Modelo DRS4531–S5
Maquina no. 45572, 45573
Aõo 2002
A Partek Company
INDICE
B Servicio
C Apéndices
Las normas ISO9000, ISO14000 e BS8800 son la base de nuestro sistema de gestión y
se utilizan como herramientas de desarrollo junto con criterios de calidad para lograr la
excelencia.
Christer Granskog
Presidente y CEO
11 MANUAL DEL OPERADOR
El manual del usuario familiariza al mismo con la técnica de la máquina, operación del equipo
de la máquina y le da instrucciones para un correcto y seguro uso de la máquina.
El manual del usuario y los manuales de mantenimiento y reparación, que serán publicados
más adelante, son una serie de manuales de operación y mantenimiento personal. Hasta que
se publique la nueva serie, enviaremos al usuario de la máquina, junto con el manual del usua-
rio, el manual de mantenimiento actualmente en vigor.
El soporte profesional de nuestra organización de mantenimiento y las instrucciones de opera-
ción y mantenimiento, hacen posible una operación segura y eficaz durante toda la vida de
la máquina.
KALMAR INDUSTRIES Oy Ab. felicita al cliente de SISU por su sensata decisión de compra.
Page Groupe Date Désignation
El Reach Stacker está diseñado para manipular contenedores. Contenedores acordes con los
standard ISO y con longitud de 20’ y 40’ pueden ser manipulados con el spreader de un equi-
pamiento standard. Con un spreader opcional, salvo los contenedores ya mencionados, se
pueden manipular contenedores de 30’ y 35’.
6 1
4 9 10 7 5 3
(37”)
(47”) 950
1200 6000 (236”) 3000 (117”)
2640 (104”)
11400 (449”)
3140 (124”)
2400 (96”)
4160 (164”)
6050 (238”)
27 t
Capacidad
Velocidad de elevación
Sin carga 0.40 m/s
Con carga 0.23 m/s
Velocidad de descenso
Sin carga 0.40 m/s
Con carga 0.30 m/s
Velocidad de marcha
Velocidad de marcha máx., con carga 22 Km/h (adelante/atrás)
Velocidad de marcha mín., sin carga 25 Km/h (adelante/atrás)
Gradiente
Con carga 25 %
Sin carga 42 %
Eje y pesos totales carga 45.0 T
Peso eje delantero sin carga 33 500 kg
Peso eje delantero con carga 100 000 kg
Peso eje trasero sin carga 35 500 kg
Peso eje trasero con carga 15 000 kg
Peso total sin carga 69 000 kg
Peso total con carga 114 000 kg
Page Groupe Date Désignation
11.7.1. Controls
10
8
9
2
3
6
1
S52 4 5
Figure 6. Cabina
P1
2 3 4
1
P7
P1 Cuenta–horas de operación
P2 Indicador de combustible
P4 Indicador temperatura refrigerante
P7 Calibre de la presión del aceite de transmisión
S28 Interruptor de la luz de trabajo y luz de señal (opcional)
S30 Interruptor del interruptor intermitente de emergencia (opcional)
S36 Interruptor intermitente y luz del indicador
S71 Interruptor del cambio de marchas automático (opcional)
S72 Interruptor del margen de velocidad del cambio de marchas automático (opcional)
S114 (optional)
S115 Interruptor de derivación del límite de rotación (opcional)
S138 Interruptor de la luz de trabajo para el esparcidor
S199 Interruptor de derivación
En caso de mal funcionamiento, abra los bloqueos de torcedura pulsando simultánea-
mente el interruptor S199 (situado en la caja eléctrica, en el bastidor) y el interruptor
’de apertura de bloqueos de torcedura’.
Nota! El contenedor debe estar en el suelo durante esta operación.
S202 Interruptor de lubricación central
S211 Interruptor on/off del dispositivo de aire acondicionado (opcional)
S910 Interruptor mini de volante(opcional)
S911 Control de circulación de la toma de aire Interruptor
S912 Interruptor de ventilador (opcional)
H203 Luz del indicador del sistema de lubricación (opcional)
1 Interruptor de control del calefactor de la circulación del soplador de aire
2 Interruptor de control del calefactor de la intensidad del soplador de aire
3 Interruptor de control del calefactor de calor
4 Interruptor de control del dispositivo de aire acondicionado del flujo de aire
Rev. B 13.03.2001
Designacón Fecha Grupe Página
P8 P5 P9 P6
P13
Rev. A 13.06.2000
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H251
H252
S192 S237 S251
S85
S112
S189 S194
Rev. B 25.09.2000
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X 7+1
7+2 S89 S90
X 2 1
S180 S92
F 3 4
B A D S86 S95
C
R58
5 6
S99
7+5
7+6
7
7
A Subir
B Bajar
C Telescopio dentro
D Telescopio fuera
E Rotación en sentido horario
F Rotación en sentido anti–horario
1 Transferencia lado izquierdo
2 Transferencia lado derecho
3 Bloqueos de la torcedura abiertos
4 Bloqueo de pendiente del longit. del esparcidor
5 Alargar el esparcidor
6 Acortar el esparcidor
7+1 Apilar la cuesta hacia la izquierda (opcional)
7+2 Apilar la cuesta hacia la derecha (opcional)
7+6 Balanceo longitudinal spreader, adelante
7+5 Balanceo longitudinal spreader, atrás
Page Group Date Description
P11
H195/ S2
H92 H12
H11
H180 H191
F S33b S33d
1
2
R
S56 S22
Rev. A 05.05.2000
Designacón Fecha Grupe Página
2. Valor amarillo; Carga 90–100% de la capacidad de elevación de seguridad; se enciende la luz y sue-
na una alarma para advertir que se acerca al límite de sobrecarga. Ante ésta situación, haga más
lentos los movimientos de la pluma.
3. Valor rojo; Carga superior al 100% de la capacidad de elevación de seguridad. Para esta-
bilizar la máquina, se pararán todas las funciones de la pluma, salvo la retracción. Las
funciones se activarán cuando la carga sea inferior al 100%.
7
6
En caso de mal funcionamiento, por ejemplo del sistema eléctrico, la cabina se puede transfer-
ir a la posición trasera usando la bomba manual
Para detalles e instrucciones completas acerca del uso de la balanza, consulte los APÉNDICES en este
manual.
Designacón Fecha Grupe Página
Aunque se han previsto alarmas sonoras para diferentes situaciones peligrosas, el uso seguro
del transportador requiere siempre especial atención y cualificación del operador.
3. Intente determinar los riesgos y evítelos. Comunique cualquier fallo que note a su superior
o a la persona a cargo de las reparaciones.
5. Observe siempre suficiente cautela y cuidado cuando suba o baje del transportador.
Camine siempre por los espacios marcados como pasillos. Mantenga éstos limpios,
quitando nieve, hielo o cualquiera otra materia extraña. Seque las pérdidas de aceite para
evitar caídas.
10. Antes de arrancar, asegúrese que no hay nadie delante ni detrás del transportador.
12. Respete la condición del ambiente de trabajo. Observar los obstáculos que restrinjan su
trabajo y las áreas que patinan, especialmente los peligros ocasionados por nieve o hielo.
Page Groupe Date Désignation
Montones de arena y superficies con aceite pueden incrementar los riesgos de su trabajo.
Informe inmediatamente de las causas de peligro a su superior o a la persona responsable
de seguridad en su zona de trabajo.
14. Conduzca siempre lejos de cualquier vehículo que esté alrededor. Nunca conduzca al
lado de otro vehículo.s.
15. Respete las señales e instrucciones indicando altura libre. Deberá saber la altura exacta
total del transportador antes de manejarlo en lugares con altura libre restringida. Sea
especialmente cuidadoso con estructuras temporales, con enganchar líneas de tensión,
etc...
16. No conduzca en la oscuridad sin luces. Avise de cualquier espacio con luces pobres.
17. Cuando cambie el sentido de la marcha, pare completamente el transportador con el freno
de servicio antes de mover la palanca selectora de dirección.
18. Esté atento a los bordes de los caminos en los que la superficie puede estar desnivelada
y causar el peligro de vuelco.
20. Parar el motor siempre que abandone el transportador, aunque sea por poco tiempo. Bajar
cualquier carga al suelo.
22. Haga un informe detallado de cualquier colisión, incluyendo desperfectos. Esto evitará
que se repitan accidentes.
23. Respete el peso del transportador y su peso total cargado. No conduzca en superficies
con insuficiente capacidad de carga.
24. Siga el plan de mantenimiento periódico. Esto asegura que los controles y que todo el
transportador sean fiables y seguros.
25. Los motores deben estar parados siempre que se lleven a cabo mantenimiento o
inspecciones.
27. El uso de una llama abierta está totalmente prohibido cuando se comprueba el
combustible o los niveles de los electrólitos de la batería.
28. El radiador está presurizado cuando el refrigerante está caliente – abrir el tapón del
radiador lenta y cuidadosamente.
30. Sólo la persona familiarizada con el control del transportador y del equipo de la cabina,
está autorizada a permanecer en la cabina durante la operación y reparaciones.
11.9.2.1. Vuelco
1. Evite frenar repentinamente, especialmente cuando la carga está arriba; una alta fuerza
de basculamiento puede provocar un vuelco. La carga no deberá estar más alta que 3000
mm. desde el suelo. Esto mantiene las fuerzas de vuelco al mínimo.
2. Evite giros bruscos en superficies inclinadas o irregulares. Una frenada fuerte cuando se
está girando, tiene un grave peligro de vuelco.
4. Tenga cuidado con los agujeros y otros daños del suelo.Estos pueden provocar que se
pinchen los neumáticos y, por lo tanto, riesgo de vuelco.
11.9.2.2. Colisiones
1. Esté siempre alerta cuando se encuentre con otro vehículo. Ajuste su velocidad, de
manera que pueda parar el transportador dentro de la pista libre visible.
2. Cuando se acerque a otro contenedor, recuerde que la suspensión del transportador cede
en caso de frenada brusca y pueden colisionar los contenedores.
En éste grupo están las instrucciones generales para el usuario de la máquina, para asegurar
el planeado y seguro uso de la máquina. Las instrucciones de seguridad para el uso, manten-
imiento y reparación de la máquina están en éste manual, en los capítulos correspondientes
a éstas materias.
Max. 15°
Punto Descripción
P. Circuito de pausa, sistema de calefacción
conectado, opcional
O. La llave de contacto sólo se debe sacar cuando está en ésta posición. Se apaga
la potencia de todos los circuitos excepto la radio y luces de cabina
I. Potencia conectada a circuitos eléctricos
II. Potencia conectada al dispositivo de arranque en frío, opcional
III. Potencia conectada al motor de arranque. La llave de contacto vuelve, mediante
muelle, desde las posiciones II y III a la posición I
11.10.1.1. Arranque
Lleve la palanca selectora de velocidades a punto muerto antes de arrancar el motor, y
asegúrese que el freno de aparcamiento está conectado.
Cuando arranque el motor en frío, empiece girando la llave de contacto a la posición arranque
en frío II durante unos 30 seg. y gire la llave a la posición III.
Si el motor no arranca en 15 seg., párelo y no vuelva a intentarlo hasta pasado medio min.
aproximadamente. Vuelva a intentarlo llevando la llave de contacto a la posición II, igual que
antes.
Suelte la llave de contacto inmediatamente una vez que arranque el motor y lleve el motor
a 1.000 rpm con el pedal de acelerador.
Page Group Date Description
Si se enciende alguna luz de alarma del panel de instrumentos o suena la alarma, localice y
repare el fallo antes de volver a utilizar la máquina.
conduzca con calma y evite frenadas y arranques bruscos. Siga, para conducir, las instruc-
ciones de seguridad de su lugar de trabajo y las instrucciones de seguridad para un uso seguro
de la máquina.
No pare nunca el motor cuando vaya cuesta abajo, ya que la dirección y los
frenos del reach stacker se operan por la presión del sistema hidráulico y és-
tas funciones no trabajan si el motor no está en marcha
Description Date Group Page
Cuando la máquina esté parada, evite giros innecesarios en las ruedas di-
rectrices, para evitar el desgaste de las ruedas.
Evite arranques violentos y altas velocidades cuando las ruedas direc-
trices estén giradas al máximo ángulo y esté seleccionada la dirección de
marcha ”hacia atrás”; no sobrecargue las llantas con esfuerzos excesi-
vos, ya que podrían romperse
Hay un sistema de control eléctrico en la máquina para asegurar la función de los componentes y su opera-
ción.
El sistema de control consta de varios indicadores, luces indicadoras, micro–interruptor del asiento y
señales sonoras en la tarjeta de circuitos.
La señal sonora H13 en la cabina suena y las luces indicadoras del grupo H9 parpadean cuando ocurre
una de las siguientes cosas:
D Potencia está conectada con la llave de contacto, el freno de aparcamiento no está con-
ectado y el conductor no está sentado en la cabina.
D La presión de aceite motor está por debajo de 1,0 bar cuando el motor está en marcha.
D La presión del hidráulico de freno está por debajo de 90 bar y el conductor está sentado
en su asiento.
4 1
5 6
Rev. A 22.05.2000
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C A B
Rev. A 22.05.2000
Designacón Fecha Grupe Página
brazo.Si uno de los pernos sensores no entrara dentro, el sensor inductivo C no se activará,
no habrá sujeción y la luz indicadora amarilla no se encenderá.
Después de que se ha encendido la luz indicadora amarilla, los bloqueos de torsión se cierran
automáticamente y se enciende la luz indicadora verde del panel de luces del brazo. La luz
indicadora verde no se encenderá hasta que cada bloqueo haya sido girado a su posición de
cerrado (D activa el sensor E).
Si por alguna razón no hubiera sujeción, puede realizarla manualmente con el interruptor
”Bloqueos de torsión cerrados” de la cabina de control de la cabina.
Después de que se haya encendido la luz indicadora verde, ya puede levantar el contenedor
en el aire y transportarlo al sitio designado. Después de que el extensor se haya movido hacia
arriba aproximadamente10 mm., los bloqueos de torsión se bloquearán mecánicamente cuan-
do los pernos sensores bajen por el factor de retracción. Los sensores inductivos se desacti-
van por lo que el bloqueo también es asegurado electrónicamente. La luz indicadora amarilla
del panel de luces del brazo se apaga.
Cuando baja el contenedor al suelo, sobre una pila o un vehículo, el extensor baja por encima
del contenedor y los pernos sensores de las esquinas del extensor entran dentro. La luz indica-
dora amarila del contacto de contenedor se enciende en el panel de luces del brazo. La función
de contacto de contenedor está activada, por lo que si uno de los pernos sensores no entrara
dentro, la luz indicadora amarilla no se encenderá y la función ”bloqueos de torsión abiertos”
no se realizará.
Después de que se haya encendido la luz indicadora amarilla de contacto de contenedor, pul-
se el interruptor ”Bloqueos de torsión” abiertos hasta que se encienda una luz indicadora roja
en el panel de luces del brazo. Después de que se haya encendido la luz indicadora roja, ya
puede elevar el extensor fuera del contenedor
Eleve el extensor bien alto antes de alejarlo del contenedor.
Rev. A 22.05.2000
Page Groupe Date Désignation
Esta función puede utilizarse sólo si no hubiera ninguna otra solución para reparar
el error de funcionamiento.
Baje el contenedor al suelo o sobre una base firme. Desactive la sujeción automática, interrup-
tor S192. Pulse el interruptor S199 (situado en la caja eléctrica del bastidor) y el interruptor
S180 ”Bloqueos de torsión abiertos” (situado en el panel de control), hasta que la luz indicado-
ra roja de ”Bloqueos de torsión abiertos” se encienda.
Rev. A 22.05.2000
Designacón Fecha Grupe Página
Deje los contenedores en la zona de almacenamiento en líneas paralelas, de manera que el apilamiento
y el transporte desde allí pueda ser hecho lo más rápido y seguro posible.
Deje los contenedores transportados a una distancia, como mínimo, de 5 cm. uno de otro, para evitar
daños en pernos, puertas y cierres durante la manipulación.
Gire hacia la línea de contenedores con el máximo radio de giro, para tener un posicionamiento vertical
de la máquina adecuado a la línea de contenedores. De ésta manera, el contenedor se puede elevar y
recoger rápida y seguramente.
Page Groupe Date Désignation
4 5 6
1 2 3
4 5 6
1 2 3
Baje el contenedor sobre el trailer de manera que los ejes longitudinales del contenedor y del
trailer estén paralelos. El posicionamiento de los contenedores lateralmente, se debe hacer
utilizando el desplazamiento lateral del spreader.
Los ganchos de elevación se pueden utilizar para elevar cargas del mismo peso que las que
se pueden cargar con los pivotes de elevación. La carga se debe fijar siempre en cada una
de las cuatro esquinas.
Designacón Fecha Grupe Página
Haga las siguientes cosas cuando abandone el transportador después del trabajo:
1. Pare el transportador con el freno de servicio.
2. Mover la palanca selectora de dirección de marcha a punto muerto.
7. Permita que el motor funcione a marcha mínima durante algunos minutos para que las
diferencias de temperatura se ecualicen y las RPM del turboalimentador disminuyan.
Rev. A 27.04.2000
Page Groupe Date Désignation
Cuando aparque por tiempo el transportador, tenga cuidado de no estar en el mismo camino
de otras operaciones.
Asegúrese que no se dejan fuente de energía cargadas en el transportador, esto es,
recipientes a presión, acumuladores de presión hidráulica, baterías eléctricas, etc... Si se deja
que se descarguen por sí solas, estas fuentes de energía pueden causar situaciones de
peligro incontrolables.
Asegúrese de que posibles fugas de aceite del transportador no puedan dañar o polucionar
el medio ambiente.
Lleve a cabo inspecciones habituales en el transportador almacenado.
Cuando vaya a utilizar el transportador después de haber estado aparcado por tiempo, estudie
el Manual del Operador cuidadosamente.
Lleve a cabo un mantenimiento exhaustivo del transportador antes de volver a utilizarlo.
Además de las inspecciones habituales, lleve a cabo esos procedimientos que se hacen
después de un largo período de almacenamiento..
Comprobar que los niveles de fluido en el sistema hidráulico, los motores, el sistemas de
frenos, la transmisión, etc..., son correctos.
Conduzca al principio con precaución para asegurarse que el transportador trabaja
correctamente.
Investigue qué partes de la máquina y fluidos están clasificados como residuos tóxicos.
Manipule estos materiales de acuerdo con las instrucciones especiales a su disposición.
Page Groupe Date Désignation
D Nivel refrigerante.
D Combustible en el indicador.
Tenga cuidado de rellenar y no se olvide del necesario mantenimiento y reparación para man-
tener la seguridad operativa y el tiempo de operación de la máquina dentro del nivel planeado.
Designacón Fecha Grupe Página
Ï ÏÏ
Ï ÏÏ
ÏÏ
Figure 11. Engine oil dipstick (A) and oil filling cap (B)
El nivel de aceite es correcto cuando está entre las marcas de la varilla de aceite. Compruebe
el nivel cuando el motor lleve parados unos minutos. El aceite se rellenará por el agujero de
relleno (B).
ÏÏ Ï
ÏÏ
Ï
ÏÏ
Ï
ÏÏ
ÏÏ
Compruebe el nivel de aceite corriendo el motor y con la temperatura del aceite de la transmis-
ión a 80–90ºC. El nivel es correcto cuando está entre las marcas de la varilla (A). Rellenar a
través del orificio de relleno (B).
Compruebe visualmente la presión y el montaje de las ruedas en los ejes. Tenga especial cui-
dado con posibles daños en la superficie de las ruedas (por ejemplo, incisiones profundas).
Page Groupe Date Désignation
B
Figure 18. A= Tapón depósito combustible, B= Pin sensor contacto
contenedor
11.13. Notes:
CONTENIDO
00 Información general/
Mainteimiento regular
01 Unidad de potencia
02 Transmisión de fuerza
03 Sistema hidráulico
04 Sistema eléctrico
05 Cabina
06 Dispositivos de trabajo
07 Chasis y protecciones
08 Equipamiento
00 INFORMACIÓN GENERAL/
MAINTENIMIENTO REGULAR
Vaya familiarizándose con cautela con el programa de planificación del mantenimiento, puntos
e instrucciones de mantenimiento y sígalas para realizar las tareas de mantenimiento, con el
fin de garantizar el elevado nivel de seguridad y fiabilidad durante la operación. Utilice los acei-
tes, grasas y líquidos de mantenimiento que se tratarán más adelante en este manual, así
como los filtros y otros equipos de mantenimiento por parte de nuestro servicio de piezas de
recambio. Es necesario el compromiso ineludible con la limpieza, especialmente en el mante-
nimiento de los dispositivos hidráulicos y de combustible. Por ello, la programación del mante-
nimiento es indispensable para garantizar una operación correcta de la máquina. Tome todas
las precauciones necesarias que se especifiquen en su zona de trabajo para los aceites, gra-
sas y líquidos lubricantes que haya cambiado durante el mantenimiento y deséchelos en el
lugar que se haya determinado con ese propósito.
Durante el proceso de mantenimiento, no vierta aceites; grasas y líquidos en el desagüe
ni al suelo! Acepte su parte de responsabilidad en la conservación del medioambiente!
Únicamente se permite el mantenimiento de esta máquina al personal cualificado.
No realice el mantenimiento de esta máquina si no está seguro de algunas instrucciones o
órdenes relativas a la seguridad. En caso de que necesite asistencia sobre un mantenimiento
seguro en su zona de trabajo, pregunte al personal responsable de la formación y recomenda-
ciones sobre los distintos puestos de trabajo; o bien, póngase en contacto con el servicio de
asistencia del fabricante.
Page Groupe Date Désignation
9. Si es necesario, consulte con la persona que esté al día sobre como proceder.
10. Cuando utilice los sistemas presurizados, proceda cuidadosamente. Fuentes de energía
no descargadas son siempre peligrosas.
11. Siga incondicionalmente las instrucciones dadas.
12. Si es necesario quitar las guardas protectoras durante el servicio, coloque señales de
alarma y tome otras medidas para proteger a otras personas del peligro.
13. Cuando cambie la dirección de marcha, pare completamente el transportador con el freno
de servicio, antes de mover la palanca selectora de dirección.
14. Esté atento a los bordes de los caminos en los que la superficie puede estar inclinada y
causar peligro de vuelco.
15. Recuerde que el transportador no está diseñado para transportar personas.
16. Pare siempre los motores cuando abandone el transportador, aunque sea por un tiempo
muy corto. Baje cualquier carga al suelo.
17. Acuérdese siempre de accionar el freno de aparcamiento antes de abandonar la cabina.
18. Haga un informe detallado sobre cualquier colisión, incluyendo los daños causados. Esto
evitará que se repitan accidentes.
19. Observe el peso del transportador así como su peso total con carga. No conduzca en
superficies con insuficiente capacidad de carga.
20. Si se utilizan sprays de arranque para ayudar al arranque en frío, siga estrictamente las
instrucciones sobre el uso de éstos aerosoles que se indican más adelante en este manu-
al.
21. Siga el plan de mantenimiento periódico. Esto asegura que los controles y que todo el
transportador operan adecuada y correctamente.
22. Los motores se deben parar siempre que se lleven a cabo trabajos de servicio o inspec-
ciones..
23. El uso de una llama abierta está totalmente prohibido cuando se compruebe el gasoil o
los niveles de los electrólitos de las baterías.
24. El radiador está presurizado cuando el refrigerante está caliente – abrir cuidadosa y lenta-
mente el tapón del radiador.
25. No abrir el interruptor principal cuando los motores estén en marcha.
26. Sólo la persona que esté bien familiarizada con el control del transportador y el equipo de
la cabina, está autorizada para permanecer en la misma durante el servicio y reparación.
27. No está permitido conducir sin los cinturones de seguridad puestos.
28. No opere nunca la máquina en un plano inclinado.
Designacón Fecha Grupe Página
00.3.2.2. Herramientas
Utilice exclusivamente herramientas adecuadas para el trabajo de servicio y reparación.
El trabajo de servicio y reparación deberá ser desarrollado en los locales adecuados para éste
uso. Aclare la extensión del trabajo de servicio. Prepárese para el trabajo de servicio o repara-
ción leyendo los manuales de servicio y reparación. Hágase con el material y herramientas
necesarios. Compruebe que las herramienta a usar están en buenas condiciones y son ade-
cuadas. Compruebe que las señales de alarma para eventuales situaciones peligrosas, están
situadas apropiadamente.
Antes de efectuar el trabajo de servicio: Compruebe las reparaciones hechas en la operación
de la máquina desde el último servicio. Comprobar el informe anterior de servicio. Intente
encontrar el nivel esperado de seguridad basado en la información recogida; qué puntos
deben ser especialmente considerados en el siguiente servicio.
Cuando lleve a cabo el servicio, informe del trabajo sistemáticamente de acuerdo con el plan
de servicio diseñado por el fabricante. Anote cuidadosamente los daños observados y las
medidas de reparación. El plan de servicio diseñado por el fabricante se presenta en la sección
”Primer servicio y servicio programado” de éste grupo principal.
