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Cummins 4bt service manual download -
Always use blocks or proper stands to support the product before performing any service work Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant freon lines in a well ventilated area. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded, Corrosion inhibitor contains alkali.
Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water, In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes.
Follow the manufacturer's instructions to provide complete safety when using these materials. Make sure you understand how to use them before performing any service work.
Do not use a fastener of lessor quality if replacements are necessary. Cummins Engine Company, Inc. Always follow the cleaner manufacturer's instructions. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [ to degrees Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc.
Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank A, Warning: The use of acid can be extremely dangerous to personnel, and can damage the machinery. Always provide a tank of strong soda water as a neutralizing agent. Rinse all of the parts in hot water after cleaning. Dry completely with compressed air.
Blow the rinse water from all of the capscrew holes and the oil drilings. I the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The rustproofing compound must be removed from the parts before installation on the engine. It is a good way to clean the oil drillings. Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat.
Do not steam clean the following parts: 1. The cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time. Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the aluminum and result in premature wear. Valves, turbocharger shafts, etc. Follow the cleaning directions listed in the procedures.
Do not use any bead blasting media on pin bores or aluminum skirts. Follow the equipment manufacturer's cleaning instructions. Bead size: - Use U. Operating Pressure: - Glass: Use kPa [90 psi] for general purpose cleaning. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after cleaning.
Rinse with hot water. Dry with compressed air. In particular, un- authorized repair to safety-related components can cause personal injury.
Always use good safely practices with tools and equipment. Contamination of the engine and componenis will cause premature wear. All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations. Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location. Engine Diagrams.. Rear View Turbocharger Side View Engine Identification..
Engine Dataplate Engine Nomenclature It provides information for fuel pump calibration. This illustration shows the dataplate location and a Lucas CAY rotary injection pump.
The Nippondenso EP-9 dataplate is located in approximately the same location as the il- lustrated Bosch dataplate. Stroke - mm fin] Displacement - litre [in. Compression Ratio - Rotary Pump Quarts] from LOW to High ern 0.
Hg] Quarts Total System - Liter U. Number of Liters U-S. Quarts] Some external components will be at different locations for different engine models. NOTE: The illustrations are only a reference to show a typical engine. Procedures and Techniques.. T10 Engine Vibration Excessive The more information known about a complaint, the faster and easier the problem can be solved. The Troubleshooting Symptoms Charts beginning on Page T-4 are organized so that a problem can be located and corrected by doing the easiest and most logical things first.
Complete all steps in the sequence shown from top to bottom. It is not possible to include all the solutions to problems that can occur; however, these charts should stimulate a thought process that will lead to the cause and correction of the problem. Follow the arrows through the chart to identify the corrective action.
Refer to Procedure 4 Clean and tighten connections. Check battery voltage. Refer to Proce- dure Check voltage to solenoid. Refer to Procedure Bar the engine to check for rotational resistance. Replace starting motor. Injection Pump Not Getting Fue! Check to be sure manual shutoff lever is in the run position. Refer to Procedures or Verity proper starting procedure. Refer to the Operation and Maintenance Manual. Drain fuelwater separator or replace fuel filter.
Refer to Procedures and Maximum inlet restriction to fuel transfer uP must not exceed mm Hg 6 in Visually check; remove the obstruction. Check exhaust system for obstruction. Refer to Procedure , Visually check fuel delivery with an externally connected injector to one of the pump outlets. Remove the fuel injection pump. Have calibration checked. Verifyltime the pump. Refer to Proce- dures Checklcorrect gear train timing align- ment. Verify that the driven units are not engaged Check the battery, starting motor, and look for loose or corroded wiring connections.
Bar the engine to check for internal rotational resistance. Verify the aids are operating. Inspect or replace filter and check for obstructions to the air supply tube. Check the flow through the filter and bleed the system. Locate and correct the air source. Refer to Procedures , and , Verify by operating the engine with clean fuel from a temporary tank of No. Maximum inlet restriction to fuel transfer ue must not exceed mm Hg [6 in ig. Adjust valves. Delivery Valves Maifunctioning Remove fuel injection pump.
Disengage driven units Adjust the idle speed. Refer to Proce- dures and Visually check for exhaust restriction and inspect the air intake. Refer to page and Refer to Procedures and , Verify by inspecting the fuel filter. Clean the system and use climatized fuel or fuel heaters. Verity by operating the engine with clean fuel from a temporary supply tank. Refer to Procedures. Speed Set Too Low for Accessories and Refer to Damaged Procedures and Refer fo Procedure , Bleed the fuel system and correct source of the leak.
