Руководство по ремонту cummins 6bt

Brand: CUMMINS
|
Category: Engine
|
Size: 15.03 MB

• Foreword

  2

• Table of Contents

  3

• Cummins 22-Group System Exploded Diagram

  4

• How to Use the Manual

  5

• Generic Symbols

  6

• Introduction

  8

• Section Contents

  8

• About the Manual

  9

• General Safety Instructions

  10

• General Repair Instructions

  11

• General Cleaning Instructions

  12

• Glossary of Terms

  13

• Engine and Component Identification

  15

• Engine Identification

  16

• Industrial Engine Nomenclature

  17

• Automotive Engine Nomenclature

  17

• Injection Pump Dataplate

  18

• General Engine Specifications

  20

• Engine Diagram-Automotive Engine

  23

• Inlet Side

  23

• Rear View

  23

• Turbocharger Side View

  24

• Front View

  24

• Engine Disassembly and Assembly

  25

• Engine Disassembly and Assembly-Service Tools

  29

• Engine Disassembly Check List

  31

• Engine Disassembly

  32

• Steam Cleaning the Engine

  32

• Engine Weight

  32

• Rollover Stand-Engine Mounting

  32

• Oil-Draining

  33

• Lifting Bracket Removal-Rear

  33

• Drive Beit-Removal

  33

• Fan Pulley-Removal

  34

• Vibration Damper/Crankshaft Pulley-Removal

  34

• Belt Tensioner-Removal

  34

• Fan Hub-Removal

  35

• Alternator-Removal

  35

• Thermostat-Removal

  36

• Turbocharger-Removal

  36

• Exhaust Manifold-Removal

  38

• Fuel Filter-Removal

  38

• Fuel Filter Head-Removal

  39

• KSB (Remote Mounted)-Removal

  39

• Fuel Lines-Removal

  40

• High Pressure Fuel Line-Removal

  40

• Fuel Drain Manifold-Removal

  41

• Low Pressure Fuel Lines-Removal

  42

• Dipstick-Removal

  43

• Manifold Cover-Removal

  43

• Aftercooler-Removal

  43

• Valve Covers-Removal

  44

• Injector Nozzles-Removal

  44

• Rocker Levers-Removal

  45

• Push Rods-Removal

  45

• Cylinder Head-Removal

  46

• Front Cover-Removal

  46

• Water Pump-Removal

  47

• Flywheel-Removal

  47

• Flywheel Housing-Removal

  47

• Accessories-Removal

  48

• Injection Pump-Removal (Rotary Type Pumps)

  48

• Gear Lash-Check

  48

• Locking the Pump

  49

• Drive Gear-Removal

  50

• Injection Pump-Removal (In-Line)