Defina y grabe el nivel de seguridad de la máquina en el informe de servicio después de cada
servicio. Si estima que la máquina no se corresponde con el nivel diseñado de seguridad,
informe de ésto a su superior responsable de la seguridad. Después de cada servicio, archive
los informes de servicio.
Designacón Fecha Grupe Página
Tabla de conversión SI
Unidad anterior Coefficiente Unidad SI
1 kp ....... .. N
1 kpm ....... 9,80665 .. Nm = J = Ws
1 kpm/s ....... (9,81) .. W = J/s = Nm/s
1 kp/mm2 ....... (10) .. N/mm2 = MPa
1 mm vp ....... .. Pa
98,1
1 kp/cm2 ....... 0,980665 .. kPa
(0,98)
(1,0)
1 mmHg ....... 133,322 .. Pa
1 atm ....... 101,325 .. kPa
1 bar ....... 100 .. kPa
1 hv ....... 0,7355 .. kW
(0,75)
1 hp ....... 0,7457 .. kW
1 cal ....... 4,1868 .. J = Nm = Ws
1 kcal/kg ....... (4,19) .. kJ/kg
(4,2)
1 kWh ....... 3,6 .. MJ
1 km/h ....... 0,278 .. m/s
1 mpk/h(solmu) .... 0,514 .. m/s
1 m3/h ....... 0,000278 .. m3/s
1 l/min ....... 0,00167 .. m3/s
1 kcal ....... 1,163 .. Wh
1 kcal/h ....... (1,16) .. W
(1,2)
Nota! Caloría (cal) de Ws
1 kWh = 860 kcal = 3,6 MJ
Page Groupe Date Désignation
Longitud
1 pulgadas = 25,4 mm 1 mm = 0,039 pulgadas
1 pie = 0,3048 m = 304,8 mm 1 cm = 10 mm = 0,39 pulgadas
1 yarda = 0,9144 m = 914,4 mm 1 dm = 10 cm = 3,9 pulgadas
1 milla náutica = 1852 m 1 m = 10 dm = 3,28 pies
1 milla terrester = 1609 m 1 km = 1000 m = 1090 yardas
Area
1 plg cuadrada = 645,2 mm2 1 mm2 = 0,0015 pulgadas cuadrados
1 pie cuadrado = 0,09290 m2 1 cm2= 100 mm2 = 0,15 pies cuadrados
1 yarda cuadrada = 0,8361 m2 1 dm2 = 100 cm2 = 15 pulgadas cuadrado
1 milla cuadrada = 2,590 km2 1 m2 = 100 dm2 = 1,19 yardas cuadrados
= 10,76 pies cuadrados
1 km2 = 1000000 m2
= 0,38 milla cuadrada
Volumen
1 Onza fluida US = 29570 mm3
1 plg cúbica = 0,01639 dm3
1 pie cúbica = 0,02832 m3
1 yarda cúbica = 0,7646 m3
1 cuarta US = 0,9464 dm3
1 galón US = 3,785 dm3
Masa
1 oz = 28,35 g 1 g = 0,0353 oz
1 libra = 0,4536 kg 1 kg = 1000 g = 35,3 oz
1 tonelada corta = 0,9072 t 1 kg = 2,205 libras
1 tonelada larga = 1,016 t
Fuerza
1 ozf = 0,2780 N 1 N = 3,597 ozf
1 lbf = 4,448 N 1 N = 0,2248 lbf
1 kp = 9,807 N 1 N = 0,1020 kp
Page Groupe Date Désignation
Presión
1 pie H2O = 2,989 kPa 1 bar = 100 kPa = 100000 Pa
1 pulgada Hg = 3,386 kPa 1 kPa = 7,5 mmHg
1 pulgada H2O = 0,2941 kPa 1 kPa = 0,33 ft H2O
1 psi = 1 lbf/sq in = 6,895 kPa 1 kPa = 0,29 pulgada Hg
1 kPa = 4,01 pulgada H2O
1 kPa = 0,15 psi
1 kPa = 0,15 lbf/sq in
Energia
1 Btu = 1055 Nm = 1055 J 1 Nm = 1 J = 1 Ws
1 ft–lbf = 1,356 Nm 1 kJ = 1000 Nm = 0,95 Btu
1 kcal = 4187 Nm 1 Nm = 0,74 ft–lbf
1 Wh = 3600 Nm 1 kJ = 0,24 kcal
1 Ws = 1 Nm 1 kJ = 0,00028 Wh
1 kpm = 9,807 Nm 1 Nm = 0,102 kpm
Potencia
1 Btu/hr = 0,2931 W 1 W = 3,412 Btu/hr
1 ft–lbf/s = 1,356 W 1 W = 0,7376 ft–lbf/s
1 hp = 0,746 kW = 746 W 1 kW = 1000 W = 1,341 hp
1 hv = 0,736 kW = 736 W 1 kW = 1000 W = 1,359 hv
Temperatura
°C = 5/9 X (°F–32)
°F = 9/5 X °C+32
K = °C + 273,15
Designacón Fecha Grupe Página
Rev. B 15.11.2000
Designacón Fecha Grupe Página
Rev. B 15.11.2000
Page Groupe Date Désignation
Î Î
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9
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4
6
10 Î Î 2
1
13
7
14
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Rev. B 27.11.2000
Designacón Fecha Grupe Página
Rev. B 27.11.2000
Page Groupe Date Désignation
2 1
4 3
5 6 7 8
Rev. B 27.11.2000
Designacón Fecha Grupe Página
Ä
Ä
X X
B B
X X
10
A B X–X 5 6
1
4
2
3 8 7
Rev. B 27.11.2000
Page Groupe Date Désignation
4 3
2
5
ÅÅ
ÅÅ 1
6
70
Rev. B 27.11.2000
Designacón Fecha Grupe Página
1
3
Rev. B 27.11.2000
Page Groupe Date Désignation
ÅÅÅ
ÀÀ
ÀÀ
ÅÅÅ
ÅÅÅ
Rev. B 27.11.2000
Designacón Fecha Grupe Página
Î
ÎÎ
Î
ÄÎ
Î
PM29
PS29
PM23 PS22
PM26
PM24
PM21
ÅÅ
ÅÅ
PM22
Rev. B 27.11.2000
Page Groupe Date Désignation
Rev. B 27.11.2000
Designacón Fecha Grupe Página
1 Respiradero de la transmisión
2 Llenado aceite de la transmisión / varilla nivel
3 Tapón drenaje aceite de la transmisión
Rev. B 27.11.2000
Page Groupe Date Désignation
00.8. Rodaje
Se puede asegurar una larga vida de la máquina si se evitan grandes cargas y altas veloci-
dades del motor durante las 300 primeras horas de operación. Durante éste tiempo, todas las
superficies finamente maquinadas, alcanzan su suavidad y dureza final.
El motor no deberá, sin embargo, ser operado a bajas velocidades ni estar al ralentí mucho tiempo.
Especialmente observe, durante el período de rodaje, que las temperaturas y presiones del
aceite de la transmisión y del motor son normales. El cambio de aceite durante el rodaje deberá
ser hecho más a menudo que normalmente.
Ver manual del fabricante del motor para instrucciones de rodaje.
Durante el rodaje, deberá prestar especial atención al apriete de tornillos y tuercas, y apretar-
los si fuera necesario.
El rodaje de un motor revisado sigue los mismos principios, pero el período de rodaje es algo más corto.
Además de las instrucciones de la tabla de mantenimiento, se deberán llevar a cabo los si-
guientes mantenimientos durante las primeras 50–150 horas:
Después del mantenimiento inicial siga el esquema del programa de mantenimiento, donde los
intervalos del servicio se basan en las horas de funcionamiento.
Designacón Fecha Grupe Página
Rev. A 08.09.2000
Page Groupe Date Désignation
Intervalo en horas de
ITEM DE MANTENIMIENTO operación Como
poco,
1 vez
al
Dai– 250 500 1000 2000 año
TRANSMISIÓN ly h h h h
EJE MOTRIZ
Rev. C 26.04.2001
Designacón Fecha Grupe Página
Intervalo en horas de
operación Como
ITEM DE MANTENIMIENTO poco,
1 vez
al
Dia- 250 500 1000 2000
EJE DIRECTRIZ rio h h h h año
Intervalo en horas de
operación Como
ITEM DE MANTENIMIENTO poco,
1 vez
al
Dia- 250 500 1000 2000
HIDRÁULICA rio h h h h año
Rev. C 26.04.2001
Page Groupe Date Désignation
Intervalo en horas de
ITEM DE MANTENIMIENTO operación
Como
poco,
Dia- 1 vez
BOOM 50 250 500 1000 al
rio
h h h h añor
1.Lubricar los cojinetes de los cilindros de elevación 1) x
2.Lubricar las piezas deslizantes en el extremo delan-
terodel boom 1)
x
3.Lubricar los cojinetes del boom 1) x
4.Lubricar las superficies deslizantes del boom más interno x
5.Lubricar los rodillos de soporte del boom x
6.Comprobar las almohadillas deslizantes x
1) Lubricación diaria, si no hay lubricación central
Intervalo en horas de
ITEM DE MANTENIMIENTO operación
Como
poco,
p ,
Dia- 1 vez
SPREADER 50 250 500 1000 al
rio
h h h h año
1. Lubricar los cojinetes de los cilindros de pendiente
longit. 2)
x
2) Lubricar los cojinetes de los cilindros de alargar 2) x
3. Lubricar los apoyos de oscilación del dispositivo
de giro 2)
x
4. Lubricar el cojinete del dispositivo de giro 2) x
5. Lubricar los planos deslizantes x
6. Lubrique los cojinetes del soporte x
7. Lubricar el borde del engranaje x
8. Lubricar Bloqueos de la torcedura x
9. Lubricar los cojinetes del cilindro de giro del blo-
queo de la torcedura
x
10. Sustituir filtros aceite transmisión x
11. Cambiar el aceite a la transmisión de giro x
12. Comprobar las almohadillas deslizantes x
Rev. C 26.04.2001
Designacón Fecha Grupe Página
Intervalo en horas de
ITEM DE MANTENIMIENTO operación
Como
poco,
p ,
Dia- 1 vez
SPREADER 50 250 500 1000 al
rio
h h h h año
13. Comprobar estado twist–lock 3) x
2) Punto de lubricación central (equipo opcional)
3) La primera vez, después de 5.000 horas de trabajo o 2 años, lo primero que ocurra.
Intervalo en horas de
ITEM DE MANTENIMIENTO operación
Como
poco,
1 vez
Dia- 250 500 1000 2000 al
OTROS rio h h h h año
Rev. C 26.04.2001
Page Groupe Date Désignation
00.10. Notes:
01 UNIDAD DE POTENCIA
1 2
1. Motor
2. Transmisión y convertidor de par
Page Groupe Date Désignation
A
C
B
45 Nm
(33 lbf.ft)
A = Motor B = Transmisión
Si los discos de tensión que conectan la transmisión y el motor, punto 1, deben cambiarse,
compruebe, montando, que los nuevos discos son válidos. Deben estar pegados contra las
superficies del motor y la transmisión. Si no, extraiga con piedra de amolar el filo agudo de la
abertura del disco.
Cara de junta de bastidores de volante del motor (C) SAE J617 N:o 3
Rev. A 13.06.2000
Description Date Group Page
01.2. Motor
Desde refrigera-
dor de aceite
Presión
Embrague lubricante
Válvula de
trasero control
Puerto presión
4º embrague
Filtros de aceite
1 st
2 nd
3 rd
4 th
Designacón Fecha Grupe Página
Válvula de seguri-
dad convertidor de
par
Punto medida
presión principal
Válvula reguladora
de presión
Page Groupe Date Désignation
Compruebe todas las uniones de la palanca de control para su correcta instalación y coloca-
ción en todos los puntos.
Antes de comprobar las presión de aceite y los fluidos de la transmisión hidráulica y del conver-
tidor de par, es necesario comprobar el nivel de aceite.
Cuando compruebe las presiones, mantenga la velocidad del motor a 33 r/s (2000 rpm), y
asegúrese que la palanca de cambios está en punto muerto.
Presiones de embrague: Normalmente 17 a 19 bar (240–280 psi).
La desviación permitida en todas las presiones de embrague en las mismas condi-
ciones, es de 0,34 bar (4 psi). El freno de aparcamiento debe estar conectado cuando
se midan las presiones.
Presión de salida del convertidor de par:
Min 1,7 bar (25 PSI) / 2000 RPM
Max 4,9 bar (70 PSI) / unloaded at max . speed
Las líneas de salida de los convertidores fluyen a 90 l./min (24 USgal/min).
Para puntos de medición, ver ilustraciones en éste grupo.
Designacón Fecha Grupe Página
12/24 Volt
Page Groupe Date Désignation
FP FWD
3RD
3P
FC 2ND
2C
2P
ST
RC 1P
RP REV
Grado 5
Tamaño
Tamaño- Nm (kpm) (lbf.ft)
rosca Rosca paso pequeño Rosca paso grande
3/8” 35–39 (3,6–4,0) (26–29) 31–34 (3,2–3,5) (23–25)
Grado 8
Tamaño
Tamaño- Nm (kpm) (lbf.ft)
rosca Rosca paso pequeño Rosca paso grande
3/8” 50–55 (5,1–5,7) (37–41) 45–49 (4,6–5,0) (34–36)
01.5.1. Comprobación
Seleccionar la dirección de marcha hacia adelante y poner la velocidad más alta. Mantener
el pedal del freno pisado y aumentar todo lo que se pueda las revoluciones del motor.
Comparar este valor con la velocidad STALL de la máquina.
01.6. Notes:
02 TRANSMISIÓN DE FUERZA
5 2
3 4
1. Motor
2. Transmisión y convertidor de par
3. Eje cardan y freno de disco cargado–muelle como freno de aparcamiento
4. Eje motriz con diferencial, eje motriz y engranajes planetarios en ambos extremos del eje
5. Bombas hidráulicas
Page Groupe Date Désignation
La carcasa del conjunto del eje motriz montado rígidamente al bastidor de la máquina, es de
construcción de acero colado robusto. En los extremos del eje motor están los engranajes
planetarios y los cubos. En los cubos están montados frenos de disco húmedo, libres de man-
tenimiento.
En una máquina nueva y/o renovada, el aceite para el diferencial o para la unidad engranaje
planetario debe cambiarse por primera vez a las 150 horas de trabajo y, después de ésto, regu-
larmente a intervalos de 1.200 horas de operación, y como poco dos veces al año.
2250 Nm
A B 3
1
2
4
02.2.3.
planetario retorno pistón Carcasa del freno
Piñón
Guía muelle retorno
Tapa carcasa freno
Pasador Tapón
Núcleo Conector
Transmisión de fuerza
Designacón
Tuerca y perno de piñón
Tapón
Anillo de bloqueo
Tornillo de fijación
00–02–15 KH02–0104
Fecha
Junta tórica
Tapón
Tornillo
Grupe
Junta tórica
Aros pistón Tornillo tapa
Disco estacionario
Juntas Disco de fricción
Carcasa separador disco estacionario
Página
3/20
Page Groupe Date Désignation
2
3
NÚM PAR
DESCRIPCIÓN TAMAÑO
ERO Lbf.ft Nm
Tornillo tapa a anillo 7/16” – 14 60–75 82–102
1
planetario 1/2” – 13 85–115 116–156
Bulón muelle retorno
2 – 61–75 81–102
pistón
Tornillo tapa y anillo 5/8” – 11 180–230 244–312
a carcasa eje–mon- 3/4” – 10 310–400 450–542
taje interior 7/8” – 9 500–650 678–881
3
7/8” – 14 500–650 678–881
1” – 12 725–950 938–1288
1–1/4” – 12 1700–2200 2305–2983
Tornillo tapa y anillo
M16 x 2.00 199–258 270–350
4 a carcasa eje–mon-
M20 x 2.50 369–479 500–650
taje exterior
Tornillo anillo plane- 3/8” – 16 35–50 48–68
5 tario a núcleo de 1/2” – 13 85–115 116–156
rueda 3/4” – 10 310–400 450–542
Tornillo de chapa
3/8” – 16 35–50 48–68
6 bloqueo tuerca de
7/16” – 14 60–75 81–102
ajuste de cojinete
Tornillo de tapa a 9/16” – 12 125–165 169–224
7 carcasa de freno M16 x 2.00 199–258 270–350
M20 x 2.50 369–479 500–650
Designacón Fecha Grupe Página
1 2
3
4 5
9
11
12 6
10
7
9 8
Torque
No: Descripción
Lbf.ft Nm
1 Purga hidráulica 15–20 20–27
2 Tapón 10 min. 14 min.
3 Tapón cubierta carcasa 20 min. 27 min.
Tapón nivel/llenado de refrigerante
4 35 min. 47 min.
– Sólo colector refrigerante
5 Tapón 10 min. 14 min.
Adaptador entrada fluido hidráulico
6 25–31 34–47
– Asiento cónico
Adaptador entrada fluido hidráulico
7 25–35 34–47
– Anillo tórico
Tapones drenaje magnético
8 20 min. 27 min.
– Sistema refrigeración
Tapones puerto entrada y salida de
9 60–75 81–102
refrigerante
10 Entrada fluido hidráulico 25–35 34–47
11 Tapón 10 min. 14 min.
12 Coolant output port plugs 60–75 81–102
Note! Se tardan diez minutos más en retirar el aire de la cubierta del freno que mediante los
frenos normales. Esto es debido a la gran capacidad de la cubierta.
Page Groupe Date Désignation
6. Apriete la tuerca eje al pre–par 1355–1630 Nm (1000–1200 lbf.ft), de manera que los coji-
netes estén sin tolerancia en el núcleo de la rueda.
7. Gire el cubo 5–10 vueltas en ambos sentidos.
8. Abra la tuerca eje media vuelta y gire el núcleo 3–5 vueltas en ambos sentidos.
9. TApriete la tuerca eje al par 745–815 Nm (550–600 lbf.ft).
10. Gire el núcleo 5–6 vueltas y compruebe el valor del par. Apriete si es necesario.
11. Bloquee la tuerca eje con el disco de bloqueo.
12. Si no puede apretar el disco, apriete la tuerca eje hasta que sea posible el montaje del
disco de bloqueo.
Page Groupe Date Désignation
Desmontar los rodamientos del eje piñón. Mida el espesor de los separadores colocados
entre las caras, y compruebe el extremo del eje piñón por el número estampado en él. Si el
número es entero, el valor está definido como milésimas de una pulgada, y si el número es
un decimal, el valor está definido como centésimas de un milímetro.
Por ejemplo, +3 o –3 = .003” y +.03 o –.03 = .03 mm.
Calcule el espesor separador nominal según los siguientes ejemplos. Tome el valor del
número estampado en el eje piñón y añádalo al espesor del separador antiguo. Las suma
es el espesor del nuevo separador cuando instale los rodamientos de un nuevo eje piñón.
Ejemplos para calcular el espesor del separador entre los rodamientos del eje piñón:
Example 1: Tespesor del separador antiguo 0,76 mm (0.030”)
Nº estampado en el viejo eje piñón: –2 –0,05 mm (0.002”)
Espesor separador nominal 0,71 mm (0.028”)
Nº estampado en el nuevo eje piñón: +5 +0,13 mm (0.005”)
Espesor del nuevo separador 0,84 mm (0.033”)
F F Fuerza
A Manguito
A
1 Flange bar
Valores par :
Tamaño rosca Valor par
7/8” – 20 271 – 373 Nm
1” – 20 407 – 542 Nm
1 1/4” – 12 949– 1220 Nm
1 1/4” – 18 949 – 1220 Nm
1 1/2” – 12 1085 – 1491 Nm
1 1/2” – 18 1085 – 1491 Nm
1 3/4” – 12 1220 – 1627 Nm
2” – 12 1627 – 2034 Nm
Page Groupe Date Désignation
1 Anillo de ajuste
Utilice el anillo de ajuste para fijar la resistencia a la rodadura de los rodamientos del difer-
encial a 1.7–3.9 Nm (1.3–3.0 lbf.ft).
Ajuste la tolerancia lateral entre el piñón y la corona dentada a 0.20–0.46 mm
(0.008”–0.018”) con un par de ruedas usadas, y a 0.30 mm. (0.012”) con un par de ruedas
nuevas.
Designacón Fecha Grupe Página
1290 Nm
Instale los ejes de pivote y las cajas de cojinete en posición. Asegure los tornillos de retención
(10) de los ejes con fijaciones de tornillo.
Lubrique las cabezas de los ejes (X) con grasa.
Instale los ejes en posición, pero no apriete los tornillos de sujeción (6).
Apriete los ejes contra la placa negra utilizando un tornillo de sujeción (4).
¡Asegúrese de que los ejes queden debidamente instalados en posición y que no tengan
juego!
Apriete los tornillos de sujeción (6) de las cajas de cojinete a una torsión de 1290 Nm (950
lbf.ft).
Finalmente, abra el tornillo de sujeción (4) 1/4 de vuelta y fíjelo con una tuerca (7).
A
6
1290 Nm
(950 lbf.ft)
10 10
4 7
X
X
A A
El apriete y lubricación del cubo de rueda se debe llevar a cabo de acuerdo con los intervalos
de la tabla de mantenimiento.
D
A
E
B
C
Medir la resistencia continua de rodado, cuyo valor nominal es 30–50 Nm (22 – 37 libras/pie).
Si la resistencia de rodado medida es distinta del valor nominal, quitar la tapa protectora del
núcleo de la rueda y variar el apriete de la tuerca de ajuste del cojinete hasta que la resistencia
continua de rodado del mismo se corresponda con el valor mencionado.
Comprobar, montando la placa de bloqueo entre las tuercas de ajuste y bloqueo, que
la rodadura qu se introduce en el chavetero del eje evita la rotación de la placa de bloqueo
sobre el eje. Lubricar ambos lados de la placa de bloqueo con grasa.
Fije la tuerca de los rodamientos a 1000 Nm (740 lbs / ft )
After tighten check that the continuous rolling resistance of wheel hub is
not more than 50 Nm ( 37 lbs / ft ).
Sitúe el borde de la placa de cierre sobre el borde de la tuerca de ajuste y tuerca de cierre y
vuelva a realizar el montaje de la tapa protectora del rodamiento.
Lubrique el rodamiento de la rueda bombeando a través del engrasador, la grasa nueva re-
comendada.
Page Groupe Date Désignation
En máquinas sin la lubricación central opcional, los puntos de lubricación se deben lubricar
manualmente, según los intervalos de la tabla de lubricación de éste manual.
Bombee a través de los engrasadores, mostrados en la figura inferior, la suficiente grasa a los
puntos de lubricación.
2
3
4
5
Rev. A 26.06.2000
Page Groupe Date Désignation
02.4. Ruedas
Las ruedas en el eje de transmisión y dirección son idénticas e intercambiables. El eje de trans-
misión está dotado con ruedas dobles.
A B
A 305 Nm B 380 Nm
El intervalo para la comprobación de la presión de los neumáticos y el par motor de las tuercas
es de 200 horas de funcionamiento.
Designacón Fecha Grupe Página
Durante un plazo de operación largo, las llantas pueden llegar a tener pequeñas grietas y
roturas. Esto puede estar causado por las siguientes razones:
S Algunas ruedas han estado vacías o la presión de las mismas estaba demasiado
baja mientras la máquina estaba cargada.
S La presión de las ruedas difiere del valor base.
S No se han usado ruedas de repuesto genuinas después de la primera instalación.
El material y resistencia de ruedas de repuesto no genuinas puede no cumplir con
los requerimientos de las máquinas pesadas.
S Deformación de la llanta causada por golpes externos.
Medidas a tomar:
Recomendamos comprobaciones anuales de grietas usando un test de partículas magnéticas
(SFS 3286 o DIN 54131).
Esto se puede llevar a cabo durante el trabajo de la rueda, una llanta después de otra. Las
llantas que han sido comprobadas se pueden reconocer fácilmente si Ud. marca la llanta
comprobada con un color, que se cambiará cada año.
Es absolutamente necesario que siempre antes del trabajo con una rueda,
la presión se elimine o se reduzca a 1 bar (15PSI).
Page Groupe Date Désignation
Procedimiento de comprobación
02.5. Notes:
03 SISTEMA HIDRÁULICO
03.1.3.1. General
Unas válvulas proporcionales controlan el telescopio y la elevación de la pluma que, a su vez,
supervisan las unidades principales de la válvula del sensor de carga. La presión de la pluma
viene determinada por la presión de motriz/dirección (carga) que es 20 bars más elevada que
la presión del cilindro. La velocidad de marcha del telescopio y de la elevación se ajustarán
una vez haya comenzado la fase de cambio de la velocidad de marcha del motor diesel. El
movimiento simultáneo del telescopio y de la elevación de la pluma, la elevación vertical, se
puede realizar ajustando las válvulas, reduciendo ligeramente el más mínimo movimiento
(palanca de movimiento cruzado del control de la pluma).