Refer to Procedures 6. Refer to Malfunctioning Procedures and Have Delivery Valves Maifunctioning calibration checked. Refer to Procedures and , Bleed the fuel system and correct the source of the air. Sheckireplace fuel transfer pump. Clean pre-tters and screens and check fuel line for restriction.
Replace fuel filter. Allow engine to warm to operating temperature. Inspecticorrect leaks in the high pressure lines, fittings injector sealing washers, or delivery valves. Refer to Procedures Refer to Procedures , and Clean pre-fiters and screens and check fuel line for restriction, Replace fuel fier. Verity by operating the engine with clean fuel from a temporary tank. Checkltime the fuel injection pump using the spill port timing if equipment is available.
Perform a compression check and repair as required. Checkireplace injectors. Remove fuel injection pump. Have calibration checked, Checkicorrect gear train timing align- ment. Inspect camshaft and tappets. B Series. Correct as required Verify high idle speed without load, Investigate operation to be sure correct gear is being used.
Throttle Linkage Worn or Incorrectly. Check the flow through the filter to locate the source of the restriction.
Checkiclean AFC tubing and fittings for obstruction. Repair turbocharger. Refer to procedures , , and Tighten the fittings, repair plumbing or repair wastegate diaphram. Bleed the fuel system and check for suction leaks. Refer to Procedures , 5. Checkicorrect oil level. Inspectireplace air cleaner element. Refer to page At. It the vehicle is equipped with a valve to switch the intake source from under the hood to outside, position the valve for the season.
Coolant passages plugged in the aftercooler. Check charge air cooler for internal restriction. Replace restricted cooler. Check catalyst for restriction. Refer to Page Verify that fuel heater is off during warm weather. Check for a restricted fuel drain line. Look for a cracked manifold, Remove extra injector sealing washer. Check injectors.
Refer to Proce- dure Valve Clearances Incorrect Checkitime fuel injection pump. Refer to Procedures Remove fuel injection pump. Have calibration checked, Perform compression check to identify Se eee malfunction. Correct as required. Look for other restrictions. Refer to page att Check exhaust restriction.
Refer to Procedures and Check for plugged charge air cooler, internal charge air restriction, or leaking charge air cooler. Remove the injector and install the proper sealing washer. Refer to Procedure , Replace injectors. Refer to Procedure , Remove fuel injection pump. Have calibration checked, Perform a compression check.
Refer to Procedure Checkhime fuel injection pump. Refer to procedure and Refer to the starting procedure in the Operation and Maintenance Manual. Verify by operating engine from a temporary tank with good quality fuel. Clean and flush the fuel supply tanks. Use a diesel fuel with cotane value of , [Check top dead center TDC. Injector installed with more than one sealing washer Remove extra washer. Locate and correct the source of the coolant leak.
Refer to troubleshooting logic for Coolant Loss. Blow debris from fins. Refer to the equipment manufacturer's procedures. Refer to Procedure 1 Remove part of the coolant from cooling system and replace with water. Verify that the gauge and temperature sensor are accurate, Refer to Procedure Inspect the shutters, repair or replace if necessary. Open radiator cover. Make sure the fill rate is not being ex- ceeded and the correct vented thermostat is installed.
Refer to Procedure If aeration continued, check for a compres- sion leak through the head gasket. Flush the system and fill with clean coolant. Contact vehicle manufacturer for confirma- tion of correct fan, radiator, and other cooling system components. Verify fue! Verify that the gauge and temperature sensor are accurate. Refer to Procedure 1 Check belt tension. Inspect hoses. Check the radiator pressure cap. Refer to Procedure Check thermostat. Refer to Procedure , Inspect the shutters.
Repair or replace if necessary. Check shutterstat setting. Check water pump operation. Replace the water pump. Verify that the gauge and sensor are accurate. Review the operation for overheati low power.
Refer to troubleshooting logic for Coolant Temperature Above Normal. Check for mixing of coolant and transmis- sion fluid. Look for Geolant in the intake manifold and in the oil.
Checkireplace the oil cooler. Look for Coolant in the oil. Refer to Procedure 2. Refer to Page , Check for a severe external oil leak that could reduce the pressure.
Verify the correct oil is being used. Check for oil dilution. Refer to troubleshooting logic for Contaminated Lubricating Oil. Pressure Switch or Gauge Verify the pressure switch is functioning Malfunctioning correctly.