  50

• Fuel Transfer Pump-Removal

  52

• Tappet Cover-Removal

  52

• Side Oil Fill-Removal

  53

• Oil Cooler-Removal

  53

• Water Inlet Connection-Removal

  53

• Oil Pan-Removal

  54

• Suction Tube-Removal

  54

• Rear Seal Housing-Removal

  54

• Camshaft-Removal

  55

• Measuring Gear Lash

  55

• Valve Tappets-Removal

  56

• Lube Pump-Removal

  56

• Measuring Backlash

  56

• Timing Pin Housing-Removal

  58

• Gear Housing-Removal

  58

• Balancer-Removal

  59

• Measuring the End Play

  59

• Locking the Balancer

  59

• Removing the Balancer

  60

• Piston and Rod Assemblies-Removal

  61

• Crankshaft-Removal

  63

• Turbocharger Drain Tube-Removal

  65

• Cylinder Block-Removing from the Rollover Stand

  65

• Engine Assembly

  65

• Cylinder Block-Prepare for Assembly

  65

• Valve Tappets-Installation

  66

• Crankshaft-Installation

  66

• Piston and Rod Assemblies-Installa­tion

  71

• Piston Grading for 1994 Automotive Applica­tions Only

  71

• Dial Indicator

  72

• Piston Protrusion

  74

• Piston and Connecting Rod Assemblies-Installation

  74

• Gear Housing-Installation

  78

• Lube Pump-Installation

  79

• Camshaft-Installation

  80

• Camshaft End Play-Measuring

  82

• Camshaft Gear Backlash-Measuring

  83

• Timing Pin-Installation

  83

• Crankshaft End Play-Measuring

  90

• Rear Seal-Installation

  90

• Suction Tube-Installation

  91

• Oil Pan-Installation

  92

• Oil Pan Sealing Surfaces-Sealants

  92

• Oil Cooler-Installation

  93

• Side Oil Fill-Installation

  93

• Fuel Transfer Pump-Installation

  93

• Tappet Cover-Installation

  94

• Injection Pump-Installation

  95

• Locked Timed Injection Pump-Installation

  96

• Injection Pumps-Unlocking

  98

• Chisel, Hammer

  99

• Unlocked CAV Injection Pump-Installation

  100

• Unlocked Stanadyne DB4 Injection Pump-Installation

  101

• Unlocked Bosch VE and P7100 Injection Pump-Installation

  104

• Disengage the TDC Pin

  107

• Pump Gear Backlash Limit

  107

• Injection Pump Installation

  108

• Accessories-Installation

  112

• Flywheel Housing-Installation

  113

• Flywheel-Installation

  113

• Water Pump-Installation

  114

• Front Cover-Installation

  115

• Cylinder Head-Installation

  116

• Push Rods-Installation

  117

• Rocker Levers-Installation

  118

• Cylinder Head-Tightening

  119

• Valve Clearance-Adjustment

  121

• Valve Stem to Rocker Lever Clearance

  122

• Injector Nozzles-Installation

  123

• Valve Covers-Installation

  124

• Manifold Cover-Installation

  124

• Aftercooler-Installation

  125

• Fuel Lines-Installation

  125

• Infection Pump Supply Line-Installation

  125

• Fuel Drain Manifold-Installation

  126

• Injection Pump Vent Line-Installation

  126

• High Pressure Fuel Lines-Installation

  127

• KSB (Remote Mounted)-Installation

  128

• Fuel Filter Head-Installation

  128

• Exhaust Manifold-Installation

  129

• Turbocharger-Installation

  130

• Thermostat-Installation

  133

• Vibration Damper-Installation

  134

• Fan Hub-Installation

  134

• Beit Tensioner-Installation

  135

• Water Inlet Connection-Installation

  135

• Alternator-Installation

  135

• Drive Belt-Installation

  137

• Oil Filter-Installation

  137

• Rollover Stand-Engine Removal

  137

• Starter-Installation

  138

• Cylinder Block

  139

• Cylinder Block-Exploded View

  141

• Cylinder Block-General Information

  144

• Cylinder Block-Service Tools

  145

• Cylinder Block Group Inspection Checklist

  146

• Cylinder Block-Precheck before Disassembly

  147

• Cylinder Block-Disassembly

  147

• Cylinder Block-Cleaning

  149

• Cylinder Block-Inspection

  152

• Cylinder Block-De-Glazing

  154

• Expansion and Pipe Plug-Installation

  157

• Camshaft Expansion Plug-Installation

  159

• Camshaft Bushing-Installation

  160

• Dipstick Tube-Replacement

  162

• Cylinder Block-Storing

  162

• Crankshaft-Cleaning

  163

• Crankshaft-Inspection

  163

• Crankshaft Gear-Replacement

  164

• Determining Mam Bearing Clearance

  164

• Camshaft-Cleaning

  166

• Camshaft and Gear-Inspection

  166

• Camshaft Lobe Pitting Reuse Criteria

  167

• Camshaft Lobe Edge Deterioration (Break­down) Criteria

  168

• Camshaft Gear-Replacement

  171

• Camshaft Gear-Removal

  171

• Camshaft Gear-Installation (Heated Gear Method)

  171

• Camshaft Gear-Installation (with Special Tool 3823589)

  173

• Camshaft Capscrew-Installation

  175

• Rubber Element Vibration Damper-Cleaning and Inspection

  176

• Piston and Connecting Rod-Disas­sembly

  178

• Piston, Pin and Connecting Rod-Cleaning

  178

• Piston Inspection

  179

• Piston Pin-Inspection

  180

• Connecting Rod-Inspection

  181

• Rod Bearing Clearance-Checking

  181

• Piston and Connecting Rod-Assem­bly

  182

• Piston Ring Gap-Checking

  183

• Piston Rings-Installation

  184

• Balancer-Disassembly

  185

• Balancer-Assembly

  188

• Gear Housing and Timing Pin Assem­bly-Inspection

  194

• Gear Housing-Disassembly

  195

• Fuel Pump Stud-Replacement

  195

• Data Plate-Replacement

  196

• Cylinder Head

  198

• Cylinder Head-Service Tools

  199

• Cylinder Head Exploded View

  200

• General Information

  202

• Cylinder Head-Precheck before Disassembly

  203

• Cylinder Head-Disassembly

  203

• Cylinder Head-Cleaning

  204

• Valve-Inspection

  206

• Valve Guide Inspection

  208

• Cylinder Head Combustion Face Inspection

  208

• Valve Seat Inspection

  208

• Cylinder Head Cracks-Reuse Guide­lines

  209

• Valve Spring Inspection

  209

• Cup Plug Replacement

  210

• Valves-Grinding

  212

• Valve Seats-Grinding

  213

• Calculating the Grinding Depth

  213

• Valve Depth

  214

• Seat Angle

  214

• Gauge Block

  214

• Seat Grinding Depth Limit

  215

• Valve Seat Width Limit

  216

• Cylinder Head-Assembly

  218

• Valve Spring Compressor

  218

• Rocker Levers

  220

• Rocker Lever Assembly-Exploded View

  221

• Rocker Lever Assembly-General Information

  223

• Rocker Levers-Disassembly

  224

• Rocker Levers and Pedestals-Clean­ing

  225

• Rocker Lever-Inspection

  225

• Rocker Lever Pedestals-Inspection

  226

• Rocker Levers-Assembly

  226

• Tappets and Push Rods

  228

• Tappets and Push Rods-Exploded View

  229

• Tappets and Push Rods-General Information

  230

• Valve Tappets-Inspection

  231

• Push Rods-Inspection

  231

• Fuel System

  233

• Service Tools-Injection Pump

  234

• Exploded View-Fuel System

  235

• Injection Pump-General Information

  236

• Injection Pump-Identification

  236

• KSB Electrical Solenoid Style-General Information

  238

• Cold Start Timing Advance System (KSB)-Electrical Solenoid Style

  238

• VE Pump Timing Advance Principles (Without KSB)

  239

• VE Pump Timing Advance Principles (with Electrical Solenoid KSB Installed)

