(1983/pubsys2/xmi/en’manual/4358365/4358365-ttlepage html) Operation and Maintenance Manual QSZ13 CM2150 2101 Bulletin Number 4358365(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information This manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenance schedule, that states the required intervals and maintenance checks, is located in Maintenance Guidelines (Section 2). Locate the interval at which you are performing maintenance; then follow the steps given in that section for all the procedures to be pertormes, Keep a record of all the checks and inspections made. A maintenance record form is located in Maintenance Guidelines (Section 2). Engine troubleshooting procedures for your engine are located in Troubleshooting Symploms (Section TS). Specifications for your engine are located in Maintenance Specifications (Section V). Last Modified: 22-Aug-2011((gs3/pubsys2hxml/enimanuali4358365/4358365-ttlepage html) Manual Change History ( 4358365) QSZ13 CM2150 Z101 Operation and Maintenance Manual Date 28-Nov-2017, Section ‘Section 5- Maintenance Procedures at 1500 Hours or 3 Years Procedure Number 267-003-004-om (/qs3/pubsys2/xml/en/procedures/267/267- (008-004-om htm) Procedure Title ‘Overhead Set Update Reason Updated the Valve Adjustment Specifications. Date (09-Apr-2015 Section Section 5 - Maintenance Procedures at 1500 Hours or 3 Years Procedure Number 267-008-016-om (/qS3/pubsys2/xml/en/procedures/267/267- (008.018-0m html) Procedure Title Cooling System Update Reason ‘Added directions to allow the engine to cool before draining coolant Date glun-2014 Section Back Procedure Number “358365 History (/qs3/pubsys2/xml/en/manual4358365/4358365- bistory til) Procedure Title Manual Change History Update Reason ‘New manual tor QSZ1s CMZ750 2107 engine released Tor use. Vast Modified: 28.New.2047(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘Some of the illustrations throughout this manual are generic and will not look ‘exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not ‘acceptable conaiion, The illustrations are intended fo show repair or replacement procedures. The procedure will be the same for all applications, although the ilustration can differ, Last Modified: 12-Mar-2002(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information This engine or system incorporates the latest technology at the time it was manufactured: yet, itis designed to be repaired using normal repair practices performed to quality standards. AWaRNING A ‘Cummins Inc. does not recommend or authorize any modifications or repairs to components except for those detailed in Cummins Service Information. in particular, unauthorized repair to safety-related components can cause personal injury or death. Below is a partial listing of components classified as safety-related: Air Compressor Air Controls Air Shutoff Assemblies Balance Weights Cooling Fan Fan Hub Assembly Fan Mounting Bracket(s) Fan Mounting Canseres 9. Fan Hub Spindle 10. Flywheel 11, Flywheel Crankshaft Adapter 12. Flywheel Mounting Capscrews 19. Furl Shiululf Asser ilies 14, Fuel Supply Tubes 415. Lifting Brackets 16. Throttle Controls 17. Turbocharger Compressor Casing 18, Turbocharger Oil Drain Line(s) 19. Turbocharger Oil Supply Lines) 20. Turbocharger Turbine Casing 21. Vibration Damper Mounting Capscrews 22, Manual Service Disconnect. 23. High Voltage Interlock Loop 24. High Voltage ConnectorsiConnections and Hamesses 25. High Voliage Battery System 26. Power Inverter 27. Generator Motor 28. Clutch Pressure Plate ‘+ Follow all safely instructions noted in the procedures ‘+ Follow the manufacturer's recommendations for cleaning solvents and other substances used during repairs. Sone solvents have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety practices with tools and equipment ‘+ Provide a clean environment and follow the cleaning instructions specified in the procedures.‘+ The engine or system and its components must be kept clean during any repair. Contamination of the engine, system or| ‘components will cause premature wear. ‘= All components must be kept clean during any repair. Contamination of the components will cause premature wear. ‘= Perform the inspections specified in the procedures ‘+ Replace all components or assemblies which are damaged or worn beyond the specifications. ‘+ Uso genuine Cummins new or ReCon® service parts and assemblies + The assembly instructions have been written to use again as many components and assemblies as possible. When itis necessary to replace a component or assembly, the procedure is based on the use of new Cummins or Cummins ReGon® components. All of he repair services described in this manual are avaliable from all Cummins Disirioutors an] most Dealer locations. «+ Follew the snerified disassembly and assembly procedures to reduce the possibilty of damage tn the camnanents Complete rebuild instructions are available in the service manual which can be ordered or purchased from a Cummins Authorized Repair Location. Refer to Section L — Service Literature for ordering instructions. [Welding on a Vehicle with an Electronic Controlled Fuel System AcautionA Disconnect both the positive (+) and negative (-) battery cables from the low voltage battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground clamp of the welder to any of the sensors, wiring harness, electronic control units or the components, Direct welding of any electronic components must not be attempted. Sensors, wiring harness, and electronic contro! unit should be removed if nearby welding will expose these components to temperatures beyond. normal operation. Additionally, all electronic control unit connectors must be disconnected Last Modified: 10-Jul-2012(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Definition of Clean Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to appear ‘Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming a seal. Itis important to maintain surface finish and flatness tolerances to form a quality sealing surface. Gaskets are designed to fil small voids in the specified surface finish ‘Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a metal to metal joint for stability, Any of the small amounts of sealing material that can stick to the parts are better removed with a blunt- ‘edged scraper on the spots rather than spending time polishing the whole surtace with an air sander or disc. For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to prevent sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in place a Jong time, has been overheated or the purpose of the release agent has been defeated by the application of some sealant. ‘The object however is just to remove the gasket without damaging the surfaces of the mating parts without contaminating the engine (don't let the litle bts fall where they can nat be removed). Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon build Lup above the top ring and in the ring grooves. There is more information an bead blasting and piston cleaning later in this document. ‘Cummine Ine. docs net rocommend canding or grinding the carbon ring at th top of oylindor liners until clean motal ic visible. The liner will be ruined and any signs of a problem at the top ring reversal point (lke a dust-out) will be destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and there wil be less damage. ‘Yes, one must look carefully for broken wires alter the piston is removed but the wires are more visible and can be altracted bya magnet, ion pars that have been removed from the engine will attract dirt in the ai. The dirt wil adhere to the oil. If possible, leave the old oil on the part until its ready to be cleaned, inspected and installed, and then clean it off along with any attracted dirt. Ifthe partis cleaned then left exposed it can have to be cleaned again before installation. Make sure parts are lubricated with eloan oil before inctallation, Thoy do net nood to be oiled all over but do need oll botwoon moving parte (oF 0 good lubo system priming process conducted before cranking the engine). Dead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again so all that needs happen is remove any loose paint. [Abrasive Pads and Abrasive Paper ‘The keyword here is "abrasive". There is no part af an engine designed to withstand abrasion. Thal is they are all supposed to lock together or slide across each other. Abrasives and ditt particles will degrade both functions, AWARNING ALAbrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material in oil Passages can cause bearing and bushing failures that can progress to major component damage beyond reuse. This is particularly true of main and rod bearings. ‘Cummins Ine, does not recommend the use of emery cloth or sand paper on any part of an assembled engine or component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or counterbores, Great care must be taken when using abrasive products to clean engine paris, particularly on partally assembled engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles, silicon carbide, of ‘sand ar same other similar hard material These nartiles are harder than mast of the parts in the engine Since they are harder, ifthey are pressed against softer material they wil either damage the material or become embedded in it. These materials fall of the holding media as the product is used. Ifthe products are used with power equipment the paricles are thrown about the engine. Ifthe particles fall between two moving parts, damage to the moving parts is likely. Ifparticles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger than the running clearance then damage will occur when the parts move relative to each ather (engine started). While the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass between the parts without damage and be trapped in the ail fer. However, particles larger than the bearing clearance will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will abrade the other part until contac! is no longer being made between the two parts. Ifthe damage sufficiently degrades the oil film, the two parts will ‘come into contact resulting in early wear-out or failure from lack of effective lubrication. Abrasive particies can fly about during cleaning itis very important to block these particles from entering the engine as much| {as possible, This is particulary true of lubricating oil ports and oil drilling holes, especially those located downstream of the lubricating oil fiters. Plug the holes instead of trying to blow the abrasive particles and debris with compressed air because the debris is often simply blown further into the oil drilling, Al old gasket material must be removed from the parts gasket surfaces. However, itis not necessary to clean and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel). What lite sealing matenal that can adhere is best removed with a blunt-edged scraper or pully knife. Cleaning gaskel surtaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time, AXWARNING AV Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which can cause early cylinder