Las válvulas de comprobación principales (V1, V2) están equipadas con válvulas de circula-
ción libre en los bloques entrantes y con la escala de presión, que ajustan la presión de bom-
beo en función de las señales de carga que emiten las guías de la copia.
Elevación acelerada
Cuando la presión de elevación cilindro de elevación es inferior a los 90 bars (23.1), la válvula
solenoide Y88 (76) se cierra y dirige el bombeo del control a la válvula de elevación. Al mismo
tiempo, la válvula solenoide Y87 (77) dirige el bombeo de la elevación superior al cilindro de
elevación y, a continuación, también se activa el solenoide válvula solenoide de libre circula-
ción Y56 (85).
Los cilindros de la pluma están equipados con válvulas de fijación (8.1 y 8.2),los troncos princi-
pales serán abiertos por las válvulas Y67 y Y68 durante la reducción. La válvula de choque
de 280 bars evita la sobrecarga de los cilindros. La reducción de la pluma se basa en el peso
de la pluma y en la carga, de forma que el bombeo no será necesario durante la reducción
Rev. A 05.03.2001
Designacón Fecha Grupe Página
Al utilizar la dirección, 1/5 del flujo del volumen de bombeo se dirige a la válvula de dirección
Orbitrol (42), montada en el volante de dirección utilizando la válvula de prioridad en la válvula
reguladora de flujo OSQ (82), y 4/5 se dirigen a la guía de la válvula reguladora de flujo. Si no
se utiliza la dirección, el flujo del volumen se dirige desde la válvula de prioridad al depósito
o a la elevación acelerada.
La velocidad de dirección viene determinada por la velocidad de giro del volante. A altas veloci-
dades, la válvula de prioridad envía un flujo más fuerte a la guía de la válvula reguladora de
flujo OQS a los cilindros de dirección (1).
El sistema se denomina sistema de sensores de carga, la señal de presión se emite desde
el tubo LS a la válvula de prioridad (82), con lo que se ajusta la presión de bombeo de la direc-
ción a unos 7 bars más que la presión de giro.
El circuito de dirección está equipado con válvulas de choque para el control de sobrecarga
y están montadas en la válvula reguladora de flujo OSQ (82).
03.1.5.1. General
Las válvulas solenoides realizan los movimientos de la tapa del tacón, algunos de los cuales
están montados en la parte superior de la pluma y algunos en la tapa del tacón.
La presión aplicada en el extremo superior de la pluma se dirige a través de un tubo de presión
adicional desde la bomba de la tapa del tacón (21) cerrando la circulación libre desde la válvula
Y56 (85), que siempre está activada, cuando uno de los movimientos de la tapa del tacón está
en funcionamiento.
El aceite de retorno al depósito fluye a través de un tubo extra del depósito. En este tubo se
ha montado una válvula de no retorno de 5 bars para evitar el drenaje de los cilindros de prolon-
gación y para mantener el borde trasero de la tapa del tacón siempre en una posición inferior
al borde delantero.
Rev. A 05.03.2001
Page Groupe Date Désignation
03.1.5.3. Rotation
La válvula reguladora Y59 es proporcional y hace posible el ajuste continuo de la velocidad
de rotación.
El circuito de rotación está equipado con una válvula de choque de 125 bars (10.1), que limita
el momento de rotación al valor máximo específico y determina, por otra parte, el retardo
máximo mediante la detención, a fin de evitar la sobrecarga de los dispositivos de rotación.
El motor de rotación es un lento motor hidráulico montado en la reductora. Entre el motor y
la transmisión existe un freno de compresor plano. La válvula de comprobación del regulador
abre automáticamente el freno (17) y se cerrará una vez se haya detenido el movimiento de
rotación.
03.1.5.5. Transferencia
Controlada por la válvula solenoide Y62. Los reguladores fijos (38) ajustan la velocidad de
movimiento y el circuito está equipado con válvulas de choque (8).
Rev. A 05.03.2001
Designacón Fecha Grupe Página
IMPORTANTE!
Se houver a mínima dúvida sobre a pureza do fluido hidráulico – envie uma
amostra do fluido ao fabricante do fluido.
Designacón Fecha Grupe Página
¡IMPORTANTE!
Cuando ajuste la cabeza del cilindro: Fije la cabeza en forma totalmente recta,
preferiblemente a mano.No la golpee, bajo ninguna circunstancia, con un mazo
o martillo.Si la cabeza del cilindro se fija torcida, el reborde del sello de la barra
del pistón puede estar dañado o cualquier función de sellado se perderá.Esto
se aplica a todos los tipos de sellos de barra de pistón.
Designacón Fecha Grupe Página
Y12 PS22
PM26 36 PM29
PM23 13.1
PS29
PM24
PM21 13.2
S13
13.3
PM22
14
A B
10
A Eje de transmisión
B Eje de dirección
10 Filtro de presión
14 Bomba
36 Válvula de ajuste de presión (freno del eje de dirección, opcional)
13.1–13.3 Acumuladores de presión
PM21 Medición de la presión
PM22 Medición de la presión
PM23 Medición de la presión
PM24 Medición de la presión
PM26 Medición de la presión
PM29 Medición de la presión (freno del eje de dirección, opcional)
PS22 Ajuste de la presión
PS29 Ajuste de la presión (freno del eje de dirección, opcional)
S13 Interruptor
Y12 Válvula del freno de raspar
La numeración corresponde al gráfico de flujo hidráulico del freno.
Designacón Fecha Grupe Página
Y12 PS22
36 PM29
PM26
PM23
PS29
PM24
S13
PM21
PM22
S52
2,S23
1
4
2
3
5
1 4
3
5
1 Tornillo de ajuste
2 2.Tornillo de desconexión del freno de aparcamiento
3 Disco de freno
4 Pastilla de freno
5 Tornillo de bloqueo
Ajuste el tornillo de ajuste 1 con una llave de gancho y cierre hasta que las pastillas de freno
(4) toquen el disco del freno (3). Después de ésto, abra el tornillo de ajuste 1, ajustándolo a
1,5 vueltas. Desconecte el freno de aparcamiento (presión en cilindro) presionando el interrup-
tor de operación y entonces abra la tuerca 5 (fig. 2), terminando el trabajo de ajuste.
Page Groupe Date Désignation
M28X1.5
SW6
1 17
5
2
8
1/2”
6
12 11
3 W24.32x1/13”
13 14
SW36
15
9
4
16 M28X1.5
1 Acumuladores de diafragma
2 Anillo de cierre
3 Diafragma
4 Válvula de cierre
5 Tornillo de cierre
6 Válvula de purga
8 Pieza intermedia
9 Anillo tórico
11 Válvula de no retorno
12 Conexión a botella nitrógeno
13 Manguera alta presión
14 Manómetro
15 Tornillo de cierre
16 Acumuladores de diafragma
17 Dispositivo de llenado para acumuladores de diafragma
Designacón Fecha Grupe Página
Los ajustes y mantenimiento del sistema de freno deben prestar especial atención a las
condiciones de operación de los acumuladores de presión. Si el acumulador de presión
común de todo el sistema se daña, ésto se detecta por la frecuente operación de la válvula
de carga y un rápido declive del efecto de frenado cuando se para el motor. Para asegurar
una operación correcta del sistema de frenos, los acumuladores de presión se deben com-
probar como poco dos veces al año. El acumulador usado en el sistema de frenos es
un acumulador de diafragma pre–cargado con un diafragma no reemplazable. La presión
de pre–carga de los acumuladores de presión del sistema de frenos es de 100 bar. Una
medición exacta de la presión de pre–carga y un posible incremento con gas nitrógeno,
se describe más adelante en éste manual en el grupo del sistema de frenos.
Compruebe la presión de pre–carga desde el ”lado aceite” como sigue:
1. Instale un manómetro de presión en el punto de medición de presión PM22.
2. Arranque el motor y córralo al ralentí un rato para incrementar la lectura de presión a 150
bar. Pare el motor.
3. Conecte el freno de aparcamiento. Si el manómetro de presión muestra una lectura en el
punto de medición PM22 todavía después de varias conexiones del freno de aparcamien-
to, los diagramas del acumulador, planos 13.2, 13.4, están correctos.
4. Para comprobar los acumuladores de presión después de las válvulas de no retorno:
Instale un manómetro de presión en el punto de medición PM24 y entonces al PM23 si
el Reach Stacker está equipado con frenos en el eje directriz. Presione el pedal del freno
varias veces mientras observa la lectura del manómetro de presión. La presión cae cuan-
do los frenos están aplicados, la presión cae rápidamente casi hasta 0. Esta lectura de
presión antes de ésta súbita caída es la presión de pre–carga del acumulador que se debe
comprobar.
Page Groupe Date Désignation
Los acumuladores de diafragma están pre–cargado con gas nitrógeno a la presión de pre–car-
ga requerida antes de su instalación. La presión de pre–carga para cada acumulador está es-
pecificada en la tabla de flujos en los manuales de operación y mantenimiento de la máquina.
Las presiones de pre–carga especificadas por el fabricante deben ser absolutamente obser-
vadas.
03.3.3.1. Llenado
Al medir el acumulador hidráulico asaegúrese que no hay presión en el sistema. El aceite debe
fluir libre fuera del acumulador hidráulico. Si no fluye libremente, la presión de llenado será muy
baja. Vaciado de presión en sistema hidráulico bombee el pedal de freno varias veces
Se utiliza un dispositivo de llenado para pre–cargar los acumuladores de presión y para com-
probar la presión de pre–carga. En primer lugar, extraiga el tapón y el cierre de laca del tornillo
de cierre. Limpie la superficie del cierre en el extremo del acumulador y la rosca externa y afloje
un poco el tornillo de desconexión con una llave allen.
Conecte el dispositivo de llenado al acumulador de presión y la manguera a una botella de gas
nitrógeno. Asegúrese que el anillo tórico está correctamente posicionado entre el dispositivo
de llenado y la superficie del cierre del acumulador. Utilizando una llave cuadrada, abra el tor-
nillo de desconexión del acumulador de presión con la ayuda de la pieza intermedia del dispo-
sitivo de llenado. Abra justo lo suficiente para conseguir la lectura de la presión de pre–carga
en el manómetro de presión.
03.3.3.2. Nota !
Como la presión de pre–carga cambia con la temperatura, compruebe de nueve la presión de
pre–carga del acumulador aproximadamente 2 min. después del llenado. Corrija las posibles
desviaciones sobre el valor especificado.
Apriete el tornillo de desconexión del acumulador de presión a 25 Nm. y cierre la válvula de
la botella de gas nitrógeno. Abra la válvula de purga del dispositivo de llenado para permitir
que salga el gas del dispositivo de llenado.
Extraiga el dispositivo de llenado y compruebe la estanqueidad de la válvula de desconexión
utilizando, por ejemplo, jabón líquido. Repare las posibles fugas inmediatamente ya que pue-
den causar daño al diafragma del acumulador de presión. Selle la válvula de desconexión con
sello de laca e instale el tapón del tornillo de desconexión. El acumulador de presión está listo
para instalarse.
Rev. A 03.05.2000
Designacón Fecha Grupe Página
El manguito rotativo desconecta el flujo de aceite a la bomba medidora, donde el rotor ha gira-
do la misma cantidad que el volante. Por lo tanto, la cantidad de aceite correspondiente al giro
del volante puede ser determinada con precisión. La dirección responde a un giro pequeño
(relativo) del volante, correspondiente a 2º del final desde el manguito rotativo de giro.
Cuando este giro es 6º como término medio, la válvula está completamente abierta. El giro de
los manguitos rotativos se restringe mecánicamente en ambas direcciones a un término medio
de 8º desde la posición media. El retorno de aceite desde los cilindros de dirección es dirigido
de vuelta al tanque.
Page Groupe Date Désignation
B A
1. Dirección lenta
a) Válvula de sobrepresión o bola del dispositivo de dirección parcialmente abierto a causa
de la suciedad y causante de un constante bypass de flujo de aceite.
b) Manguera de presión apretada restringiendo el flujo de aceite.
V1 V2
69
FS69
V1 V2
Y88
Y58a Y52a Y57a Y51a 82
Pm5
Pm2
Y52b Y57b Y51b
Y58b
Pm1
X
22 1
Y87 Pm4
X
24
40.1
85
21
20
69 70
Designacón Fecha Grupe Página
03.5.1. Bombas
40.1
21 20
40.2
V2 V1
20 Bomba
21 Bomba
40.1 Válvula sin retorno
40.2 Válvula sin retorno
V1 Válvula principal
V2 Válvula principal
Designacón Fecha Grupe Página
S97A,S97B 1
2
5
4
3 Obturar el tubo (A) por el lado de presión de la bomba y llenar el depósito (2,8l) por el
tapón de llenado (5) .
4 Mover la cabina hacia adelante y hacia atrás 1–2 veces y comprobar la cantidad
de aceite.
60 60
120
Rev. C 18.12.2000
Designacón Fecha Grupe Página
32.2
4.2 4.3 4.4
33.1 33.2
32.1 3.2
4.1
8
2.2
A 1.1
3.1
A K5687320
Rev. A 19.01.2001
Page Groupe Date Désignation
4.4
4.2
4.3
33.2
PM41
PM33
Rev. A 19.01.2001
Designacón Fecha Grupe Página
03.8. Notes:
04 SISTEMA ELÉCTRICO
04.1.1. Seguridad
El material aislante del conductor es resistente al aceite. El cableado no debe, sin embargo,
estar en contacto con otros aceite u otros fluidos disolventes.
Cerca del motor y de otros componentes calientes, se deberá prestar especial atención para
evitar que el calor dañe el aislante del cableado. Cables con aislantes dañados se deben cam-
biar inmediatamente para evitar cortocircuitos y peligro de incendio.
La fusión de un fusible indica siempre un fallo en el sistema eléctrico. Repare el fallo antes de
colocar un nuevo fusible.
04.2.1. Baterías
04.2.2. Alternator
04.2.2.1. Advertencias
S Cuando conecte la batería, asegúrese que la batería y el alternador estén conectados al
bastidor con terminales de la misma polaridad.
S Si la máquina está equipada con un interruptor principal, puede no abrirse cuando el mo-
tor esté en marcha.
S Al reparar el vehículo mediante soldadura eléctrica, todos los terminales del alternador
y regulador deben de ser desconectados
Si el fallo está en el motor de arranque o en circuitos del alternador, desconecte el cable nega-
tivo entre la batería y el bastidor mientras lleva a cabo las reparaciones.
Î
S10–R4
G1
Î ÎÎ
ÎÎ ÎÎ
R7
ÎÎ
Î ÎÎ
Î
B1
ÎÎ
S11–R6
B1
Î ÎÎ
Î
B2 B2 R9
ÎÎ
Î ÎÎ
R4 S9
Y6 S9
K2
R5
S12
X81
R7
ÎÎ
ÎÎ
Y3
ÎÎ
Î Î
Y5 R5 S10
M1 Y2
Y1
Y4
ÎÎ ÎÎ
R6 S11
S11
R9
ÎÎ
ÎÎ
R6
S12
S12 R7 B1
Y1–Y5
X81
Rev. A 25.04.2000
Page Groupe Date Désignation
El sistema de control de sobrecarga consta de una galga de tensión en el eje directriz, una unidad
central y un indicador analógico. En la operación, se mide la carga del eje motriz y éste resultado es
verificado por la alarma automática pre–fijada y valores de corte mediante la unidad central. En situa-
ción de carga máxima, la carga del eje directriz alcanza su valor mínimo.
Con una carga superior al 90%, se enciende una luz continua y suena una alarma, hasta que la carga
esté por debajo del 90% del valor de carga máximo. Si la carga es del 100%, el sistema de control
de sobrecarga permite sólo la función de retracción telescópica de la pluma. Cuando la carga está
por debajo del 100%, las funciones bloqueadas de la pluma se desbloquearán.
Está instalado un indicador analógico en el panel de instrumentos, en la cabina, con las siguientes
indicaciones:
W1 R3 R4
R7
R8
R9
W2
TP 1 LIMIT 1
TP 6 +12V W3
R14 R15
W4
TP 5 +
– 0V TP 2 LIMIT 2
TP 7 +4V
POWER ON LED TP 8 –4V
TP 9 IN 2
500 mA
Ajuste de la amplificación
S Eleve el 70–80% de la carga comparado con la máxima carga, a 1/2 metro del suelo. Ex-
traiga el telescopio lentamente hasta que se reduzca mucho la carga del eje directriz, de
manera que las ruedas directrices empiecen a despegar del suelo.
S Ajuste, mediante el corrector R14, el voltaje, midiendo en el punto de voltaje TP11 a
+2,0V.
S Si el display gira en dirección negativa, cambie los cables sensores VERDE y AMARILLO
y repita el punto 1, calibración del amplificador.
S Baje la carga.
Fijación del límite 2 (100% carga, sólo función telescopio fuera en operación)
S Ajuste el voltaje en el punto de test TP2 a +1,65V, mediante el corrector R8.
El propósito de la unidad de control para la velocidad de marcha y velocidad del motor cuando
se cambia la dirección de marcha es para prevenir impactos en la transmisión y facilitar los
automatismos de cambio de marchas. La unidad de control está montada sobre un panel en
la cabina.
A Iniciador de impulsos
0,5....0,7 mm
B Sensor de impulsos:
B
Si se tiene que sustituir la unidad de control, tarar los ajustes especificados para velocidad del
motor y velocidad de marcha con el interruptor de la unidad de control en el panel del circuito.
Las posiciones del interruptor aparecen en el diagrama
Page Groupe Date Désignation
1
F71–F76
1 Tarjeta circuitos
2 Module del control
F71–F76 Fusible
Rev. B 13.03.2001
Designacón Fecha Grupe Página
1601
1602
1600
1603
1604
681
650
766
700
446
CAN Shield
CAN HIGH
CAN LOW
+24V out
PRO8
DO10
GND
GND
GND
GND
GND
VCC
VCC
DI12
DO9
DO8
DI11
DI3
DI6
DI5
DI4
12 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
1 PRO7 443
689 DI1 9 X3 X4 X5 GND
678 8 2
DI2 3 PRO6 433
478 +24Vout 7 PRO5
4 439
GND 6 5 DO7 898
673 DI7 5 X1 X6 DO6
862 DI8 4 6 606
7 GND
4780 DI9 3 DO5
2 8 945
32 DI10 A81 9 DO4 944
AI8 1 PRO4
AI7 9 1 442
2 GND
836 AI6 8 3 PRO3 834
833 AI5 7 4 DO3
AI4 6 861
434 X7 5 PRO2 441
419 AI3 5 X2 6 DO2
879 AGND 4 GND 607
3 7
435 AI2 8 PRO1 837
431 AI1 2 DO1
1 9 609
421 Ref out
71.2
Rev A 30.08.2001
Page Groupe Date Désignation
Rev A 30.08.2001
Designacón Fecha Grupe Página
Rev A 30.08.2001
Page Groupe Date Désignation
04.6. Notes:
05 CABINA
PX3 TX3
Optional
9 7 9 7
3 1
K52 K50 K48 3 1
X48
RK–5.1
X47 X46
7
1
9 PX2 7 9 TX2 7
3
T5653510
3 1 3 1
9 PX1 7 9 TX1 7
D59
D58
D57
D56
D55
D54
D53
3 1 3 1
D62
D61
F50
C50
C49
–
D51
D52
XR1
3
1
1
1
7
RK–5 K5204350
9
X21
LCU F12
1
F36
X13 K21 K25 F35
3
F34
F33
RSV F32
F11 K20 K24
1
F31 X22
X12 F30
3
9
3
F29
K19 K23
F28
1
7
1
F27 X23
F26
3
F23
+
K15
–
X11
1
1
7
F4,F5
Page Groupe Date Désignation
+24V
V40
L3
R19
LED61
A
X30
LED62
R20
V39
9 7 9 7
3 1 3 1
RK–5.1
1
7
1
7
1
9 7 9 7
3
9
3
9
3
T5653510
3 1 3 1
9 7 9 7
D59
D57
D56
D55
D54
3 1 3 1
D60
D58
D53
D62
D62
D61
X19 X20
C50
C49
–
+
D51
3
3
9
D52
1
7
1
7
1
1
1
7
1
7
3
9
3
9
3
K14 X30 A RK–5 K5204350
9
X21
1
7
H13 X21
3
9
3
7
X21
9
3
1
1
7
7
F36
K25
9
F35
7
+
F34
3
9
–
F33
1
1
7
A Tester
D61 Luz verde
D62 Luz roja
V39 Diodo
V40 Diodo
R19 Resistor
R20 Resistor
En el conector X30 de la tarjeta de circuito está un comprobador para verificar la condición del
suministro y líneas de tierra y equipos eléctricos del panel de control. Activar la corriente me-
diante la tecla de encendido antes de iniciar la comprobación.
05.1.2.1. Comprobando la línea de suministro
Toque con el comprobador una línea en la cual el voltaje esté de acuerdo con el diagrama de
cableado sobre 18V. La luz roja (LED V62) indica que la línea de suministro desde el acumula-
dor hasta el punto de comprobación están en condición.
En la unidad de dirección eléctrica y el sistema EHC están algunos circuitos con voltaje por
debajo de 18V. Midiendo estos circuitos la luz roja no indica la condición de los circuitos. La
condición de este tipo de circuitos debe ser medida por medio del voltímetro.
05.1.2.2. Comprobando la línea de tierra
Toque con el comprobador la línea que de acuerdo con el diagrama de cableado está en con-
exión con el armazón de la máquina. La luz verde (LED V61) se enciende en la tarjeta de circui-
tos si la línea de tierra desde el acumulador al punto de comprobación está en condición.
H
A
C
1
8
F41 F42 F43 F44 F45 F46 F47 F48
X31 XRMH1 XN
K8 K9
X32 XRMH2
X34 OLI3
12V
X35 X105
X37 X113 2
X44 S2X
Shiftronic
XR2/XR5 XR3/XR4
XKJT XR8
1
KISKO
05.2.1. General
A311 2
Y150
La tarjeta electrónica en la unidad pedal tiene, bajo la cubierta de goma del pedal, un display
digital.
Compruebe el código del display que muestra, por una posible disfunción del sistema de con-
trol de la velocidad del motor, la causa de la disfunción de la unidad pedal.
Si el display no muestra ningún código, la unidad pedal está trabajando en condiciones.
12 significa disfunción en el potenciómetro del pedal. Cambie la unidad pedal para corregir la
disfunción.
Designacón Fecha Grupe Página
1 2
U C O
• Extraiga la cubierta de caucho del pedal y el tornillo junto al display. El tornillo cubre el inter-
ruptor de programación.
• Active la alimentación, el display (1) visualiza rápidamente 88.
• Pulse una vez el interruptor (2) con un alfiler o la punta de un bolígrafo, el display (1) visualiza
rápidamente A1 y después de esto se debe visualizar U0–U2. Si no es así, ajuste el potencio-
metro (4) debajo del pedal hasta que se visualice U0–U2.
• Desactive la alimentación.
• Active la alimentación, el display visualiza rápidamente 88.
• Pulse una vez el interruptor, el display muestra III y luego 00.
• Pulse una vez el interruptor, el display muestra II y luego 00.
• Pulse una vez el interruptor, el display muestra I y luego 0.
• Ajuste el valor pulsando el pedal. Cuando presione el pedal, los dígitos comienzan a desfilar.
Cuando se alcance el valor de 35 libere el pedal.
• Pulse una vez el interruptor, – 0 relampagueará y el display mostrará la corriente de inicio
(00).
• Ajuste el valor presionando el pedal. Cuando presione el pedal, los dígitos comienzan a desfi-
lar. Cuando se alcance el valor de 20 libere el pedal.
• Pulse una vez el interruptor, – 1 relampagueará y el display mostrará la corriente final (00).
• Ajuste el valor presionando el pedal. Cuando presione el pedal, los dígitos comienzan a desfi-
lar. Cuando se alcance el valor de 42 libere el pedal.
• Pulse el interruptor las veces que sea necesario hasta que el display muestre A5.
• Presione el pedal en la parte inferior y manténgalo presionado durante unos pocos segun-
dos, libere el pedal y el display mostrará 88. El programa se ha guardado.
• Instale el tornillo y la cubierta de caucho.
Page Groupe Date Désignation
8/8 Cabina
05.3. Notes:
06 DISPOSITIVOS DE TRABAJO
4 4
7 7
1
2 5
A
3
2 2
Item Obs.
1 Los extremos del cilindro y los pernos de Lubricación diaria, si no hay lubrica-
apriete del dispositivo de elevación ción central
2 Las piezas deslizantes en el extremo de- Lubricación diaria, si no hay lubrica-
lantero del boom ción central
3 Cojinetes del boom Lubricación diaria, si no hay lubrica-
ción central
4 Calzos para los cojinetes Coloque el mismo grosor de calzos a
ambos lados
5 Superficies deslizantes del boom más in- Esparza la capa
terno
6 Rodillos de soporte del boom Lubricación
7 Calzos para los cojinetes Centralizar el boom con calzos.
Page Groupe Date Désignation
2
1
3 11
1
8
A-A
11
4
6
7
11
5 10
12 9
A B
4
28
B
19 Min
X63
Pm6 1 2
* *
Para ensamblar el cilindro se precisa una limpieza absoluta; por lo tanto, lavar todas las piezas
utilizadas cuidadosamente antes de comenzar el ensamblaje, cerrar con tapones de plástico
los puntos de conexión abiertos y abrir los paquetes de las juntas en el mismo momento en
que se vaya a comenzar la operación. Asegurarse de que antes de empezar a trabajar, las
grasas y aceites utilizados para el ensamblaje son los adecuados para un montaje hidráulico.