  240

• Warm Engine Operation (more than 90°F IMT), Retarded Timing

  242

• KSB Electrical Solenoid Style-Inspec­tion

  244

• KSB Electrical Solenoid-Inspection

  244

• KSB Electrical Solenoid Style Wiring Harness-Inspection

  246

• Injection Pump Repairs-Bosch VE

  247

• Delivery Valve Holder/Sealing Washer-Replacement

  248

• Shutdown Solenoid-Replacement

  249

• Shutdown Lever/Spring-Replacement

  250

• Overflow Adapter/Sealing Ring-Replace­ment

  251

• Fuel Inlet Adapter/Seal-Replacement

  252

• Injection Pump Timing-Bosch VE

  253

• Injection Pump Repairs-Lucas CAV DPA

  257

• Back Leakage Valve-Replacement/Inspection

  258

• Bleed Screws/Sealing Washers-Replacement

  260

• Vent Fitting/Sealing Washer-Inspection/Replacement

  261

• Fuel Inlet Fitting/Sealing Washer-Replacement

  262

• Control Lever-Replacement

  262

• Inspect the Lever Components

  263

• Automatic Timing Advance-Disassembly

  265

• Timing Advance Components-Inspection

  266

• Timing Advance-Assembly

  267

• Injection Pump Repairs

  271

• Injection Pump Timing-Stanadyne DB4

  271

• Return Connection Replacement, Stanadyne DB4

  272

• Shutoff Solenoid Replacement, Stanadyne DB4

  273

• Speed Droop Adjustment off Engine-Stanadyne DB4

  275

• Injection Pump Timing-Nippondenso EP9

  276

• Seals Replacement, Nippondenso EP9

  278

• Shut down Lever or Spring Replacement, Nippondenso EP9

  278

• Pressure Relief Valve and Sealing Washer Replacement, Bosch P7100

  280

• Seal Replacement, Bosch P7100

  282

• Fuel Inlet Banjo Connector Replacement, Bosch P7100

  282

• Fuel Shut off Solenoid Replacement, Bosch P7100

  283

• Fuel Shut off Solenoid Adjustment, Bosch P7100

  283

• Fuel Shut off Solenoid Bracket Replacement, Bosch P7100

  284

• Fuel Pump Shut off Lever Replacement, Bosch P7100

  284

• Throttle Lever Replacement, Bosch P7100

  285

• Shutdown Solenoid Inspection, Bosch P7100

  286

• Wiring Guidelines

  286

• Solenoid Resistance Check

  286

• Solenoid Voltage Check

  287

• Injectors

  288

• Injector-Service Tools

  289

• Injector Group-Exploded View

  290

• General Information-Injectors

  291

• Fuel Transfer Pump-General Information

  292

• Fuel Transfer Pump-Identification

  292

• Injector-Disassembly

  294

• Injector-Clean and Inspect

  295

• Nozzle Cleaning Kit

  296

• Injector-Assembly

  297

• Injector-Testing

  299

• Chatter Test

  300

• Fuel Transfer Pump-Cleaning and Inspecting

  300

• Fuel Transfer Pump-Piston Style Rebuild

  301

• Cleaning

  302

• Assembly

  302

• Fuel Lines-Clean and Inspect

  303

• High Pressure Fuel Lines

  303

• Fuel Drain Manifold

  304

• Low Pressure Fuel Lines

  305

• Lubrication Oil System

  307

• Oil Pan and Suction Tube-Exploded View

  308

• Oil Pan and Suction Tube-General Information

  309

• Oil Pan and Suction Tube-Cleaning and Inspection

  310

• Lubricating Oil Cooler-Exploded View

  311

• General Information-Lubrication System

  312

• Pressure Regulator Valve-Disassem­bly

  313

• Pressure Regulator Valve-Inspection

  313

• Pressure Regulator Valve-Assembly

  314

• Filter Bypass Valve-Replace

  314

• Oil Cooler-Cleaning

  315

• Oil Cooler-Inspection

  315

• Lubricating Oil Pump-Exploded View

  317

• Lubrication Oil Pump-General Information

  318

• Oil Pump-Inspection

  319

• Cooling System

  322

• Water Pump-Exploded View

  323

• Water Pump-General Information

  324

• Water Pump-Inspection

  325

• Belt Tensioner and Fan Hub-Exploded View

  326

• Belt Tensioner and Fan Hub-General Information

  327

• Fan Hub-Inspection

  328

• Fan Hub-Disassembly

  328

• Fan Hub Assembly

  329

• Belt Tensioner-Inspection

  331

• Thermostat Housing Assembly-Exploded View

  332

• Thermostat Housing Assembly-General Information

  333

• Thermostat-Inspection

  334

• General Information about Fans

  335

• Drive Units

  336

• Accessory Drive Adapter-Exploded View

  337

• Drive Units-General Information

  338

• Accessory Drive-Cleaning

  339

• Accessory Drive-Inspection

  339

• Accessory Drive Adaptor-Disassem­bly

  339

• Accessory Drive Adaptor-Assembly

  340

• Air Intake System

  342

• Air Intake System-Exploded View

  343

• Air Intake System-General Information

  345

• Turbocharger-Cleaning and Inspec­tion for Reuse

  346

• Inspection

  346

• Aftercooler Assembly-Cleaning and Inspection for Reuse

  347

• Pressure Test the Aftercooler Core

  348

• Aftercooler Assembly-Rebuild

  348

• Air Transfer Pipe-Cleaning and Inspection for Reuse

  348

• Air Crossover Tube-Cleaning and Inspection for Reuse

  349

• Charge Air Cooler (CAC)-Cleaning and Inspection for Reuse

  349

• Charge Air Cooler (CAC)-Pressure Testing

  350

• Exhaust System

  352

• Exhaust Manifold-Exploded View

  353

• Exhaust Manifold Inspection

  355

• Turbocharger Mounting Stud Replace­ment

  355

• Air Equipment

  356

• Air Equipment-General Information

  357

• Air Compressor-Cleaning and Inspection for Reuse

  358

• Power Steering Coupling (if Applicable)

  358

• Power Steering Adapter

  359

• Electrical Equipment

  360

• Electrical Equipment-General Information

  361

• Alternator Inspection

  362

• Starter Inspection

  362

• Engine Testing

  363

• Engine Testing-Service Tools

  364

• Engine Testing-Engine Side Views

  366

• Engine Testing-General Information

  368

• Blowby Measurement

  369

• Engine Dynamometer Test-Installa­tion of the Engine

  370

• Engine Dynamometer Test-Engine Run-In

  376

• Engine Dynamometer Test-Perfor­mance Checking

  380

• Chassis Dynamometer-Operation

  382

• General Engine Test Procedures-(Chassis Dynamometer)

  384

• Engine Run-In Procedure-(Chassis Dynamometer)

  387

• Engine Run-In Procedure “In Chassis”-(On-And Off-Highway Vehicles)