Refer to Proce- dure , Change lubricating oil filter; review change interval. Replace lubricating oil cooler. Verify that the correct lubricating oil Bump is inetaled. Refer to troubleshooting logic for Coolant Temperature Below Normal Make sure the correct lubricating oil is being used. OK Look for reduced viscosity from dilution with fuel. Fuel dilution in lubricating oil can originate from fuel injection pump driveshaft seal or fuel transfer pump. Measure the blowby and Out the Breather perform the required repairs.
Check for lubricating oil in the coolant. Refer to Lubsoating Oil Procedure Perform a compression check. Repair as required. Fill with correct mixture of antifreeze and water. Review the coolant change interval. Refer to equipment manufacturer's procedures. Refer to troubleshooting logic for Lubricating Oil Loss. Review lubricating oll and filter change intervals Make sure the correct lubricating oll is being used Review the operation for excessive idling resulting in the engine running below normal temperature.
Repair or replace fuel transfer pump. Refer to Procedures and Remove the fuel injection pump and have repaired. Remove the fuel injection pump and have repaired. Review operation for excessive idling. Locate and replace malfunctioning injector. Starting Aid Bleed the fuel system.
Verity by operating from a temporary tank with good fuel; clean and flush the fuel supply tanks. Verify that engine load rating is not being exceeded, Checkitime fuel injection pump. Review operation for correct gear shifts, deceleration, and idling Check for external leaks and engine lubricating oil dilution.
For fuel dilution, check for internal leaks at the fuel transfer pump and injection pump. If the seals are broken, remove and recalibrate fuel injection pump.
Refer to Proce: dure Check the air intake ducts for the source of the fumes. Fan Damaged or Accessories Refer to equipment manufacturers service a instructions. Vibration Damper Malfunctioning Inspectireplace the vibration damper. Six-Cylinder Only Refer to Procedure Checkireplace engine mounts.
Refer to the equipment manufacturer's service instructions. Make sure water pump, tensioner pulley, fan hub and alternator turn freely.
Refer to the equipment manufacturer's rocedures. Make sure the accessories turn freely. Refer to troubleshooting logic for Excessive Exhaust Smoke Adjust valves. Make sure the push rods are not bent or the rocker levers are not severely worn, Refer to Procedure Check turbocharger impeller and turbine wheel for housing contact.
Visually inspect and measure gear backlash. Replace gears as required. Refer to page Corroded Refer to Procedure Load test the battery. If battery charge is low, charge the battery and load test again. If the battery fails the load test, replace the battery. Repairltighten pulley, Repair wiring. Refer to the vehicle manufacturer's instructions for troubleshsooting the alternator and charging circutt Replace alternator.
Coolant is drawn from the radiator by the integrally mounted water pump. The coolant tien circulates around each cylinder and crosses the block to the fuel pump side of the engine. Coolant then flows up into the cylinder head, crosses over the valve bridges and down the exhaust manifold side of the engine to the integral thermostat housing. As the coolant flows across the head toward the thermostat housing, it provides cooling for the injector.
When the engine is below operating temperature, the thermostat is closed, and the coolant flow bypasses the radiator and goes to the water pump inlet through internal drillings in the block and cylinder head. When operating temperature is reached, the thermostat open, blocking the bypass passage to the water pump, and opening the outlet to the radiator. Caution: Never operate the engine without a thermostat. Without a thermostat, the coolant will not flow to the radiator and the engine will overheat.
Coolant System 1. Coolant Flow Past Cylinders 5. Coolant to Cylinder 1. Goolant Flow from Cylinder Block 2. Thermostat 6. Coolant Flow Back to 3. Some of the heat generated by the engine is absorbed by the coolant flowing through the passages in the cylinder block and head. Then, heat is removed from the coolant as it flows through the radiator. When you troubleshoot overheat- ing, remember that too much oil in the oil pan can cause additional heat from friction when the rod journals are submerged in oil.
Overfilling with oil raises the oil temperature which is transferred to the coolant system at the oil cooler. The system is designed to use a specific quantity of coolant. If the coolant level is low, the engine will run hot NOTE: The engine or system has a leak if frequent addition of coolant is necessary. Find and repair the leak. Caution: The engine coolant passages must be com- pletely filled with coolant. During operation entrapped air mixes with the coolant which results in cavitation corrosion and poor heat trans- fer.