Montar la banda de segmentos guía del pistón (pieza 6: 3 partes) en el surco del pistón y pegar
los extremos de dicha banda con una gota de adhesivo al fondo del surco.Montar los segmen-
tos guía de forma que sus puntos de conexión no se encuentren en la misma línea central.
Lubricar el conjunto de juntas (pieza 7) y la superficie de los segmentos guía con vaselina
antes de montar el pistón en la camisa.
Introducir con cuidado el pistón en la camisa previamente limpiada asegurándose de que las
líneas centrales de la barra del pistón y la línea del pistón están tan paralelas como sea posible.
Engrasar la barra del pistón con aceite hidráulico. Al introducir el pistón en el tubo, utilizar una
grúa elevadora o una carretilla elevadora, ya que el cilindro tiene un peso bruto de unos 800
Kg.
Rev. 07.12.2001
Page Groupe Date Désignation
1 2
1
3 3
3 4 3
7
1 3
8
330–350 Nm 5 6
3 1
3
2 5
A
5 4 1
A
3
7 6 6
10 5 3
3 1
10
7 7 6
A–A
Page Groupe Date Désignation
X61
E36 E37
S122 S135
S124 S123
S136 S121
1 300 Nm 2
4
5
3 6
6. Mientras realiza el montaje ajuste la llave y las arandelas de cierre y asegure la tuerca
de montaje de 300 Nm.
7. Verifique que las piezas están funcionando <>en forma correcta de acuerdo con las
otras.
Designacón Fecha Grupe Página
1 = Área de ensayo.
06.4. Notes:
07 CHASIS Y PROTECCIONES
07.1. Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
07 CHASIS Y PROTECCIONES
Designacón Fecha Grupe Página
07.1. Notes:
08 EQUIPAMIETO
L H
1 Compresor 5 Evaporador
2 Enfriador L Presión baja
3 Filtro y mirilla de cristal H Presión alta
4 Válvula de expansión
Page Groupe Date Désignation
08.1.3. Mantenimiento
El sistema se deberá comprobar una vez a la semana, llevando a cabo las siguientes instruc-
ciones:
S Mirilla. Sólo deben aparecer burbujas cuando se arranca y para el compresor.
S Compruebe que la conexión entre la placa de presión del compresor y la polea, no patina
y está limpia
S Compruebe que el cable entre el termostato y el embrague electromagnético está en bue-
nas condiciones.
S Compruebe la tensión de las correas y el montaje del compresor.
S Limpie o sustituya los filtros de aire fresco y recirculación.
S Compruebe la evacuación del agua condensada desde el fondo del acondicionador de
aire.
S Compruebe todas las conexiones de las mangueras.
Designacón Fecha Grupe Página
1 Mirilla
2 Depósito de fluido
3 Interruptor de pres-
ión
08.1.3.2. Periodos secos y frio con uso minimo del acondicionador de aire
Arranque el acondicionador de aire y permita que el compresor trabaje unos pocos minutos
cada semana, para mantener lubricadas las conexiones, juntas, etc... Si se conecta al sistema
un interruptor de baja presión, se debe hacer un by–pass si la temperatura ambiente está por
debajo de –1ºC. En caso contrario, no se podrá arrancar el compresor.
Cuando se sustituye un componente, una parte del aceite del compresor se va con él. Rellenar
el sistema según la siguiente tabla:
1
El líquido R134 requiere anillos
tóricos verdes. Nunca utilice
anillos tóricos negros con
R–134a. Figure 3. Anillo tórico verde
Aceite compresor
Los compresores nuevos se entregan con 1,8 dl. de aceite, cantidad que es suficiente para
sistemas con 1,25 Kg. de refrigerante. Para sistemas con más de 1,6 Kg. de refrigerante, la
cantidad de aceite a añadir se calcula como sigue:
Cantidad de refrigerante en Kg. x 1,3 + 0,4.
Ejemplo: 1,5 Kg. x 1,3 + 0,4 = 2,35 ³ añadir 0,55 dl. (2,35 – 1,8 = 0,55) dl.
Utilice sólo aceite sintético PAG como ZXL 100 o PG en los dispositivos del aire
acondicionado.
08.1.3.5. Troubleshooting
No refrigera
Comprobar:
S fusibles, conexiones eléctricas, toma tierra compresor, embrague electromagnético del
compresor, controlador de caudal y controlador de presión.
S correa.t S válvula reguladora de temperatura.
S compresor S mangueras refrigerante.
S válvula
Potencia de refrigeración
Comprobar:
S ventilador.
S tensión correa.
S que no ha pasado aire al evaporador.
S que no estén obstruidos evaporador y condensador.
S que el filtro de aire fresco no esté sucio ni obstruido.
S que el tubo capilar de la válvula de expansión está correctamente sujeto a la tubería de
salida del evaporador.
S que no salta muy pronto el termostato.
Refrigeración desigual
Comprobar:
S que todas las conexiones eléctricas de los interruptores de control, embrague magnético
y controlador de presión están correctamente sujetas.
S que no está bloqueada la válvula de expansión.
S que el sistema está llenado correctamente.
S que no está defectuoso el termostato
Ruido anormal
Comprobar:
S que la correa del compresor está correctamente tensada.
S que los tornillos de montaje del compresor están correctamente montados.
S que la cantidad de refrigerante en el sistema es correcta.
Los ruidos anormales pueden estar provocados por un montaje incorrecto de los
componentes. Si, por ejemplo, el compresor es ruidoso a una cierta velocidad y el ruido
desaparece cuando se sube o baja la velocidad, el fallo no está en el compresor.
Todas las máquinas tienen su frecuencia de resonancia específica en la que ocurren
vibraciones. La velocidad de rotación a la que se pueden escuchar ruidos, varía entre las
diferentes máquinas.
A menudo estas vibraciones se pueden eliminar aumentando o disminuyendo el tensado de
la correa, o sustituyéndola por otra de diferente longitud. Demasiada tensión provoca un
desgaste más rápido de los rodamientos del compresor, la correa y las poleas. Por lo tanto,
la correa de accionamiento no se debe tensar mucho.
Designacón Fecha Grupe Página
Compruebe también que el condensador está limpio y que el flujo de aire es suficiente, y que
el sistema no tiene demasiado refrigerante.
Como el compresor tiene muchas partes móviles, no se pueden evitar todos los ruidos. Por
ejemplo, los pistones del compresor generan ruido y vibraciones de relativamente alta
frecuencia.
Page Groupe Date Désignation
8/8 Equipamieto
08.2. Notes:
APÉNDICES
Contents
1.1 KALMAR ENVIRONMENTAL POLICY ........................................................................................................ 3
1.2 PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS ................................................................ 3
1.2.1 Effects of exhaust gases on health and the environment............................................................................. 3
1.2.2 Use of materials.......................................................................................................................................... 4
1.2.3 Energy consumption ................................................................................................................................... 4
1.2.4 Emissions into water and soil ..................................................................................................................... 4
1.2.5 Environmental problems............................................................................................................................. 4
1.2.6 Occupational health and safety .................................................................................................................. 4
1.2.7 Use of products........................................................................................................................................... 4
1.2.8 Complete overhaul or disposal................................................................................................................... 5
1.2.9 Preventive actions....................................................................................................................................... 5
1.3 RECOGNISING ENVIRONMENTAL ISSUES ............................................................................................... 5
1.3.1 Enhancing your environmental awareness................................................................................................. 5
1.3.2 Laws and regulations.................................................................................................................................. 5
1.4 RECYCLING ..................................................................................................................................................... 6
1.4.1 General ....................................................................................................................................................... 6
1.4.2 Sorting ........................................................................................................................................................ 6
1.5 REMEMBER THESE ........................................................................................................................................ 6
3
ENVIRONMENTAL POLICY
The management of environmental issues at Kalmar Industries Oy Ab’s Tampere factory is based on Kalmar
Industries AB's operational policy, to which this environmental policy is a supplement.
Our operations are based on making continual improvements to prevent pollution of the environment, and on
developing environmentally friendly products and services.
The operations of the factory are developed in accordance with the principles of sustainable development.
Each year, the factory management looks at the main environmental concerns, determines its environmental
objectives and develops an environmental management programme to meet the objectives.
The management will keep track of the environmental objectives and corrective actions by conducting
internal audits as part of the operations system.
Reacting to possible environmental abnormalities and taking the necessary corrective actions is the
responsibility of the entire staff.
Kalmar Industries Oy Ab’s Tampere factory adheres to the current legislation and regulations in its
operations.
Our operations comply with the international environmental system standard ISO 14001 and the principles of
sustainable development set by the International Chamber of Commerce.
Hazardous emissions are mainly the result of incorrect adjustment of the motor and lack of maintenance. For
this reason, it is essential that adjustments and maintenance are as described in the instruction manuals.
1.4 RECYCLING
1.4.1 General
The primary goal of environmental protection is to decrease the amount of waste produced. If waste is
produced, you must try to utilise it as a material or source of energy. Appropriate and safe processing must
be arranged for all kinds of waste. The sorting of the waste created in our operations is influenced by the
legislation, environmental factors and general tidiness, among other things. The amount of waste driven to
the landfill can be decreased by sorting the waste in the appropriate, labelled receptacles. The most effective
way of protecting the environment is to save material and energy and use environmentally friendly methods
and products.
Become familiar with the waste disposal and recycling instructions of your unit.
1.4.2 Sorting
Metal waste can be collected, sorted and delivered to the industry for use as a raw material and alloying
element. Recycling saves approximately half of the energy that would be consumed if the same amount of
metal were obtained from a mine.
When recovering oil, light oil waste is separated from black oil into a separate receptacle. Used oil of good
quality can be recycled. Take special care when handling oils, as even the smallest amount of oil can cause
extensive damage to the environment and ground water courses. Collect all oil filters and other oily waste,
such as rags, hydraulic hoses, absorbents (sawdust etc.) in the appropriate, labelled receptacles.
Toxic waste means waste that can be hazardous to health or the environment because of some chemical or
other property. When collecting and handling toxic waste, these health and environmental risks need to be
taken into account. Toxic waste typically includes batteries and accumulators, paints, solvents, other special
liquids, fuel waste, coolant waste, aerosols and used fluorescent tubes. Sort all toxic waste and make sure it
is treated appropriately.
- Contact your supervisor or the person responsible for environmental issues if necessary.
Keeping your own working environment tidy and in good order is your personal
responsibility. Tidiness and orderliness influence how the workplace functions, decrease
the number of accidents at work, and contribute to the positive image of the company and
its employees.
Plano hidráulico T561200T70
1 Dirección
2 Elevación
3 Pluma
4 Rotación
5 Amortiguación inclinación del spreader
8 Válvula piloto de control de presión para el descenso
9 Válvula descentrado pluma
10 Válvula de golpe de presión en rotación
12 Válvula control rotación
13.1 Válvula inclinación longitudinal
13.2 Ajuste velocidad de amortiguación
15 Ajuste velocidad inclinación
17 Válvula shutle
18 Freno de rotación
19 Filtro retorno
20 Bomba para dirección, elevación y pluma
21 Bomba para elevación, pluma y spreader
22 Enfriador
23 Interruptor presión para control descenso y elevación
24 Válvula no retorno
30 Válvula shock presión para inclinación
40 Válvula no retorno
42 Dispositivo de dirección
69 Válvula de control de flujo
70 Indicador servicio filtro
71 Válvula no retorno
76 Electroválvula
77 Electroválvula
82 Amplificador flujo
85 Válvula limitadora de presión para libre circulación
N:o 3K5688290 Tila: APP Nimitys: HYDR.SCHEMA
Diagrama hidráulico
Spreader
Diagrama hidráulico
Transfiriendo la cabina
Plano hidráulico
Freno
68 Cilindro
69 Válvula de control
N:o 4K5691600 Tila: APP Nimitys: Säätöohje Karojen lukitus
F Fusibles
G1 Generador de carga
G2, G3 Baterías
M1 Motor de arranque
S2 Interruptor de contacto
Arranque/Parada gum
LCU–002
Módulo control lubricación en la tarjeta de circuito, opcionalmás detalles en plano extra
S7 Asiento
Relés
K2 Arranque
K13 Control parada motor automática, opcional
K17 Relé del interruptor limitador
K19 Arranque imposible, embrague activado
K22 Prevención arranque
K96 Parada motor automática 10 min., opcional
válvulas
Y6 Válvula de parada
T5656990 13
Alarmas
Manómetros
P1 Cuenta horas
P2, R2 Medidor combustible
P4, R4 Medidor de la temperatura del agua del motor
P5, R5 Presión aceite motor, opcionall
P6, R6 Sensor temperatura transmisor, opcional
P7, R7 Calibre de la presión del aceite de transmisión
P8 Voltímetro, opcional
P9, R9 Indicador temperatura aceite hidráulico, opcional
P13, R13 Medidor de la temperatura del aceite del motor, opcional
T5653760 15
Luces
Luces de trabajo
Control de transmisión
Transmisión
Aire acondicionado
Hidr. on–off
Control de estabilidad
Spreader
Interruptor de derivación
Cantidad de lubricación
Control de bomba
Límite de rotación
NOTA!
El cilindro debe ser ensamblado a la línea central de las abrazaderas.
1 pieza 12 mm y 1..2 piezas 2 mm cuñas a ambos lados.
KG6027/3
NOTA!
El cilindro debe ser ensamblado a la línea central de las abrazaderas.
1 pieza 12 mm y 1..2 piezas 2 mm cuñas a ambos lados.
KG6027/4
Note: Warranty information is located in Section W. Make sure you are familiar with the warranty or warranties
applicable to your engine.
Table of Contents
Section
I
Introduction . . . . . . ..._..........................................................................................................................
:...
Specifications ..................................................................................................................................... V
Warranty ............................................................................................................................................. w
Index ......................................................................,.........
. . . . . . . . . . . .._..... . . . . . . . . . ,. ,.......................... X
Important Reference Numbers
Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service
or maintenance is required.
Engine Model
Engine Serial Number (ESN)
Zontrol Parts List (CPL)
%el Pump Part Number
=ilter Part Numbers:
l Air Cleaner Element
a Lubricating Oil Filter
- Bypass
- Full-flow
- Combination
@ Fuel
l Fuel-Water Separator
3elt Part Numbers
1
Ml1
Section i - Introduction Page i-a
Section i - llntroductim
Section Contents
Page
About the Manual ........................................................................................................................ ....................
i-1
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....i-8
General Safety Instructions ,.......,......,...........,,.....,.........,.,...,,,..........,....,..,...,..........,....,..............,...,......,... ; . . . . i-7
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........i-7
HOW to Use the Manual ........................................................................................................................ i-l
...........
ll~ustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............................
.... i-6
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....................................
... i-2
To the Owner and Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 .....
Ml1 To the Owner and Operator
Section i - Introduction Page i-l
Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. When one .‘,’
of the symbols appears, it conveys the meaning defined below:
WARNING - Serious personal injury or extensive property damage can result if the warning instructions
are not followed.
CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if
the caution instructions are not followed.
INSPECTION is required.
Refer to another location in this manual or another publication for additional information.
The component weighs 23 kg [50 Ibj or more. To avoid personal injury, use a hoist or get assistance to
lift the component.
Illustrations Ml1
Page i-6 Section i - Introduction
Illustrations
Some of the illustrations throughout this manual are ge-
neric and will not look exactly like the engine or parts used
in your application. The illustrations can contain symbols
to indicate an action required and an acceptable or not
acceptable condition.
l Make sure the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose tools, parts,
ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.
* Always wear protective glasses and protective shoes when working.
l Rotating parts can cause cuts, mutilation or strangulation,
l Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
* Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag
in the operator’s compartment or on the controls.
* Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to Kotate+he
0 crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
l If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
l Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
@ Relieve all pressure in the air, oil, fuel 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 fuel and liquid refrigerant
(freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly
emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmo-
sphere. Federal law requires capturing and recycling refrigerant.
* To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more.
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.
l Corrosion inhibitor, a component of SCA and lubricating oil, 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. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
l Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
l To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes,
and compartments.
l Always use tools that are in good condition. Make sure you understand how to use them before performing any
service work. Use ONLY genuine Cummins or Cummins ReCone replacement parts.
* Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lessor quality if replacements are necessary.
l Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
l Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
Acronyms and Abbreviations Ml1
Page i-8 Section i - Introduction
Engine Mentification
Engine Dataplate
The engine dataplate shows specific information about
your engine. The engine serial number and control parts
list (CPL) provide information for ordering parts and service
needs. The engine dataplate must not be changed unless
approved by Cummins Engine Company, Inc.
The dataplate is located on the fuel pump side of the
engine, on the side of the rocker housing. Have the fol-
lowing engine data available when communicating with a
Cummins Authorized Repair Location. The information on
the dataplate is mandatory when sourcing service parts.
1. Engine Serial Number (ESN)
2. Control Parts List (CPL)
3. Model
4. Horsepower and rpm rating
z*zio”
71.
Cummins Engine Nomenclature
The Cummins engine nomenclature provides the data as
TTL
illustrated in the graphic. M II-C 335
NOTE: The following letters designate some of the different
market applications for a Cummins engine. = Brake Horsepower
=Market Application (See Note
9 A = Agriculture
* C = Construction
* G = Generator Drive
Specifications Ml1
Page E-2 Section E - Engine Identification
Specifications
General Specifications
Horsepower (Refer to engine dataplate)
Engine speed @ Maximum Output:
Standard Rating (rpm) ............................................................................................................................... 2100
Sore a n d S t r o k e ....................................................................................... 125 mm 14.921 in] x 147 mm [5.787 in]
Displacement ...................................................................................................................... 10.8 liters 1661 C.I.D.]
Firing Order ..................................................................................................................................... 1 -5-3Y6-2-4
Engine Weight (with Standard Accessories):
Dry Weight .............................................................................................................................. 9 2 9 Kg [2045 lb]
Wet Weight .............................................................................................................................. 9 8 1 Kg [2160 lb]
Crankshaft Rotation - (viewed from the front of the engine) ................................................................. Clockwise
Fuel System
For performance and fuel rate values, refer to the engine data sheet or the fuel pump code for the particular model
, -.
involved.
Fuel Inlet Maximum Restriction:
Clean Fuel Filter .............................................................................................................. 102 mm Hg [4 in Hg]
Dirty Fuel Filter ................................................................................................................ 204 mm Hg [8 in Hg]
Fuel Drain Line Maximum Restriction
Without Check Valves ..................................................................................................... 6 3 m m H g [2.5 in Hg]
W i t h Check Valves ........................................... . ............................................................ 165 m m H g [6.5 in Hg]
Fuel Inlet Maximum Temperature ..................................................................................................... 71% [160°F]
Engine Minimum Cranking S p e e d .......................................................................................................... 150 R P M
Lubricating Oil System
Oil Pressure:
Low Idle (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 0 kPa [IO psi]
At 1200 rpm or Torque Peak (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]
Oil Capacity of Standard Engine:
Combination Filter ,.._.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 liters [0.7 U.S. gallon]
Oil Pan (High-Low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . 34 - 26.5 liters [9 - 7 U.S. gallon]
Cooling System
Coolant Capacity (Engine only-Aftercooled) ,........_............,.............................................. 12.9 liters [3.4 U.S. gal.]
Standard Modulating Thermostat-Range .,.................................,......................... I.... 82” to 93°C [180 to 200°F]
Cylinder Block Coolant Pressure (Pressure Cap Removed):
Minimum
Closed Thermostat - 1800 RPM - No Load . . . . . . . . . . . . . . . I I . . . . . 138 kPa [20 psi]
Maximum
Closed Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . ..,........................................................ . . . . . . . . . . . . . . . . . . . 275 kPa [40 psi]
Maximum Allowable Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . IOOT [212’F]
Minimum Recommended Operating Temperature . . . . . ..,..........,..,..,.....................,........... . . . . . ,. . . . . . . . . 71% [16OOF]
Maximum Allowable Deaeration Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . minutes
Minimum Recommended Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . kPa [7 psi]
Ml1 Specifications
Section E - Engine Identification Page E-3
Exhaust System
Maximum Back Pressure From Piping and Silencer (Combined):
7 6 m m 13 in]
H g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................
Hz0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................
1016 m m [40 in]
Exhaust Pipe Size (Normally Acceptable Inside Diameter) ................................................. 102 mm [4 in.]
Electrical Svstem
s
A minimum of 9 volts at the ECM connector is required to power-up the ECM on CENTRY engines.
Engine Diagram
The following illustrations contain information about engine components, filter locations, drain points and access
locations for instrumentation and engine controls. The information and configuration of components shown in these
drawings are of a general nature. Some component locations will vary depending on applications and installations.
Heater Supply
Pmvtnl.n tor
Coolc,t Heater
Exhaust Side
Ml1
Section 1 Operating Instructions Page l-a
transmission in neutral.
l Activate the ignition switch to open the fuel pump
shutoff valve.
l Start the engine with the throttle in the idle position.
NOTE: Engines equipped with air starting motors require
a minimum of 480 kPa [70 psi].
Do not keep the engine at low idle for long periods. Long
periods at low idle, more than IO minutes, can damage an
engine because combustion chamber temperatures drop
so low the fuel will not burn completely. This will cause
carbon to build up around the injector spray holes and
piston rings and can cause the valves to stick.
WARNING
T O avoid possible arcing, always disconnect the nega-
tive (-) cable first, and connect it last.
A CAUTiON A
When using jumper cables to start the engine, make
sure to connect the cables in parallel: positive (.t) to
positive (+) and negative (-) to negative (-). When using
an external electrical source to start the engine, turn
the disconnect switch to the “OFF” position. Remove
the key before attaching the jumper cables.
The accompanying illustration shows a typical parallel bat-
tery connection. This arrangement doubles the cranking
amperage.
1
f
WARNING A
Starting fluid is highly flammable and exploslve. Keep
flames, sparks, and arcing switches away from starting
fluid.
Due to increased safety hazards and potential for engine
damage, do NOT use starting fluid without metering
equipment.
@I A CAUTION A
Do not use excessive amounts of starting fluid when
starting an engine. The use of too much starting fluid
will cause engine damage.
4. While cranking the engine, inject a metered amount of
starting fluid.
Ml1 Operating the Engine
Page 1-5
Section .l - Operating instructions
Do not increase the engine speed above low idle until the
coolant temperature gauge needle starts to move or IO
minutes have elapsed. This will provide adequate lubrica-
tion to the bearings.
3 TO 5 MINUTES
Use 50 percent ethylene glycol an- Use 50 percent ethylene glycol an- Use 60 percent ethylene glycol an-
tifreeze and 50 percent water in tifreeze and 50 percent water in tifreeze and 40 percent water in.
your coolantmixture. your coolant mixture. your coolant mixture.
Use multi viscosity oil meeting API, Use multi viscosity oil meeting API Use Arctic oil meeting API CG-4 or
CG-4 or CF-4 specifications. CG-4 or CF-4 specifications. CF-4 specifications.
Fuel to have maximum cloud and Fuel to have maximum cloud and Fuel to have maximum cloud and
pour points 6X [lOoF] lower than pour points 6’S [lOoF] lower than pour points 6OC [lOoF] lower than
ambient temperature in which en- ambient temperatures in which en- ambient temperature in which en-
gine operates. gine operates. gine operates.
The following cold weather operating aids are required for cold weather situations:
It sensing Fan
Coalant Sansmg
Fan Control:
Coolsntsanshg
Shutter CO”?rol
Thermostat
f”takD Manmd
COnt,Ol:
Intake ManHold
sensing silulter
TEMPERATURE
M11 Engine Shutdown
Section 1 - Operating Instructions Page i-9
Winterfronts
Canvas or plastic “winterfront” and “engine compartment
covers” can be required when operating in cold tempera-
tures. Winterfront and engine compartment covers will pro-
tect the engine and engine compartment from cold air flow
and eliminate shutter leakage. Winterfronts are designed
so that the cover opening must be adjusted manually de-
pending on the ambient temperature and operation of the
radiator shutters. Engine compartment covers must not
restrict the air intake and exhaust systems during operation.
Shutters
The flow of air across the radiator core into the engine
compartment can be prevented by installing radiator shut-
ters. Because air flow has a major effect on heat loss
through radiation, reducing the air flow with shutters will
reduce the time required for engine warm-up and help
maintain engine operating temperature.
Shutters must operate in the same temperature range as
the thermostat with which they are used.
Engine Shutdown
1. Allow the engine to idle 3 to 5 minutes before shutting
it off after a full load operation. This allows adequate
cool down of pistons, cylinders, bearings, and turbo-
charger components.