  389

• Engine-Painting

  390

• Engine Storage-Short Term

  391

• Removing the Engine from Short-Term Storage

  393

• Engine Storage-Long Term

  393

• Removing the Engine from Long-Term Storage

  396

• Mounting Adaptations

  400

• Flywheel Housing

  401

• Flywheel and Ring Gear

  401

• Front Support

  401

• Flywheel and Ring Gear Inspection

  402

• Ring Gear Replacement

  402

• Flywheel Housing Inspection

  403

• Flywheel Housing Assembly

  403

• Wet Clutch Application

  404

• Front Support-Cleaning and Inspec­tion

  405

• Engine Component Specifications

  406

• Specifications-General Information

  407

• Engine Component Torque Values

  408

• Component Specifications and Torque Values

  411

• Engine Assembly-Specifications

  411

• Engine Assembly-Capscrew Torque Values

  415

• Cylinder Block-Rebuild Specifications

  421

• Cylinder Block-Torque Values

  427

• Cylinder Head-Rebuild Specifications

  428

• Cylinder Head-Torque Values

  430

• Tappet and Push Rods

  431

• Lubricating Oil System-Specifications

  434

• Fan Hub-Specifications

  436

• Thermostat, Coolant Operating Temperature

  436

• Combustion Air System

  436

• Compressed Air System Torque Values

  438

• Electrical System

  439

• Engine Testing-Test Specifications

  440

• Drive Belt Tension

  441

• Weight and Measures-Conversion Factors

  443

• Newton-Meter to Foot-Pound Conversion Chart

  444

• Capscrew Markings and Torque Values-U.S. Customary

  445

• Capscrew Markings and Torque Values

  446

• Pipe Plug Torque Values

  447

• Tap-Drill Chart-U.S. Customary & Metric

  448

• Service Literature

  449

• Additional Service Literature

  450

• Service Literature Ordering Location

  451

• Service Literature Order Form

  452

• Component Manufacturers

  454

• United States and United Kingdom Offices

  455

• Index

  458

• Cummins Customized Parts Catalog

  461

Brand: CUMMINS
|
Category: Inverter
|
Size: 4.04 MB

• Table of Contents

  3

• Important Safety Instructions

  5

• Safety Precautions

  7

• Introduction

  7

• Ac Control

  9

  • General

    9

  • Standard Control Panel Components

    9

  • Optional Control Panel Components

    9

  • Automatic Voltage Regulator (AVR) Adjustments

    10

  • Principle of Generator Operation

    15

• Engine Control

  17

  • Control Panel

    17

  • Standard Control Panel Components

    17

  • Optional Control Panel Components

    18

  • Control Box Interior

    20

  • Engine Control Monitor (A11)

    20

  • Engine Sensors

    22

  • Auxiliary Control Components

    26

  • Sequence of Operation

    32

• Troubleshooting

  33

  • The Engine Does Not Crank

    34

  • The Engine Cranks but Does Not Start

    36

  • The Engine Runs until Fault Shutdown (Red Shutdown Lamp On)

    38

  • The Engine Lacks Power or Stable Speed

    40

  • Amber Warning Lamp on

    42

  • The Green Run Lamps Stay off but the Set Runs Normally

    43

  • There Is no Output Voltage (Engine Speed Is Stable)

    44

  • Output Voltage Is too High or too Low

    48

  • Output Voltage Is Unstable

    49

  • The Field Circuit Breaker Keeps Tripping

    50

  • The Phase Currents Are Unbalanced

    51

  • Wiring Diagrams

    91

Brand: CUMMINS
|
Category: Engine
|
Size: 54.8 MB

• Product View

  2

• Table of Contents

  4

• Introduction

  6

• Section Contents

  6

• Introduction

  7

• B3.9, B4.5, B4.5 RGT, and

  7

  • About the Manual

    8

  • General Information

    8

  • General Information

    9

    • How to Use the Manual

      9

    • Symbols

      10

    • Illustrations

      11

    • General Safety Instructions

      12

    • General Repair Instructions

      14

    • Welding on a Vehicle with an Electronic Controlled Fuel System

      15

  • Abrasive Pads and Abrasive Paper

    16

  • Definition of Clean

    16

  • General Cleaning Instructions

    16

  • Gasket Surfaces

    17

  • Solvent and Acid Cleaning

    17

  • Plastic Bead Cleaning

    18

  • Steam Cleaning

    18

    • Fuel System

      19

    • Acronyms and Abbreviations

      21

  • General Information

    21

  • Fuel System — Group 05

    24

  • Service Tools

    28

  • AFC Assembly (005-001)

    30

  • Engine Fuel Heater, Electric (005-008)

    30

  • Preparatory Steps

    30

  • Initial Check

    30

  • Finishing Steps

    32

  • Measure

    33

  • Fuel Consumption (005-010)

    33

  • Fuel Flow (005-011)

    36

  • Pressure Test

    36

  • Fuel Injection Pumps, In-Line (005-012)

    38

• Fuel System — Group

  39

  • Fuel Injection Pump (In-Line Type)

    41

  • Prime

    49

  • Fuel Injection Pump, In-Line, Spill Port Timing (005-013)

    50

  • Injection Pumps — Venting

    50

  • Time

    50

  • QD Contact Cleaner, Part Number 3824510

    56

  • Plunger Lift Timing

    57

  • Fuel Injection Pump, Rotary (005-014)

    66

  • Fuel Injection Pump (Distributor Type)

    67

  • Advance Timing Mechanism

    68

  • Distributor-Type Pump Governor

    68

  • Manual Shutdown Levers

    68

  • Electrical Shutoff Valves

    69

  • Front Gear Train

    70

  • Rotary Distributor Type Fuel Injection Pumps

    70

  • Bosch® VE

    71

  • Lucas CAV DPA Pump and Delphi DP210

    71

  • Stanadyne DB4 Pump

    71

  • Rear Gear Train

    72

  • Tier 2/Stage II Timing Adjustment

    80

  • Fuel Pump Control Lever and Spring (005-018)

    85

  • Fuel Pump High Idle Speed (005-028)

    85

  • Fuel Pump Idle Speed (005-029)

    85

  • Bosch® RSV Governor

    87

  • Bosch® RQV and RQV-K Governor

    88

  • Fuel Pump Support Bracket (005-033)

    88

  • Bosch®; and Stanadyne Rotary Pumps

    89

  • Four-Cylinder

    89

  • In-Line Fuel Injection Pumps

    89

    • Fuel Pump Timing (005-037)

      91

    • CAV DPA/DPS Fuel Injection Pump Timing

      97

    • Bosch® VE Pumps with Round Mounting Holes

      98

    • Bosch® VE Pumps with Slotted Mounting Holes

      98

    • Fuel Shutoff Valve (005-043)

      100

    • Bosch® a Pump with RSV Governor

      102

  • Lucas CAV DPA or DPS

    103

  • Stanadyne DB4

    103

  • Voltage Checking

    103

  • Bosch® VE

    104

    • Delivery Valves (Back Leakage Valves on Lucas CAV Pumps)

      104

    • Bosch® P Pump with RQVK Governor

      107

  • Install

    107

  • Stanadyne DB4

    108

  • Bosch® a Pump with RSV Governor

    109

  • Bosch® P Pump with RQVK Governor

    111

    • Fuel Lift Pump (005-045)

      112

    • Cold Start Timing Advance System (KSB) Remote (005-046)