Open the petcock during filing. NOTE: A 50 percent mixture of antifreeze and water must be premixed before filing the system. The ability of anti- freeze to remove heat from the engine is not as good as. Caution: Never use water alone for coolant. Damage from corrosion can be the result of using water alone for coolant. The small holes in the head gasket are espe- cially susceptible to plugging. These holes are orifices and their size is critical. Do not enlarge the size of the orifices.
To do s0 will disturb the coolant flow and will not solve an overheating problem. Air in the coolant can result in loss of coolant from the overflow when the aerated coolant is hot. The heated air expands, increasing the pressure in the system causing the cap to open.
Similarly, coolant can be displaced through the overflow ifthe head gasket leaks compression gasses to the cool- ant system. NOTE: Transmission fluid can also leak into the coolant through radiator bottom tank transmission oil coolers. Reduced or interrupted flow will resuit in the engine running hot.
The pump is belt driven from the crankshaft pulley. An automatic belt tensioner is used to prevent the belt from slipping on the pump pulley. A malfunction of the ten- sioner will cause the water pump impeller to rotate at a slower speed reducing the amount of coolant flow. A hose will usually not col- lapse while the engine is running at low speed. Check the hose while the engine is running at rated speed. Radiator, Fans and Shutters Air forced through the fins of the radiator by a fan cools the coolant pumped through the radiator.
Environmental debris paper, straw, lint, dust, etc. Ifthe fanis beltdriven, aslipping belt will resultina slower fan speed and reduced cooling. A malfunctioning auto- matic belt tensioner can be the problem. NOTE: Check the bearings in the fan hub and other pulleys to make sure they are not causing excessive belt vibration and slippage. Interruption of the circuit to an electrically driven fan can result in insufficient air flow and cause the engine to run hot.
NOTE: Make sure that the temperature sensor is functioning correctly. These fans oper- ate only as needed to keep the coolant at the correct temperature.
Ifthe fan does not operate when the coolant temperature increases, the engine will run hot. If the fan does not shut off when coolant temperature decreases, the engine will run cold. NOTE: Make sure that the coolant temperature sensor is functioning correctly.
Shutters are designed to control air flow across the ra- diator. If the shutters fail to open when needed, the en- gine can run hot. Failure of the shutters to close can result in too much air flow and the engine running cold. NOTE: Make sure that the air temperature sensor is func- tioning correctly. Check the air operated shutter controls. Check for air leaks. Winterfronts can be used on a charge air cooled engine, but must be designed to partially cover the frontal area of, the cooling system.
A minimum of square inches of charge air cooled frontal area must be left open to airflow. NOTE: Check to be sure air is not recirculating.
Check for missing baffles. When the coolant temperature is below the operating range, coolant is bypassed back to the inlet of the water pump.
When the coolant temperature reaches the operating range, the thermostat opens, sealing off the bypass, forc- ing coolant to flow to the radiator. Caution: Never operate the engine without a thermo- path of least resistance is through the bypass to the pump inlet. This will cause the engine to overheat. Section 1 - Cooling System B Series After the engine is vented and filled, the jiggle pins act as check valves to block the flow of coolant through the opening during engine operation.
NOTE: A missing jiggle pin can cause the engine to run cold. With the jiggle pins sealing the openings, the flow to the radiator is controlled by the thermostat opening in re- sponse to the engine coolant temperature. Gauges, Overfueling and Loading Gauges and sensors are used in the system to measure the coolant temperature.
These can malfunction and pro- vide an incorrect temperature indication. Caution: Overfueling can cause the engine to overheat. Each section is equivalent to a group used in Cummins' filmcard system. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable.
Page Symbols B3. When one of the symbols appears, it conveys the meaning defined below Page Illustrations Illustrations B3. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.
Make sure you understand how to use the tools before performing any service work. Do not use a fastener of lesser quality if replacements are necessary. Page 13 General Safety Instructions B3. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. 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 All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations.
The liner will be ruined and any signs of a problem at the top ring reversal point like a dust-out will be destroyed. Page Gasket Surfaces The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.
If a liquid gasket remover is used, check the directions to make sure the material being cleaned will not be harmed. Never use sand as a blast media to clean engine parts. Page Fuel System Cummins Inc. Glass media is too easily embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's recommend are used.
Page 20 B3. One micron measures 0. The contaminants being filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope. Page 22 B3. Page 23 Acronyms and Abbreviations B3. Page 24 B3. Page 25 B3. Page 26 B3. Page 27 B3. Page 28 Service Tools Fuel System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure.