2. Turn the ignition key switch to the “OFF” position.
NOTE: If the engine fails to stop running, rotate the manual
fuel stlutoff thumb screw counterclockwise to make sure
the valve is not being held open by the manual override
a screw.
D position,
3. Adjust the variable speed control lever (1) to the speed
desired.
PTO Application with Variable Speed Ml1
Page l-10 Section 1 - Operating Instructions
If your engine is equipped with a component or an accessory not manufactured by Cummins Engine Company, lnc,
refer to the component manufacturer’s maintenance recommendations. A listing of supplier’s addresses and telephone
numbers is provided in Component Manufacturers (Section M).
Use the chart provided at the end of this section as a convenient way to keep a record of maintenance performed.
To@ Requirements
Most of the maintenance operations described in this manual can be performed with common hand tools (metric and
S.A.E. wrenches, sockets, and screwdrivers).
The following is a list of special service tools required for some maintenance operations:
Tool Part No. Description
3375044 Torque Wrench Kit rorque Wrench and Screwdriver Adapter)
3375049 Oil Filter Wrench
3376592 Torque Wrench (Valve and Injector Adjustment)
3823024 Injector Puller
3376807 Engine Coolant and Fuel Filter Wrench
3622524 Belt Tension Gauge, Click Type (v-belts and v-ribbed with 4 or 5 ribs)
3822525 Belt Tension Gauge, Click Type (v-ribbed with 6 to 12 ribs)
ST-537 Dial Depth Gauge
ST-669 Torque Wrench Adapter (Used with 3376592 Torque Wrench)
ST-1138 Belt Tension Gauge (v-belts)
ST-l 225 Thermostat Seal Mandrel
ST-1272-11 Chip Removing Tool
ST-1 293 Belt Tension Gauge (v-ribbed belts)
Contact your nearest Cummins Authorized Repair Location for the required service tools.
Maintenance Schedule Ml1
Page 2-2 Section 2 - Maintenance Guidelines
Maintenance Schedule
fill Industrial
-..-- Ermine
--.a-.--Maintenance Schedule
----..--------.---- ----- (‘)* (‘)
Daily or Weekly @) Every 250 Hours Eve’;X 1500 Every 6000 Ever& 6000
Refueling or 6 Hours Hours or Hours
Mo,,~,,s’2’.‘%‘4) 2 Years (3)
Check Check Change Adjust Clean Clean and
Calibrate
1 Operator’s . Air intake sys- e Lubricating oil 0 Valves and e Coaling sys- 0 injectors
report tern for wear o Lubricating oil injectors tern * Fuel pump
1 Engine oil points or filter
level damage to o Fuel filter
) Coolant level piping, loose e Coolant filter
cl;gps, and
0 Air cleaner
restriction
Visually Check and Replace Check Change Inspect
Inspect Clean
3 Cooling Fan l Air cleaner e Element on e Torque on e Heavy duty o Turbochirger ’
I Engine for element Cummins two turbocharger coolant * Air compres-
damage, cylinder air mounting nuts sor
leaks, and compressor, if B Torque on en- e Fan hub
loose equipped with ;;insmounting 0 Fan idler pul-
chunked or an air cleaner ley assembly
frayed belts * Shutterstats a Vibration
D Crankcase and thermatic damper
breather tube fans (if
equipped)
Drain Drain Check Inspect
l Fuel-water Q Moisture from a Engine coolant e Water pump
separator air tanks SCA concen-
tration level
Clean
0 Water pump
weep hole
NOTE: Refer to the appropriate sections for complete inspection and maintenance procedures.
1, Follow the equipment manufacturer’s recommended maintenance procedures for all non-CuFmins manu-
factured engine accessories. Common accessories include: air compressor, alternator, batteries and electri-
cal components, engine brake, exhaust brake, fan clutch, freon compressor, and starter. Refer to SeCtiOn M
for addresses and telephone numbers.
2. For standby generator applications, the recommended oil change interval is 250 hours or 12 months, which-
ever comes first.
3. These maintenance intervals must be performed at hours or months, whichever occurs first. At each sched-
uled maintenance interval, perform ALL previous maintenance procedures which are due for scheduled
maintenance.
4. Do not change the coolant filter if the SCA concentration level is over 3 units.
Ml1 Page References for Maintenance instructions
Section 2 - Maintenance Guidelines Page 2-3
Weekly
Air intake system _ visual check _____________ ______________ ____________ _ ____ ______ ______ -______ ________________ _______- _______ ___- _-__ - 4-5
Air cleaner restriction _ check ________________ ____
-_ ____
__-__ _______
______-_______-________ __________________
--_---
_ _ --------
~-~-,---- 1-1
Air cleaner element _ check _____ -__-_____-______________ ____ ___ ____ -____ _________ - ______________ _-____ ____ _ ___________ -_-.- ______.___ _ 4.1
Air tanks and resevoirs _ drain -__I_ ----- _--_ -___________________.--- _ .________---.-- _ --_-- _ --------- __-_-_-_ ------ ----__-_-_---___--_-__ 4-7
Maintenance Record
Engine Serial No: Engine Model:
Owner’s Name: Equipment Name/Number:
M11
Section 3 - Maintenance Procedures at Daily Interval Page 3-a
Fuel-Water Separator
Drain
Cummins EngineCompany, inc. requires afuel-watersepa-
rator to be installed in the fuel supply system. Drain the
water and sediment from the separator daily.
Shut off the engine. Use your hand to open the drain valve.
Turn the valve counterclockwise approximately 1 I/2 to 2
turns until draining occurs. Drain the filter sump of water
untit clear fuel is visible.
When closing the drain valve, do not overtighten the valve.
Overtightening can damage the threads. Turn the valve
clockwise to close the drain valve.
Dispose of the drained water in accordance with local en-
vironmental regulations.
Coolant Level
Maintenance Check
A WARNING
Do not remove the radiator cap from a hot engine. Wait
until the temperature is below 50°C [1200P] before re-
moving the pressure cap. Failure to do so can result in
personal injury from heated coolant spray or steam.
Remove the filler cap slowly to relieve coolant system
pressure.
Never use a sealing additive to stop leaks in the cooling
system. This can result in cooling system plugging and
inadequate coolant flow causing the engine to overheat.
The coolant level must be checked daily.
Ml1 Coolant Level
Section 3 - Maintenance Procedures at Daily Interval Page 3;3
A CAUTION A I I I. I
Do not add cold coolant to a hot engine. Engine cast-
ings can be damaged. Allow the engine to cool to below
‘1 50°C [120°F] before addlng coolant.
Cummins Engine Company, Inc. recommends using either
a 50/50 mixture of good quality water and fully formulated
antifreeze, or fully formulated coolant when filling the coal-
ing system. The fully formulated antifreeze or coolant must
meet TMC RP 329 or TMC RP 330 specifications. Refer to
Coolant Recommendations and Specifications in Section
V.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill or expansion tank. G6
0
NOTE: Some radiators have two fill necks, both of which
must be filled when the cooling system is drained.
,
Ml1
Section 3 - Maintenance Procedures at Daily Interval
Fan, Cooling
Inspect for Reuse
0
A visual inspection of the cooling fan is required daily.
a Check for cracks, loose rivets, and bent or loose blades.
Check the fan to make sure it is securely mounted. Tighten
the capscrews if necessary.
A WARNING a
Do not straighten a bent fan blade, or continue to use
a damaged fan. A bent or damaged fan blade can fail
during operation and cause serious personal injury or
‘p property damage.
Drive Belts
Maintenance Check
as
0
Visually inspect the belts daily. Replace the belt if it is
frayed or has chunks of material missing. Small cracks are
acceptable. Adjust belts that have a glazed or shiny surface
which indicates belt slippage. Correctly installed and
tensioned belts will show even pulley and belt wear. Refer
to Section A for belt adjustment and replacement proce-
dures.
Belt damage can be caused by:
l Incorrect tension
l Pulley misalignment
l incorrect installation
l Severe operating environment
l Oil or grease on the belts
N A CAUTION A
Holes, loose end seals, dented sealing surfaces, and
other forms of damage render the cleaner inoperative
and require immediate element replacement.
Elements that have been cleaned several times will finally
clog and air flow to the engine will be restricted. After
cleaning the element, check the restriction as previously
described. Replace the element if necessary.
A CAUTION A
Pull the cover and the element straight out when re-
moving them from the housing to avoid damage to the
element.
Remove the wing nut (1) that secures the bottom cover (2)
to the cleaner housing (3). Remove the cover.
Pull the element (6) down from the center bolt (4).
Remove the gasket (5) from the outlet end (7) of the hous-
ing.
Install the element in the reverse order.
Loosen the wing nut (2). Remove the dust shield (3) from
63 4 the dust pan (1). Clean the dust pan and shield.
\
Remove the wing nut (5) and secure the air cleaner primary
Clean the element from the clean air side with compressed
air not exceeding 207 kPa 130 psi]. Inspect the element
after cleaning. Install the cleaned primary element or a new
element.
Make sure the gasketwasher is in place under the wing nut
before tightening.
Assemble the dust shield and dust pan again. Position
them to the air cleaner housing and secure with the band.
On the dual element type Cyclopac cleaner, check the air
restriction indicator. If the air restriction is excessive, dis-
assemble the air cleaner. Remove the wing nut (7) and
replace the safety element (8).
Assemble the air cleaner as described above.
Air Cleaner Element, Cartridge Type Ml1
Page 4-4 Maintenance Procedures at Weekly Interval
Clean the pre-cleaner openings (2) of all soot, oil film, and
any other objects that can become lodged in the openings. *j
Remove any dust or dirt in the lower portion of the pre-
cleaner and aspirator tubing. inspect the inside of the air
cleaner housing for foreign material.
Inspect the dirty cartridge for soot or oil. If there is soot
inside the Pamic tubes, check for leaks in the engine ex-
haust system, exhaust blow-back into the air intake, and
exhaust from other equipment. If the cartridge appears oily,
check for fumes escaping from the crankcase breather.
Excessive oil mist shortens the life of any dry-type car-
tridge. Troubleshooting at this point can appreciabiy ’
lengthen new cartridge life.
0
inspect for damage. Tighten loose clamps.
q Torque Value: 8 N*m 172 in-lb]
0
l turbocharger to exhaust manifold mounting gasket
%@
Replace the gasket. Refer to Section A for turbocharger
removal and installation. +..
e=
‘ . .
.,
.I
‘..
‘. NOTE$
Maintenance Procedures at 250 Hours or 6 Months Page 5-a
.
Maintenance Procedures - General Information
Maintenance Procedures at 250 Hours or 6 Months Page 5-l
Install
+= .
Use the correct filter(s) for your engine. Cummins Engine a3
a r
Company, inc. requires a fuel-water separator be installed
in the fuel supply system. It must remove a minimum of 94
percent of free water (per SAE J1839) and 88 percent of at
emulsified water (per SAE J1488). ti
Fuel-Water Separator (Superfilter)
Cummins, Part No. 3315843
Fleetguard@, Part No. FS-1212
Install a new thread adaptor sealing ring supplied with the
new filter. Apply a light coating of clean engine oil to the
filter gasket surface.
Fill the filter(s) with clean fuel.
Lubricating Oil and Filters Ml1
Page 5-2 Maintenance Procedures at 250 Hours or 6 Months
-7 A CAUTION Q
- +I/2 to 3/ Turn
rn8bdM
A WARNING
Some state and federal agencies in the United States of
America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid
Inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
Avoid direct contact of hot oil with your skin. Hot oil can
cause personal injury.
Change the lubricating oil and filter at the specified oil
change interval. Referto Lubricating Oil Recommendations/
Specifications in Section V to find the correct change in-
terval for you application.
Operate the engine until the water temperature reaches
60°C [140°F]. Shut off the engine. Remove the oil drain
plug from the bottom of the lubricating oil pan. Do not
remove the plugs on either side of the oil pan to drain the
oil. They will not allow the oil to drain completely.
NOTE: Fittings used in the bottom drain opening of the oil
pan other than Cummins specified parts must not exceed
the following size and weight limits:
Oil Drain Fittina Soecs
Length 63.50 mm [2.500 i n ]
Diameter 41.28 mm [1.6?5 in]
Weight 0.363 mm [0.80 lbf]
Do not use fittings other than the Cummins suljolied
fitting in the side drain location.
Ml1 Lubricating Oil and Filters
Maintenance Procedures at 250 Hours or 6 Months Page 5-3
On standby generator applications, Cummins Engine Com-
pany, Inc. recommends oil sampling and analysis at the
time of oil change to monitor oil contaminant levels.
.
Use the correct oil filter for your engine. Cummins Engine
Company, Inc. requires a lubricating oil filter(s) be used that
meets the specifications given in the table following this
text block per Gummins SAM 10,509/10,547/10,634.
Combination Lube Filter
Cummins Part No. 3318853
Fleetguard@ Part No. LF-3000
A CAUTION A 2 .
*
.*
The lack of lubrication during the delay until the filter @
is pumped full of oil at startup is harmful to the engine.
Fill the filter with clean 15W-40 oil.
A CAUTION A
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
Install the filter on the filter head. Tighten the filter until the
gasket contacts the filter head surface.
Use oil filter wrench, Part No. 3375049, to tighten the filter
to the specifications supplied with the filter.
Clean and check the oil drain plug threads and the seal
surface.
Install the oil drain plug in the lubricating oil pan.
Torque Value: 88 N-m [66 ft-lb]
0
(7
e=
Lubricating Oil and Filters Ml1
Page 5-6 Maintenance Procedures at 250 Hours or 6 Months
Fill the engine with clean oil to the correct level. Total
e-
0 system capacity including filter is approximately 39 liters
pO.3 U.S. gal].
NOTE: The oil pan capacity is 34 liters 19 U.S. gal]. ihe
filter capacity is 2.6 liters IO.7 U.S. gal].
Coolant Filter e-
Remove
Change the coolant filter at every oil and filter change
interval unless the supplemental coolant additive (SCA)
level is over three units. Refer to Coolant Additive Con-
centration - Check in this section.
NOTE: The SCA level must be tested every six months.
The correct coolant filter to be used is determined by the
total cooling system capacity and other operational factors.
Refer to Coolant Recommendations and Specifications
(Section V) for the correct filter selection.
1
* L
+ A CAUTION A
@1=
Mechanical over-tightening can distortthe filterthreads
or damage the filter head.
* install the new filter on the filter head. Tighten the filter until
the gasket contacts the filter head surface.
Tighten the filter an additional one-half to three-fourths of
a turn, or as specified by the filter manufacturer.
I
‘I- ,i, i,
NOTES
._
..
Ml1
Maintenance Procedures at 1,500 Hours Page 6-a
WARNING A
Do not pull or pry on the fan to manually rotate the
crankshaft. To do so can damage the fan blades. Dam-
aged fan blades can cause premature fan failures which
can result in serious personal injury or property dam-
age. .
The valve set marks are located on the accessory drive
pulley. The marks align with a pointer on the gear cover.
Use the accessory drive shaft to rotate the crankshaft.
Ml1 Overhead Set
Maintenance Procedures at 1,500 Hours Page 6-3
The adjustment can begin on any valve set mark. In the
following example the adjustment will begin on the “‘A”
valve set markwith cylinder number five valves closed and
cylinder number three injector ready for adjustment.
Rotate the accessory drive shaft clockwise until the “A”
valve set mark on the accessory drive pulley is aligned with
the pointer on the gear cover.
When the “A” mark is aligned with the pointer, the intake
and exhaust valves for cylinder numberfive must be closed.
If these conditions are not correct, cylinder number four
injector and cylinder number two valves must be ready to
set.
Both valves are closed when both rocker levers are loose
and can be moved from side to side.
A C A U T I O N A
An overtightened setting on the injector adjusting screw
will produce Increased stress on the injector train and
the camshaft injector lobe which can result in engine
damage.
Use torque wrench, Part No. 3376592, to tighten the ad-
justing screw while holding the tappet in the maximum
upward position.
Torque Value: 0.6 to 0.7 Nom [5 to 6 in-lb]
Advance to
Advance tc
Advance lo
Advance to
Intake
Exhaust
Valve Lash Specificatign
2;
0.69
in
0.014
0.027
Insert the feeler gauge between the top of the crosshead
69 .0.36 mm
[0,014 in.]
!
Repeat the process to adjust all injectors and valves. Bar Engine
in Direction Pulley Set Cylinder
After adjusting all the injectors and valves, check the torque Of Flotaih! Position Injector V&e
on the adjusting screw locknuts to make sure none were A
Sk%-!
overlooked. 8
Advance 10
Advance to , C
Advance 10 A
Advance IO B
Advance to c
Firing Order: l-5-3-6-2-4
Water Pump .
Maintenance Check
Every 1500 hours visually check the water pump body for
indications of water leakage at the weep hole.
A streak or chemical buildup’at the weep hold is not jus-
tification for water pump replacement. If a steady flow of
coolant or oil is observed, replace the water pump with a
new or rebuilt unit.
Refer to Section A for the replacement procedure.
;;&F60g Shutter Assembly Ml1
Maintenance Procedures at 1,500 Hours
0
a Radiator Shutter Assembly
Maintenance Check
e Check the shutters and the thermatic fan every 1500 hours.-..
Check the shutters in the closed position to be sure they
are completely closed.
NOTE: If the shutters are not closed, refer to the manu-
facturer’s instructions.
Be sure the shutters open completely at the desired tem-
perature setting.
NOTE: If the shutters are not open, refer to the manufac-
turer’s instructions.
Turbocharger ’
Maintenance Check
0
Every 1500 hours check the turbocharger mounting nuts.
% Tighten the mounting nuts if necessary.
Torque Value: 61 N*m [45 ft-lb]
Ml1 Engine Mounting Bolts
Maintenance Procedures at 1,500 Hours Page 6-9
0
Check the compressor housing sealing surface for leaks.
@B
If a leak is found, tighten the compressor housing capscrews
or v-band clamp nut.
Torque Value:
Capscrews
V-Sand
9 Nern
9 Nom
[75 in-lb]
[75 in-lb]
0
(T
0
Engine Mounting Boks
-4s
Maintenance Check
Every 1500 hours check the torque on the engine mounting e
nuts and bolts. Tighten any that are loose. Refer to the
equipment manufacturer for torque specifications. Inspect
the rubber for deterioration and age hardening. Replace
any broken or lost bolts, capscrews, or damaged rubber.
I NOTES : I..: , ~ _’
L.‘
.-,
.’ : , j
...
Ml1
Maintenance Procedures at 6,000 Hours or 2 Years Page 7-5
k
Maintenance Procedures at 6,000 Hours or 2 Years
Section Contents
Page
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ .,..................,.,.,..............,........~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-l
....
Clean _... . . . . . . . . . . . . . ...s.............
. . . . . . . . . . 9. . . . . . . . . . . . .I...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
........... 7-l
Maintenance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................
............... 7-3
Antifreeze ,.,.....,....,............, .,...,..............................................................................................................., 7-3
Maintenance Procedures - General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Ml1 Maintenance Procedures - General Information
Maintenance Procedures at 6,000 Hours or 2 Years Page 7-1
Cooling System
Clean
Every 6,000 hours or 2years of operation, whichever comes
first, change the coolant and antifreeze.
A CAUTION A
PO not use caustic cleaners in the cooling system.
Aluminum components will be damaged.
The cooling system must be clean to work correctly and to
eliminate buildup of harmful chemicals.
WARNING a
Wait until the temperature is below 50°C [12O’F] before
removing the coolant system pressure cap. Failure to
do so can cause personal injury from heated coolant
spray.
I
RESTORE is a heavy duty cooling system cleaner which
removes corrosion products, silicate gel and other depos-
its. The performance of RESTORE is dependent on time,
temperature, and concentration levels. An extremely scaled
or flow restricted system, for example, can require higher
concentrations of cleaners, higher temperatures, or longer
cleaning times or the use of RESTORE PLUS. Up to twice
the recommended concentration levels of RESTORE can
be used safely. RESTORE PLUS must be used only at its
recommended concentration level. Extremely scaled or
fouled systems can require more than one cleaning.
Ml1
Maintenance Procedures at 6,000 Hours or 2 Years
A CAUTION A
Fleetguarda RESTORE contains no antifreeze. Do not
allow the cooling system to freeze during the cleaning
operatlon.
Immediately add 3.8 liters [l U.S. gal.] of Fleetguard” RE-
STORE, RESTORE PLUS, or equivalent, for each 38 to 57
liters [IO to 15 U.S. gal.] of cooling system capacity, and fill
the system with plain water.
-
Turn the heater temperature switch to high to allow maxi-
mum coolant flow through the heater core. The blower does
not have to be on.
I!
I- Fill the cooling system with clean water.
Ml1 Cooling System
Maintenance Procedures at 6,000 Hours or 2 Years Page 7-3
Operate the engine at high idle for five minutes with the
coolant temperature above fWC [165OF].
1 Shut off the engine and drain the cooling system.
If the water being drained is still dirty, the system must be
flushed again until the water is clean.
t:
Maintenance Check
I’
Antifreeze
Fully formulated antifreeze must be mixed with good qual-
‘1 ity water at a 50/50 ratio (40 to 60% working range). A 50/50
mixture of antifreeze and water gives a - 36OC [ - 34OF]
I freeze point and a boiling point of IIOC (228F3, which is
adequate for locations in North America. The actual lowest
. freeze point of ethylene glycol antifreeze is at 68%. Using
higher concentrations of antifreeze will raise the freeze
“,: point of the solution and increase the possibility of a silicate
.I:: gel problem.
:i Refer to Section V for water and antifreeze
recommendations,
, ,. ’ ?
; The Fleetguarda refractometer, Part No. C2800, provides a
reliable, easy to read, and accurate measurement of freeze
’ point protection and glycol (antifreeze) concentration.
The freeze point protection must be checked if coolant is
added to the cooling system. Refer to the manufacturer’s
instructions for correct operation.
Cooling System Ml1
Page 7-4 Maintenance Procedures at 6,000 Hours or 2 Years
Nlll
Maintenance Procedures at 6,000 Hours Page 8-a
Injector
Remove
STC
Every 6,000 hours, clean and rebuild or replace the injec-
tors.
NOTE: Calibration requires special equipment and must
be done at a Cummins Authorized Repair Location.
l
cylinder.
F?emove the crossheads. Mark the position and orieritatior?
of the crossheads as they are removed. Due to wear pat-
terns, they must be installed in the same locations from
which they were removed.
Loosen the injector hold down capscrew and remove the
hold down.
install
STC
Install three new o-rings over the injector into the retaining
grooves. Do not twist the o-rings.
Lubricate the o-rings with clean 15W-40 oil just before
installation.
0
q
Make sure the push rods are properly seated in the cam
follower sockets.
0
Inspect the rocker lever cover gasket for cuts or damage.
If necessary, install a new gasket. @ i%
Install the rocker lever cover.
install the 16 isolators and capscrews. Tighten the
capscrews in the sequence shown.
Fuel Pump
Remove
s-l-c
Every 6,000 hours, clean and calibrate the fuel pump.
Calibration requires special equipment and must be done
at a Cummins Authorized Repair Location.
Clean the fuel pump and the surrounding area before re-
moving it from the engine.
Fuel Pump Ml1
Page 8-8 Maintenance Procedures at 8,000 Hours
Clean the gasket surfaces of the pump support and the air
compressor.
Fuel Pump
Maintenance Procedures at 6,000 Hours Page 6-7
‘I, I n s t a l l
.i STC
: Install the fuel pump drive coupling.
,’ Use a new gasket when installing the fuel pump.
Install the four 12 point fuel pump mounting capscrews.
Install the electric wire to the fuel shutoff valve. The wire
connection nut must be clean and tight.
Torque Value: 3 Nom [25 in-lb]
Install the linkage to the throttle lever.
Turbocharger
Maintenance Check
Every 6,000 hours, inspect the turbocharger. Remove the
air intake and the exhaust piping. Check the turbocharger
as follows:
l Look for damaged or cracked compressor or turbine
blades. Check to see that the turbocharger shaft
spins freely.
If visual inspections or dimensional checks indicate a prob-
lem, contact a Cummins Authorized Repair Location for
assistance. Referto the model number on the turbocharger
dataplate.
With the feeler gauge in the same location, gently push the
compressor wheel away from the compressor housing and
measure the clearance between the compressor wheel and
housing.
Record this clearance.
Push the rotor assembly toward the gauge and record the
data.
Axial Clearance
in
078 MIN 0.0015
0.089 MAX 0.0035
Replace the turbocharger if the clearance does not meet
the specifications. Refer to Section A for the replacement
procedure.