      116

    • Wax-Motor Style

      116

    • Electrical Solenoid-Style KSB

      117

    • KSB Hardware Definition

      117

    • Remote Mounted KSB

      117

    • Wax Motor Style KSB

      117

    • Electrical Solenoid Style

      118

    • Wax Motor-Style KSB

      118

    • Assemble

      122

    • Test

      122

    • Resistance Check

      123

    • Adjust

      125

    • Speed Droop Governor (005-058)

      125

    • Stanadyne DB4 (Generator Application) Speed Droop Governor

      125

    • Fuel Pump Back Leakage Valve (005-059)

      126

    • Speed Droop Adjustment

      126

    • Inspect for Reuse

      127

    • Clean and Inspect for Reuse

      128

    • Fuel Pump Pressure Regulator (005-060)

      128

    • Cold Start Timing Advance System Temperature Switch (005-069)

      129

    • Cold Start Timing Advance System Pump Mounted (005-070)

      132

    • Pump-Mounted KSB

      133

    • Cold Start Timing Advance System (KSB)

      134

    • Pump-Mounted Wax Motor-Style KSB

      135

    • Injectors and Fuel Lines — Group 06

      140

    • Injectors and Fuel Lines

      142

  • Service Tools

    142

    • AFC Air Tube (006-001)

      144

    • Air in Fuel (006-003)

      146

    • Fuel Drain Line Restriction (006-012)

      148

    • Drain

      149

    • Fuel Filter (Spin-On Type) (006-015)

      149

    • Low Pressure Fuel Line(S)

      153

    • Fuel Filter Head (006-017)

      154

    • Fuel Inlet Restriction (006-020)

      157

    • Fuel Manifold (Drain) (006-021)

      158

    • Distributor-Type Pump

      159

    • In-Line Pump

      160

  • Install

    161

  • Fuel Supply Lines (006-024)

    162

  • Remove

    162

  • Install

    165

  • Low Pressure Fuel Line(S)

    165

    • Injector (006-026)

      167

    • Rust-Penetrating Solvent

      169

    • O-Rings and Sealing Washers

      172

    • Chatter Test

      174

    • Leakage Test

      174

  • Canister Type

    188

  • Drain

    188

    • Fuel-Water Separator (006-043)

      188

    • Fuel Return Overflow Valve (006-044)

      189

  • Spin-On Type

    189

  • General Information

    190

  • Injector Supply Lines (High Pressure) (006-051)

    190

  • Finishing Steps

    197

  • Fuel Connector (Headmounted) (006-052)

    197

  • Preparatory Steps

    198

  • Remove

    198

    • Lubricating Oil System — Group 07

      202

    • Lubricating Oil System

      204

  • Service Tools

    204

  • Clean and Inspect for Reuse

    206

  • Engine Oil Heater (007-001)

    206

  • Finishing Steps

    207

  • Install

    207

  • Lubricating Oil Cooler (007-003)

    208

  • Clean and Inspect for Reuse

    210

  • Finishing Steps

    212

  • Lubricating Oil Dipstick (007-009)

    213

  • General Information

    214

  • Lubricating Oil Dipstick Tube (007-011)

    214

  • Preparatory Steps

    214

  • Remove

    214

  • Lubricating Oil Filter (Spin-On) (007-013)

    216

  • Remove

    216

  • Finishing Steps

    217

  • Install

    217

  • Lubricating Oil Pan (007-025)

    217

  • Clean and Inspect for Reuse

    220

  • Six-Cylinder

    222

  • Finishing Steps

    224

  • Lubricating Oil Pressure Regulator (Main Rifle) (007-029)

    224

  • Clean and Inspect for Reuse

    225

  • Finishing Steps

    226

  • Install

    226

  • Lubricating Oil Pump (007-031)

    227

  • Remove

    228

  • Install

    231

  • Lubricating Oil Suction Tube (Block-Mounted) (007-035)

    233

  • Clean and Inspect for Reuse

    234

  • Finishing Steps

    235

• Lubricating Oil System — Group 07

  236

  • Drain

    238

  • Fill

    238

  • Lubricating Oil Contamination (007-044)

    240

  • General Information

    245

    • Low-Lubricating Oil Pressure

      245

    • Lubricating Oil Pressure Regulating Valve

      245

    • Lubricating Oil System Diagnostics (007-048)

      245

    • Lubricating Oil Coolers

      246

    • Lubricating Oil Filter Bypass Valve

      246

    • Bearings and Lubricating Oil Pump

      247

    • Incorrect Lubricating Oil Pump

      247

    • Lubricating Oil Gauge

      247

    • Lubricating Oil Suction Tube

      247

    • Lubricating Oil Leaks

      248

    • Lubricating Oil Pressure Sensor, OEM (007-052)

      249

    • Lubricating Oil and Filter Analysis (007-083)

      250

    • Cooling System

      252

  • Service Tools

    256

    • Drive Belt, Cooling Fan (008-002)

      258

    • Coolant Heater (008-011)

      261

    • Coolant Thermostat (008-013)

      267

    • Cooling System (008-018)

      276

    • Flush

      278

    • Cooling System — Air or Combustion Gas Test (008-019)

      282

    • Combustion Gas Leak

      283

    • Fan, Shutter, or Heater Air Control Valve

      283

    • Air Compressor

      284

    • Combustion Gas Leak Test Kit, Part Number 3822985

      285

    • Cooling System Diagnostics (008-020)

      288

    • Water Pump

      290

    • Radiator, Fans, and Shutters

      291

    • Gauges, Overfueling, and Loading

      293

    • Fan Clutch, Electric (008-026)

      294

    • Fan Hub, Belt Driven (008-036)

      298

    • Fan Shroud Assembly (008-038)

      301

    • Fan Spacer and Pulley (008-039)

      301

    • Fan, Cooling (008-040)

      304

    • Radiator (008-042)

      305

    • Pressure Caps

      306

    • Radiator Hoses (008-045)

      306

    • Radiator Pressure Cap (008-047)

      306

    • Radiator Shutter Assembly (008-049)

      308

    • Heat Exchanger (008-053)

      309

    • Sea Water Pump (008-057)

      311

  • General Information

    315

  • Water Pump (008-062)

    315

  • Initial Check

    316

  • Install

    318

  • Coolant Temperature Sensor (008-070)