Tool No. Page 29 Service Tools B3. Page 30 B3. The AFC regulates the fuel-to-air mixture by sensing manifold pressure. Disconnect the connector from the water-in-fuel WIF sensor. Push on the fuel drain valve for approximately 5 seconds to reduce fuel spillage during filter removal. Page 32 B3. Install the fuel filter spud. Page 33 Fuel Consumption B3. NOTE: The most accurate method to check the fuel consumption is to weigh the fuel used.
Page 34 B3. In addition to the measurement of the fuel used, the following factors provide points for running a test similar to the recognized Type II Society of Automotive Engineers Fuel Test. Page 35 Fuel Consumption B3. All of the test results are based on comparing the fuel used by the test truck to the fuel used by the control truck. Page 36 B3. A single test drive is unreliable. Use the same experienced drivers for all of the tests. Page 37 Fuel Flow B3. Page 38 B3. In cold weather check for gelled diesel fuel blocking the prefilter.
Clean or replace the prefilter. Page 40 B3. Page 42 B3. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. Push the top dead center pin into the hole in the camshaft gear while slowly barring the engine. Page 44 B3. Remove the fuel injection pump. Install Make certain that the engine has cylinder Number 1 at top dead center. Page 46 B3. Wear goggles and protective clothing to avoid personal injury. Page 48 B3.
Failure to do so can result in premature governor wear. Page 50 B3. This can be done by forming a piece of wire that can be tightened under one of the gear cover capscrews. Page 52 B3. This could cause the inside of the fuel line to flake and cause injector failure. Page 54 B3. Check the fuel pressure. The pressure must be between psi and psi. This is spill port static timing. Page 56 B3. Flying debris and dirt can cause personal injury.
Page 58 B3. Flying debris and dirt can cause bodily injury. Place these pieces on a clean surface with the delivery valve holder. Page 60 B3. Page 62 B3. Page 63 If a gasket was removed from under the delivery valve, install a new delivery valve gasket Cummins Part Number into the fuel injection pump. Do not use a gasket if this is a pump with gasketless delivery valves. Page 64 B3. Fuel coming from the high- pressure fuel lines is under extreme pressure and can cause serious injury by penetrating the skin.
Pumps used in ratings developed after these will use delivery valves without gaskets. Page 66 B3. Page 68 B3. If the fuel Page 70 B3. Locate top dead center for cylinder Number 1 by barring the engine slowly, while pushing in on the top dead center pin. Page 72 B3. Failure to do so can result in difficult reassembly and incorrect timing of the fuel pump.
Page 74 B3. Remove the fuel pump retaining nut and washer. Failure to make certain the drive shaft is free of oil can result in the drive gear slipping on the shaft. Page 76 B3. Page 78 B3. Rear Gear Train Verify cylinder number 1 is at top dead center by barring the engine slowly while pushing in on the top dead center pin. Page 80 B3. Remove the fuel pump gear retaining nut and washer.
To remove the fuel pump gear, use gear puller, Part Number ST or , to separate the fuel pump gear from the shaft. Page 82 B3. Remove the top dead center timing pin from the camshaft and the timing pin on the damper, if used. Page 84 B3. Page 86 B3. The adjustment screw on the DB4 fuel injection pump is mounted on the control lever assembly. The high-idle adjustment screw must be adjusted by an authorized service dealer. Page 88 B3. Loosen the locknut, and turn the idle speed screw counterclockwise to increase the rpm and clockwise to decrease the rpm speed.
Page 90 B3. Page 91 Fuel Pump Timing B3. NOTE: Tighten bracket to block before tightening the bracket to the pump. Page 92 B3. The first step is the location of TDC of the compression stroke for cylinder Number 1. Page 93 Fuel Pump Timing B3. Page 94 B3. Page 95 Fuel Pump Timing B3.
During production, after the locked pump is fitted to the Page 96 B3. Page 97 Fuel Pump Timing B3. Page 98 B3. Doing so can result in fuel system failure. Page 99 Fuel Pump Timing B3. Page B3. Page Fuel Shutoff Valve B3. Color Description Weather-Pack Port Black Ground White Pull-in Hold-in Refer to the chart below to find the correct gauge size and length of continuous wire for the white pull-in wire which connects to the solenoid wiring.
Removal of the shutoff lever, filter, and supply line is not necessary if the solenoid can be accessed from the bottom of the fuel pump. To perform the solenoid voltage check, disconnect the The purpose of the valve is to control the residual pressure in the high- pressure line.
