Factory Operation And Maintenance Cummins QSB4.5 QSB6.7. Manual for owners and operators. It contains important information and instructions for maintenance description of the functions and capabilities of the system. Description of possible faults/problems and their solution.
Format: PDF
Language: English
Pages: 342
Model
Cummins QSB4.5, QSB6.7
Contents
-INTRODUCTION
–ABOUT THE MANUAL
General Information
–ACRONYMS AND ABBREVIATIONS’
General Information
–GENERAL CLEANING INSTRUCTIONS
Abrasive Pads and Abrasive Paper
Definition of Clean
Gasket Surfaces
Plastic Bead Cleaning
Solvent and Acid Cleaning
Steam Cleaning;
–GENERAL REPAIR INSTRUCTIONS
General Information”
Welding on a Vehicle with an Electronic Controlled Fuel System
–GENERAL SAFETY INSTRUCTIONS
Important Safety Notice
–HOW TO USE THE MANUAL
General Information
–ILLUSTRATIONS
General Information
–SYMBOLS
General Information
–TO THE OWNER AND OPERATOR
General Information
-ENGINE iDENTIFICATION
–ENGINE DIAGRAMS
Engine Views
–ENGINE IDENTIFICATION
Air Compressor
Cummins* Engine Nomenclature
ECM Dataplate
Engine Dataplate
Fuel Injection Pump Dataplate
-INDUSTRIAL FEATURES
–ACCELERATOR OPTIONS
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–ALTERNATE DROOP
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–AUTOMATIC BOOST POWER
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–FAN CONTROL
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–FUEL CONSUMPTION RATE LOGGER
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–HOT SHUTDOWN MONITOR
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–IDLE SHUTDOWN
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–INTERMEDIATE SPEED CONTROL (ISC)
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–MULTIPLE UNIT SYNCHRONIZATION
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–SWITCHABLE (ALTERNATE) TORQUE
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
–WATER-IN-FUEL SENSOR
Disadvantages
Driver Activation/Deactivation
Feature Description
Interaction with other Features and Parameters
Visual Aids
-OPERATING INSTRUCTIONS
–COLD WEATHER STARTING
General Information
Using Starting Aids
–ELECTROMAGNETIC INTERFERENCE (EMI)
General Information
System EMI Radiation Levels
System EMI Susceptibility
–ENGINE OPERATING RANGE
General Information
–ENGINE SHUTDOWN
General Information
–NORMAL STARTING PROCEDURE
General Information
Jump Starting
–OPERATING INSTRUCTIONS – OVERVIEW
General Information
–OPERATING THE ENGINE
Ambient Temperature
0 to -32°C (32 to -25°FJ
-32 to -54°C (-25 to -65°F]
Cold Weather
Normal
Winterfronts and Shutters
–STARTING PROCEDURE AFTER EXTENDED SHUTDOWN OR OIL CHANGE
General Information
-MAINTENANCE GUIDELINES
–MAINTENANCE GUIDELINES – OVERVIEW
General Information
–MAINTENANCE RECORD FORM
Maintenance Data
–MAINTENANCE SCHEDULE
General Information
Oil Drain Intervals
–TOOL REQUIREMENTS
General Information
-MAINTENANCE PROCEDURES AT DAILY INTERVAL
–AIR TANKS AND RESERVOIRS
Drain
–CRANKCASE BREATHER TUBE
Maintenance Check
–DAILY MAINTENANCE PROCEDURES – OVERVIEW
Engine Operation Report