    319

  • Preparatory Steps

    319

  • Remove

    319

  • Water Inlet Connection (008-082)

    321

  • Cooling Fan Belt Tensioner (008-087)

    323

  • Sea Water Hoses (008-104)

    327

• Drive Units — Group 09

  328

  • Accessory Drive (009-001)

    330

  • Clean and Inspect for Reuse

    330

  • Disassemble

    331

  • Finishing Steps

    334

  • Initial Check

    334

  • Install

    334

  • Hydraulic Pump Drive (009-016)

    335

  • Remove

    335

  • Accessory Drive Cover (009-039)

    338

  • Clean

    338

  • Preparatory Steps

    338

  • Remove

    338

  • Finishing Steps

    339

  • Install

    339

    • Air Intake System

      340

    • Aftercooler (010-001)

      346

  • Preparatory Steps

    346

  • Remove

    346

  • Air Crossover (010-019)

    348

  • Air Intake Manifold (010-023)

    349

  • Air Leaks, Air Intake and Exhaust Systems (010-024)

    354

  • Damage from Nonfiltered Air

    356

  • Turbocharger Engines — Air Leaks, Pressure Side

    357

  • Charge-Air Cooler (010-027)

    357

  • Temperature Differential Test

    360

  • Air Intake Restriction (010-031)

    361

  • Turbocharger (010-033)

    362

  • Axial Clearance Check

    363

  • Radial Clearance Check

    364

  • Turbocharger Oil Drain Line (010-045)

    371

  • Turbocharger Oil Supply Line (010-046)

    373

  • Turbocharger Wastegate Actuator (010-050)

    375

  • Calibrate

    379

  • Turbocharger Wastegate Valve Body (010-055)

    380

  • Intake Manifold Pressure (010-057)

    381

  • Air Intake Manifold Heater (010-072)

    382

  • Air Intake Heater Controller Interconnection Diagram

    384

  • Cold Starting System

    385

  • Grid Heater Component Connections

    385

  • 6B Industrial Grid Heater

    387

  • Maintenance Check

    389

  • Intake Manifold Air Heater Wiring Harness (010-122)

    393

  • Intake Manifold Air Heater Temperature Sensor (010-123)

    397

  • Intake Manifold Air Heater Element (010-124)

    398

  • Intake Manifold Air Heater Control Module (010-125)

    403

  • Post Heat Cycle

    405

  • Post Heat Recycle

    407

  • Intake Manifold Air Heater Solenoid Switch (010-126)

    409

  • Intake Manifold Air Heater Speed Sensor (010-127)

    411

  • Air Intake Connection Adapter (010-131)

    414

  • Exhaust System

    418

• Exhaust System — Group

  419

  • Exhaust Manifold, Dry (011-007)

    421

  • Exhaust Restriction (011-009)

    424

  • Compressed Air System

    426

• Compressed Air System — Group

  427

  • Air Compressor Carbon Build up (012-003)

    430

  • Air Compressor Coolant Lines (012-004)

    431

  • Air Compressor Pin Bore Wear (012-010)

    432

  • Air Compressor Unloader and Valve Assembly (012-013)

    435

  • Air Compressor (012-014)

    439

  • Compressor Timing Procedure

    442

  • Air Governor (Air Compressor will Notpump) (012-017)

    444

  • Air Governor (Air Compressor Pumps Continuously) (012-018)

    445

  • Air Compressor Cylinder Head (Holset® SS191 Model) (012-101)

    447

  • Air Leaks, Compressed Air System (012-019)

    447

  • Air Compressor Seat Socket, Part Number 3823528

    451

  • Valve Discs

    452

  • Inlet Valve Seat

    452

  • Exhaust Valve Seat

    453

  • Inlet Valve Cage

    453

  • Measure the Valve Guide Diameter

    454

  • Measure the Top of the Cage to the Valve Stop

    454

  • Exhaust Valve Stop

    454

  • Unloader Pin

    455

  • Valve Springs

    455

  • Cylinder Head

    456

  • Spring Data

    456

  • Air Compressor Cylinder Head (Holset® QE Models) (012-104)

    461

  • E-Type Air Compressor

    461

  • E-Type System with Air Dryer

    461

  • E-Type System Without Air Dryer

    462

  • QE, European

    473

  • Electrical Equipment

    480

• Electrical Equipment — Group

  481

  • Alternator (013-001)

    483

  • One Wire System, Typical Alternator (Delco-Remy™) with Combined Metri-Pack™ Connector

    483

  • Three Wire System, Typical Alternator (Delco-Remy™)

    484

  • One Wire System, Typical Alternator (Delco-Remy™)

    484

  • Typical Alternator (Bosch™ K1)

    485

  • Spool Mount

    489

  • Hinge Mount

    489

  • Bosch™ K1 Alternator

    491

  • Alternator Bracket (013-003)

    491

  • Alternator Pulley (013-006)

    495

  • Batteries (013-007)

    496

  • Battery Cables and Connections (013-009)

    500

  • Starter Magnetic Switch (013-017)

    501

  • Starter Switch (013-018)

    503

  • Starter Solenoid (013-019)

    505

  • Solenoid Control Circuit Voltage Drop on Delco® Starters

    508

  • Starting Motor (013-020)

    511

  • Cummins® Branded Starters

    515

  • Non-Cummins® Branded Starters

    515

  • Engine Testing

    516

• Engine Testing — Group

  517

  • Engine Testing (Chassis Dynamometer) (014-002)

    520

  • Engine Run-In (Chassis Dynamometer) (014-003)

    526

  • Engine Run-In (Without Dynamometer) (014-004)

    527

  • On-Highway Applications

    527

  • Off-Highway Applications

    528

  • Engine Lifting Fixture, Part Number 3822512

    529

  • Engine Testing (Engine Dynamometer) (014-005)

    529

  • Water Manometer, Part Number ST-1111-3

    530

  • Air Inlet Restriction

    530

  • Pressure Gauge, Part Number ST-1273

    530

  • Exhaust Restriction

    530

  • Blowby Checking Tool, Part Number 3822476

    534

  • Vacuum Gauge, Part Number ST-434

    534

  • Engine Run-In (Engine Dynamometer) (014-006)