0
172 in-lb]
%
Remove the air inlet and outlet connections from the air
ID of &bon Build UF
0
Inspect any air driers, spitter valves, pressure relief valves
@ and alcohol injectors for carbon deposits or malfunctioning
parts. Inspect for air leaks. Maintain and repair the parts
according to the manufacturer’s specifications.
e=
Ml1 Air Compressor Maintenance
Maintenance Procedures at 6,000 Hours Page 6-13
0
The air compressor is built with one of the two types of E-type Non-E-Type
unloader valves. One is referred to as a flat hat type and the @
other is a three prong. (11
The cleaning pro‘cedure is the same for both. 42%
0
Visually inspect the unloader valve for carbon buildup. If
carbon or heavy varnish is present, remove, clean and @
inspect the compressor head and the valve assembly. Re-
place parts as necessary. Referto the Master Repair Manual
Holset Air Compressors, Bulletin No. 3666121 for proce- Q
dures or contact your nearest Cummins Authorized Repair G
Location:
0
The open side of the rectangular seal must face the top of
the unloader body. e
Air Compressor Maintenance Ml1
Page 8-14 Maintenance Procedures at 6,000 Hours
Remove
Loosen the fan idler pulley shaft locknut.
A CAUTION A
To prevent damage to the pulley and new belt, do not
roll the belt over the pulley or pry it on with a tool.
Install a new fan belt on the pulleys.
0%
Tighten the idler pulley shaft locknut.
Torque Value: 190 N-m [140 ft-lb]
install
Install a new belt on the water pump and alternator pulleys.
To prevent damage, do not roll a belt over the pulley or pry
it on with a tool.
Turn the adjusting screw (1) clockwise to increase the belt
tension.
Use belt tension gauge, Part No. ST-1293, to measure the
belt tension. Refer to Drive Belt Tension in Section V for the
correct tension value for the belt you are installing.
NOTE: A belt is considered used if it has been in operation
for 10 minutes or longer.
NQTE: If the alternator drive belt has more than five ribs,
refer to the belt tension chart in Section V for correct belt
adjustment.
Belts must not touch the bottom of the pulley grooves, nor
must they protrude over 3 mm [3/32inchj above the top
edge of the groove.
Water Pump
Remove
Remove the water pump. Twist the pump outward from the
top and angle the rear of the pump downward as it is being
removed to allow the pump to pass the thermostat housing
support.
Install
install a new o-ring on the water pump mounting flange.
NOTE: The water pump must be twisted outward from the
top until the transfer outlet clears the thermostat housing
support during installation.
Install the water pump.
I
Water Pump Ml1
Page a-a Section A - Adjustment, Repair and Replacement
Equally space the bypass hose over the water pump con-
nection and thermostat housing connection, and tighten
the bypass hose clamps.
0
Torque Value: 3 N-m [30 in-lb]
(7 Install the upper radiator hose. Refer to the manufacturer’s
specifications for the correct torque value.
e Insta!l,the,lower radiator hose. Refer to the manufacturer’s
speclflcatrons for the correct torque value.
’.
+ Ir
The oil seal must be installed with the lip of the seal and
the shaft clean and dry. Do not lubricate. The yellow dust
63 lip must be facing out.
Install the new gasket and oil seal. Use the installation
sleeve provided with the new seal to install the seal.
The capscrew threads must be coated with thread sealant,
Part No. 3823494, to prevent oil leakage.
Torque Value: Step 1 7 N-m [ 60 in-lb]
2 20 N-m [ISO in-lb]
Ml1 Water Pump
Sectlon A - Adjustment, Repair and Replacement Page A-9
-
Place a light film of oil or antifreeze on the inside diameter
of the oil seal dust seal. 0,
III
Install the dust seal onto the shaft with the larger outside
diameter facing towards the engine.
Push the dust seal back by handon the shaft until the entire
dust seal contacts the oil seal case.
0e
-
Use the Part No. 3377401 Pulley Pusher Adapter (1) and
the Part No. 3376326 Pulley Pusher (2) to install the pulley.
Install the capscrew in the shaft.
Torque Value: 75 N-m [55 ft-lb]
0
Fill the cooling system.
e
Operate the engine until it reaches a temperature of 80°C
[ISPF] and check for coolant leaks.
Coolant Thermostat
Remove
WARNING A
Do not remove the radiator cap from a hot engine. Wait
until the temperature is below 50°C [120°F] before re-
moving the coolant system pressure cap. Failure to do
so can cause serious personal injury from heated cool-
ant spray.
Remove the radiator cap after the engine is cool.
Install
Install the thermostat in the housing.
Install a new seal in the groove on the thermostat housing
mounting surface.
0
Tighten the coolant bypass hose clamps.
q Torque Value: 3 N*m 130 in-lb]
Remove the roil pin and washer from the idler pulley ad-
justing screw.
Remove the locknut and washer from the back of the idler
pulley shaft.
Remove the adjusting screw.
Remove the fan idler pulley from the fan hub support
bracket.
Install
NOTE: Do not tighten the locknut until the fan drive belt has
been installed and adjusted.
Install the idler pulley in the fan hub support bracket.
install the washer and locknut on the idler pulley shaft.
Install
Install the new fan hub and four capscrews.
Torque Value: 47 P+m [35 f&lb]
0
T
0
Tighten the fan idler pulley shaft locknut.
Torque Value: 190 N*m [I40 f&lb] T
Check the belt tension again after the locknut is tightened.
Turbocharger Ml1
Page A-16 Section A - Adjustment, Repair and Replacement
G3Q Turbocharger
Remove
Remove the intake and exhaust pipes from the turbocharger
Install
Apply a film of high temperature anti-seize compound to
the turbocharger mounting studs in the exhaust manifold
and the turbocharger.
Use a new gasket when installing the turbocharger.
install the aftercooler air inlet hose evenly over the turbo-
charger outlet and the aftercooler inlet.
Install and tighten the four mounting nuts.
Torque Value: 61 N*m [45 it-lb]
0
Tighten the hose clamps.
T
Torque Value: 8 Nom [75 in-lb]
Install a new gasket on the turbocharger oil drain line con- ,&Jh
nection and install the drain line to the bottom of the turbo //
charger. Tighten the turbocharger the two capscrews. W -I
Torque Value: 27 Nam [20 ft-lb]
fin
0(7
Torque Value: 35 Nom [25 ft-lb]
Fill the cooling system. Refer to Section 7.
0(7
NOTES
Ml1
Section D - System Diagrams Page D-a
10,
9-
1. Oil Pump
2. Pressure Regulator Valve 9. Combination Oil Filter
3. Oil Return to Pan 10. Filter By-pass Valve
4. High Pressure Relief Valve 11. Accessory Drive/Air Compressor
5. Oil Return to Pan 12. Idler Gears
6. Oil Thermostat 13. Viscosity Sensor
7. Oil Cooler 14. STC Control Valve
6. By-pass Filtered Oil Return 15. STC Oil Manifold
,. - .- -.. _,.
Coolant System
1. Water Pump Coolant Inlet
2. Coolant to Lower Manifold
Cavity
3. Coolant to Cylinder Liner
Block Cavity
4. Coolant to Cylinder Head
5. Coolant to Upper Manifold
Cavity
6. Lower Manifold Coolant
to Oil Cooler
7. Oil Cooler to Upper
Manifold Cavity
Intake System
1. Filtered Intake Air to
Turbocharger
2. Turbocharger Air to
Aftercooler
3. Aftercooler
4. intake Manifold
5. Intake Valve Ports
Ml1
Flow Diagram, Exhaust System Section D - System Diagrams
Page D-6
Exhaust System
1. Exhaust Valve Ports
2. Exhaust Manifold
3. Turbocharged Exhaust
Outlet
Ml1
Section D - System Diagrams Flow Diagram, Compressed Air System
Page D-7
Flow Diagram, Compressed Air System
Flow Diagram
NOTES
Section L - Service Literature Page L-a
1
.~,I’...
:,.
I
‘,
,’
6
,’
$
I Order Total
I I I
$
Order Total
Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor.
FROM:
Name:
Street Address:
City: State/Province: Zip/Postal Code:
Country:
Street Address:
City: State/Province: Zip/Postal Code:
Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor.
FROM:
Name:
Street Address:
City: State/Province: Zip/Postal Code:
Country:
Street Address:
State/Province: Zip/Postal Code:
Ml1
Section M - Component Manufacturers Page M-a
NOTES
Ml1
Section S - Service Assistance Page S-a
Service Assistance
Routine Service and Parts
Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your engine.
Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained to
provide sound advice, expert service, and complete parts support. Check the telephone directory yellow pages or refer
to the directory in this section for the nearest Cummins Authorized Repair Location.
Problem Solving .,
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a Cummins
Authorized Repair Location in your area. Refer to the telephone directory yellow pages for the one nearest you. If the
problem has not been handled satisfactorily, follow the steps outlined below:
1. If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreement.
2. If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, most
problems are solved below the Division or Regional office level. Telephone numbers and addresses are listed in
this section. Before calling, write down the following information:
a. Engine model and serial number
b. Type and make of equipment
C. Total kilometers [miles] or hours of operation
d. Warranty start date
e. Nature of problem
f. Summary of the current problem arranged in the order of occurrence
.. .
g. Name and location of the Cummins Distributor or Dealer
3. If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location or Division Office,
write to:
Customer Relations - 41403, Cummins Engine Company, inc., Box 3005, Columbus, IN 47202-3005
Ml1 Service Assistance
Section S - Service Assistance Page S-3
NOTE: The following list contains offices in U.S., Canada, Australia, New Zealand, and Puerto Rico.
Auckland
Eu$mins Diesel Sales &Service (NZ)
Private Bag 92804
Penrose, Auckland, New Zealand
Location:
440 Church Street
Penrose
Telephone: (64-9) 579-0085
Branches:
Auckland
Cummins Diesel Engines
Private Sag 92804
Penrose, Auckland, New Zealand
Location:
440 Church Street
Penrose
Telephone: (64-9) 579-0085
Christchurch
Cummins Diesel Engines
p.0. Box 16-149
Hornby, Christchurch, New Zealand
Location:
35 Parkhouse Road
Sockburn, Christchurch
T e l e p h o n e : ( 6 4 - 3 ) 348-8170
Mt. Maunganui
Cummins Diesel Engines
p.0. Box 4005
Mt. Maunganui, New Zealand
Location:
101 Totara Street
Mt. Maunganui
T e l e p h o n e : (64-7) 575-0545
Milan Regional Office - Italy South And East Asia Area Office -
Cummins Diesel ltalia SPA. Singapore
Piazza Locatelli 8 Cummins Diesel Sales Corporation
Zona lndustriale 8 Tanjong Penjuru
20098 San Giuliano Milanese Jurong Industrial Estate
Milan, Italy Singapore 2260
T e l e p h o n e : ( 3 9 - 2 ) 982-81235/W’ T e l e p h o n e : ( 6 5 ) 2650155
country Countries
Covered: Italy Covered: Bangladesh Malaysia
Brunei Mongolia
North Asia Regional Office - Japan Burma/Mynamar Philippines
Cummins Diesel Sales Corporation Cambodia Singapore
I-12-10 Shintomi China Sri Lanka
Chuo-ku, Tokyo 104 Hong Kong Taiwan
Japan Indonesia Thailand
T e l e p h o n e : (81-3) 3555-3131/2/3/4/5 Laos Vietnam
country Macau
Covered: Japan
Taipei Regional Office - Taiwan
Seoul Regional Office - Korea Cummins Corporation -Taiwan
Cummins Korea Ltd. 12th Floor, No. 149
5th Floor, Hye Sung Building Min-Sheng E. Road
35-26 Sam Sung Dong. Kang Nam Ku Section 2
Seoul, South Korea Taioei, T a i w a n
Telephone: (82-2) 5160431/2/3, 517-3370/l R.6.C. 104
T e l e p h o n e : (886-2) 5150891
Country
Covered: South Korea Country
Covered: Taiwan
Cummsa Regional Office - Mexico
Turkey and Iran Regional Office - Turkey
Cummins, S.A. de C.V.
Arquimedes No. 209 Cummins Corporation
COI. Polanco Istanbul Office
11560 Mexico, D.F. Buyukdere Cad.
Mexico Beytem Han, Kat 11
T e l e p h o n e : ( 5 2 - 5 ) 2543822/3783/3622 Sisli 80220
Istanbul
Mailing/Shipping Address:
Telephone: (90-l) 246-2575/2775/2545
Gonzalez de Castilla Inc.
PO. Box 1391 Countries
4605 Modern Lane Covered: Iran
Modern Industrial Park Turkey
Laredo, TX 78040
Telephone: (512) 722.5207
Country
Covered: Mexico
Moscow Regional Office - Russia
Cummins Engine Co.. Inc.
Park Place
Office E708
Lenin& Prosoect 1 1 3
Russia j1798
Telephone: (7-502) 256-5122 or 256.5123
Countries
Covered: Armenia Lithuania
Azerbaijan Moldova
Bolarus Russia
Estonia Tadzhikstan
Georgia Turkmenistan
Kirghizia Ukraina
Latvia Uzbekistan
Ml1 Service Assistance
Section S - Service Assistance Page S-17
Distributors - International
ABU DHABI BAHRAIN BHUTAN
- See United Arab Emirates
Bahrain Pune (Office in India)
AFGHANISTAN Yusuf Bin Ahmed Kanoo W.L.L. Cummins Diesel Sales &
- See Middle East Regional Office PO. Box 45, Manama Service (India) Ltd.
Bahrain 35Af112, Erandawana
ALBANIA T e l e p h o n e : ( 9 7 3 ) 400414/400506 Pune . 411 038, India
- See Germany Regional Office - (State of Maharashtra) India
Gross-Gerau BALEARIC ISLANDS Telephone: (61-212) 331234/331554/
331635/330066/
ALGERIA Madrid (Office in Spain) 330166/330356/
Cummins Ventas Y Servicio. S.A. 31703
Algiers Torrelaguna, 5 6
Cummins Corporation 28027 Madrid. Soain BOLIVIA
Bureau de Liaison Telephone: (34-91) 367-2000
38, Lotissement Benachour Abdelkader 376.2404 La Paz
Cheraga Machinery & Auto Sewice
43200 Wilaya de Tipasa BANGLADESH Casilla 4042
Algeria La Paz, Bolivia
Dhaka , *
Telephone: (213) 237-43-26 Location:
Equipment & Engineering Co., Ltd. Av. 20 de Octubre Esq.
AMERICAN SAMOA G.P.O. Box 2339 Rosendo Gutierrez
- See South Pacific Regional Office Dhaka 1000, Bangladesh Telephone: (591-2) 379650, 366394
Location:
ANDOXRA 56, Dilkusha Commercial Area BONAIRE, ISLAND OF
- See European Regional Office . 2nd Floor/Eastern Block . See Netherlands Antilles
Mechelen T e l e p h o n e : (880.2) 234357, 234060
BOTSWANA
ANTIGUA BARBADOS - See East and Southern Africa Re-
Miami (Office In U.S.A.) gional Office - Harare
Miami (Office in U.S.A.)
Cummins Southeastern Power, Inc.
Cummins Southeastern Power, Inc. BRAZIL
9900 N.W. 77 Court
9900 N.W. 77 Court
Hialeah Gardens, FL 33016
T e l e p h o n e : ( 3 0 5 ) 821-4200
Hialeah Gardens, FL 33016 Ananindeua
T e l e p h o n e : ( 3 0 5 ) 821-4200 Marcos Marcelino & Companhia
ARGENTINA Ltda.
BELGIUM Aodovia B&316, Km 9
Buenos Aires 6 7 0 2 0 - 0 1 0 Ananindeua, Para,
Brussels
Distribuidora Cummins, S.A. Brazil
Cummins Distributor
(DICUMAR) T e l e p h o n e : ( 5 5 - 9 1 ) 2354100/4132/
Belgium S.A.
Av. Del Libertador 602 Piso 5 4143/4012
623/629 Chaussee de Haecht
Buenos Aires, Argentina
B-1030 Brussels, Belgium Belo Horizonte
T e l e p h o n e : (54-1)814-1895/1395/1393
T e l e p h o n e : ( 2 4 hr.) Distribuidora Cummins
ARUBA, ISLAND OF (32-2) 216-81-10 Mines S.A.
- See Netherlands Antilles BELIZE 31950640 Olhos D’Agua Norte
Belo Horizonte, MG
AUSTRIA Tampa (Office in U.S.A.) Brazil
Cummins Southeastern Power, Inc. T e l e p h o n e : ( 5 5 - 3 1 ) 2881344
Neudoerfl
5421 N. 59th Street
Cummins Diesel Motorenvertriebsges Campo Grande
m.b.H. Trenner & Co. Tampa, FL 33610
Distribuidora Cummins
Eickfordstr. 25 T e l e p h o n e : ( 8 1 3 ) 621.7202
Mato Gross0 Ltda.
A-7201 Neudoerfl BENIN Rodovia BR 163 Km 01
Austria 79060.000 Campo Grande
- See Togo
Telephone: (432622) 7741807625 Mato Gross0 do Sul, Brazil
BAHAMAS BERMUDA T e l e p h o n e : ( 5 5 - 6 7 ) 787-1166
Fortaleza B U R M A COLOMBIA
Distribuidora Cummins Diesel
Do Nordeste Ltda. Kuala Lumpur (Office In Malaysia) Barranquilla
Av. da Abolicao, 3882, Contact: Scott & Cummins de Colombia S.A.
Mucuripe English (M) Sdn Bhd Apartado Aereo 5347
60165-061 Fortaleza. Ceara P.O. Box 10324 Barranquilla, Colombia
B r a z i l 50710 Kuala Lumpur Location: Calle 30, No. 19 - 21
Telephone: (55-85) 263-1212 West Malaysia Telephone: (57-56) 40.02.06/40-13-46
Location:
Goianian 16 Jalan Chan Sow Lin Bogota
Distribuidora de Motores Cummins 55200 Kuala Lumpur Cummins Colombiana Ltda.
Centre Oeste Ltda. West Malaysia Apartado Aereo No. 7431
Av. Caiapo 777 - Setor Sta. Genoveva T e l e p h o n e : (60-3) 2211033 Bogota, D.E. Colombia
74672-400 Goiania, Goias Location:
Brazil BURUNDI Av. Americas X Carrera
Telephone: (55-62) 207.1010 42C No. 19-45
Brussels (Office in Belgium) Telephone: (57-l) 2445666/5662
Manaus Bia, S.A.
Distribuidora Cummins Rameistraat, 123 Bucaramanga
Amazonas Ltda. B-3090 - Overijse, Belgium Cummins API, Ltda.
Estrada da Ponta Negra, 6060 - Sao Telephone: (32-2) 6692611 Apartado Aereo 352
Jorge Bucaramanga, Colombia , qi
CAMBODIA Location:
69037 Manaus. Amazonas.
Brazil - See South & East Asia Regional Office Autopista a Giron, Km 7
Telephone: (55.92) 6565444 - Singapore Telephone: (57-76) 466060
NIGERIA PARAGUAY
Lagos Asuncion
SCOATRAC MOSEL Automotores y Maquinaria.
P.M.B. 2 1 1 0 8 S.R.L.
Ikeja, Lagos Yegros y Fulgencio R. Moreno
Nigeria P.O. Box 1160
31-90-56, 31-70-44 Location: Asuncion, Paraguay
Apapa-Oshodi Expressway Telephone: (595-21) 493111, 493115
$gMOZAMB,Q”E
es&.: lsolo Industrial Estate,
.p;:, . See East and Southern Africa Re- lsolo PERU
$? gional Office. Harare Telephone: (234-l) 52-15-39, 52-19-31,
g.. , Lima
52-46-70
g5 ~:NAMIEtIA (Southwest Africa) Comercial Diesel
;y Paris (Office in France) del Peru S.A.
1:;:. Windhoek SCOATRAC MOSEL P.O. Box 14.0234
!:i,,;Propower, Namibia c/o SCOA Lima, Peru
E-;.: PO. Box 3637, Windhoek 9000 9 et 11 rue Robert de Flers Location:
-2. Namibia (Southwest Africa) 75740 Paris, Cedex 15 Ave. V.R. Haya
-..r Location: France de la Tone 2648
‘of,, 7 Nasmyth Street Lima 3, Peru
Telephone: (33-l) 40-58-48-48
$- S o u t h e r n lnudustria ,
Tsleohone: (51-14) ~74.3173/4374/
,-i Telephone: (264-61) 37693 NORTHERN IRELAND 314412281
- See United Kingdom
‘1, N E P A L PHILIPPINES
NORWAY
:’ Pune (Office in India) EDSA
‘t Cummins Diesel Sales & Oslo Power Systems, Inc. EDSA
Service (India) Ltd. Cummins Diesel Salg & Service A/S P.O. B o x 3 2 4 1
35A/1/2, Erandawana P.0. 6288 Manila
; Pune, - 411 038, (State of Maharashtra) Etterstad 0603. Oslo 6 Philippines 1501
India Location:
Telephone: (91-212) 331234, 331554, Location: 79E. Delos Santos Ave.
331635, 330066, Verkseler Furulunds vei 11 Mandaluyong, Metro Manila
330166, 330356, Telephone: (47) 22326110 Teleohone: (63-2) 7 9 1 7 6 9 . 7 9 1 7 7 1 ,
331703 5311945, 5315448,
OMAN 5311934, 5312531,
.,’ N E T H E R L A N D S 53414513
Ruwi
.’ Dordrecht Universal Engineering POLAND
Cummins Diesel Sales & Services L.L.C. - See Germany Regional Office - Gross-
Service, b.v. P.O. Box 5688 Gerau
Galvanistraat 35 Ruwi
3316 GH Dordrecht Sultanate of Oman PORTUGAL I
: Netherlands Telephone: (968) 590830, 591304
T e l e p h o n e : ( 3 1 - 7 8 ) 18-12-00 Lisbon
PAKISTAN Eiectro Central
NETHERLANDS ANTILLES Vulcanizadora, Lda.
Karachi RO. Box 3077
! Miami (Office in U.S.A.) - See Middle East Regional Office . 1302 Lisbon, Portugal
Cummins Southeastern Power, Inc. Daventry Location:
9900 N.W. 77 court Rua Conselheiro
Hialeah Gardens, FL 33016 PANAMA Martins de Carvalho
T e l e p h o n e : ( 3 0 5 ) 821-4200 Lote 1480
Panama City
1400 Lisboa (Restelo)
NEW CALEDQNIA Grupo Tiesa, S.A.
Telephone: (351-l) 3015361
- See South Pacific Regional bffice . Apartado Postal #55-0549
Melbourne Partillo, Panama GATAR
Telephone: (597) 67-3866
NEW GUINEA Doha
_ See Papua New Guinea PAPUA NEW GUINEA Jaidah Motors & Iadina Co.
Sydney (Office in Australia) PO. Box 150
NICARAGUA Doha, Qatar (Arabian Gulf)
Cummins Diesel Sales & Service
Telephone: (974) 810000
Managua P.O. Box 150
F. Alf. Pellas & Cia. Cabtamatta, 7 . 1 6 6 REUNION
Apartado Postal No. 46 New South Wales. Australia - See Lyon Regional Office . Lyon
Managua, Nicaragua
Location: RIO DE OR0
6a. Calle - See Soain
30 y 31 Avs. N.O., Zona 5
T e l e p h o n e : (505.2) 660616
Service Assistance Ml1
Page S-24 Section S - Service Assistance
U.S.S.R. ZAMBIA
- See Moscow Regional Office - Moscow
Ndola
VATICAN CITY N.E.I. (Zambia) Ltd.
- See Italy P.O. B o x 7 1 5 0 1
Ndola, Zambia
VENEZUELA Telephone: (260-2) 610729
/,Zone lndustrielle CNPPME
%’ Telephone: (228) 21-23-95 ZIMBABWE
Sudimat
f TONGA. ISLAND OF Apartado Postal 1322 Harare
Carmelitas Cummins Zimbabwe (Pti) Ltd.
- See South Pacific Regional Office
Caracas 1010 P.0. Box ST363
Melbourne
Venezuela Southerton
TRINIDAD and TOBAGO Location: Harare, Zimbabwe
Final Avenida San Martin Location:
Miami (Office in U.S.A.) Urb. la Quebradita 72 Birmingham Road
Cummins Southeastern Power Inc. Caracas 1061 Southerton, Harare
9900 N.W. 77 Court T e l e p h o n e : ( 5 8 - 2 ) 442-616112647 Telephones: (263-4) 67645, 69220
Hialeah Gardens, FL 33016
Telephone: (305) 821-4200 VIETNAM
TURKEY Hanoi
Diethelm & Co. Ltd. Engineering
Istanbul Room No. 1, 2nd Floor
Hamamcioglu Muesseseleri 8 Trang Thi Street
Ticaret T.A.S. Hanoi, Vietnam
P.K. 136 Telephone: (84-4) 260-332, 244-394
80222 Sisli
Istanbul, Turkey Ho Chi Minh City
Location: Diethelti & Co. Ltd. Engineering
Buyukdere Caddesi, 13/A 3rd Floor, IBC Building
80260 Sisli 1 Me Linh Square
Istanbul, Turkey District 1
Telephone: (90-I) 231.3406, 234-5123 Ho Chi Minh City, Vietnam
T e l e p h o n e : ( 8 4 - 8 ) 2 9 4 - 1 0 2 , 294-103
UKRAINA
. See Moscow Regional Office. Moscow WESTERN SAMOA
- See South Pacific Regional Office _
UNITED ARAB EMIRATES Melbourne
Abu Dhabi YEMEN ARAB REPUBLIC
Technical Oilfield Supplies Centre
P.O. Box 2647 Sana’a
Abu Dhabi, Zubieri Trading Co.