wear-out or piston ring failures. ape off or plug all openings to any component interior before using abrasive pads or wire brushes, If really necessary because of time to use a power tool with abrasive pads, tape the oil drilings closed or use plug and clean as much of the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination of the driling. ‘Then remove the tape oF plug and clean the remaining area carefully and without the tool. DO NOT use compressed air to blow the debris out of oil driling on an assembled engine! More likely than not, the debris can be blown further into the iiling. Using compressed air is fine ifboth ends of the driling are open but that is rarely the case when dealing with an assembled engine, Gasket Surfaces “The object of cleaning gasket surfaces is to remove any gasket material not refinish the gasket surface of the part. (Cummins inc. does not recommend any specific brand of liquid gasket remover. Ifa liquid gasket remover is used, check the directions to make sure the material being cleaned will not be harmed,Air powered gasket scrapers can save time but care must be taken to net damage the surface. The angled part of the ‘Scraper must be against the gasket surtace to prevent the blade 1rom digging into the surtace, Using air powered gasket scrapers on paris made of soft materials takes skill and care to prevent damage. Do not scrape or brush across the gasket surface if at all possible. [Solvent and Acid Cleaning ‘Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See Below) Experience has shown that the best results can be obtained using a cleaner that can be heated to 90° to 95° Celsius (180° to 200° Fahrenheit). Kerasene emulsion based cleaners have different temperature specifications, see below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Cummins Inc. does not recommend any apecific cleaners, Always follow the cleaner manufacturer's inatructiona. Remove all the gaalcet material, o rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank. AXWARNING A When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations for us Wear goggles and protective clothing to reduce the possibility of personal injury. Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners should not be heated to temperature in excess of 77°C (170°F), The solution begins to break down at temperatures in excess of 82°C (180°F) and wil be less effective Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components. They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly. Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline solutions. Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away from the neutral 7.0, the chemicals become highly alkaline or highly acidic. Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high pressure water or steam clean the parts before putting them in the cleaning tank, Removing the heaviest dirt before placing in the tank will allow the cleaner to work more effectively ang te cleaning agent will last longer. Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the ‘capscrew noles and tne o1 anings. Ifthe parts are not to be used immediately after cleaning, cip them in a suitable rust proofing compound. The rust proofing compound must be removed from the parts before assembly or installation on the engine. [Steam Cleaning ‘Sieam cleaning can be used fo remove all lypes of dit that can contaminaie the cleaning tank. Its a good method for leaning the oil drilings and coolant passages AXWARNING A When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can ‘cause serious personal injury. Do not steam clean the following components:‘+ Electrical Components ‘+ winng Hamesses = Bolts and Hoses ‘= Bearings (ball or taper roller) ‘+ Electronic Control Module (ECM) + ECM Connectors + Capacitive Coll Driver Module (CCD) + Ignition Coils and Leads + NOx Sensor ‘+ Fuel Control Valve «+ Throttle Driver and Artuator Plastic Bead Cleaning ‘Cumming Ine, does not recommend the use of glass bead blast or walnul shell media on any engine parl, Cumming Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use sand as a blast media to clean engine parts. Glass and walnut shell madia when nat used to the media manufacturer's recommendations can cause excess dust and can embed in engine parts that can result in premature failure of components through abrasive wear, Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is controlled by the use of plastic beads, the operating pressure and cleaning time. ACAUTION A Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result in premature war of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, ote., can also be damaged. Follow the cleaning directions listed in the procedures. AXCAUTION A Do not contaminate wash tanks and tank type solvent cleaners with the toreign material and plastic beads. Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before placing them in tanke or oloanore. Tho foraign matorial and plastic baade can contaminato tho tank and any othor ongino parte cleaned in the tank. Contaminated parts may cause failures from abrasive wear. Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any bead blasting media on piston pin bores or aluminum skirts Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting machine to the bead manufacturer's recammendations. Tuming up the pressure can move material an the part and cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to manufacturers instructions: 1. Bead cizo: U.S. size Numbor 18 20 for picton cloaning with plastic boad modia, Part Numbor 3829735 2. Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should nat cause beads to break. 3, Steam clean or wash the parts with solvent to remove all ofthe foreign material and plastic beads after cleaning. Rinse with hot water. Dry with compressed air ‘Acaution A ‘The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine can be ‘damaged due to increased parts clearance or inadequate surface finish on parts that move against other parts.‘When cleaning pistons, itis not necessary to remove all the dark stain from the piston. All that is necessary is to remove the carbon on the rim and in the rng grooves. Inis is best done by directing the blast across the part as opposed to straight at the par. Ifthe machining marks are disturbed by the blasting process, then the pressure is too high or the blast is being held ‘on one spot ico lang. The blast operation must not disturb the metal surface. Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting produces @ {great amount of dust particularly when the prosoure ifthe air prosaure on the blasting machine is inoroased above modia manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to clean engine parts due to the risk media embedment and subsequent contamination of the engine. ‘Cummins Ine. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily ‘embedded into the material particulary in soft materials and when air pressures greater than media manufacturer's recommend are used. The glass is an abrasive so when itis in a moving part, that part is abrading all the parts in contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats easily inthe air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water) is used to blow the media after itis removed from the blasting cabinet (blowing the part off inside the cabinet may remove large accumulations but never removes all the medi). Bead blasting is best used on stubborn dirtlcarbon build-up that has not been removed by first steam/higher pressure washing then washing in a healed wash tank. This is particularly true of pistons. Steam and soak the pistons first then use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of damaging the surface finish of the groove with a wire wheel ar end of a broken piston ring. Make sure the parts are dry and oil free before bead blasting to prevent clogging the return on the blasting machine. Always direct the bead blaster nazzle "across" rather than directly at the part. This allows the bead to get under the unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nazzle directed at one-place too Jong causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or earbon, Ifthe machining marks on the piston groove or rim have been disturbed then there has not been enough movement of the nozzle and/or the air pressure is too high. Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across the seat surface and radius rather than straight at them. The object is to remove any carbon build up and continuing to blast to remove tne stain is a waste of te. Fuel System When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. Ifthe surrounding areas are not leanea, airtor contaminants can be introduced into the fuel system. The internal drilings of some injectors are extremely small and susceptible to plugging from contamination. Some fuel injection systems can operate at very high pressures. High pressure fuel can convert simple parties of dirt and rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors. Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather than compressed air, to wash dirt and debris away from fuel system fitings. Diesel fuel on exposed fuel system parts attracts sirbome contaminants ‘Choose lint free towels for fuel system work. Cap and plug fuel ines, ftings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the fuel ‘system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material When removing fuel lines or fitings from a new or newly-painted engine, make sure to remove loose paint flakesichips that can be created when a wrench contacts painted line nuts or fitings, or when quick disconnect fitings are removed, Fuel fiters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter. The micron rating is the size of the smallest particles that will be captured by the fiter media. As a reference, a human hair is 76 microns [0.003 in] in diameter. One micron measures 0.001 mm [0.00004 in,]. The contaminants being fitered out aresmaller than can be seen with the human eye, a magnifying glass, or & low powered microscope. ‘The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points regarding your fuel system tools: ‘+ Fuel system tools are to be kept as clean as possible. ‘+ Clean and dry the tools before returning them to the tool box. ‘+ If possible, store fuel system tools in sealed containers. = Make sure fuel system tools are clean before use. Last Modified: 30-Apr-2013(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘The following list contains some of the acronyms and abbreviations used in this manual. ANSI ‘American National Standards Institute art “American Petroleum Institute ASTM ‘American Society of Testing and Materials ‘ATDC After Top Dead Center bhp Brake Horsepower BTU British Thermal Unit BTDC Before Top Dead Center “*c Celsius ‘CAN Controller Area Network ‘CARB California Air Resources Board ‘CCA Cold Cranking Amperes cov (Closed Crankcase Ventilation CES ‘Cummins Engineering Standard cB Customer Interface Box CLD. ‘Cubic Inch Displacement ‘CNG Compressed Natural Gas co ‘Carbon Monoxide CPL Control Parts List St Centistokes DEF Diesel Exhaust Fluid oc Diesel Oxidation Catalyst DPF Diesel Particulate Filter ECM Engine Central Madule EFC Electronic Fuel Control EGR Exhauet Gae Reciroulaton EPA Environmental Protection Agency cen [Engine Serial Number °F Fahrenheit ft-lb) Foot-Pound Force FM Fallure Mode Indentifier ow (Gross Vehicle Weight Hg Mercury hp Horsepower HO ‘Water inHg Inches of Mercury in H20 Inches of WaterIcm Ignition Control Module IEC International Electrotechnical Commission ISA ‘Job Safety Assessment kml Kilometers per Liter kPa Kilopascal LNG Liquefied Natural Gas. LPG Liquefied Petroleum Gas LTA Low Temperature Aftercooler MCRS ‘Modular Common Rail System ML Malfunction Indicator Lamp MPa Megapascal ‘mph Miles Per Hour mpq Milos Por Quart Nem: Newton-meter NOx Nitrogen Oxides NG Natural Gas 02 Oxygen ‘OAT (Organic Acid Technology ‘OBD ‘On-Board Diagnostics ‘OEM (Original Equipment Manufacturer OSHA ‘Occupational Safely and Health Administration PID Parameter Identification Descriptions PPE Personal Protective Equipment ppm Parts Per Milion Psi Pounds Per Square Inch PTO Power Takeoff asoL QuickServe® Online REPTO Rear Engine Power Takeoff RGT Rear Gear Train rpm Revolutions Per Minute ‘SAE Society of Automotive Engineers ‘SCA ‘Supplemental Coolant Additive ‘SCR Selective Catalytic Reduction ‘STC Step Timing Control ‘SID ‘Subsystem Identification Descriptions Toe ‘Top Dead Centor TSB Technical Service Bulletin ULSD Ultra Low Sulfur Diecol voc Volts of Direct Current GT Variable Geometry Turbocharger vs Variable Speed vss ‘Vehicle Speed Sensor Last Modified: 16-Dec-2016(1983/pubsys2/xmi/en’manual/4358365/4358365-ttlepage html) iCummins® Engine Nomenclature ‘The Cummins® Service Engine Model Identification procedure describes how to use the Cummins® Service Model Name to identify an engine. Refer to Procedure 100-005 in Section E. (/qs3/pubsys2/xmVen/procedures/99/99-100- 005.n1mi) ‘The Cummins® Product Technology procedure provides the Cummins® Service Model Name and describes the unique techniology used by the engine covered, by this manual. Refer to Procedure 100-006 in Section E. (/q83/pubeys2/xmilen/procedures/267/267-100-006. html) ~ Engine Dataplate “The engine dataplate, located on top of the rocker lever cover, provides the model ideniificalion and other important data about the engine. Have the following engine data available whon communicating with a Cumminc® Authorized Repair Location. Tho data on the dataplate are mandatory when sourcing service parts: = Crgine serial number (CSN) ‘+ Control pars list (CPL) = Model ‘+ Advertised horsepower and rpm. Engine Control Module Dataplate ‘The engine control module (ECM) dataplate is located on the front of the ECM. ‘The abbreviations on the dataplate are explained as follows: + PIN = partnumberLastModified: 24-Jun-2014(1983/pubsys2/xmi/en’manual/4358365/4358365-ttlepage html) iCummins® Engine Nomenclature ‘The Cummins® Service Engine Model Identification procedure describes how to use the Cummins® Service Model Name to identify an engine. Refer to Procedure 100-005 in Section E. (/qs3/pubsys2/xmVen/procedures/99/99-100- 005.n1mi) ‘The Cummins® Product Technology procedure provides the Cummins® Service Model Name and describes the unique techniology used by the engine covered, by this manual. Refer to Procedure 100-006 in Section E. (/q83/pubeys2/xmilen/procedures/267/267-100-006. html) ~ Engine Dataplate “The engine dataplate, located on top of the rocker lever cover, provides the model ideniificalion and other important data about the engine. Have the following engine data available whon communicating with a Cumminc® Authorized Repair Location. Tho data on the dataplate are mandatory when sourcing service parts: = Crgine serial number (CSN) ‘+ Control pars list (CPL) = Model ‘+ Advertised horsepower and rpm. Engine Control Module Dataplate ‘The engine control module (ECM) dataplate is located on the front of the ECM. ‘The abbreviations on the dataplate are explained as follows: + PIN = partnumberLastModified: 24-Jun-2014(1983/pubsys2/xmi/en’manual/4358365/4358365-ttlepage html) Engine Views ‘The following illustrations show the location of the major external engine components, fiers, and other service and ‘maintenance points. Some external components will be at different locations for different engine models. 13, Front View Thermostat housing . Oil fil cap Front gear cover Fan pulley Oi fil cover Vibration damper Lubricating oil pan Front engine mount 9. Water pump 10, Belt tensioner, alternator ana water pump 11. Alternator 12 Alternator idler pulley assembly 13. Turbocharger 14, Alternator bracketLor sice view Intake manifold connection (air intake connection) Intake manifold . Rocker lever cover Fuel rail pressure relief valve 5. Crankcase breather housing . Cylinder head Fuel return line Fuel pump, high-pressure 9. Crankcase breather vent tube 10. Engine speed sensor (flywheel) 11, Starter motor 12. Fuel filter, suction-side 19. Fuel filter, pressure-side 114. Engine control moaule (ECM) power connector 15, ECM original equipment manufacturer (OEM) hamess connector 46 FCM angina hamass eonnactar 17. Front gear housing 18. Camshaft position sensor 419. Lubricating oil dipstick 7. Fuel return tine 2. Coolant temperature sensor 3. Thermostat housing 4. Flywheel5. Flywheel housing 6. Crankcase breatner vent tube 7. Rear gear cover plate 8. Intake manifold pressure/temporature sensor Right Side View Turbocharger Turbocharger oil supply line Wastegate valve Exhaust manifold ‘Water outlet connection Front engine lifting bracket Thermostat housing Fan puillay 9. Alternator 10. Water transfer tube 11, Water pump 412. Lubricating oil cooler 19. Front engine mount 44, Coolant filter 15. Coolant inlet cannection 16. Lubricating oll filter 17. Lubricating oil filter head 18. Turbocharger oil drain tube 19. Rear gear housing . Flywheel housing . Turbocharger wastegate air signal line 2. Rear enaine lifting bracket Ollfil cap. BRB- Coctant iamperature sensor Turbocharger exhaust outlet }. Turbocharger wastegate ai signal ine (optional par fr the wastegate turbocharger) Turbocharger compressed air outlet . Turbocharger air inlet 5. Exhaust manifold Rear gear housing Flywheel housing 9. Injector fuel return 10. Fuel rail supply tine 41. Injector supply line 12.Iniake manifold pressure/temperature sensor 13, Intake manifold 14, Fuel rll pressure sensor.(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘The Cummins® Service Engine Model Identification procedure describes: ‘+ The purpose of the Cummins® Service Model Name. ‘+ How to interpret a Cummins® Service Model Name to identify a Cummins® Engine. This includes 2013 and later products. 18x15 CM2350 X101 The Cummins® Service Model Name differs from the Cummins® marketing ‘model name. Service model names are more specific and help to match the correct Cummins® service information to the correct engine. Marketing engine model names are more genetic and can capture multiple engine variations in the same model name. Marketing Engine Model Name Service Model Name 1SXi5 1SX15 OM2350 X101 Marketing engine model names (2) can be found on the engine dataplate, ‘Cummins® brochures, and Cummins® promotional iterature. Examples of Cummins® service information and products that use service model + QuickServe™ Online + INSITE™ electronic service tool + Owner's Manual ‘+ Operation ang Maintenance Manual ‘+ Master Repair Manual ‘+ Service Manual ‘+ Wiring Diagram ‘+ Fault Code Troubleshooting Manual ‘+ Standard Repair Times ‘+ Technical Service Bulletins = Service Dulletins ‘The Cummins® Service Model Name begins with the marketing engine model name. Note : For engines released specifically for the European market, marketing model names may include an “e” between the engine platform designation and the engine liter displacement. Service model names will not display this “e’. ‘18X15 CM2350 X101 isxis—‘Typically, the first two letters of the marketing model name contain an "IS" or “QS" ifthe engine is an electronic engine, {18X15 CM2350 X101 "IS" prefix designates an On-Highway automotive engine. "QS" prefix designates an Off-Highway industrial engine. Note : Not all electronic engines use the “IS” or “QS" prefix. To verify if the engine is an electronic engine, check to see if an electronic control 1S or @g —— system is isted in the service model name. Ine control system that is identified as part of the service model name is referenced later in this oe procedure. Non-electronic engines do not have an “IS” or “QS" prefix and do not have an electronic control system iste in the service model name, ‘Typically, tho third lator fe the engine platformisorios designation followed by the engine liter displacement. For the example shown in the graphic, the engine is a: = is i. sepneine ns 18x15 M2350 x101 X Series engine 415 Liters in Displacement Note : Some legacy engines will use the cubic inch rather than liter for engine displacement. x15 — Ifa "@" indicator is located after the iter displacement, the engine is fueled by natural ga. ° 1Sx15 G Cmr2350 x101 Note : Not all engines fueled by natural gas will have a “G" located after the displacement. Ifa "MIs located after the liter displacement, the engine isin a marine apolication, a Note : Not all engines used in a marine application will have "M" located after the displacement. oe Ita "DF" is located after the iter displacement, the engine is a dual fue! application, ‘Tho engine control eystem ie idantfied with tha loltore “CM followed by tho control system model number. 18X15 M2350 X101 Noto : Uso of a paronthosis ( ) indicates that eithor ongino control module (ECM) has been used on the product. Use of a slash "Y" indicates that the product has multiple ECMs. cwaas0 — The identifier after the control system isa letter and number combination to identity variations between products. 