    535

  • Engine Testing (in Chassis) (014-008) Initial Check

    539

  • B3.9, B5.9, and B4.5 Engines

    539

  • Piston Ring Sealing

    540

  • Intake and Exhaust Valve Sealing

    540

  • B4.5 RGT Engines

    541

  • Cylinder Head Gasket Sealing

    541

  • Crankcase Blowby, Measure (014-010)

    544

  • Blowby Conversion Table (5.61-MM [0.221-In] Orifice, Blowby Tool, Part Number 3822476)

    546

  • Blowby Conversion Table (7.67-MM [0.302-In] Orifice, Blowby Tool, Part Number 3822566)

    547

  • Midrange Blowby Specifications Chart

    549

  • Engine Blowby Contribution

    555

  • Turbocharger Blowby Contribution

    556

  • Preferred Turbocharger Isolation Method

    557

  • Air Compressor Blowby Contribution

    561

  • Exhaust Brake Blowby Contribution

    564

  • Base Engine Component Blowby Contribution

    565

  • Air Compressor Is Malfunctioning

    568

  • Piston or Piston Rings Are Worn or Damaged

    569

  • Mounting Adaptations

    570

  • Engine Support Bracket, Front (016-002)

    574

  • Engine Support Bracket, Rear (016-003)

    576

  • Flexplate (016-004)

    578

  • Mechanical

    579

  • Electrical

    579

  • Flywheel (016-005)

    581

  • Bore Runout

    587

  • Face Runout

    588

  • Flywheel Housing (016-006)

    590

  • All Applications

    591

  • Face Alignment

    596

  • Determine the Total Indicator Reading (TIR)

    597

  • Bore Alignment

    599

  • Flywheel Ring Gear (016-008)

    606

  • Engine Mounts (016-010)

    607

  • Propeller Shaft (016-025)

    607

  • Out of Water

    608

  • Specifications

    609

  • Marine Vibration Isolator (016-026)

    610

  • Miscellaneous

    616

• Miscellaneous — Group

  617

  • Cup Plug (017-002)

    620

  • Pipe Plug (017-007)

    621

  • Straight Thread Plug (017-011)

    623

  • Expansion Plug (017-015)