United Arab Emirates P.O. Box 535
Telephone: (971-2) 723863, 723298 Sana’a. Yemen Arab Republic
Location:
UNITED KINGDOM Zubieri Street
Telephone: (967-l) 244400/79149
Wellingborough
Cummins Diesel YEMEN, SOUTH
Denington Estate - See Middle East Regional Office -
Wellingborough
Daventry
Northants NN8 ZQH, England
Telephone: (44-933) 276231 YUGOSLAVIA
- See Southeastern Europe
UPPER VOLTA
- See Burkina. Faso ZAIRE
URUGUAY Brussels (Office in Belgium)
N.V. Bia, S.A.
Montevideo Rameistraat, 123
Santaro .%A. B-3090 . Overijse, Belgium
p.0. Box 379 Telephone: (32-2) 689-28-H
Montevideo
Uruguay
Location:
Avenida Millan No. 2441
Telephone:(598-2) 293908
Service Assistance Ml1
Page S-26 Section S - Service Assistance
NOTES
Ml1
Section TS - TroubleshooZing Symptoms Page TS-a
Intake Air Restriction to Air Compressor Replace air compressor air cleaner (if in-
stalled). Check engine intake air restriction if
air compressor inlet is installed in intake piping
between air cleaner and turbocharger.
OK
OK
w
OK
SYMPTOM: Air Compressor Pumping Excess Lubricating Oil Into Air System
Cause Correction
r I I
Verify correct oil drain intervals. Refer to
Engine Oil Drain Intervals Excessive Section V.
/ I
OK
t
I I I
Replace air compressor air cleaner (if in-
Intake Air Restriction to Air Compressor stalled). Check engine intake restriction if air
Excessive (Naturally Aspirated Air Compressor . compressor inlet is installed in intake piping
Only) between air cleaner and turbocharger.
I I I I
OK
t
r I I 1
Check air compressor duty cycle. Refer to
Air Compressor Pumping Time Excessive installation Recommendations - Compressed +..
Air Systems, Bulletin No. 3382886.
OK
*
L~-,-~-, SYMPTOM: Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping
Continuously)
Cause Correction
I I
Block vehicle wheels and check for system air
leaks with spring brakes applies and released.
Check for air compressor gasket, hoses, and
fitting leaks. Refer to Air Compressor Inspsc-
Air System Leaks . . tion. Check for safety pressure valve leaks.
Rating must be 150 psi. Check safey pressure
valve location. Refer to the manufacturer’s
instruction for the other air system leaks.
OK
*
*
I
Contact a Cummins Authorized
Repair Facility
Troubleshooting Symptoms Charts
Symptoms Page TS-7
OK
‘t
OK
t
OK qi
w
OK
OK
OK
w
OK
C o n t a c t a C u m m i n s Authorized
Repair Facility
Troubleshooting Symptoms Charts
Page TS-9
OK
w
’
Radiator Fins. Freon Condenser Fins. or Both
Damaged or ‘Obstructed with Debriq’lnsects, Inspect radiator and condenser fms.
. . . . . ..I]
or Dirt (External)
I I
OK
*
Cold Weather Radiator Cover or Winterfront Open cold weather radiator cover or winter-
Closed . . .... front.
OK
w
OK
w
Fan Drive Belt Loose . . Check belt tension and tighten if necessary.
OK
w
OK
t
OK
*
Cooling Fan Shroud Damaged or Missing. Air Inspect shroud and recirculation baffles.
Recirculation Baffles Damaged or Missing. ’ Repair, replace, or install.
OK
t
Radiator Cap Incorrect or Malfunctioning . . . .... Check the radiator pressure cap.
OK
w
(Continued)
Troubleshooting Symptoms Charts Ml1
Page TS-10 Section TS - Troubleshooting Symptoms
Cause Correction
OK
OK
-c
OK
*
Fan Drive Belt Broken ....... Replace belt if broken. Refer to Section A.
*..
OK
w
I I
Radiator Cap Incorrect or Malfunctioning. Cap Check the radiator pressure cap.
Rate Pressure Tool Low .
I I
i
OK
c
OK
Continuously Operating in Low Ambient Refer to Cold Weather Operation, Bulletin No.
Temperature ’ 3387266-R.
OK
t
Radiator Shutters Stuck in Open Position or Check shutter operation. Repair or replace if
Opening Early ... necessary.
OK
Temperature Gauge and/or Sensor Malfunc- Test the gauge and sensor. Repair or replace if
tioning ... necessary.
OK .. .
e
OK
OK
SYMPTOM: Engine Cranks But Will Not Start (No Smoke From Exhaust)
Cause Correction
OK
w *..
Fuel Filter Plugged or Suction Line Broken or ....... Replace fuel filter and suction line.
Plugged
OK
w
Fuel Connection Loose on Suction Side of Tighten all fuel fittings and connections from
......
Pump fuel tank to fuel pump.
Return Fuel Lines Restricted or Plugged ...... Replace return fuel lines.
OK
*
OK
*
OK
w
OK
w
OK
w
OK
*
OK
I I
1
. . .
L
Check for loose wires and verify that the
solenoid is functioning.
t
I r
I Starting Aid Needed for Cold Weather or
Malfunction . Check and repair or replace cold starting aid if
necessary.
OK
I
Fuel Filter Plugged
I. . . . . . . I
J I
Replace fuel filter.
OK
t
a
Page TS-18 Section TS - Troubleshooting Symptoms
Engine Oil Supply Insufficient or Engine Oil Check engine oil level. Refer to symptom chart
Pressure Low ... Lubricating Oil Pressure Low.
i
OK
*
OK
w
r I
Fan Belt Malfunctioning (Too Loose, Tight or
Not in Alignment) . . . Check fan belt. Refer to Section A.
-:
OK
Vehicle Drive Train Not Correctly Matched to Review specifications of engine and drive train
Engine .... components.
OK
1 Excessive Load for Engine Horsepower Rating 1.. ..,. Reduce vehicle load.
I I
Engine Operation Above Recommended
Altitude
OK
I
Derate engine above 3600 meters [12,000
.“’ f e e t ] .
4%
OK
*
Fuel Suction Line or Fuel Filter Restricted Check fuel line for restriction. Replace fuel
. filter.
OK
*
Lubricating Oil Level Too High Check dipstick calibration and oil pan capacity.
I
I
Throttle Linkage Adjustment Incorrect
I
. . ... Check throttle linkage adjustment for full
opening of throttle lever.
OK
v
I I
I
1
Intake or Exhaust
OK
System Restricted
I I
Check intake and exhaust systems for restric-
tio”s,
J
OK
w
(Continued)
Troubleshooting Symptoms Charts
;$on T+ - Troubleshooting Symptoms Page TS-21
*
I.’
!.. SYMPTOM: Engine Power Output Low (Continued)
e, 1
$;.2
““. Cause Correction
;.I
\T, ,:i ,/
r;::; Check fuel drain line for loops crimps or
,f’- Fuel Drain Line Restricted or Fuel Tank Vents clamped points. Remove, clean, or replace
.&i . . . . . ;I
\ <% ,A. Plugged
I r I
Verify by operating engine from a temporary
Fuel Quality Poor ...... tank that contains good fuel. Refer to Fuel Oil
Specifications.
OK
qF*y _
r‘, ;:.
&;: High Fuel Temperatures (Above 70°C [158OF]) . . . . Fill fuel tanks. Turn off fuel heater.
.!.’ 1 I
OK
Engine Operating in Low Ambient Tempera- Refer to Cold Weather Operations, Bulletin No.
tures ’ ’ ’ 3387266-R.
OK
OK
t
OK -..
*
OK
*
OK
*
C o n t a c t a C u m m i n s Author&d
Repair Facility
Troubleshooting Symptoms Charts
Troubleshooting Symptoms Page TS-23
OK
*
OK
OK
Engine Will Not Restart . Refer to symptom chart Engine Will Not Start
OK
*
OK
t
OK *..
t
Fuel Shutoff Solenoid Voltage Low. Fuel Check fuel shutoff solenoid valve circuit.
. . .
Shutoff Valve Closed
OK
*
I I
Contact a Cummins Authorized
Repair Facility
I
Ml1 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-25
OK
*
Fuel inlet Restriction or Air in the Fuel .... Change fuel filter(s). Check for air in the fuel.
Tighten the fuel line connections and filter(s).
OK
w
OK
OK
w
OK
*
OK ‘.
t
OK
*
OK
Replace fuel filter. Weather
require fuel heater.
conditions can
OK
*
OK
r)
OK
w
OK
OK
v
OK
t
SYMPTOM: Engine Will Not Crank or Cranks Slowly (Air Starting Motor)
Cause Correction
Air Pressure Insufficient in Air Tank . . . . Increase pressure using external air supply.
OK
OK
*
I I r I
I
I
Oil Incorrect for Operating Conditions
I
I
. . . . .
I
I
Change oil and filters. Use the type recom-
mended (15W-40). Check operation. I
I
OK T<
*
SYMPTOM: Engine Wilt Not Crank or Cranks Slowly (Electric Starting Motor)
Cause Correction
OK
w
Battery Connections Broken, Loose, or Car- . Check for damage. Clean and tighten if
roded necessary.
OK
w
OK -<
*
Battery Rating Too Low ....... Replace battery with correct rating.
OK
*
OK
t
OK
*
OK
w
OK
Fuel Pump Shutoff Valve Disc Stuck . . . Check operation of fuel shutdown solenoid.
OK
t
OK
*
OK
w
I
Engine Running on Fumes Drawn into Air Locate and isolate the source of fumes.
Intake ...
OK
Intake Air Restriction Excessive . .. Visually inspect air filter and restriction
indicator. Replace air filter if necessary. % -.
1
OK
w
OK
*
Vehicle and Environmental Factors: (Ambient Consider vehicle and environmental factors
Temperature, Wind, Tires, Axle Alignment, when evaluating fuel consumption.
Routes etc.)
OK
*
I. . . . . . I
, I r I
Check coolant supply. Drain coolant and
Bulk Coolant Supply Contaminated replace with non-contaminated coolant.
I I L /
OK
t
Replace the fuel heater. Refer to the manufac-
Fuel Heater Malfunctioning ....... turer’s recommendations.
OK
Bulk Oil Supply Contaminated ....... Check oil supply. Drain oil and replace with
non-contaminated oil. Replace oil filters.
OK
OK
t
OK
Crankcase Breather or Breather Tube Plugged Check crankcase breather and tube. ,tg;
OK
*
OK
*
OK -:
*
Coolant in the Oil , Internal Engine Component Contact an Authorized Repair Facility
Leaks
Troubleshooting Symptoms Charts Ml1
Page TS-38 Section TS - Troubleshooting Symptoms
!
1
Oil Pressure Switch/Gauge/Sensor Malfunc-
tioning or Incorrect Location
OK
I 1
Verify the
functioning
oil pressure
correctly:
switch/gauge/sensor is
JI
t
I I I I
Refer to symptom tree Coolant Temperature
Engine Coolant Temperature Too Low Below Normal.
II
I I I
OK
Oil Does Not Meet Specifications (Oil Viscosity Change the oil and check oil specifications.
Too High) . Refer to Section V.
OK
*
I I
Contact a Cummins Authorized
Repair Facility
Ml1 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-39
OK
t
OK
OK
t
OK
Oil Temperature Above Normal (120aC Refer to symptom tree Lubricating Oil Tem-
[250°F]) . perature Above Normal.
OK
OK
Oil Drain Interval and/or Oil Filter Replacement Check records. Compare to specifications.
. ’ Refer to Section V.
Interval incorrect
OK
*
OK
-z
OK
t
OK
*
OK
Engine Coolant Temperature Excessive (Above Refer to symptom tree Coolant Temperature
IOOT [212”Fj) . Above Normal - Sudden Overheat.
OK
OK
9- *..
I
Contact a Cummins Authorized
Repair Facility I
Troubleshooting Symptoms Charts Ml1
Page TS-42 Section TS - Troubleshooting Symptoms
Intake Air System Restricted Check intake air system for restrictions.
OK
*
OK
w
Intake Air Leaks Between Turbocharger and Check for air leaks.
Cylinder Head
OK
*
OK
w
OK
\t
I Coolant Temperature
OK
Too Low ” ”
Refer to symptom
Below Normal.
chart Coolant Temperature
OK
OK
OK
t
Operating for Extended Periods Under Light or Review vehicle operation. Refer to Section 1.
. . . .
No-Load Conditions (Slobbering)
OK
*
OK
*
I ......
I
Check and clean line.
I
NOTES
,- ” M 11
$. Page V-a
,.. :‘Section V - Maintenance Specifications
.“?
:’ i
>5 > i-
$ ‘, ’ ; Section V - Maintenance Specifications
E Section Contents
.3.+;y: Page
*,
3: Arctic Operation . . . . . . . . . . . . . . . . .._......................................................................................................................... V-20
9.. Capscrew Markings and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . v-21
>g’
I=..: Capscrew Markings and Torque Values - Metric . . . ..I...................,.,.,,,,....,................................................. V-22
.‘~. ‘,. Capscrew Markings and Torque Values - US. Customary .,.....,..,....,..,...,................................................. V-23
I.. : Coolant Recommendations and Specifications ,...............,....,..,...,..,..,.....,....,.............................................. V-10
‘:,
,f: Coolant Replacement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...~..... ........... V-17
;,y Cooling S y s t e m Sealing Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ;:;;
./
i:. Cooling System Soluble Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . .
),?: Fleetguarda D C A 4 S e r v i c e Filters a n d Liquid Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-13
<. Fully Formulated Coolant/Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-10
,. :a
Ji Supplemental Coolant Additive (SCA) ..,...........,..............,,................,......................................................... V-14
.:&, Test Intervals . . . . . . . . . . . ..I....._.................................,...,......,...,...,......,.....,.,...,.,.,,.,..,......,....,............................ V-l 6
:.-: Testing S C A Concentration Level CC-2602 Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-15
‘:
$ : Precautions and instructions for Proper Kit Use . . . . . . . . .._........................................................................... V-15
Drive Belt Tension . . . . . . . . . . .._.......................................................................,,.....,,,........................................... V-18
a,
<.‘.‘, Engine Component Torque Values ..,......................,...... , . . . . . . . . . . . 1. 1.. . . I.. . . . . c-19 -i
e
;; Fuel Recommendations and Specifications ..,..............,.,..,..............,.,,.......,,................................................. V-5
,.
:_ Lubricating Oil Recommendations and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-7
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-8 .............
-. , New Engine Break-in Oils .,....._..,..............,....,......,..,..........,.,.,............,.,,,.,...,...,....,..,..........,,..,...........,..,... V-7
,? Arctic Operation Engine Oil . . . . . . . . . . . . . . . . . . . . ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . z:i .......
i:
i3.: Oil Drain Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Specifications... ,,...,.._........,........................................................,....,.,,................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V . -l
Air Intake S y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... V-2 ~.......
‘r’ Batteries (Specific Gravity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ .. . . .. . . . . . . . . . V-4
‘;1
I~/ Compressed Air System ,..,..,.............,............,,,............,.......,..........,,,.....,,...,.....,,...............................,........ V-2
,.,;- HolsetQ SS296/SS296E/QE296 A/C Models .,_.............,.,.........,............,...............,................................... V-3
t.:‘?- Holset@ SS338lQE338 A/C Models .,,....,_...,I.,....,.....,,.,....,,..,,,,,.........................,...,................................. V-2
.; Holset@ ST676 AIC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y:T
:.-- Cooling System .,.....................................................................,................................................. ...........
Cummins/Fleetguard@ Filter Specifications . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . V-5
,..,
>%1 : Lubricating Oil Filters . . . . . . . . . . . . . . . .._............................................................................................................. V-5
Electrical S y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. V-4
Exhaust S y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... Z-T
Fuel S y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . .,..,......,........,........,..,.,.,.............,..................................... ‘........................ -
General Specifications ..,.......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Lubricating Oil System .,.............,.........................,................................ ................................................
: ’
.;
e.
<:
‘.
:
a, Ml1
Section V - Maintenance Specifications
Specifications
Page V-l
Specifications
General Specifications
Horsepower (Refer to engine dataplate)
Engine speed @ M a x i m u m O u t p u t :
Standard Rating (rpm) ............................................................................................................................... 2100
Bore and S t r o k e ....................................................................................... 125 mm [4.921 in] x 147 mm f5.787 in1
Displacement ...................................................................................................................... 1 0 . 8 titers ]661 C.I.D.1
Firing Order ..................................................................................................................................... l-5-3-6-2-4
Crankshaft Rotation - (viewed from the front of the engine) ................................................................. Clockwise
Fuel System
For performance and fuel rate values, refer to the engine data sheet or the fuel pump code for the particular model ..
involved.
Fuel Inlet Maximum Restriction:
Clean Fuel Filter .............................................................................................................. 102 m m H g (4 in Ml
Dirty Fuel Filter ................................................................................................................ 204 m m Hg ]8 in Ml
Fuel Drain Line Maximum Restriction
Without Check Valves ..................................................................................................... 63 mm Hg 12.5 in Hgl
W i t h Check Valves ......................................................................................................... 165 m m H g L6.5 in H g l
Fuel Inlet Maximum Temperature ..................................................................................................... 71 ‘C ]16O”F]
Engine Minimum Cranking Speed .......................................................................................................... 150 RPM
Lubricating Oil System
Oil Pressure:
Low Idle (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 0 kPa IlO Psi]
At 1200 rpm or Torque Peak (Minimum Allowable) .,..,....,,...,.._.,....,.,..,,....,.,...,,.,....,................ 207 !@a 130 Psi]
oil Capacity of Standard Engine:
Combination Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . 6 liters ]0.7 U.S. gallon1
Oil Pan (High-Low) . . . . . . . . . . . . .._...__.................................................................... 34 - 26.5 liters [9 - 7 U.S. gallon]
Cooling System
Coolant Capacity (Engine only-Aftercooled) _..__..............,.........,................,..,.....,.....,...,,.. 12.9 liters [3.4 U.S. gal.]
Standard Modulating Thermostat-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I. . 82== to 93°C [I80 to 200°F]
Cylinder Block Coolant Pressure (Pressure Cap Removed):
Minimum
Closed Thermostat - 1800 RPM - N o Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 kPa ]20 Psi]
Maximum
Closed Thermostat . . . . . . . .._...._.................... :: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
. . . . . . kPa ]40 Psi]
Maximum Allowable Operating Temperature ..,..................,.......,.......,....,..,........,...,,....................... 1OO’C [212”F]
wlnimum Recommenoeo Operating Temperature ,.,....................,..........,.........,....,.....,..,....,............. 77°C ]ISO-P>
M a x i m u m Aifowabie Deaeration Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 minutes
Minimum Recommended Pressure Cap . . . . . . . . .._............................................................................... 48 kPa 17 psi]
-_--
Specifications Ml1
Page V-2 Section V - Maintenance Specifications
Exhaust System
Maximum Back Pressure From Piping and Silencer (Combined):
76 mm [3 in]
H g . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............
1016 m m 140 in]
H$ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................
Exhaust Pipe Size (Normally Acceptable Inside Diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm (4 in.]
Specifications Ml1
Page V-4 Section V - Maintenance Specifications
Electrical System
Minimum Recommended Battery Capacity
System Voltage Ambient Temperature
-18°C [OOF] O°C[32”F]
Cold Cranking Reserve Cold Cranking Reserve
Amperes Capacity’Amperes Amperes Capacity’ Amperes
12 Volt 1800 640 1260 480
24 Volt’ 900 320 640 240
1. The number of plates witin a given battery size determines reserve capacity. Reserve capacity determines
the length of time which sustained cranking can occur.
2. CCA ratings are based on two 12 volt batteries in series.
A minimum of 9 volts at the ECM connector is required to power-up the ECM on CENTRY engines.
1. OK. ONLY if fuel lubricity is adequate. Refer to Fuel for Cummins Enginss, Bulletin No. 3379001.
2. Acceptable ONLY if
- chrome plated injector plated injector plungers fuel additive AND the heavy duty carbon graphite bushed gear pump are used, pr
- the fuel is blended with enough fuel additive to increase the lubricity abovs the minimum level. Refer to Fuel for CUmmlns Engines,
Bulletin No. 3379001.
NOTE: Any adjustment to compensate for reduced performance with a fuel system using substitute fuel is not warrantable.
Additional information for fuel recommendations and specifications can be found in Fuel for Cummins Engines, Bulletin
No. 3379001. See ordering information in the back of this manual.
Ml1 Lubricating Oil Recommendations and Specifications
Section V - Maintenance Specifications Page V-7
A CAUTION A
A sulfated ash limit of 1.85 percent has been placed on all engine lubricating diis recommended for use in
Cummins engines. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.
Additional information regarding lubricating oil availability throughout the world is available in the E.M.A. Lubricating
Oils Data Book for Heavy Duty Automotive and Industrial Engines. The data book can be ordered from the Engine
Manufactti~ersAssbciation, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S. A. 60601. The telephone
number is: (312) 644-6610.
A CAUTION A
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals
can decrease engine life due to factors such as corrosion, deposits, and wear. -3
If an engine is operated in ambient temperatures consistently below - 23OC [ - lOoF] and there are no provisions to
keep the engine warm when it is not in operation, use a synthetic GE/SF engine oil with adequate low temperature
properties such as 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications
Lubricating Oil Recommendations and Specifications Ml1
Page V-8 Section V - Maintenance Specifications
General Information
The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals is a critical
factor in maintaining engine performance and durability.
Cummins Engine Company, Inc. recommends the use of a high quality SAE 15W-40 heavy duty engine oil, such as
Cummins Premium Blue, which meets the American Petroleum Institute (API) performance classification CG-4 or CF-4.
NOTE: In areas where CG-4 or CF-4 engine oils are not yet available, contact your Cummins Distributor for other oil
recommendations.
A sulfated ash limit of 1 .O mass percent is suggested for optimum valve and piston deposit, and oil consumption control.
The sulfated ash must not exceed 1.85 mass percent.
For further details and discussion of engine lubricating oi\s for Cummins engines, refer to Cummins Engine Oil
Recommendations, Bulletin No. 3810340.
Fully formulated antifreeze contains balanced amounts of antifreeze, SCA, and buffering compounds, but does NOT
contain 50% (percent) water. Fully formulated coolant contains balanced amounts of antifreeze, SCA, and buffering
compounds already premixed 50/50 with deionized water.
The following pages will give an explanation of water, antifreeze, and SCA’s. They will also explain how to test antifreeze
and SCA levels,
This section also contains information on cooling system maintenance and a coolant treatment chart that is used to
determine the correct SCA service filter.
Alternative maintenance practices for cooling systems can be found in Cummins Coolant Requirements and Main-
tenance, Bulletin No. 3666132.
Maintenance Intervals for Cooling System up to 1514 Llters 1400 U.S. Gallons]
Install service filter(s) and/or l i q u i d c o n t a i n i n g n u m b e r o f S C A u n i t s b e l o w :
Service System Size in Liters pJ.S. G a l l o n s ]
Interval 79.144 117-169 193.264 266.376 362.566 572.757 761-946 950-1135 1139.1325 1329.1574
HOLES [21.30] 131.501 [S-75] (76.1001 [IOI-1501 1151.ZOO] [ZOl-2501 [251-3001 (301.3501 [351.400]
751-1000 25 50 80 100 150 200 250 300 350 400
501.750 20 35 60 75 110 150 190 225 260 300
261.500 15 25 40 50 75 100 125 150 175 200
o-250 IO 15 20 25 40 50 65 75 90 100
Notes:
A. Consult the vehicle equipment manufacturer’s maintenance information for total cooling system capacity.
B. When draining and replacing the coolant, always pre-charge the cooling system to a SCA level of 1.5 units
per gallon. This concentration level must never be allowed to go below 1.2 units and must be controlled when
the level is greater than 3 units. Action needed when the level goes below 1.2 is a filter and liquid pre-charge;
from 1.2 to 3.0 units, filter only; above 3.0, test at every oil change until level falls to 3.0 or below.
NOTE: When performing service which requires draining the cooling system, take special precautions to collect it in
a clean container, seal it to prevent contamination, and save for reuse.
C. Change coolant filters at each oil change to protect the cooling system. Consult the coolant capacity chart to
determine the correct coolant filter for a given cooling system capacity and oil drain interval.
Coolant Recommendations and Specifications Ml1
Page V-14 Section V - Maintenance Specifications
Test Intervals
Testing is recommended if the operator is not sure of his
cooling system condition due to leaks, uncontrolled topping
off of the system, or major coolant loss.
Testing is also recommended twice a year to monitor the
SCA level. If the SCA level is above 3 units, test at sub-
sequent oil drain intervals until the concentration is back
under 3 units. When the concentration is back under 3
units, start installing the correct service filters at each drain
interval.
“..
0
ta
rl
0
OK
3 Units of SCA
3 + Units of SCA
Ml1 Coolant Recommendations and Specifications
Section V - Maintenance Specifications Page V-l 7
CC2602 Coolant Test Kit - Works with any SCA formulation (Call 1-800-521-4005 if you have this
test kit and the color chart does not show the number of units of , “..