18x15 M2350 X101 The letter is the engine platform designation ‘The number increments as new variations of the engine platform/series are released. The first number is 101 x101 —LastModified: 31-May-2016(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘The service model name for this product is QSZ13 CM2150 2101 This engine is being released to meet the following emission regulations: Curopean Union + Euro Stage Il + Euro Stage il, United States and Canada + EPA Tier Il + EPA Tier Il. EPA Products: This engine has the following Agency defined Emissions Control System (ECS) hardware, which can also be found on the engine dataplate. Use the following procedure for the location of the engine dataplate. Refer to Procedure 100- 001 in Section E. (/qs3/pubsys2/sml/en!procedures/267/267-100-001 html) Charge-Air Cooler (CAC) Direct Diesel Injection (OD!) Enyine Gunisol Module (ECM) Turbocharger (TC), This engine uses the folowing product technology: Engine « Number of Cylinders - 6 ‘+ Engine Configuration - Inline '* Cylinder Block Material - Cast Iron + Cylinder Head Material - Cast lun ‘+ Camshaft Location - Cylinder Block. ‘+ Engine Control Module (ECM): CM2150 + Electrical System Voltage: © 24-VDC. ‘+ Fngine Conlant Temperature Sensor ‘+ Engine Oil Pressure Sensor ‘+ Fuel Ral Pressure Sensor ‘+ Fuel Pump Actuator + Water-in-Fuel Sensor + Camshaft Position Sensor ‘+ Crankshaft Position Sensor ++ Intake Manifold Pressure/Temperature Sensor ‘+ Turbocharger Compressor Intake Temperature Sensor ‘+ Ambient Air Temperature Sensor. Air Handling+ Turbocharger (Single) ‘+ Charge-air Cooler. Fuel System = Diesel ‘+ Common Rail Fuel System © Cummuins®) XPI Gorman Kail Fuel System. Market applications that will use this engine include, but are not limited to: Power Generator + Genset + G-Drive. Last Modifiod: 21-May-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information Correct care of your engine will result in longer life, better performance, and more: economical operation, Follow the daily maintenance checks listed in Maintenance Guidelines (Section 2) ‘The new Cummins® engine associated with this manual does not require a "break-in" procedure, This section of the manual provides all of the necessary information required for proper engine operation. ‘Check the oil pressure indicators, temperature indicators, warning lights, and other gauges daily to make sure they are operational, Check the oil pressure, colant temperature, and other engine parameters daily via the OEM front pane! to make sure they are operational. Check the panel regularly for any alarm messages. Take appropriate action to rectify the alarm ‘condition or contact your nearest Authorized Cummins® Distributor. ‘Awarnne A Do not operate a diesel engine where there are or can BE COMBUSTIBLE vapore. Thoee vapore can be euckod through tho air intake eyetom and cause engine acceleration and over speeding that can result in a fire, an explosion, and extensive property damage. Numerous safety devices are available, such as air intake shutoff devices, to minimize the risk of over ‘speeding where an engine, due to its ap ‘operating ina ‘combustible environment, such as due to a Tuel spill or gas leak. Remember, Cummins Inc. has no way of knowing the use you have for your engine. The equipment owner and operator ARE responsible for safe ‘operation in a hostile environment. Consult A Cummins® Authorized Repair Location for further information. Acaution A Do not expose the engine to corrosive chemicals. Corrosive chemicals can| damage the engine. ‘Cummins recommends the installation of an air intake shutoff device or a similar safety device to minimize the risk of overspeeding when an engine is operating in ‘2 combustible environment, such as due to a fuel spill or gas leak.LastModified: 16-Jun-2016(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information Follow the Normal Starting Procedure in this section, In cold weather, the engine can run longer at idle but only until the minimum specified oil pressure is detected by the engine control module (ECM). Using Starting Aids Cold weather staring aids are availabe forthe engine. Contact a Cummins Authorized Repair Location for mare information, aa © ES Last Modified: 14-Oct-2016(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information Follow the Normal Starting Procedure in this section. The engine will run at idle only until the minimum specified oil pressure is detected by the engine control module (ECM). Last Modifiog: 14-0¢t-2016(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Normal equipped, monitor the oil pressure and coolant temperature gauges frequently. Refer to Lubricating Oil System specifications and Cooling System specications, in Maintenance Specifications (Section \V) for recommended operating pressures ‘ana temperatures. Snut of the engine if any pressure or temperature does not meet the specifications, Continuous operation with engine coolant temperature above or below the engine coolant temperature specifications listed in Maintenance Specifications, (Section V) can damage the engine. ifan overheating condition starts to occur, reduce the power output of the engine by releasing the accelerator pedal or lever or shifting the transmission to a lower gear, or both, until the temperature retums to the normal operating range. Ifthe engine temperature does not return to normal, shut off the engine, and refer to Troubleshooting Symptoms (Section TS), or contact a Cummins® Authorized Repair Location. AcauTion A Do not idle for extended periods of time. Excessive idle time can cause poor engine performance. Intemal combustion engines must not operate at low idle speed for extended periods of time. This operating condition may ead lu pour enyine perfunnianas. The idle slulduws feature, available un must Cunmiis® engines, cant be prorated shut the engine down after a period of low idle speed operation with no driver activity. A flashing waming lamp will inform the river of an impending shutdown. Ifan engine must idle for an extended period of time, it should be done at fast idle (1000 pm or greater). The Power Take-Off (PTO) feature, available on mast Cummins® engines, can be programmed to adjust engine speed with the use of OEM switches to pre-programmed set points. [Ambient Temperature lO to -32°C [32 to -25°F] Use 50-percent ethylene glycol antifreeze and 50-percent water for the engine coolant mixture. ‘The Diesel fuel must have maximum cloud and pour points 6°C [10°F] lower than the ambient temperature in which the engine operates. -32 to -54°C [-25 to -65°F]Use 60-percent ethylene glycol antifreeze and 40-percent water for the engine coolant mixture. ‘The Diesel fuel must have maximum cloud and pour points 6°C [10°F] lower than the ambient temperature in which the engine operates. The cold weather overatina aid is reauired for cold weather situations. Winterfronts and Shutters Winteifronis and shutters can be used on a vehicle or equipment t9 reduce air flow through the radiator core into the engine compartment. This can reduce the time required to warm the engine and help maintain the engine coolant temperature. The engine coolant temperature specifications are in the Maintenance Specification (Section V). Last Modified: 10-Feb-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information AXCAUTION A Do not operate the engine at full throttle below peak torque rpm (refer to engine dataplate far peak torque rnm) for more than 30 seconds. Onerating| the engine at full throttle below peak torque will shorten engine life to overhaul, can cause serious engine damage, and is considered engine abuse. AXCAUTION A Do not operate the engine beyond the maximum engine speed. Operating the engine beyond the maximum engine speed can cause severe engine damage. Use proper operating techniques for the vehicle, vessel, or equipment to prevent engine overspeed. The maximum engine speed specification is listed in Maintenance Specifications (Section V). ‘Cummins® engines are designed to operate successfully at full throttle under transient conditions down to peak torque engine speed. This is consistent with recommended operating practices. AXCAUTION AL Do not idle the engine for excessively long periods. Long periods of idling, more than 10 minutes, can cause poor engine performance. Last Modified: 25-Feb-2015(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information AXCAUTION A Failure to follow the correct shutdown procedure may result in damage to. ‘the turbocharger, if equipped, and shorten the turhocharger life. Allow the engine to idle 3 to 5 minutes before shutting the engine olf after a full load operation. This allows adequate cool down of pistons, cylinders, bearings, and turbocharger, if equipped. sos umures Note : For engines equipped with an electronic control module (ECM) ensure the Keyswitch is turned off for a minimum of 100 seconds prior to disconnecting the continuous (unswitched) battery power supply. if the unswitched battery power supply is disconnected in less than 100 seconds after the keyswitch is tumed off active fault codes and incorrect ECM information can occur. ‘Tur the ignition switch to the OFF position. Ifthe engine does not shut down, contact a Cummins® authorized repair location. Last Modified: 20. Mor 2017(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘The CM2150 fuel system is an electronically operated fuel control system that provides many operator and vehicle features, ‘The base functions of the control system include fueling and timing control, limiting the engine speed operating range between the low and the high idle set paints while optimizing engine performance. The system also controls the engine brakes and diesel exhaust afertreatment system ‘The control system uses inputs from the operator and its sensors to determine the fueling and timing required to operate at the desired engine speed at the required emissions level. |Engine Control Module Inputs “The engine control module (ECM) is the control center of the system. It processes all ofthe inputs and sends commands to the fuel system, vehicle, and engine control devices. ‘The ECM performs diagnostic tests on most of is circuits and will activate a fault code if a problem is detected in one of these circuits. Along with the fault code identifying the problem, a snapshot of engine operating parameters at the time of {fault activation is also stored in memory. Active fault codes will cause a diagnostic lamp to activate to signal the driver. ‘The control system uses a number of sensors to provide information on engine ‘operating parameters. These sensors include: y ‘+ Engine coolant temperature sensor. so 4 4 t Le 7 Take mani empeure and ressire sensor @ @ 2 + Engine speed (crankshaft position) sensor + Camshaft position sensor.