    625

  • Coolant Passages

    626

  • Service Literature

    628

• Service Literature

  629

  • Additional Service Literature

    630

  • Contact Information

    631

  • Cummins Customized Parts Catalog

    632

• Specifications

  634

  • Cylinder Block — Group 01 — Specifications

    638

  • Cylinder Block — Group 01 — Torque Values

    648

  • Cylinder Head — Group 02 — Specifications

    654

  • Cylinder Head — Group 02 — Torque Values

    657

  • Rocker Levers — Group 03 — Specifications

    659

  • Rocker Levers — Group 03 — Torque Values

    660

  • Cam Followers/Tappets — Group 04 — Specifications

    663

  • Cam Followers/Tappets — Group 04 — Torque Values

    664

  • Fuel System — Group 05 — Specifications

    665

  • Fuel System — Group 05 — Torque Values

    666

  • Injectors and Fuel Lines — Group 06 — Specifications

    674

  • Injectors and Fuel Lines — Group 06 — Torque Values

    675

  • Lubricating Oil System — Group 07 — Specifications

    679

  • Lubricating Oil System — Group 07 — Torque Values

    681

  • Cooling System — Group 08 — Specifications

    682

  • Cooling System — Group 08 — Torque Values

    683

  • Drive Units — Group 09 — Specifications

    686

  • Drive Units — Group 09 — Torque Values

    687

  • Air Intake System — Group 10 — Specifications

    688

  • Air Intake System — Group 10 — Torque Values

    689

  • Exhaust System — Group 11 — Specifications

    692

  • Exhaust System — Group 11 — Torque Values

    693

  • Compressed Air System — Group 12 — Specifications

    694

  • Compressed Air System — Group 12 — Torque Values

    696

  • Electrical Equipment — Group 13 — Specifications

    699

  • Electrical Equipment — Group 13 — Torque Values

    700

  • Mounting Adaptations — Group 16 — Specifications

    702

  • Mounting Adaptations — Group 16 — Torque Values

    703

  • General Engine

    705

  • Fuel System

    707

  • Lubricating Oil System

    708

  • Cooling System Specifications

    710

  • Air Intake System Specifications

    711

  • Exhaust System Specifications

    717

  • Electrical System Specifications

    718

  • Compressed Air System Specifications

    720

  • Engine Testing Specifications

    722

  • Cummins®/Fleetguard® Filter Specifications

    723

  • Fuel Recommendations and Specifications

    724

  • Drive Belt Tension

    725

  • Engine Component Torque Values

    726

  • Capscrew Markings and Torque Values

    727

  • Fraction, Decimal, Millimeter Conversions

    729

  • Newton-Meter to Foot-Pound Conversions

    730

  • Pipe Plug Torque Values

    731

  • Tap-Drill Chart — U.S. Customary and Metric

    732

  • Weights and Measures — Conversion Factors

    733

  • Index

    734

Brand: CUMMINS
|
Category: Portable Generator
|
Size: 38.93 MB

Brand: CUMMINS
|
Category: Engine
|
Size: 9.1 MB

• Table of Contents

  4

  • Introduction

    7

    • To the Owner and Operator

      8

    • About the Manual

      9

    • How to Use the Manual

      10

    • Symbols

      11

    • Illustrations

      12

    • General Safety Instructions

      13

    • General Repair Instructions

      15

      • Welding on a Vehicle with an Electronic Controlled Fuel System

        16

    • General Cleaning Instructions

      17

      • Gasket Surfaces

        18

      • Plastic Bead Cleaning

        19

      • Fuel System

        20

    • Acronyms and Abbreviations

      22

  • Engine and System Identification

    25

  • Operating Instructions

    55

  • Maintenance Guidelines

    56

  • Maintenance Procedures at Daily Interval

    70

  • Maintenance Procedures at 250 Hours or 3 Months

    70

  • Maintenance Procedures at 500 Hours or 6 Months

    70

  • Maintenance Procedures at 1000 Hours or 1 Year

    70

  • Maintenance Procedures at 2000 Hours or 2 Years

    70

• Section 3 — Maintenance Procedures at Daily Interval

  74

  • Air Intake Piping

    77

    • Maintenance Check

      77

  • Air Tanks and Reservoirs

    77

    • Maintenance Check

      78

  • Crankcase Breather Tube

    78

    • Drain

      81

      • Canister Type

        81

      • Spin-On Type

        82

  • Lubricating Oil Level

    82

    • Maintenance Check

      82

• Section 4 — Maintenance Procedures at 250 Hours or 3 Months

  84

  • Air Cleaner Restriction

    86

    • Maintenance Check

      86

  • Air Compressor

    87

    • Maintenance Check

      87

  • Charge-Air Cooler

    87

  • Charge-Air Piping

    88

    • Maintenance Check

      88

  • Closed Crankcase Ventilation Hoses

    88

  • Fuel Pump

    88

  • Maintenance Procedures — Overview

    89

    • Radiator Pressure Cap

      89

      • General Information

        89

      • Inspect for Reuse

        90

      • Pressure Test

        90

  • Radiator Hoses

    89

• Section 5 — Maintenance Procedures at 500 Hours or 6 Months

  92

  • Engine Coolant Antifreeze

    94

    • Maintenance Check

      94

  • Fuel Filter (Canister Type)

    94

    • Preparatory Steps

      94

    • Prime

      95

    • Remove

      95

  • Fuel Filter (Spin-On Type)

    97

    • Drain

      97

    • Install

      98

    • Prime

      99

    • General Information

      99

    • Remove

      101

  • Lubricating Oil and Filters

    101

    • Drain

      101

• Section 6 — Maintenance Procedures at 1000 Hours or 1 Year

  104

  • Cooling Fan Belt Tensioner

    106

    • Maintenance Check

      106

  • Fan Hub, Belt Driven

    107

    • Maintenance Check

      107

  • Overhead Set

    109

  • Maintenance Procedures — Overview

    109

    • Adjust

      109

      • B3.9, B5.9, and B4.5 Engines

        109

    • Finishing Steps

      111

• Section 7 — Maintenance Procedures at 2000 Hours or 2 Years

  112

  • Air Compressor Discharge Lines

    114

    • General Information

      114

    • Maintenance Check

      114

  • Adjustment, Repair, and Replacement

    114

    • System Diagrams

      114

  • Cooling System

    115

    • Drain

      115

    • Flush

      116

  • Vibration Damper, Rubber

    119

    • Inspect

      119

  • Maintenance Procedures — Overview

    119

  • Vibration Damper, Viscous

    120

    • Inspect

      120

• Section a — Adjustment, Repair, and Replacement

  122

  • Air in Fuel

    124

    • General Information

      124

  • Alternator

    124

    • Initial Check

      124

    • Install

      127

  • Charge-Air Cooler

    127

    • General Information

      127

    • Initial Check

      127

  • Cooling Fan Belt Tensioner

    129

    • Inspect for Reuse

      129

    • Install

      129

    • Remove

      129

  • Drive Belt, Cooling Fan

    130

    • Inspect for Reuse

      130

    • Install

      131

    • Remove

      131

  • Fan Spacer and Pulley

    131

    • Inspect for Reuse

      131

    • Preparatory Steps

      131

    • Remove

      132

  • Starting Motor

    132

    • Finishing Steps

      133

    • Install

      133

    • Service Literature

      157

    • Service Assistance

      163

• Section Ts — Troubleshooting Symptoms

  214

  • Troubleshooting Symptoms

    215

  • Troubleshooting Procedures and Techniques

    216

    • General Information

      216

  • Troubleshooting Symptoms Charts

    217

    • General Information

      217

    • Air Compressor Air Pressure Rises Slowly

      218

    • Air Compressor Cycles Frequently

      219

    • Air Compressor Noise Is Excessive

      220

    • Air Compressor Pumping Excess Lubricating Oil into the Air System

      221

    • Air Compressor will Not Maintain Adequate Air Pressure (Not Pumping Continuously

      222

    • Air Compressor will Not Stop Pumping

      223

    • Alternator Not Charging or Insufficient Charging

      224

    • Alternator Overcharging

      225

    • Coolant Contamination

      226

    • Coolant Loss — External

      227

    • Coolant Temperature above Normal — Gradual Overheat

      228

    • Coolant Temperature above Normal — Sudden Overheat

      230

    • Coolant Temperature below Normal

      231

    • Engine Acceleration or Response Poor

      232

    • Engine Difficult to Start or will Not Start (Exhaust Smoke

      234

    • Engine Difficult to Start or will Not Start (no Exhaust Smoke

      237

    • Engine Noise Excessive

      239

    • Engine Noise Excessive — Combustion Knocks

      241

    • Engine Power Output Low

      242

    • Engine Runs Rough at Idle

      245

    • Engine Runs Rough or Misfires

      246

    • Engine Shuts off Unexpectedly or dies During Deceleration

      247

    • Engine Speed Surges at Low or High Idle

      248

    • Engine Speed Surges under Load or in Operating Range

      249

    • Engine Starts but will Not Keep Running

      250

    • Engine Vibration Excessive

      251

    • Engine will Not Crank or Cranks Slowly (Air Starter

      252

    • Engine will Not Crank or Cranks Slowly (Electric Starter

      254

    • Engine will Not Reach Rated Speed (RPM

      256

    • Engine will Not Shut off

      258

    • Exhaust Smoke Excessive under Load

      259

    • Fuel Consumption Excessive

      260

    • Fuel in Coolant

      261

    • Fuel in the Lubricating Oil

      262

    • Fuel or Lubricating Oil Leaking from Exhaust Manifold

      263

    • Intake Manifold Air Temperature above Specification

      264

    • Intake Manifold Pressure (Boost) Is below Normal

      266

    • Lubricating Oil Consumption Excessive

      267

    • Lubricating Oil Contaminated

      268

    • Lubricating Oil Loss

      269

    • Lubricating Oil Pressure High

      270

    • Lubricating Oil Pressure Low

      271

    • Lubricating Oil Sludge in the Crankcase Excessive

      273

    • Smoke, Black — Excessive

      274

    • Smoke, White — Excessive

      275

    • Turbocharger Leaks Engine Oil or Fuel

      277

    • Maintenance Specifications

      279

    • Warranty

      307

      • All Engines United States and Canada Industrial (Off-Highway

        308

      • All Engines International Industrial (Off-Highway

        311

      • California Emission Control System Warranty, Off-Highway

        313

      • Owner’s Warranty Responsibilities

        315