Cummins QSB4.5 Engine - Operation and Maintenance Manual

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CUMMINS QSB4.5 ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL

- Operation and Maintenance Manual, for Cummins QSB4.5 Engine.
 

CONTENTS:

- About the Manual  i-2
- General lnformation  i-2
- Accelerator Options  FB-3
- Disadvantages  FB-3
- Driver Activation/Deactivation  FB-3
- Feature Description  FB-3
- Interaction with other Features and Parameters  FB-3
- Visual Aids  FB-3
- Acronyms and Abbreviations  i-13
- General lnformation  i-13
- Additional Service Literature  L-1
- General information  L-1
- Air Cleaner Restriction  4-1
- Maintenance Check  4-1
- Air Compressor  4-2
- Maintenance Check  4-2
- Air Compressor Air Pressure Rises Slowly  TS-3
- Air Compressor Discharge Lines  7-1
- General lnformation  7-1
- Maintenance Check  7-1
- Air Intake Piping  4-3
- Maintenance Check  4-3
- Air Intake System  V-5
- Specifications  V-5
- Air Tanks and Reservoirs  3-2
- Drain  3-2
- Alternate Droop  FB-4
- Disadvantages  FB-5
- Driver Activation/Deactivation  FB-5
- Feature Description  FB-4
- Interaction with other Features and Parameters  FB-5
- Visual Aids  FB-5
- Alternator  A-1
- Finishing Steps  A-6
- General lnformation  A-1
- Initial Check  A-1
- lnstall  A-5
- Preparatory Steps  A-3
- Remove  A-4
- Test  '  A-2
- Automatic Boost Power  FB-7
- Disadvantages  FB-7
- Driver Activation/Deactivation  FB-7
- Feature Description  FB-7
- Interaction with other Features and Parameters  FB-7
- Visual Aids  FB-7
- California Emission Control System Warranty, Off-Highway  W-6
- Capscrew Markings and Torque Values  V-18
- Capscrew Markings and Torque Values - Metric  V-18
- Capscrew Markings and Torque Values - US Customary  V-18
- General lnformation  V-18
- Charge-Air Cooler  4-2
- Maintenance Check  4-2
- Charge-Air Cooler  A-6
- Clean  A-6
- Inspect for Reuse  A-7
- Leak Test  A-7
- Pressure Differential Test  A-9
- Temperature Differential Test  A-8
- Charge-Air Piping  4-2
- Maintenance Check  4-2
- Cold Weather Starting  1-4
- General lnformation  1-4
- Using Starting Aids  1-5
- Component Manufacturers' Addresses  M-1
- Air Compressors  M-1
- Air Cylinders  M-1
- Air Heaters  M-1
- Air Starting Motors  M-1
- Alternators  M-1
- Auxiliary Brakes  M-1
- Belts  M-1
- Catalytic Converters  M-1
- Coolant Level Switches  M-1
- Clutches  M-1
- Coolant Heaters  M-2
- Drive Plates  M-2
- Electric Starting Motors  M-2
- Electronic Switches  M-2
- Engine Protection Controls  M-2
- Fan Clutches  ,  M-2
- Fans  M-2
- Fault Lamps  M-2
- Filters  M-2
- Flexplates  M-2
- Fuel Coolers  M-2
- Fuel Pumps  M-2
- Fuel Warmers  M-2
- Gauges  M-3
- Governors  M-3
- Heat Sleeves  M-3
- Hydraulic and Power Steering Pumps  M-3
- In-Line Connectors  M-3
- Oil Heaters  M-3
- Prelubrication Systems  M-3
- Radiators  M-3
- Throttle Assemblies  M-3
- Torque Converters  M-3
- Coolant Contamination  TS-11
- Coolant Level  4-4
- Maintenance Check  ;  4-4
- Coolant Loss - External  TS-12
- Coolant Recommendations and Specifications  V-13
- Cooling System Sealing Additives  V-14
- Cooling System Soluble Oils  V-15
- Fully Formulated Coolant/Antifreeze  V-13
- Coolant Temperature Above Normal - Gradual Overheat  ,  TS-13
- Coolant Temperature Above Normal - Sudden Overheat  TS-15
- Coolant Thermostat  A-1 o
- Clean and Inspect for Reuse  A-12
- Finishing Steps  A-14
- General Information  A-1 o
- lnstall  A-14
- Preparatory Steps  A-11
- Remove  A-12
- Fan, Cooling  4-3
- Inspect for Reuse  4-3
- Cooling Fan Belt Tensioner  6-1
- Maintenance Check  6-1
- Cooling Fan Belt Tensioner  A-15
- Maintenance Check  A-15
- Cooling System  5-1
- Drain  :  5-2
- Fill  5-5
- Flush  5-3
- General lnformation  5-1
- Maintenance Check  5-2
- Cooling System  7-2
- Drain  7-3
- Fill  7-6
- Flush  7-4
- General lnformation  7-2
- Cooling System  V-4
- Specifications  V-4
- Crankcase Breather Tube  3-2
- Maintenance Check  3-2
- Cummins Customized Parts Catalog  L-3
- General lnformation  L-3
- Ordering the Customized Parts Catalog  L-3