‘+ Baromeiric air pressure sensor. ‘+ Fuel ral pressure sensor. Ea ee ond ‘+ Fuel pump actuator. ‘+ Accelerator pedalilever position sensor ‘+ Idle validation switch ‘+ Engine coolant level sensor ++ Vehicle speed sensorsFeature control switches (2. cruise control switches) Fan control switen Air conditioner pressure switch + Remote accelerator ‘+ Remote power take-off (PTO). Note : These inpute are application dependent. Some applications do not use all of these inputs. [Engine Control Module Outputs ‘The ECM can communicate with service tools and other vohicle controllers (such as (ranemissions, ABS, ASR, electronic dash displays) through the SAE J1939 data link or the SAE J1708 data link. Gome vehicles and equipment feature GAE J1039 networks that link many of the “amart’ controllers together. Vehicle contrat devices can temporarily command engine speed or torque to perform one of their functions (that is, transmission shifting, anti-lock braking, etc. Diagnostic Fault Codes "The electronic engine control system displays and records certain detectable {fault conditions, These malfunctions are displayed as fault codes, which make troubleshooting easier. The fault codes are retained in the ECM, ‘There are three types of diagnostic codes: ‘+ Engine electronic control system fault codes inform the operator nat tnere Is SSS a problem with the control system that requires troubleshooting Siaee Ei «+ Fngina alactronie contra! eystam faut endas infarm tha anarator that thera ic ZS ace a problem with the control system that requires troubleshooting the vehicle. + Information and engine protection fault codes inform the operator that the control system has detected an engine condition outside the normal operating range. All fault codes recorded will elther be active (fault code is presently active on the engine) or inactive (fault code was active at some time, but is not presently active). ‘The "STOP" or “STOP ENGINE” lamp is red and indicates the need to stop the ‘engine as soon as it can be safely done. The engine must remain shut down ‘nll he engine Gan be repaired, ‘When ilurinated, the yellow "WARNING" or "CHECK ENGINE” lamp indicates that the engine or exhaust gas treatment system is in need of repair atthe fist available opportunity. Note : The "WARNING" or "CHECK ENGINE" lamp (yellow lamp) will illuminate if the diese! exhaust fluid level is low. ‘Another function of the WARNING or CHECK ENGINE lamp (yellow lamp) is to flash for 30 seconds at Key ON when one ofthe following occurs: ‘+ Maintenance is required (if the Maintenance Monitor feature is enabled)‘+ Water-in-fuel is detected. Ifthe warning light flashes for 30 seconds at key ON and water is drained from the suction-side water-separating fuel iter, the pressure-side fuel filter must be replaced ‘The "MALFUNCTION" or "ENGINE MALFUNCTION’ lamp is a blue lamp and indicates that the vehicle may be exceeding emission level limits. When Mluminated, the MALFUNCTION or ENGINE MALFUNG ION lamp (biue Iamp) indicates the engine or diesel exhaust gas aftertreatment system is in need of repair atthe first available opportunity. ‘Another function of the MALFUNCTION or ENGINE MALFUNCTION lamp (blue lamp) is to flash when the diesel exhaust fluid tanlc ia empty. Fault codes can be accessed using the electronic service tool or by fault code flash out To check for active engine electronic fuel system and engine protection system fault codes, turn the keyswitch OFF and move the diagnostic switch to the ON. position. ‘Tur the vehicle keyswitch to the ON position. Ine active fault codes are recorded, bath lights will came on and stay on. Ifactive fault codes are recorded, both lights will come on momentarily, then bogin to lach the oodo of the recorded fault eodee. The fault code flashes in the following sequence: ‘+ AWARNING (amber) light flashes, ices * —— ‘+ Following a short ane- or two-second pause, the number of the recorded fault code flashes in the STOP (red) lamp. ‘+ There is a one- or two-second pause between each number. ‘+ Afier the number finishes flashing in red, an amber light appears again. The lights flash each fault code out three times before advancing to the next code, To skip to the next fauit code, move the IncrementiDecrement switch, if equipped, momentarity to the increment (+) position. To go back to the previous fault code, momentarily mave the Increment/Decrement switch, if equipped, to the decrement (-) position. If only one active fault code is recorded, the same fault code will continuously be displayed when either (+) or (-} switch is depressed. Wu‘The explanation and correction of the fault codes can be found in the troubleshooting and repair manual for your appicaton. “The diagnostic switch must remain in the OFF position (shorting plug removed) while the engine is being operated forall fault cades to be logged. S The diagnostic ON/OFF switch circuit signals the system that the operator is one” requesting to read any active fault code recorded in the ECM, Note : Some OEMs use a shorting plug rather than a switch, ‘When the ECM receives the signal from the diagnostic ON/OFF switch, the yellow and red WARNING lights come on and start flashing if any active fault code is recorded in the ECM. If both warning lights remain on and do not flash, there are ne active fault codes present. Note : The equipment must be stationary. If road speed is detected, the flashing sequence will not occur. ‘Tum the diagnostic switch to the OFF position when the diagnostic system is not Throttle Activated Diagnostic Switch ‘The throttle-activated diagnostic switch feature Is intended to eliminate the need fora dach mounted diagnostic switch, which ic used to activate the fault code flashout on the lamps. The fault code flashout is activated through a simple ‘sequence of throttle movements. When this feature is enabled, the engine is in stop state and the Keyswitch is turned ON. Every successive cycle of the throttle leads to the next fault code to be flashed on the lamps, in the same manner as if the increment switch were depressed. ‘To activate this feature, the engine must be siopped and the keyswitch turned to ‘som the ON position. Depress the accelerator pedal completely three times. The feature should then be enabled. Transitioning to the next fault code occurs ‘automatically after the first fault cade is flashed out twice or if the throttle pedal is cycled. Note : There is an optional, error sensitive mode for this feature. If any of the throttle-related errors ocour, this feature tums on the diagnostic ‘switch automatically when the engine is stopped and the keyswitch is ‘ON. During this mode, only the increment switch can be used to flash out the next fault code.Engine Protection System AXCAUTION A illuminated, the driverloperator must pull to safe to do s0, to reduce the possibility of engine damage. When the red STOP lamp is the side of the road, when This engine is equipped with an engine protection system, The systern monitors critical engine temperatures and pressures, and logs diagnostic faults when an over or under normal condition occurs. If an out-of-range condition exists and engine derate action is to be initiated, the operator is alerted by an in-cab WARNING lamp. The ETOP lamp biinla or flashes when out-of range conditions continue to worsen. The driver must pull to the side of the road, when itis safe to do 50, to reduce the possibilty of engine damage. Note : Engine power and speed will gradually be reduced, depending on the level of severity of the observed condition. The engine protection system will not shut down the engine unless the engine protection shutdown feature has been enabled, Fault Code Snapshot Data ‘When a diagnostic fault code is recorded in the ECM, the ECM input and output cata Is recorded trom all sensors ana switcnes. Snapsnot data allows ine relationships between ECM inputs and outputs to be viewed and used during troublashnating Fault code snapshot data can only be viewed using INSITE™ electronic service to INSITE™ Electronic Service Tool Description INSITE™ electronic service tool is a service tool for the electronic engine control system, Use INSITE™ electronic service tool to: ‘+ Program customer-specified information into the ECM (parameter and features) Aid in troubleshooting the engine Change the engine power or rated speed calibration Transfer new or update calibration files to the ECM ‘+ Create and view trip reports, etc.INSI1E'™ Electronic Service lool Monitor Mode The INSITE™ electronic service tool monitor mode is @ useful troubleshooting aid that displays the key ECM inputs and outputs. This feature is used to spot ‘constant or abnormally fluctuating values. Last Modified: 10-Mar-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘Some applications utilize accessories such as (CB radios, mobile transmitters, etc.) not installed and used correctly the radio frequency energy generated by these accessories can cause electromagnetic interference (EMI) conditions to exist between the accessory and the Cummins electronically controlled systems. Cummins is not liable for any performance proplems win ener tne electronically controlled systems or the accessory due to EMI. EMM! Is not considered oy Cummins to be a system failure and therefore is not warrantable System EMI Susceptibility Your Cummins product has been designed and tested for minimum sensitivity to incoming electromagnetic energy. Testing ‘has shown that there is no performance degradation at relatively high energy levels; however, if very high energy levels are encountered, then some noncritical diagnostic fault code logging can occur. The electronically controlled systems EMI ‘susceptibity level will protect your systems from most, if not all, electromagnetic energy-emitting devices that meet the legal requirements, System EMI Radiation Levels. Your Cummins product has been designed to emit minimum electromagnetic energy. Electronic components are required to pase various Cumming and industry EMI specifieatione. Tasting has chown that when the systems are properly installed, they will not interfere with onboard communication equipment or with the vehicle's, equipment’s, or vessel's ability to meet any applicable EMI standards and regulated specifications. Ian interference condition is observed, follow the suggestions below to reduce the amount of interference: 4. Locate the transmitting antenna as far avay from the electronically controlled systems and as high as possible, 2. Locate the transmitting antenna as far away as possible from all metal obstructions (e.g., exhaust stacks) 3. Consulta representative of the accessory supplier in your area to: ‘+ Accurately calibrate the device for proper frequency, power output, and sensitivity (both base and remote site devices must he properly calihrated) ‘+ Obtain antenna reflective energy data measurements to determine the optimum antenna location Obtain optimum antenna type and mounting arrangement for your application ‘+ Make sure your accessory equipment model is built for maximum fitering to reject incoming electromagnetic noise. Last Modified: 04-Jun-2012(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information ‘Cummins Ine. recommends that the system be maintained according to the Maintenance Schedule in this section Ifthe system is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], perform maintenance at shorter intervals. Shorter maintenance intervals are also required ifthe system is operated in a dusty environment or if frequent stops are made. For gas fueled generator sets, shorter maintenance intervals are also required, if operating at loads below 70% for prolonged periods. Contact your local Cummins® Autharized Repair Location for recommended maintenance intervals, ‘Some of these maintenance procedures require special tools or must be completed by quaified personnel. Contact your ocal Cummins® Authorized Repair Location for detailed information. It your system is equipped with a component or accessory not manufactured or supplied by Cummins Inc., refer to the component manufacturer's maintenance recommendations, OEM supplied equipment and components can impact on the performance and reliability of the engine if they are not correctly maintained. Use the chart provided in this section as a convenient way to record maintenance performed. Last Modified: 23-Oct-2012(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information Most of the maintenance operations described in this manual can be performed with common hand tools, metric and Society. Cf Automotive Engineers (SAE) wrenches, sockets, and screwdrivers, ‘The following is alist of special service tools required for some of the maintenance operations: Tool Part Number: Description: ‘3400187 Oilfilter wrench ‘3376592 ‘Torque wrench (valve and injector adjustment) 4919363 ‘Overhead setting kit ‘3400158 (General use strap-lype filter wrench (up to 152 mm [5.9 in] aah oes a ‘gauge, click type (v-belis and ribbed with four 13822525 Bell tension gauge, click type (v-ribbed with 6 to 12 ribs) ‘ST-1138 Beit tension gauge (v-belts) ‘STS? Dial depth gauge 3164019 Chip removal tool ‘ST41293 Belt tension gauge (v-ribbed belts of six o nine ribs) ‘CC-2800 (Fieetguard® Part Number) Refractometer ‘CC-2602 (Flestguard® Part Number) Coolant test kit Contact a Cummins® Authorized Repair Location for the required service tools. Last Modified: 07-May-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information For your convenience, listed below are the section numbers that contain specific instructions for performing the maintenance checks listed in the maintenance schedule. Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance, tenance Procedures at Daily Interval'") (Section 3) ‘+ Fuel-Water Separator - Drain + Lubricating Oil Level - Check + Coolant Level - Check ‘+ Fan, Cooling - Inspect for Reuse ‘+ Drive Belts - Check “+ Air Intake Piping - Check + Crankease Breather Tube - Check + Air Cleaner Restriction (ifequipped) - Check + Charge-Air Piping - Check Maintenance Procedures at 500 Hours or 1 Year (Section 4) Pressure Fuel Fiter- Change + Fuel Filter Suction - Change Fuel System Priming - Prime Lubricating Oi and Filters - Crange® Cooling Fan Belt Tensioner - inspect for Reuse Coolant Filter - Change + Charge-Air Cooler - Test + Radiator Prosouro Cap. Inopest for Rouse + Radiator Hoses - Check + Cold Starting Aid - Check Maintenance Procedures at 1500 Hours or 3 Years (Section 5) + Engine Mounting Dotts - Check + Vibration Damper, Viscous - Check + Coolina System - Flush ‘+ Fan Hub, Belt Driven - Inspect for Reuse + Coolant Filter - Change + Overhead Set - Agust + Engine Steam Cleaning - Clean 1. Follow the manufacturer's recommended maintenance procedures for the starter, alternator, generator, batteries, electrical components, charge-air cooler, air compressor, and fan clutch. 2. The lubricating oil and lubricating oil fiter interval can be adjusted based on oil type, fuel consumption, and gross vehicle weight for automotive applications. Reference the Maximum Oil Drain Intervals Table 1 and 2.Oil Drain Intervals |Maximum Oil Drain Intervals 1, Select maintenance items from the chart below. Maintenance rem Approved Reterence Refer to Procedure 018-017 in Section v. _ eid \iqsSipubsys2%xni/eniprocedures/267/ 267-018-017.himi) . jaa , Rater Frome TO FS i Viscosity Ere Stn Y Haid eater tet ste rei ‘GES 20071 (CH, AGEA ES) Refer to Procedure 076-003 in Section iia CES 20078 (Ci-4, ACEAE7) v. CES 20081 (CJ-4, ACEA E9, JAMA DH-2) (IgsS/pubsys2/xmlleniprocedures/267/ 267-018-003.himl) 2. Change oil based on fixed hours of operation or months in service, whichever occurs first. Oil Drain Interval - All Ratings Except cr ‘Application ‘Sump Size ‘Change Interval ‘Standby Power 75 liters [20 gall 250 hours or 12 months: All Other Applications 765 iters [20 gall ‘500 hours or 12 months Oil Drain Interval - G7 Application ‘Sump Size ‘Change Interval ‘Standby Power All Other Applications 75 liters [20 gal) 75 liters (20 gal) 7250 hours or 12 months 250 hours or 12 months: Last Modified: 18-Jun-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Maintenance Data Maintenance Record Product Serial No.: Product Model (Owner's Name: Equipment Model/Number: Key to table headings: Date B= Schedule km (Miles), Hours or Time Interval (C= Actual km [Miles] Hour or Time D = Maintenance Check Performed E = Check Performed By F = Comments A 8 iS D E Last Modified: 04-Aug-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Maintenance Data Maintenance Record Product Serial No.: Product Model (Owner's Name: Equipment Model/Number: Key to table headings: Date B= Schedule km (Miles), Hours or Time Interval (C= Actual km [Miles] Hour or Time D = Maintenance Check Performed E = Check Performed By F = Comments A 8 iS D E Last Modified: 04-Aug-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information The fuel system requires the use of two fuel fiters, The suction-side fier must have the following characteristics: + Water-separatina ‘= T-micron rating ‘+ Water-in-fuel sensor with shunt resistor ‘= Water-drain valve ‘+ Engine or chassis mounted. ‘The pressure-side fiter must have the following characteristios: ‘+ 3-micron rating + Engine mounted. Use the following procedure for fuel fiter recommendations. Refer to Procedure 018-024 in Section V, (/qs3/pubsys2/xmUerv/provedures/267/267-018-024. htm!) Preparatory Steps ‘AWARNING A Bamteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, ramave the nagative (.) hattary cable firet and attach the negative (-) battery cable last. ‘+ Disconnect the batteries. Refer to the original equipment manufacturer (OEM) service manual. “AAWARNING dy Wear appropriate eye and face protection when using compressed air. Flying debris and alrt can cause personal injury. WARNING A When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. Before servicing any fuel system components, (such as fue lines, fuel pump, injectors, et.) which would expose the fuel system or internal engine component to potential contaminants prior to disassembly, lean the fitings, mounting hardware, and the area around the component to be removed. Dirt orcontaminants can be introduced into the fuel system and engine if the ‘surrounding areas are not cleaned, resulting in damage to the fuel system and engine, Clean the fuel fter head connections, fittings, and mating components with contact cleaner, Part Number 3824510, or equivalent Remove AXWARNING Ay Depending on the circumstance, diesel fuel is flammable. When inspecting or performing service or repairs on the fuel system, to reduce the possibility of fire and resulting severe personal injury, death, or property damage, never smoke or allow sparks or fiames (such as pilot lights, electrical switches, or welding equipment) in the work area. Remove the fuel filter with fer wrench, Part Number 3400187. Make sure the seal ring does not stick to the filler head, Remove the ring with an o-ring pick, ifnecessary. Install Use the correct filter(s) for your engine. It must remove a minimum of 98.7 poroont of free and emulsified wator. It muet ala have a @ mioron particle removal efficiency. Use the following procedure for additional information. Refer to Procedure 018-024 in Section V. (/qs3/pubsys2xmilen/procedures/267/267- (018-024.html) Apply a thin coating of clean engine cil to the filter gasket surface and the center seal Note : Cummins@/Fleetguard® filters are supplied with a disposable insert that will prevent fuel from entering the clean side of the filter media during pre filling. For engines that are not equipped with lit pumps, the pressure-side and suction- aide fue! fitera ahould be pre-filled prior to inatallation, AXCAUTION A Mechanical overtightening of the filter can distort the threads and damage the fuel filter seal.Note : Engines equipped with priming pumps do not require the fuel filter to be filled prior to installation if the following filing procedure is followed. Incall tho fitor onto the filter hoad. Turn the ftor until the gasket eontacte tho: filter head surface. Tighten the filter an additional 344 of a turn after the gasket contacts the filer head surface, or as specified by the filter manufacturer. Finishing Steps AWARNING A Batteries can emit explosive gases. To reduce the possibility of personal injury. always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. + Connect the batteries. Refer to the OEM service manual ‘+ Prime the fuel system. Refer to Procedure 005-234 in Section 4, (/as3ipubsys2/xmiV/en/procedures!267/267-005-234-0m.himl) ‘+ Operate tne engine ana check for leaks. Last Modified: 27-May-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information The fuel system requires the use of two fuel fiters, The suction-side fier must have the following characteristics: + Water-separatina ‘= T-micron rating ‘+ Water-in-fuel sensor with shunt resistor ‘= Water-drain valve ‘+ Engine or chassis mounted. ‘The pressure-side fiter must have the following characteristios: ‘+ 3-micron rating + Engine mounted. Use the following procedure for fuel fiter recommendations. Refer to Procedure 018-024 in Section V, (/qs3/pubsys2/xmUerv/provedures/267/267-018-024. htm!) Preparatory Steps ‘AWARNING A Bamteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, ramave the nagative (.) hattary cable firet and attach the negative (-) battery cable last. ‘+ Disconnect the batteries. Refer to the original equipment manufacturer (OEM) service manual. “AAWARNING dy Wear appropriate eye and face protection when using compressed air. Flying debris and alrt can cause personal injury. WARNING A When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. Before servicing any fuel system components, (such as fue lines, fuel pump, injectors, et.) which would expose the fuel system or internal engine component to potential contaminants prior to disassembly, lean the fitings, mounting hardware, and the area around the component to be removed. Dirt orcontaminants can be introduced into the fuel system and engine if the ‘surrounding areas are not cleaned, resulting in damage to the fuel system and engine, Clean the fuel fter head connections, fittings, and mating components with contact cleaner, Part Number 3824510, or equivalent Remove AXWARNING Ay Depending on the circumstance, diesel fuel is flammable. When inspecting or performing service or repairs on the fuel system, to reduce the possibility of fire and resulting severe personal injury, death, or property damage, never smoke or allow sparks or fiames (such as pilot lights, electrical switches, or welding equipment) in the work area. Remove the fuel filter with fer wrench, Part Number 3400187. Make sure the seal ring does not stick to the filler head, Remove the seal ring with an o-ring pick, if necessary. Install Use the correct fiter(s) for your engine. The suction-side filter must remove @ minimum of 05 peroont of free and omuloified water. It must aloo have a7 micron particle-removal efficiency. Use the following procedure for more fiter information. Refer to Procedure 018-024 in Section V. ((qs3/pubsys2/xml/en/procedures/267/267-018-024.html) Apply a thin laver of clean engine oil to the filter gasket surface and center the seal For engines that are nor equipped witn lit pumps, the pressure-side and suction- side fue! fiters should be pre-filled prior to instalation. Install the fiter onto the filter head. Turn the fiter until the gasket contacts the fiter head surface, Tighten the filter an additional 3/4 of a turn after the gasket contacts the filer head surface, or as specified by the filter