The valve for Lucas CAV is located at the bottom of the pump. Remove the stop screw and bracket assembly. Connect the electric wire. Distortion to the fuel pump body can result causing the rack to stick in the fuel pump. If the rod end is installed incorrectly, improper operation of the shutoff solenoid assembly can occur. Make certain to install the spacer between the rod end and the shutoff lever. Page Fuel Lift Pump B3.
Fuel prefilters, in-line and water separator type, can become clogged and cause a loss of fuel flow. The specifications below apply to both diaphragm and piston low output pumps. Residual fuel in the injection pump can cause the engine to start.
As the capscrews are tightened, the fuel lift pump plunger is pushed into the pump. The remote mounted option is necessary in applications where the pump-mounted KSB causes interference i. This shim must be reassembled between the cover plate and the timing piston. Two types of electrical solenoid-style KSB valves are available. Check for extensional movement of the plunger. The wiring harness used on the electric solenoid-style KSB can be inspected using a multimeter.
Page Speed Droop Governor B3. Inspect the sealing surfaces for possible leak paths. Use a small screwdriver to check that the check ball is not sticking in the high-pressure relief valve assembly. White smoke will be present if the wrong temperature switch is used. The remote-mounted option is necessary in applications where the pump-mounted KSB causes interference with the air compressor. The two-line version was superseded in Page Injectors and Fuel Lines The following special tools are recommended to perform procedures in this section.
Page Service Tools B3. Assemble in the reverse order of removal. Page The low-pressure fuel system for a Cummins diesel installed in the vehicle consists of the fuel tank, lines between the tank and the engine, transfer pump and lines, and fuel filter and lines. Page Air in Fuel B3. Keep all cigarettes, flames, pilot Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the Because the engine can start, be sure to follow all safety precautions.
Page Fuel Filter Head B3. Remove the four capscrews holding the fuel filter head to the fuel filter head bracket. Page Fuel Inlet Restriction B3. Page Fuel Manifold Drain B3. Wear goggles and protective clothing to reduce the possibility of personal injury. Remove the fuel line support bracket capscrew from the intake manifold.
NOTE: The banjo connection seals must be discarded when removed. The seals must not be used again. Page Fuel Supply Lines B3. Remove the fuel drain manifold line at the filter head. NOTE: To prevent loosening the fuel injection pump inlet fitting, use two wrenches when removing the fuel supply line. NOTE: To prevent overtightening the fuel injection pump inlet fitting, use two wrenches when installing the fuel supply line.
Page Use only the specified injector for the engine. All engines use closed nozzle, hole-type injectors. However, the injectors can have different part numbers for different engine ratings. Fuel is then injected into the cylinder. Page Injector B3.
Hold the injector body with an adjustable wrench while loosening the hold-down nut with a mm box wrench. Tilt the hold-downs up, and slide them out.
Use an injector puller, Part Number , to remove the injectors from the head. Inspect the nozzle holes for any signs of damage, such as erosion or plugging. If the engine continues to misfire after replacing the injector, check for leaks in the high-pressure line.
Also, check for a damaged delivery valve that lets the fuel drain back into the injection pump. There is a good crisp "pop" when the nozzle opens.
An audible sound can be heard as the valve rapidly opens and closes. Install the depth gauge assembly, Tool Number , on the cylinder head combustion deck and zero it. Use a brass wire brush and a piece of hardwood dipped in test oil. Contact from the skin will corrode the finely lapped surface. NOTE: The needle valve and nozzle tip are precisely matched for fit. Inspect Front Gear Train Inspect the injector. Inspect the o-ring for damage.
Inspect for burrs on the inlet to the injector. With the needle valve in the vertical position, the needle valve must slide all the way back into the nozzle body under its own weight. Use the pressure spring to make sure the shims are installed flat. Use only one copper washer. Service Tip: A light coat of clean lubricating engine oil between the washer and injector can help to keep the washer from falling during installation.
After tightening the injector, be sure to push the o-ring into the groove. Page Drain the water-fuel separator into a container and dispose of in accordance with local environmental regulations. Drain the water and sediment from the separator daily. Use your hand to open the drain valve. This will cause damage to the overflow valve. Connect the fuel line s to the injectors. Page Lubricating Oil System The following special tools are recommended to perform procedures in this section.
Page Engine Oil Heater B3. Test Perform a resistance test on the engine lubricating oil heater element. The readings must be a minimum of 91 ohms to a maximum ohms. Please see the video below for a quick overview of our business. This manual will be emailed to you shortly after purchase! If you would like the manual mailed to you on a DVD or print and bound, please select this option at checkout.
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