- Ordering by Telephone  L-3
- Ordering On-Line  L-3
- Cummins/Fleetguard® Filter Specifications  V-8
- General Information  V-8
- Daily Maintenance Procedures - Overview  3-1
- Engine Operation Report  3-1
- General lnformation  3-1
- Unusual Engine Noise  3-1
- Distributors - International  S-31
- Locations  S-31
- Distributors and Branches  S-4
- Australia  S-22
- Canada  S-19
- New Zealand  S-26
- United States  S-4
- Division and Regional Offices  S-2
- Locations  ,  8-2
- Drive aelt Tension  V-16
- Tension Chart  V-16
- Drive Belt, Cooling Fan  A-16
- Inspect for Reuse  A-16
- Install  A-17
- Remove  A-16
- Drive Belts  3-3
- Maintenance Check  3-3
- Poly-Vee Belt  3-3
- Cogged Belt  3-4
- Electrical System  V-7
- Batteries (Specific Gravity)  V-7
- Specifications  V-7
- Electromagnetic Interference (EMI)  1-B
- General lnformation  1-8
- System EMI Radiation Levels  1-8
- System EMI Susceptibility  1-8
- Emergency and Technical Service  S-1
- General Information  S-1
- Engine Acceleration or Response Poor  TS-18
- Engine Diagrams  E-4
- Engine Views  E-4
- Engine Difficult to Start or Will Not Start (Exhaust Smoke)  TS-20
- Engine Difficult to Start or Will Not Start (No Exhaust Smoke)  TS-22
- Engine Identification  E-1
- Air Compressor  E-3
- Cummins® Engine Nomenclature  E-2
- ECM Dataplate  E•3
- Engine Dataplate  E-1
- Fuel Injection Pump Dataplate  E-2
- Engine Noise Excessive - Combustion Knocks  ,  TS-26
- Engine Operating Range  1-8
- General Information  1-8
- Engine Power Output Low  TS-27
- Engine Runs Rough at ldle  TS-29
- Engine Runs Rough or Misfires  TS-30
- Engine Shutdown  1 •8
- General lnlormation  1-8
- Engine Shuts Off Unexpectedly or Dies During Deceleration  TS-32
- Engine Speed Surges at Low or High ldle  TS-33
- Engine Speed Surges in PTO or Cruise Control  TS-36
- Engine Speed Surges Under Load or in Operating Range  TS-34
- Engine Starts But Will Not Keep Running  TS-37
- Engine Will Not Crank or Cranks Slowly (Air Starter)  TS-39
- Engine Will Not Crank or Cranks Slowly (Electric Starter)  TS-41
- Engine Will Not Reach Rated Speed (RPM)  TS-42
- Exhaust System  V-6
- Specifications  V-6
- Fan Control  FB-1
- Disadvantages  FB-1
- Driver Activation/Deactivation  FB-1
- Feature Description  FB-1
- Interaction with other Features and Parameters  FB-1
- Visual Aids  FB-1
- Fan Hub, Belt Driven  6-2
- Maintenance Check  6-2
- Fan Spacer and Pulley  A-17
- Inspect for Reuse  A-17
- lnstall  :  A-18
- Preparatory Steps  A-17
- Remove   A-17
- Flow Diagram, Air Intake System  D-10
- Flow Diagram   D-10
- Flow Diagram, Compressed Air System  :  D-14
- Flow Diagram  D-14
- Flow Diagram, Cooling System    D-9
- Flow Diagram    0-9
- Flow Diagram, Exhaust System    D-11
- Flow Diagram  D-11
- Without EGR    D-11
- With EGA   0-12
- Marine Applications  D-13
- Flow Diagram, Fuel System  D-2
- Flow Diag,ram                      D-2
- With Electric Lift Pump  D-3
- Flow Diagram, Lubricating Oil System  D-4
- Flow Diagram  D-4
- Fuel Consumption Excessive  TS-46
- Fuel Consumption Rate Logger  FB-8
- Disadvantages  FB-8
- Driver Activation/Deactivation   FB-8
- Feature Description  FB-8
- Interaction with other Features and Parameters  FB-8
- Visual Aids  FB-8
- Fuel Filter (Spin•On Type)  5-6
- lnstall  ,  5-6
- Prime  5-7
- Remove  5-6
- Fuel in the Lubricating Oil  TS-49
- Fuel Recommendations and Specifications  V-9
- Fuel Recommendations   V-9
- Fuel System   V-2
- Preparatory Steps  V-2
- Fuel-Water Separator    3-2
- Drain   3-2
- Canister Type     3-2
- Spin-on Type   3-3
- General Cleaning Instructions      i-9
- Abrasive Pads and Abrasive Paper  i-9
- Definition of Clean   i-9
- Gasket Surfaces   i-10
- Plastic Bead Cleaning  i-11
- Solvent and Acid Cleaning   i-10
- Steam Cleaning  i-11
- General Repair Instructions  i-6
- General Information  i-6
- Welding on a Vehicle with an Electronic Controlled Fuel System  i-6
- General Safety Instructions  i-6
- Important Safety Notice  i-6
- General Engine  V-1
- Specifications  V-1
- Hot Shutdown Monitor  FB-6
- Disadvantages  FB-7