General Information
Unusual Engine Noise
–DRIVE BELTS
Maintenance Check
Poly-Vee Belt
Cogged Belt
–FUEL-WATER SEPARATOR
Drain
Canister Type
Spin-on Type
–LUBRICATING OIL LEVEL
Maintenance Check
-MAINTENANCE PROCEDURES AT 250 HOURS OR 3 MONTHS
–AIR CLEANER RESTRICTION
Maintenance Check
–AIR COMPRESSOR
Maintenance Check
–AIR INTAKE PIPING
Maintenance Check
–CHARGE-AIR COOLER
Maintenance Check
–CHARGE-AIR PIPING
Maintenance Check
–COOLANT LEVEL
Maintenance Check
–FAN, COOLING
Inspect lor Reuse
–MAINTENANCE PROCEDURES – OVERVIEW
General Information
–RADIATOR HOSES
Maintenance Check
-MAINTENANCE PROCEDURES AT 500 HOURS OR 6 MONTHS
–COOLING SYSTEM
Drain
Fill
Flush
General Information
Maintenance Check
–FUEL FILTER (SPIN-ON TYPE)
Install
Prime
Remove
–LUBRICATING OIL AND FILTERS
Drain
Fill
Install
Remove
–MAINTENANCE PROCEDURES – OVERVIEW
General Information
-MAINTENANCE PROCEDURES AT 1000 HOURS OR 1 YEAR
–COOLING FAN BELT TENSIONER
Maintenance Check
–FAN HUB BELT DRIVEN
Maintenance Check
–MAINTENANCE PROCEDURES – OVERVIEW
General Information
-MAINTENANCE PROCEDURES AT 2000 HOURS OR 2 YEARS
–AIR COMPRESSOR DISCHARGE LINES
General Information
Maintenance Check
–COOLING SYSTEM
Drain
Fill
Flush
General Information
–MAINTENANCE PROCEDURES – OVERVIEW
General Information
–VIBRATION DAMPER, RUBBER
Inspect
–VIBRATION DAMPER, VISCOUS
Inspect
-MAINTENANCE PROCEDURES AT 5000 HOURS OR 4 YEARS
–MAINTENANCE PROCEDURES – OVERVIEW
General Information
–OVERHEAD SET
Adjust
Finishing Steps
Install
Preparatory Steps
Remove
-ADJUSTMENT, REPAIR, AND REPLACEMENT
–ALTERNATOR
Finishing Steps
General Information
Initial Check
Install
Preparatory Steps
Remove
Test
–CHARGE-AIR COOLER
Clean
Inspect for Reuse
Leak Test
Pressure Differential Test
Temporature Differential Test
–COOLANT THERMOSTAT
Clean and Inspect for Reuse
Finishing Steps
General Information
Install
Preparatory Steps
Remove
–COOLING FAN BELT TENSIONER
Maintenance Check
–DRIVE BELT, COOLING FAN
Inspect for Reuse
Install
Remove
–FAN SPACER AND PULLEY
Inspect for Reuse
Install
Preparatory Steps
Remove
–STARTING MOTOR
Clean and Inspect for Reuse
Install
Cummins Branded Starters
Non-Cummins Branded Starters
Measure
Remove
Rotation Check
-SYSTEM DIAGRAMS
–FLOW DIAGRAM, AIR INTAKE SYSTEM
Flow Diagram
–FLOW DIAGRAM, COMPRESSED AIR SYSTEM
Flow Diagram
–FLOW DIAGRAM, COOLING SYSTEM
Flow Diagram
–FLOW DIAGRAM, EXHAUST SYSTEM
Flow Diagram
Without EGR
With EGR
Marine Applications
–FLOW DIAGRAM, FUEL SYSTEM
Flow Diagram
With Electric Lift Pump
–FLOW DIAGRAM, LUBRICATING OIL SYSTEM
Flow Diagram
System Diagrams – Overview
General Information
-SERVICE LITERATURE
–ADDITIONAL SERVICE LITERATURE
General Information
–CUMMINS CUSTOMIZED PARTS CATALOG
General Information
Ordering the Customized Parts Catalog
Ordoring by Telephone
Ordering On-Line
–SERVICE LITERATURE ORDERING LOCATION
Contact Information
-COMPONENT MANUFACTURERS
–COMPONENT MANUFACTURERS’ ADDRESSES
Air Compressors
Air Cylinders
Air Heaters
Air Starting Motors Alternators
Auxiliary Brakes
Belts
Catalytic Converters
Coolant Level Switches