manufacturer,Finishing Steps AWARNING A Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. + Connect the batteries. Refer to the OEM service manual ‘+ Prime the fuel system. Refer to Procedure 005-234 in Section 4, (las3ipubsys2/xmi/en/procedures!267/267-005-234-0m.html) ‘+ Operate the engine and check for leaks. LastModified: 06-Jun-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Prime ‘The fuel system should be primed after replacing the fuel fiter or running the engine out of fuel. ‘To prime the fuel system, fil the suction-side and pressure-side fuel fiters with clean diesel fuel Pour clean diesel fuel into the outer openings (dirty side) of the fiter. Use a clean side block-off plug, if available, to prevent fuel from entering the clean side of the filter. Install the suction-side fuel filer. Refer to Procedure 006-066 in Section 4 (Igs3/pubsys2/xmilen/procedures/267/267-006-066-om.html) Install the pressure-side fuel fer. Refer to Procedure 006-065 in Section 4. (Iqs3/pubsys2/xmilen/procedures/267/267-006-065-om him) ‘To assist in fuel system priming and removing air from the fuel system, an orificed diagnostic fuel line, Part Number 3164621, may be used to bleed air from the low-pressure fuel system, Attach the diagnostic fuel line to the Compuchek™ fiting at the inlet to the pressure-side fuel fiter, Crank or start the engine and allow it to run unti the air is, removed from the fuel system and a solid stream of fuel exits the diagnostic fuel line. Stop the engine after a solid stream of fuel begins exiting the diagnostic fuel line Wait 4 to 5 seconds to allow any compressed air trapped in the fuel fier head to exit through the diagnostic fue line. Repeat this process until air no longer exits the diagnostic fuel line when cranking or starting the engine. If air continues to exit the diagnostic fuel fine after {four or more repetitions, check the suction side of the fuel system for leaks. Repeat this process until air no longer exits the diagnostic uel line when cranking or starting the engine. If air continues to exit the diagnostic fuel ine after {our or more repetitions, chieck the suction side of the fuel system forleaks. Refer to Procedure 006-003 in Section 6. (/qs3/pubsys2/xmi/en/proceduresi267/267- (096.00 hte!) Last Modified: 20-Jan-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Drain AXWARNING Av ‘Some state and federal agencies have determined that used engine oll can be carcinagenia and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations. AWARNING A To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin. ‘Change the lubricating oil and fer at the specified oll change interval for your pplication, See the Maintenance Schedule in Section 2. Refer to Procedure 102-002 in Section 2. (/qs3/pubsys2/xm\/en/procedures/267/267-102-002- ‘om.htmi), ‘Operate the engine until the water temperature reaches 60°C [140°F]. Shut off ae the engine. Remove the oil drain plug from both of the lubricating oil pan sumps. Do not remove the plugs on either side of the oil pan to drain the oil. They will not allow the ail to drain completely, Note : Fittings used in the botiom drain opening of the oil pan other than ‘Cummins Inc. specified parts must not exceed the size or weight limits. See Lubricating Oil Syatem in Section V. Refer to Procedure 018-017 in Section V. (/qs3/pubsys2/xml/en/procedures/267/267-018-017.html) Clean the area around the lubricating all fiter head. Use oil iter wrench, Part Number 3400157, to remove the oil fiter(s) Clean the gasket surface of the oil filter head, The o-ring can stick on the filter head; be sure itis removed Fill f AXCAUTION ANever replace a lubricating filter with any other lubricating filter without — veritying adequate clearance with suspension andjor chassis at extremes of travel, The engine can be damaged. Use the following procedure to locate lubricating oil fiter part numbers. See Lubricating Oil System in Section V. Refer to Procedure 010-017 in Section V. (/qs3/pubsys2/xmi/en/procedures/267/267-018-017.himl) Use the correct oll ter for your engine. Cummins inc. requlres a lubricating alt fter(s) be used that meets the specifications in Cummins® Source Approval Methnds (SAM) 10,785 ‘AcAUTION A The lack of lubrication caused by an empty oil filter is harmful to the engine. Acaution A Mechanical overtightening of the filter can distort the threads or damage the filter element seal. Fil the fiter with clean oil. Choose the correct oil for your operating climate, as outlined in Section V. Fillo the correct capacity. See Lubricating Oil System in Section V. Refer to Procedure 018-017 in Section V. ((qs3/pubsys2/xml/en/procedures/267/267-018-017.htmn!) Apply a light flm of lean engine oil o the gasket sealing surface before installing the new filter. Install the fiter on the fiter head, Tighten the fiter until the gasket contacts the Iter nead surtace. Use oil fiter wrench, Part Number 3400157, to tighten the fiter to the ‘specifications supplied with the fiter. Clean and check the oil drain plug threads and the seal surface. Install the oil drain plugs in both of the lubricating oil pan sumps. Torque Value: 80 nem [59ft1b] Note : Check the torque of the side and bottom drain plugs to be sure both are tight. Use a high-quality multiviscosity oll such as Valvoline® Premium Blue™, \Valvoline® Premium Blue™ 2000, or equivalent. Choose the correct oll for the specific operating climate. See Lubricating Oil Recommendations and ‘Spesifications in Section V. Refer to Procedure 018-008 in Section V. (/qs3/pubsys2/xmilen/procedures/267/267-018-003. html)Fill the engine with clean oll to the H (high) mark on the dipstick. Use the tolloving procedure to kentty the total system capacity incluaing the titer. See Lubricating Oil System in Section V, Refer to Procedure 018-017 in Section V. (gs3/pubsys2/emileniproceduras/287/287-018.017.himl) ‘Acaution & Engine oil pressure must be indicated on the gauge within 15 seconds after starting, If oll pressure 1s not registered within 19 seconds, shut off the engine immediately to avoid engine damage. Confirm the correct oil level ie in the oil pan. Operate the engine at idle speed and inspect for leaks atthe filer and the drain plugs. ‘Shut off the engine. Wait approximately 10 minutes for the oll to drain back from the upper parts of the engine to the ail pan. ‘Check the oil level again. Add oil as necessary to bring the level up to the (high) mark on the dipstick. Last Modified: 15-May-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Initial Check ‘Check the tensioner arm, pulley, and stops for cracks. If any cracks are detected, the tensioner must be replaced, With the belt installed, verify that neither tensioner arm stop is in contact with the spring casing stop. If either stop is touching, the drive belt must be replaced. ‘After replacing the bet, ifthe tensioner arm stops are stil in contact with the spring case stop, replace the tensioner. ‘Check the lacation af the drive belt on the bait tensioner pulley. The belt should be centered on, or close to the middle of, the pulley. Uneligned belts, ether too far forward or backward, can cause belt wear, belt roll-off fallures, or increase uneven tensioner bushing wear, il i ill Preparatory Steps AXWARNING A Batteries can emit explosive gases. To reduce the possi lity of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.‘+ Disconnect the batteries. Refer to the original equipment manufacturer (GEM) service manual. ‘+ Remove the cooling fan drive belt, Refer to Procedure 008-002 in Section A. (gs3ipubsys2/mUlen(procedures/287/267.008.002.0m html) Remove ‘With the belt removed, veriy that the tensioner arm stop 1S m contact with the spring case stop. If these two components are not touching, the tensioner must be replaced. Remove the capscrew and belt tensioner from the bracket (Clean and Inspect for Reuse ‘Check the belt for damage. Transverse (across the belt width) cracks are acceptable. Longitudinal (direction of the belt length) cracks that intersect with transverse cracks are not acceptable, Ifthe belt is frayed or has any piece of material missing, the belt s unacceptable and needs to be replaced. ‘AWARNING A Belt tensioner is spring loaded. Do not attempt to disassemble the tensioner. Personal injury can result. AWARNING A When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.‘heck the tensioner for air busicup. It te tensioner has air bulidup, remove ang use solvent to clean the belt tensioner, Measure the clearance between the tensioner spring case and the tensioner arm lw verily Wrsioner weer-vul and uneven bearing meat ITUie clearances exceeds 3 ‘mm (0.12 in] at any point, the tensioner failed and must be replaced as a complete assemnly Experience has revealed that tensioners generally will show a larger clearance ‘gap near the lower portion of the spring case, resulting in the upper portion rubbing against the tensioner arm. Always replace the belt when a tensioner is replaced. 1. Tensioner cap 2. Tensioner arm 3. Spring case 4, Tensioner pulley 5, Clearance gap. ‘Check the belt tensioner pulley and body for cracks. Ifcracks are found, replace the tensioner. Inspect the tensioner for evidence of the tensioner arm contacting the tensioner cap. If there is evidence of contact, the pivot tube bushing has failed and the tensioner must be replaced. ‘Spin the tensioner pulley. The pulley must spin freely. Ifthe pulley does not spin freely, replace the belt tensioner. Install IAlign the dowel pins on the tensioner with the alignment holes in the mounting bracket, Install the tensioner and mounting capserew. Tighten the capscrew, Torque Value: 50 nem [37 Lib] After checking the torque, use a breaker bar with a 1/2-inch ratchet to rotate the tensioner slowly away from the area of belt contact (clockwise and down). Ifthe arm rotates with any roughness or hesitancy, replace the tensioner. Finishing Steps AXWARNING Av Batteries can emit explosive gases. To reduce the possibility of personal jury, always ventilate the compartment hefore servicing the hatteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. + Connect the batteries. Refer to the OEM service manual ‘+ Install the cooling fan drive belt. Refer to Procedure 008-002 in Section A. (las3/pubsys2/xmi/en/procedures!267/267-008-002-0m.html) ‘+ Uperate the engine ang check tor proper operation. Last Modified: 06-Jun-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) |General Information The correct coolant fiter to be used is determined by the total cooling system capacity and other operational factors. Use the following procedure in the QSZ13 (M2150 2101 Operation and Maintenance Manual, Bulletin 4358365, to select the correct cooiant nter. Refer to Procedure 018-004 In Section V. (Igs3/pubsys2/xmilen/procedures/267/267-018-004.himl) | ‘An onloff valve is provided to prevent coolant leakage while changing the coolant filter, \With the valve in the ON position (1),the coolant flows to and from the coolant filter. In the OFF position (2), the coolant flow is cut off to and from the coolant filter. Remove “WARNING A Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Remove the cooling system pressure cap. AXWARNING Av Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. ‘Turn the coolant on/off valve to the OFF position. Do not use force to open or close the onioff valve.Use the following procedure if the valve does not tum freely. Refer to Procedure UU8-UU/ In Section 8. (/gss/pubsyszZixmU/ervprocedures!Z0//26/-UUS-UU/-tr ntl) Remove and discard the coolant filter. Clean the gasket surface on the fiter head. Install ‘Apply a thin fim of clean engine oll, or equivalent, to the coolant filter gasket sealing siiface hefnee installing the enolant fiter AXCAUTION A Mechanical overtightening can distort the threads or damage the filter, head. Install the coolant filter. Tighten the coolant fiter % to % of a turn after initial gasket contact, or as specified by the manufacturer, ‘Tur the coolant on/off valve to the ON (1) positon, Tnetall tho radiator proseure cap. ‘WARNING A Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Operate the engine until the coolant temperature is above 82°C [180°F] and cheek for coolant leaks. After the air has been purged from the system, check the coolant level again.Last Modified: 15-May-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) \Clean and Inspect for Reuse Ifthe engine experiences turbocharger damage or any other occasion where oil (or debris is put into the charge-air cooler, the charge-air cooler must be cleaned, Brush away any loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine. Remove the charge-air cooler piping and charge-air cooler from the vehicle, Refer to the original equipment manufacturer (OEM) service manual ACAUTION A Do not use caustic cleaners to clean the charge-air cooler. Damage to the charge-air cooler will result. Flush the charge-air cooler internally with solvent in the opposite direction of normal alow. Shako the charge sir coolor and lightly top on the ond tanke with a rubber mallet to dislodge trapped debris. Continue flushing untl all debris or oll is removed. Note : Make sure the tubes are in a vertical orientation when flushing, Ifthe dobris can net be totally removed from the charge air cooler, the chargo ir cooler must be replaced, AcauTion A ‘The charge-air cooler must be rinsed, dried, and free of solvent, oil, and debris or engine damage will result. Alter the charge-air cooler has been thoroughly cleaned of al oil and debris with solvent, wash the charge-air cooler internally with hot, soapy water to remove the remaining solvent. Rinse thoroughly with clean water. Biow compressed air through the inside of the charge-air cooler in the opposite irection of normal ar flow until the charge-air cooler is dry intemally Inspect the charge-air cooler for cracks, holes, or other damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. If any damage causes the charge-air cooler to not pass the air leak check, the charge- air cooler must be replaced Install the charge-air cooler and charge-air cooler piping on the vehicle. Refer to the OEM service manualLeak Test To check the charge-air cooler for cracked tubes or header, remove the inlet and outlet hoses from the cooler. The charge-air cooler does not have to be removed from the chassis. AWARNING A To prevent possible injury if either plug blows off during the test, secure safety chains on the test plugs to any convenient capscrew on the radiator assembly. This test must not be performed without securely fastened safety chains. Install the charge-air cooler tester, Part Number 4919085, ‘Apply 207 kPa [20 psi of air pressure to the cooler. Close the air pressure regulator. Determine if the pressure decay is caused by a leak in the charge-air cooler or from a leaky connection. Use a spray bottle filed with soapy water applied to all hose connections. Watch for bubbles to appear at the location of the leak. Ifthe pressure drop is caused by a leaky connection, repair the connection, and repeat the test. If the leak is within the charae-air cooler, repeat the test to verify the accuracy of the pressure drop measurement. Similar pressure drop readings must be obtained in a minimum of three consecutive tests before the reading can be considered accurate. Monitor the pressure gauge and determine the rate of pressure decay with a stopwatch. Charge-Air Cooler Pressure Drop koa, psi 49 MAX 7Leak Test To check the charge-air cooler for cracked tubes or header, remove the inlet and outlet hoses from the cooler. The charge-air cooler does not have to be removed from the chassis. AWARNING A To prevent possible injury if either plug blows off during the test, secure safety chains on the test plugs to any convenient capscrew on the radiator assembly. This test must not be performed without securely fastened safety chains. Install the charge-air cooler tester, Part Number 4919085, ‘Apply 207 kPa [20 psi of air pressure to the cooler. Close the air pressure regulator. Determine if the pressure decay is caused by a leak in the charge-air cooler or from a leaky connection. Use a spray bottle filed with soapy water applied to all hose connections. Watch for bubbles to appear at the location of the leak. Ifthe pressure drop is caused by a leaky connection, repair the connection, and repeat the test. If the leak is within the charae-air cooler, repeat the test to verify the accuracy of the pressure drop measurement. Similar pressure drop readings must be obtained in a minimum of three consecutive tests before the reading can be considered accurate. Monitor the pressure gauge and determine the rate of pressure decay with a stopwatch. Charge-Air Cooler Pressure Drop koa, psi 49 MAX 7Ittne pressure crop 1s greater ian the specication, ine charge-air cooler must be replaced. Refer to the OEM service manual. Note : if a charge-air cooler leaks more than 49 kPa [7 psi] in 15 seconds, it will appear as a major leak in a leak tank, Note : Charge-air coolers are not designed to be 100-percent leak free. If the pressure drop is less than 49 kPa [7 psi] in 15 seconds, then the charge-air cooler does not need to be replaced. ‘Temperature Differential Test Inspect the charge-air cooler fins for obstructions to airflow. Remove obstructions, such as a winterfront or debris, Manually lock shutters, if equipped, inthe OPEN position. Install a thermocouple, Part Number 3164492, from multimeter kit, Part Number 3400162, into the intake air connection, Install another thermocouple at the air cleaner inlet to measure the ambient air temperature. Connect digital multimeter, Part Number 3164489, from multimeter, Part Number 3400162, to each thermocouple and record the corresponding temperatures, ‘Test with the engine at peak power. Record the intake air temperature and the ambient air temperature, Calculate the differential temperature: (lilahe Air Ternper ature) ~ (AmmLiznl Air Temperature) ~ Differential Teanperalures Intake Air “Ambient Air Differential Temperature Temperature Temperature lithe temperature differential is greater than the specifications, check the charge- alr cooler for dirt and debris on the fins and clean as necessary. I the problem still exists, check the charge-air cooler for debris in the fins or between the charge-air cooler and radiator. Canim full fan engagement. Charge Air Cooler Temperature Rise celsius ‘fahrenheit 1 MAX 20 Ambient air temperature above 0°C [32°F] BA rothPressure Differential Test Measure the charge-air cooler system pressure drop with a manometer, Part Number ST-1111-3. Install one end of a manometer to the tap in the turbocharger compressor outlet = , [tari Se i an east aS BP ‘Operate the engine at the maximum advertised horsepower and correlating rpm. Record the readings on the manometer. (Charge-Air Cooler System Differential mm-hg inca) 182 MAX 6 Charge-Air Cooler System Differential koa psi 24 MAX 3 Ifthe differential pressure is greater than specification, check the charge-air cooler and associated piping for plugging. Clean or replace, if necessary. st Modified: 03-Feb-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Inspect for Reuse Make sure the correct radiator cap is being used. Refer to Procedure 018-078 in Section V. (I4s3/pubsys2/xml/eniprocedures/267/267-018-018.himl) Inspect the rubber seal of the pressure cap for damage. Inspect the radiator fl neck for cracks or other damage. Reference the radiator original equipment manufacturer (OEM) for instructions if the fll neck is damaged C & @® Last Modified: 20-May-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Maintenance Check ‘Check all hoses for cracks, cuts, or collapsing. Note : The silicone engine coolant hose will exhibit swelling due to the elasticity of the hose. If damage is found, replace damaged hoses. Contact your local Cummins Authorized Repair Location, Last Modified: 13-Jan-2011(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Maintenance Service Note : Porallc! control ayatems are required for automatic radiator ‘shutters and thermatic fans. Shutters must open and fans turn on when the intake manifold air temperature, the engine coolant outlet temperature, or the refrigerant compressor pressure rises above the sensor set points. Any one of the following conditions must activate the ‘shutters, fan, or both: ‘+ High refrigerant compressor pressure (1) ‘+ High intake manifold temperature (2) ‘+ High coolant temperature (3). (Check the shutterstats and the thermatic fan. ‘Air Soneng Fan Coo «en on Feige 1s 150 155 160 168 (170 17810 TEMPERATURE ‘Shuflarstat and thermatic fan controls must operate in the sama famperature range as the thermostat with which they are used, Consult the Thermal Control Settings Graph shown. Winterfronis can be used in a vehicle equipped with charge-air-cooling (CAG), but must be designed to cover the frontal area ofthe cooling system partially. A minimum of 75 cm? [120 in’] or approximately 28 cm x 28 cm [11 in x 11 in] of frontal area must be left open to allow adequate airflow for the CAC to function correctly.LastModified: 02-Apr-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Maintenance Check ‘Check the torque on the engine mounting nuts and bolts. Tighten any that are loose. Refer to the original equipment manufacturer (OEM) service manual. Inspect the rubber for deterioration and age hardening. Replace any broken or lost boits, capscrews, or damaged rubber. HE TI iC Last Modified: 10-Mar-2014(!gs3/pubsys2/xmi/en’manual/4358365/4358365-ttlepage htm!) Inspect AXCAUTION A ‘The silicone fluid in the vibration damper will become solid after extended service and will make the damper inoperative. An inoperative vibration ‘damper can cause major engine or drivetrain failures. Check the vibration damper for evidence of fluid loss, dents, and wobble. Inspect the vibration damper thickness for any deformation or raising of the damper cover plate. Itany of these conditions are identfied. contact your local Cummins Authorized Repair Location to replace the vibration damper. For vibration damper location, refer to Engine Diagrams in Engine kéentification (Section E). Lastmoamed: 22-06-2007