- Driver Activation/Deactivation  FB-7
- Feature Description  FB-6
- Interaction with other Features and Parameters  FB-7
- Visual Aids  ,  FB-7
- How to Use the Manual  i-3
- General lnlormation  i-3
- Idle Shutdown  FB-2
- Disadvantages  FB-2
- Driver Activation/Deactivation  FB-2
- Feature Description  FB-2
- Interaction with other Features and Par,meters  FB-2
- Visual Aids  FB-2
- Illustrations  i-5
- General Information  i-5
- Intermediate Speed Control (ISC)  ,  FB-3
- Disadvantages  FB-4
- Driver Activation/Deactivation  FB-4
- Feature Description  FB-3
- Interaction with other Features and Parameters  FB-4
- Visual Aids  FB-4
- Lubricating Oil and Filters  5-7
- Drain  5-7
- Fill  5-9
- lnstall  5-6
- Remove  :  5-6
- Lubricating Oil Consumption Excessive  TS-53
- Lubricating Oil Contaminated  ,  TS-54
- Lubricating Oil Level  3-3
- Maintenance Check  3-3
- Lubricating Oil Loss  TS-55
- Lubricating Oil Pressure High  TS-57
- Lubricating Oil Pressure Low  TS-56
- Lubricating Oil Recommendations and Specifications  V-10
- General lnformation  V-10
- New Engine Break-in Oils  V-12
- Lubricating Oil Sludge in the Crankcase Excessive  TS-60
- Lubricating Oit System  V-3
- Specifications   V-3
- Maintenance Guidelines• Overview  2-1
- General Information  2-1
- Maintenance Procedures - Overview  4-1
- General lnformation  4-1
- Maintenance Procedures - Overview  5-1
- General lnformation  5-1
- Maintenance Procedures• Overview    6-1
- General lnformation  6-1
- Maintenance Procedures  Overview  7-1
- General Information  7-1
- Maintenance Procedures - Overview   8-1
- General Information  6-1
- Maintenance Record Form  2-4
- Maintenance Data  2-4
- Maintenance Schedule  2-3
- General Information   2-3
- Oil Drain lntervals  2-3
- Multiple Unit Synchronization  FB-5
- Disadvantages  FB-6
- Driver Activation/Deactivation  FB-6
- Feature Description  FB-5
- Interaction with other Features and Parameters  FB-6
- Visual Aids  FB-6
- Normal Starting Procedure  ,  1-2
- General Information  1-2
- Jump Starting  1-4
- All Engines lnternationallndustrial (Off-Highway)  ,  W-4
- All Engines United States and Canada Industrial (Off-Highway)  W-1
- Operating Instructions - Overview  H
- General Information   1-1
- Operating the Engine  :  1-5
- Ambient Temperature  1-6
- to -32°C 132 to -25°FJ  1:6
- -32 to -54°C [-25 to -65°FJ  1•6
- Cold Weather  1-6
- Normal  1-5
- Winterfronts and Shutters   1-7
- Overhead Set  8-1
- Adjust   8-3
- Finishing Steps  8-7
- lnstall  6-5
- Preparatory Steps  8-1
- Remove  8-1
- Problem Solving  8-1
- General lnformation  $-1
- Radiator Hoses  4-3
- Maintenance Check  4-3
- Regional Offices - International  $-27
- Locations   $-27
- Routine Service and Parts  8-1
- General Information  S-1
- Sealants  V-17
- General lnformation  V-17
- Service Literature Ordering Location  L-2
- Contact lnformation  L-2
- Starting Motor  A-18
- Clean and Inspect for Reuse  A-20
- lnstall  A-21
- Cummins Branded Starters  A•22
- Non-Cummins Branded Starters  A-22
- Measure  A-21
- Remove  A-19
- Rotation Check  A-18
- Starting Procedure After Extended Shutdown or Oil Change  1-5
- General Information  1-5
- Switchable (Alternate) Torque  FB-5
- Disadvantages  FB-5
- Driver Activation/Deactivation  FB-5
- Feature Description  FB-5
- Interaction with other Features and Parameters  FB-5
- Visual Aids  FB-5
- Symbols  i-4
- General Information  i-4
- System Diagrams - Overview  D-1
- General lnformation  D-1
- To the Owner and Operator  i-1
- General Information  i-1
- Tool Requirements  2-2
- General Information   2-2
- Troubleshooting Procedures and Techniques  TS-1
- General lnformation  TS-1
- Troubleshooting Symptoms Charts  TS-2
- General Information    TS-2
- Turbocharger Leaks Engine Oil or Fuel  TS-64
- Vibration Damper, Rubber  7-7
- Inspect    7-7
- Vibration Damper, Viscous c   7-7
- Inspect   7-7
- Water-in-Fuel Sensor   FB-1
- Disadvantages   FB-2
- Driver Activation/Deactivation  FB-2
- Feature Description   FB-1
- Interaction with other Features and Parameters   FB-2
- Visual Aids   FB-2