Clutches
Coolant Heaters
Drive Plates
Electric Starting Motors
Electronic Switches
Engine Protection Controls
Fan Clutches
Fans’I”*””’”””
Fault Lamps
Filters
Flexplates
Fuel Coolers
Fuel Pumps
Fuel Warmers
Gauges
Governors
Heat Sleeves
Hydraulic and Power Steering Pumps In-Line Connectors
Oil Heaters
Prelubrication Systems
Radiators
Throttle Assemblies
Torque Converters
-SERVICE ASSISTANCE
–DISTRIBUTORS – INTERNATIONAL
Locations
–DISTRIBUTORS AND BRANCHES
Australia
Canada
New Zealand
United States
–DIVISION AND REGIONAL OFFICES
Locations
–EMERGENCY AND TECHNICAL SERVICE
General Information
–PROBLEM SOLVING
General information
–REGIONAL OFFICES – INTERNATIONAL
Locations
–ROUTINE SERVICE AND PARTS
General Information
-TROUBLESHOOTING SYMPTOMS
–TROUBLESHOOTING PROCEDURES AND TECHNIQUES
General Information
–TROUBLESHOOTING SYMPTOMS CHARTS
General Information
Air Compressor Air Pressure Rises Slowly
Coolant Contamination
Coolant Loss – External
Coolant Temperature Above Normal – Gradual Overheat
Coolant Temperature Above Normal – Sudden Overheat
Engine Acceleration or Response Poor
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
Engine Noise Excessive — Combustion Knocks
Engine Power Output Low
Engine Runs Rough at Idle
Engine Runs Rough or Misfires
Engine Shuts Off Unexpectedly or Dies During Deceleration
Engine Speed Surges at Low or High Idle
Engine Speed Surges in PTO or Cruise Control
Engine Speed Surges Under Load or in Operating Range
Engine Starts But Will Not Keep Running
Engine Will Not Crank or Cranks Slowly (Air Starter)
Engine Will Not Crank or Cranks Slowly (Electric Starter)
Engine Will Not Reach Rated Speed (RPM)
Fuel Consumption Excessive
Fuel in the Lubricating Oil
Lubricating Oil Consumption Excessive
Lubricating Oil Contaminated
Lubricating Oil Loss
Lubricating Oil Pressure High
Lubricating Oil Pressure Low
Lubricating Oil Sludge in the Crankcase Excessive
Turbocharger Leaks Engine Oil or Fuel
-MAINTENANCE SPECIFICATIONS
–AIR INTAKE SYSTEM
Specifications
–CAPSCREW MARKINGS AND TORQUE VALUES
Capscrew Markings and Torque Values – Metric
Capscrew Markings and Torque Values – US Customary
General Information
–COOLANT RECOMMENDATIONS AND SPECIFICATIONS
Cooling System Sealing Additives
Cooling System Soluble Oils
Fully Formulated Coolant/Antifreeze
–CODLING SYSTEM;
Specifications
–CUMMINS/FLEETGUARD’ FILTER SPECIFICATIONS
General Information
–DRIVE BELT TENSION
Tension Chart
–ELECTRICAL SYSTEM*
Batteries (Specific Gravity),
Specifications
–EXHAUST SYSTEM
Specifications
–FUEL RECOMMENDATIONS AND SPECIFICATIONS
Fuel Recommendations
–FUEL SYSTEM
Preparatory Steps
–GENERAL ENGINE
Specifications
–LUBRICATING OIL RECOMMENDATIONS AND SPECIFICATIONS
General Information;
New Engine Break-in Oils
–LUBRICATING OIL SYSTEM
Specifications
–SEALANTS
General Information
-WARRANTY
California Emission Control System Warranty, Off-Highway
All Engines Intemationallndustrial (Off-Highway)
All Engines United States and Canada Industrial (Off-Highway)
What you get
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