : {Olea (i (5) ea rer : a5 {ef came tenses —— Sc wl, 1f i 33 Tome ale Q 4 Eg ! 2 | om Pls : E ee 4 a £ | ee zg = 3 ios : 5 3 [Loxw Responssnty | | Oy mene a ah, — gents = ‘pele [CUMMINS POWER PRODUCTS New Hudson, MI [Seras wae see TT yo) J.) DD DD 27WIRING SCHEMATIC B3.3NA TIER 3 WIRING SCHEMATIC HIGH CURRENT 83.3T and B3.3 NA oo0074 [rl seme rose |_E— FROM ENGINE HARNESS 2) sare STARTER SOLENOID @ ecnmne BLOCK! | C E E a ALTERNATOR |= m0 s0h Fee a, © z nla i S16 oOlo seco0478 a,o nln i. Ww +—H w| a Glow Plugs a|= ans a: Ww FROM ENGINE SS) HARNESS 99000359 REV. 5WIRING SCHEMATIC — HEATER GRID, 12V QSB3.3/B3.3TAA TIER 3 WIRING SCHEMATIC HIGH CURRENT QSB3.3/B3.3TAA 99000331 REV. 4 an ecm MAGNETIC SWITCH FROM_ ENGINE HARNESS. STARTER SOLENOID BLOCK! | ALTERNATOR = ‘ao Arad ca) a Zz oO soot a “ uy i a~ FROM ENGINE a HARNESS a | GRID HEATER oO coocotss |, PosmVve BATTERY PACK NEGATIVE, OEM RESPONSIBILITY 29WIRING SCHEMATIC — HEATER GRID, 12V QSB4.5 TIER 3 WIRING SCHEMATIC QSB4.5 12 Volt GRID HEATER 120 A Fuse Starter 90000446 90000443 Mag SW Positive Side 90000425 MAGNETIC FROM_ ENGINE HARNESS. il 90000444 {|1 GRID HEATER 99000308 REV. 3. 30WIRING SCHEMATIC — HEATER GRID, 12V QSB6.7, QSC8.3, QSL9 TIER 3 WIRING SCHEMATIC 12 Volt GRID HEATER 120 A Fuse 90000446 90000173 STARTER POSITIVE 120 A Fuse 90000150 90000109 STARTER 90000110 J ly ||, GRID HEATER 90000102 MAGNETIC. ‘SWITCH FROM. ENGINE HARNESS {|1 GRID HEATER 90000677 U 99000099 REV. 3.WIRING SCHEMATIC — HEATER GRID, 24V QSB3.3 TIER 3 WIRING SCHEMATIC HIGH CURRENT QSB3.3 MAGNETIC SWITCH FROM ENGINE HARNESS: STARTER SOLENOID BLOCK! | ALTERNATOR a a 7) Zz oO cent & on WwW FROM ENGINE I” | E ce HARNESS: = oo a GRID_HEATER oO 99000265 REV. 2 G a OEM RESPONSIBILITY 32WIRING SCHEMATIC — HEATER GRID, 24V QSB4.5 TIER 3 WIRING SCHEMATIC QS84.5 24 Volt GRID HEATER 60 A Fuse 90000446 90000443 STARTER POSITIVE MAGNETIC ‘SWITCH 90000425, FROM_ ENGINE HARNESS: 90000444, {1 GRID HEATER 99000309 REV. 3WIRING SCHEMATIC — HEATER GRID, 24V QSB6.7, QSC8.3, QSL TIER 3 WIRING SCHEMATIC 24 Volt GRID HEATER 120 A Fuse 90000446 90000173 STARTER POSITIVE MAGNETIC ‘SWITCH 90000425 FROM_ ENGINE HARNESS. 90000110) {|1 GRID HEATER 99000100 REV. 2WIRING SCHEMATIC-HIGH CURRENT W/STARTER GROUND QSB4.5 TIER 3 WIRING SCHEMATIC HIGH CURRENT WITH STARTER GROUND. FOR GE11122 AND GE11123 STARTER SOLENOID AA Wi STARTER MAGNETIC SWITCH Block Ground Optional 1 | W/Non-lIsolated Starter 90000442 FROM_ ENGINE HARNESS LTERNATOR CPP RESPONSIBILITY 99000306 REV. 1 POSITIVE [—® BATTERY PACK [Oo NEGATIVE, OEM RESPONSIBILITY 35WIRING SCHEMATIC-HIGH CURRENT W/STARTER GROUND QSB4.5 TIER 3 WIRING SCHEMATIC HIGH CURRENT WITH STARTER GROUND. FOR GE11142 AND GE11143 90000359 STARTER SOLENOID Block Ground Optional | W/Non-Isolated Starter STARTER MAGNETIC SWITCH GND 90000361 \. 9) 90000442 FROM_ ENGINE HARNESS 11S ALTERNATOR CPP RESPONSIBILITY 99000307 REV. 1 POSITIVE |-8 BATTERY PACK [oO NEGATIVE OEM RESPONSIBILITY 36WIRING SCHEMATIC-HIGH CURRENT W/STARTER GROUND QSB6.7 TIER 3 WIRING SCHEMATIC HIGH CURRENT WITH STARTER GROUND ! POSITIVE STARTER cf i—_+—-@ SOLENOID BATTERY Block Ground PACK Optional 1| W/Non-lIsolated [~~ Storter NEGATIVE STARTER | MAGNETIC = ‘SWITCH | & st f=} FROM_ ENGINE = HARNESS, | a | no Zz | oO a | n LTERNATOR ie = | au I oO CPP RESPONSIBILITY s9000191 REV. 1 37WIRING SCHEMATIC-HIGH CURRENT W/STARTER GROUND QSC8.3, QSL9 TIER 3 WIRING SCHEMATIC HIGH CURRENT WITH STARTER GROUND FOR GE11128 AND GE11129 90000360 POSITIVE STARTER (4 SOLENOID [ cee r BATTERY 0000361 GND \.) Ae WW Optional | W/Non-Isolated NEGATIVE Starter STARTER MAGNETIC SWITCH bt FROM_ ENGINE HARNESS 90000441 LTERNATOR OEM RESPONSIBILITY CPP RESPONSIBILITY 99000304 REV. 1 38WIRING SCHEMATIC-HIGH CURRENT W/STARTER GROUND QSC8.3, QSL9 TIER 3 WIRING SCHEMATIC HIGH CURRENT WITH STARTER GROUND FOR GE11151 AND GE11152 STARTER 1 SOLENOID Block Ground Optional 1] W/Non-Isolated Starter STARTER MAGNETIC SWITCH 90000441 FROM_ ENGINE HARNESS, 11Sl_ Delco ALTERNATOR CPP RESPONSIBILITY 99000305 REV. 1 POSITIVE [— BATTERY PACK [So NEGATIVE OEM RESPONSIBILITY 39POWER UNIT OPERATION PRACTICES Refer to the manual(s) provided by Cummins, Inc., included with the engine, for proper operation of the engine, Follow the pre-start instructions in this manual before starting the unit. Follow the maintenance and service instructions issued by Cummins for the engine and Power Unit General Operating Instructions of this manual. Failure to follow these instructions may result in shortened engine life. 4010, Me POWER UNIT PRE-START CHECK LIST AND OPERATING PROCEDURES Check to be certain that the engine oil level is correct. Refer to the Engine Operations Manual supplied by Cummins included with the engine. The provided coolant level switch is designed to shut the engine offif the coolant level falls too low for proper engine cooling. It must not be used as a fill indicator. Refer to the Engine Operations Manual supplied by Cummins included with the engine. Visually check fan, pulleys, and belts for cracks, dings, nicks, debris, signs of wear, ete. and take appropriate corrective action as indicated by the inspection. Refer to the Engine Operations Manual supplied by Cummins included with the engine. Check engine and radiator for visual signs of leaks. Also check the radiator for debris, which might be clogging the fins. Remove any debris that is observed. Refer to the Engine Operations Manual supplied by Cummins included with the engine. Check air restriction gauge if applicable. Replace air cleaner element if the indicator so states, Refer to the Engine Operations Manual supplied by Cummins included with the engine. Disengage any clutches or power take off before engaging the cranking motor. Tum key switch to the operate position and remain momentarily allowing fuel pump, etc. to initiate. Then turn the key to the start position for starting engine. For proper starting instructions refer to the Engine Operations Manual supplied by Cummins included with the engine. Operate the engine at idle, and note the oil pressure is normal, there are no leaks, and no unusual noises are heard from the engine. If the oil pressure is too low, or the engine is making strange noises, immediately shut down the engine. Determine and repair the causes of the unusual operating conditions, Refer to the engine Trouble shooting section of the Operations and Maintenance Manual supplied by Cummins included with the engine. Ifeverything appears to be normal, then the engine speed and load can be set to standard operating conditions. Retum the engine to low idle for 3 to 5 minutes prior to shutting engine off after a full load operation. Never shut down the engine when in run mode or at full throttle. Shut the engine down by pushing the red “engine stop” button, if equipped, or turn the key switch to its off position. If engine stop button is used, be sure to turn off key switch as well. This will help prevent battery discharge. 4Cummins 2022 Parts Manual Part No. 99000083