SCA per gallon of coolant.
Probablizer:
3316169s Plug - Installs on the engine for easy coolant sampling
3316168s Cap - Use with Monitor C bottle to sample coolant
CC2700 Monitor C - Lab analysis of coolant samples
Call the following numbers to get answers to any questions you may have about cooling system maintenance.
I.380 in
T- Belt Tension Gauge Part No.
Click-type
3822524
Burroughs T- Belt Tension New
N
620
Ibf
140
Belt Tension Range Used*
N
270 to 490
Ibf
60 to 110
I.440 in 3822524 620 140 270 to 490 60 to 110
112 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11116 in 3822524 ST-II 38 620 140 270 ta 490 60 to 110
314 in 3822524 ST-1138 620 140 270 to 490 60 to 110
718 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-I 293 710 160 290 580
to 65 to 130
8 rib 3822525 ST-1293 a90 200 360 to 710 a0 to 160
10 rib 3822525 3823138 1110 250 440 t0 890 100 to 200’
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 a90 to 1070 200 to 240
NOTE: This chart does not apply to automatic belt tensioners.
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Ml1 Engine Component Torque Values
Section V - Maintenance Specifications Page V-19
Arctic Operation
A CAUTION A
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals
can decrease engine life due to factors such as corrosion, deposits, and wear.
If an engine is operated in ambient temperatures consistently below -23T [ - lOoF] and there are no provisions to
keep the engine warm when it is not in operation, use a synthetic CElSF engine oil with adequate low temperature
properties such as 5W-20 or SW-30.
The oil supplier must be responsible for meeting the performance service specifications
Ml1 Capscrew Markings and Torque Values
Section V - Maintenance Specifications Page V-21
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than IO, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
hi;;2; Markings and Torque Values Ml1
Section V - Maintenance Specifications
@@Q,
Ca~screw Torque - Grade 5 Caoscnw Capscrew Tcque - Grade 8 Capscraw
NOTES
Ml1 Page W-a
Section W -Warranty
Section W --Warranty
Section Contents
Page
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items
replaced during repair of a Warrantable Failure.
DURING THE BASE ENGINE AND EXTENDED MAJOR COMPONENTS WARRANTIES
Owner is responsible for the operation and maintenance of the Engine as specified in the applicable Cummins
Operation and Maintenance Manual. Owner is also responsible for providing proof that all recommended main-
tenance has been performed.
Before the expiration of the applicable warranty, Owner must notify a Cummins distributor, authorized dealer or
other repair location approved by Cummins of any Warrantable Failure and make the product available for repair
by such facility. Locations are listed in the Cummins International Sales and Service Directory.
Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of a
Warrantable Failure.
Owner is responsible for non-Engine repairs, “downtime” expenses, cargo damage, fines, all applicable taxes,
all business costs and other losses resulting from a Warrantable Failure.
Limitations
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or ,
neglect, including, but not limited to: operation without adequate coolants or lubricants; overfueling; overspeed-
ing; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or
shutdown practices; unauthorized modifications of the Engine. Cummins is also not responsible for failures
caused by incorrect oil or fuel or by water, dirt or other contaminants in the fuel or oil.
Accessories, except for clutches and filters, supplied by Cummins as part of a fire pump or power unit (package
units) are covered for the duration of the Base Engine Warranty period.
Starters, alternators, power steering pumps and non-Cummins air compressors supplied by Cummins on B or
C Series Engines that are not supplied as part of a package unit are covered for six months from the date of delivery
of the Engine to the first user, or the date the Engine is first leased, rented or loaned, or from when the Engine
has been operated for 50 hours, whichever occurs first.
Except for the accessories noted previously, Cummins does not warrant accessories which bear the name of
another company. Such non-warranted accessories include, but are not limited to: fans, air conditioning com-
pressors, clutches, filters, transmissions, torque converters, steering pumps, non-Cummins fan drives, and air
cleaners.
Cummins Compusave units are covered by a separate warranty.
Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation
t0 show that consumption exceeds Cummins published standards.
Failures of belts and hoses supplied by Cummins are not covered beyond the first 500 hours or one year of
operation, whichever occurs first.
Parts used to repair a Warrantable Failure may be new Cummins parts, Cummins approved rebuilt parts, Or
repaired parts. Cummins is not responsible for failures resulting from the use of parts not approved by Cummins.
A new Cummins or Cummins-approved rebuilt part used to repair a Warrantable Failure assumes the identity of
the part it replaced and is entitled to the remaining coverage hereunder.
CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS IN REGARD
TO THESE ENGINES. CUMMINS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MER-
CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
In case of consumer sales, in some countries, the Owner has statutory rights which cannot be affected or limited
by the terms of this warranty.
Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties.
Ml1 Cummins Warranty - United States and Canada industrial
Section W - Warranty Page W-3
Emission Warranty
Products Warranted
This emission warranty applies to new Engines marketed by Cummins that are used in the United States” in
vehicles designed for Industrial off-highway use. This warranty applies to Engines delivered to the ultimate
purchaser on or after January 1, 1996.
Coverage
Cummins warrants to the ultimate purchaser and each subsequent purchaser that the Engine is designed, built
and equipped so as to conform at the time of sale by Cummins with all U.S. Federal emission regulations
applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause
it not to meetthese regulations within the longer of the following periods: (A) Five years or 3,000 hours of operation,
whichever occurs first, as measured from the date of delivery of the Engine to the ultimate purchaser, or (8) The
Base Engine Warranty.
If the vehicle in which the Engine is installed is registered in the state of California, a separate California Emission
Warranty also applies.
Limitations
Failures, other than those resulting from defects in materials, or workmanship, are not covered by this warranty,
Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or
neglect, including, but not limited to: operation without adequate coolant or lubricants; overfueling; overspeeding;
lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or
shutdown practices; unauthorized modifications of the Engine. Cummins is also not responsible for failures
caused by incorrect fuel or by water, dirt or other contaminants in the fuel.
Cummins is not responsible for non-Engine repairs, “downtime” expenses, cargo damage, fines, all business costs
or other losses resulting from a Warrantable Failure.
CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
‘Includes American S a m o a , t h e C o m m o n w e a l t h o f N o r t h e r n Mariana I s l a n d s , G u a m , P u e r t o R i c o , a n d t h e U . S . V i r g i n I s l a n d s .
California Emission Control System Warranty Statement Ml1
Page W-6 Section W - Warranty
The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed,
built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and
that it is free from defects in materials and workmanship which cause the failure of a warranted part.
Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only
for regular inspection to the effect of “repair or replace as necessary” is warranted for the warranty period.
Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of
time prior to the first scheduled replacement point for that part.
The owner will not be charged for diagnostic labor which leads to the determination that a warranted Part is
defective, if the diagnostic work is performed at a warranty station.
The manufacturer is liable for damages to other engine components caused by the failure under warranty Of any
warranted part.
Cummins is not responsible for failures resulting from improper repair or the use of parts which are not genuine
Cummins or Cummins approved parts.
These warranties, together with the express commercial warranties and emission warranty are the sole warranties
of Cummins. There are no other warranties, express or implied, or of merchantability or fitness for a particular
purpose.
Service Bulletin
Subject 340
Cummins Engine Oil Recommendations
This Service Bulletin outlines the proper application and maintenance of engine oil for Cummins engines. The purpose
of this Service Bulletin is to update and simplify Cummins recommendations and guidelines for the end user.
Cummins recommends the use of a high quality SAE 15W-40 engine oil. Refer to Section 1 for Diesel engine oil
specifications and Section 2 for Natural Gas engine oil specifications.
Cummins bases oil drain specifications on oil contamination. Maintaining the correct oil and filter change interval is
a vital factor in preserving the integrity of an engine. Consult your Operation and Maintenance manual for detailed
instructions on determining the oil change interval for your engine.
The following sections are included in this Service Bulletin:
Section Title Page -..
1 Diesel Engine Oil Recommendations 2
2 Natural Gas Engine Oil Recommendations 3
3 Function of Engine Oil 3
4 Viscosity 4
5 Oil Performance Classification 6
6 Oil Contamination 6
7 Oil Filtration 7
8 Oil Change Interval 8
9 Used Oil Analysis 9
Appendix A Used Oil Analysis Applications 11
Appendix B Examples of Oil Change Interval Calculations 13
Failure to follow applicable drain intervals and recommendations in this Service Bulletin can result in severe (
engine damage which may not be covered under warranty.
SECTION 1: DIESEL ENGINE OIL RECOMMENDATIONS
Cummins Engine Company, Inc. recommends the use of oil that meets the American Petroleum Institute (API)
performance categories of CF-4, CG-4, CF-WSG, or CG-4/SH. Oil with an older API classification of CD or CE may
be used in areas of the world outside North America wnere oils meeting the current API categories are not available.
However, if using CD or CE classification oil, the oil must be changed at the standard service interval and only extended
if scheduled oil sampling is used for close monitoring of oil condition. Oil with an API classification of CC may be used
in areas of the world outside North America where oils meeting the current API categories are not available, but if used,
they must be changed at one half the normally recommended service intervals. Oil with an API classification of CA
or CB must not be used.
NOTE: B and C series engines must use an oil with an SG or SH rating for lubrication of the sliding tappets.
The oil supplier is responsible for the quality and performance of their product.
Cummins Engine Company, Inc. recommends engine oil with a nominal ash content of 1 to 1.5 percent mass. Oils with
higher ash contents, up to 1.85 percent mass, can be used in areas where the sulphur content of the fuel is normally -..
1 to 1.5 percent mass. Limiting ash content is critical to the prevention of valve and piston deposit formation.
The primary recommendation is for multigrade oil of the viscosity grade indicated in Table 1. For normal ambient
temperature operating conditions (temperatures above -15°C [SOF]) SAE 15W-40 is preferred. The use of multigrade
oil reduces deposit formation, improves engine cranking in low temperature conditions and increases engine durability
by maintaining lubrication during high temperature operating conditions. Since multigrade oils have been shown to
provide approximately 30 percent lower oil consumption, compared with monograde oils, it is important to use
multigrade oils in order to make sure your engine will meet applicable emissions requirements. While the preferred
viscosity grade is 15W-40, lower viscosity multigrades can be used in colder climates. Refer to Table 1. However, use
15W-40 when conditions permit.
Table 1: Cummins Recommended SAE Oil Viscosity Grades versus Ambient Temperatures
Synthetic engine oils, API category III, are recommended for use in Cummins engines operating in ambient temperature
conditions consistently below -25OC [-13OF]. Above this temperature it is recommended that mineral oil based
multigrade lubricants be used. Use of synthetic OW-30 synthetic oils which meet the API category Ill may be used in
operations where the ambient tempreature never exceeds 0 degree C. OW-30 oils do not offer the same level of
protection for fuel dilution as do the higher multigrade oils. Higher cylinder wear may be experienced when using OW-30
oils in high load situations.
Rerefined lubricating oils can be used in Cummins engines if they have an API quality designation signifying they have
been tested and meet the minimum standards for that quality level. It is important to be certain these oils are actually
rerefined and not just reclaimed. Rerefined oils have been treated to remove additive and wear metal debris, distilled
and refortified with additives.
Do not use friction modified oil in Cummins diesel engines unless the oil supplier can provide evidence of satisfactory
performance in Cummins engines. Obtain the oil supplier’s commitment that they will make sure the oil is satisfactory
or do not use this product.
Cummins Engine Oil Recommend;;ien;
Special “break-in” oils are not recommended for use in new or rebuilt Cummins engines. Use the same lubricating
oil that will be used in normal engine operation. Synthetic or partially synthetic engine oils, however, cannot be used
.I’- in a new or rebuilt engine during break-in. Use a standard petroleym-based oi! for the first drain interval.
!
Correct oil and filter change intervals must be maintained for each specific Cummins engine model. A sharp increase
in component wear and damage can occur if excessive drain intervals are followed.
Use of a full flow and a bypass engine oil filter is mandatory on all Cummins engines except for B series engines. B
series engines must use a full flow engine oil filter. The alternative recommendation is to use a combination filter that
meets both the specified full flow and bypass filter standards. These standards can be found in the engine’s Operation
and Maintenance manual.
Monograde Oils
Shortened drain intervals may be required with monograde oils as determined by close monitoring of the oil condition
with scheduled oil sampling. Use of single grade oils may affect engine oil control.
Non-API Classified Oils
Advice may be required when using non-API classified oils. Oil suitability and service intervals can be determined by
close monitoring of the oil condition with scheduled oil sampling.
SECTION 2: NATURAL GAS ENGINE OIL RECOMMENDATIONS
The use of quality engine oils combined with appropriate oil and filter change intervals are critical factors in maintaining
t
0 engine performance and durability.
Cummins Engine Company, Inc. recommends the use of a high quality SAE 15W-40 engine oil for natural gas engines.
The specifications meeting Cummins’ recommended 15W-40 oil blends for natural gas engines are:
API CD Quality
SAE 15W40 Viscosity
Less than 0.5% Sulfated Ash
.I
TBN (ASTM D2696) - 5E.5
TAN (ASTM D664) - .5/.?
Including: For LIO and Ml1 natural gas engines:
250/350 PPM Phosphorous
2501360 PPM Zinc
1200 PPM Calcium
Including: For B and C series natural gas engine:
600/600 PPM Phosphorous
600/650 PPM Zinc
Cleaning
Oil acts as a cleaning agent in the engine by flushing contaminants from critical components. Sludge, varnish and
oxidation buildup on the pistons, rings, valve stems, and seals will lead to rapid engine failure if not controlled by the
oil. An oil formulated with the optimal additives will hold these contaminants in suspension until they are removed by
the oil filtration system or during the course of an oil change.
Protection
Oil provides a protective barrier, isolating non-like metals to prevent corrosion. Corrosion, like wear, results in the removal
of metal from engine parts. Corrosion works like a slow acting wear mechanism.
Cooling
Engines require the cooling of internal components that the primary cooling system cannot provide. The lubricating
oil provides an excellent heat transfer medium. Heat is transferred to the oil through contact with various Components
then transferred to the primary cooling system at the oil cooler.
Sealing
Oil acts as a combustion seal filling the uneven surfaces of the cylinder liner, piston, valve stem, and other internal
engine components.
Shock - Dampening
The oil film between contacting surfaces provides cushioning and shock-dampening. The dampening effect iS essential
to highly loaded areas such as the bearings, pistons, connecting rods, and gear train.
Hydraulic Action
Oil acts as a working hydraulic media within the engine, Examples of this are the use of oil to operate engine brakes
and STC injector tappets.
Engine oil must be formulated in such a manner that it-does not foam as a result of the mechanical agitation processes
associated with its many functions, Foamed oil results in engine damage similar to oil starvation due to insufficient oil
film protection.
SECTION 4: VISCOSITY
Viscosity is a measure of the resistance offered when one layer of oil molecules move relative to an adjacent layer. This
resistance comes from the friction generated by the oil molecules as they move past each other. This shearing action
occurs constantly in the oil films lubricating all moving parts of an engine.
The viscosity characteristics of all fluids are affected by temperature, Multigrade oil viscosities tend to be less sensitive
to temperature changes due to the addition of viscosity enhancements in their formulation. The viscosity of multigrade
oils is also a function of their rate of shear, or the relative speed of moving parts. The lower the relative speed, the greater
the apparent viscosity of most multigrade oils.
Oils have traditionally been selected for use with viscosities appropriate for the expected operating temperature which
often required the use of very heavy engine oils. Most of the wear an engine ordinarily experiences occurs at initial
startup in some applications before oil has time to fully circulate.
The correctly formulated multigrade oil is the ideal engine lubricant for a heavy duty engine. Relatively thin Oil iS
available for rapid lubrication and easy cranking while starting. To combat oil consumption, multi-viscosity oils exhibit
higher viscosity in the piston ring grooves which blocks this leakage path, and lower viscosity at the liner wall which
results in better ring wiping action. The overall result is less oil reaching the high temperature zone where deposits
can form, and cause excessive oil consumption.
Oil Viscosity and Engine Performance
The selection of oil of the correct viscosity is extremely important for optimum performance and for maximum engine
life. If the oil is too viscous, engine drag is increased with the following effects:
l Engine is difficult to start.
l Engine power output is reduced
Viscosity Recommendations
Cummins Engine Company, Inc. recommends the use of multigrade lubricating oils with viscosity grades shown in Table
St for the ambient temperatures indicated. Only the preferred oil grades are shown in the table. Monograde oils can
be substituted for multigrade oils in areas where multigrades are not currently available.
When using monograde oils, shortened drain intervals may be required as determined by close monitoring of the oil
condition with scheduled oil sampling. Use of single grade oils may affect engine oil control.
A CAUTION A
yak;;inglegrade oil is used, make sure the oil will be operating within the temperature ranges indicated in
additive combination can no longer satisfactorily protectthe engine, Progressive contamination of the oil between drain
intervals is normal, and can vary as a function of engine operation and load factor.
Oil Contaminants
In normal diesel engine operation a wide variety of contaminants are introduced to the lubricating oil.
1. Combustion by-products (exhaust gases or blowby gases) that leak past the piston rings, valve guides and
turbocharger seals into the crankcase. These gases contain particles of carbon, water, acids, partially burned fUel%
varnish and lacquers. All of these particles contaminate the oil.
2. Acids, varnish and sludge. As the lubricating oil comes in contact with hot engine components, or when heated
oil comes in contact with entrapped air, oxidation and decomposition occur creating contaminants such as acids,
varnish and sludge.
3. Abrasives or foreign materiai can enter the engine through the combustion air, fuel, worn engine parts and
inadequate service practices. They find their way to the crankcase with the combustion by-products.
4. Fuel or coolant in the oil are generally associated with engine malfunction. Fuel dilution, however, can also be
caused by excessive engine idling or stop-and-go operation.
5. Soot is caused by retarded injection timing and burning fuel mixing with oil on the liner. Excessive SOOt causes
abnormal valve and injector train wear.
0 6. Other contaminants are introduced by the specific operating environment. Examples are dust and abraslves such
as grit and road salt.
Oil Additives
Lubricating oil is formulated with additives designed to combat the specific contaminants listed in the previous section
throughout its usable life. The additives used are more important to overall engine performance than the oil itself.
Without additives, even the highest quality oil willhot be able to satisfy engine requirements. Additives include:
1. Detergents or dispersents which keep insoluble matter in suspension until the oil is changed. They are not removed
“. by the oil filtration system. Excessively long oil drain intervals result in sludge and carbon deposit formation in the
engine.
2. Inhibitors that maintain the stability of the oil, prevent acids from attacking metal surfaces and prevent rust formation
when the engine is not in operation.
3. Other lubricating oil additives assist the oil in lubricating highly loaded areas of the engine (such as valves and
the injector train), prevent scuffing and seizing, control foaming, and prevent air retention in the oil.
Friction Modifiers
There are generally two ways of improving engine oil frictional characteristics. One of these involves adjustments in
oil viscosity or viscosity temperature characteristics. Asecond consists of including additives in the oil formulation which
modify the metal surface frictional characteristics, These additives are known as friction modifiers.
The performance of the chemical additives used to change surface frictional characteristics is influenced by the engine
materials, the loads the part will carry, the oil contaminants introduced by the blowby process and the operating
temperatures.
There is firm evidence that certain friction modifiers, molybdenum dithiophosphate for example, can in certain
formulations result in cam follower roller pin failure at relatively low mileage. Although other friction modifiers or
formulations are not necessarily harmful, there is no definitive way to make certain oil performance is satisfactory other
than running the oil in the engine.
While friction modifiers, such as graphite, can reduce friction by plating the working surfaces of an engine, there is
a high probability of these chemicals dropping out on the filtering media. If this occurs, it can result in plugging of the
filter and other associated problems,
Cummins Engine Company, Inc. neither approves nor disapproves of any additives not manufactured or sold by
Cummins or its subsidiaries. Engine failure or performance problems which result from the use of such additives are
not warrantable by Cummins Engine Company, Inc.
SECTION 7: OIL FILTRATION
Maximum engine life is dependent upon the correct use and maintenance period of full flow, bypass or combination
lubricating oil filters that protect vital engine components from the abrasive contaminants which are held in suspension
in the lubricating oil. Cummins Engine Company, Inc. requires the use of full flow filters on all of its engine models.
Cummins Engine Oil Recommendations
Page 8
Except for B Series models, bypass filters are mandatory on all turbocharged engines and are strongly recommended
for use on all naturally aspirated engines.
The full flow filter will remove contaminant particles of 30 microns and larger which can be suspended in the engine i
oil. Particles of this size can cause immediate bearing damage.
The bypass filter receives approximately ten percent of the total pump output, filters it, and returns it to the oil pan.
The purpose of the bypass filter is to remove the smaller abrasive particles, down to ten microns, which the full flow
filter does not capture, and to maintain the oil contaminant concentration at a level low enough to prevent engine wear.
Many Cummins engines use a combination lubricating oil filter which contains both a full flow and a bypass filter in
one filter can.
Filter Plugging
During normal engine operation, the engine oil becomes contaminated from the combustion process as well as from
wear debris and oxidation products. Engine oil filters do not plug as long as the engine oil remains suitable for use
in an engine. A filter that plugs is performing its intended function of removing particulate matter from the oil. Filter
plugging is the result, not the cause, of an engine or lubricating oil problem.
There are several types of filter plugging. The most frequently observed are outlined below.
Excessive Oil Contamination occurs when the oil’s limit for handling combustion contaminants is exceeded. Filters
plugged in this way have a heavy buildup of loosely held sludge. This type of contamination is caused by fuel soot
oxidation products, and products of combustion which have accumulated in the oil to the point that the filter is no longer
able to function. Causes of this type of plugging include excessive oil change intervals, poor maintenance practices,
and high blowby.
Impaired Dispersancy is caused by coolant leaks into the crankcase, or a buildup of condensed moisture. This moisture
impairs the operation of the oil’s dispersant, so that fuel soot and carbon cling together and dropouttakes place. COOlant
or moisture in the crankcase can also cause part-of the oil’s additive package to precipitate from the oil and plug the
filter.
Gel or Emulsion Formation is a form of plugging caused when water or coolant contaminates oil. It often occurs when
oil in a bulk storage tank contains a small amount of water, less than 0.5 percent. Filter plugging can take place rapidly
after such oil has been added to the engine.
Chart Method
The chart method for calculating oil drain intervals allows for establishing individual engine baseline oil drain intervals.
Since engines and applications are different, the rate at which they consume fuel and, therefore, the rate at which
lubricating oil contamination levels are generated will also differ. In order to calculate oil drain intervals using the chart
method, it is necessary to consider the application, fuel and oil consumption rates, and the actual lubricating system
capacity of the specific engine model. To use the chart method effectively, accurate fuel and oil consumption records
must be maintained. As oil and fuel consumption rates change as a result of a change in operation or duty cycle of
a particular engine, the oil change interval established by the chart method must be re-evaluated based on the change
in oil or fuel consumption.
Consult the Operation and Maintenance manual for the chart that applies to the specific engine. See Appendix B for
an example of the chart method.
SECTION 9: USED OIL ANALYSIS
Oil Sample Collection
Oil sample collection intervals must be set in such a manner that trend comparisons can be made. Background data
is required if oil analysis is to be utilized correctly. Such data must include:
l Engine model/serial number.
%
l Miles/hours of oil use.
a
l Miles/hours on engine since new or since rebuild.
l Type of oil (brand name and viscosity grade).
l Date sample was collected.
l Type of engine application.
l Amount of new oil added since previous oil change.
l Any recent engine maintenance.
NOTE: It is important to conduct oil analysis on new (unused) oil to establish a baseline.
The sample to be used for analysis must be representative of the oil in the engine. Use the following guidelines when
collecting oil samples:
l Bring the engine to operating temperature prior to sampling. This will assure representative contaminant levels
are in the sampled increment.
l Successive samples must be taken in the same manner and from the same location.
l Take the use oil sample before adding any new oil to the engine.
l Always collect the oil in a clean, dry container.
arhree methods are commonly used to collect oil samples for analysis. Collect a minimum of 4 fluid ounces of oil. The
methods for collecting oil samples are:
Sample Valve Method: A valve is installed on the inlet side of the filter. When collecting a sample, the valve is wiped
clean, and after the engine is brought up to operating temperature, the valve is opened. Stagnant oil is allowed to flow
out, and a sample can be collected from the oil stream being pumped by the engine at idle.
Compuchek@ Fitting Method: A length of hose with a Compucheke adapter on one end can be attached to the filter
head Compuchekefitting. When collecting asample, the Compuchekefitting is wiped clean. Afterthe engine is brought
up to operating temperature, the oil is drawn through the Compucheks fitting while the engine is at idle.
Vacuum Pump Method: A length of tubing, measured against the dipstick, long enough to reach 25.4 to 51 mm [I
to 2 inches] below the oil level in the sump is attached to a hand operated vacuum pump. Immediately after stopping
the engine at operating temperature, pump the sample into a clean dry bottle. Do not allow the tube to draw oil from
the bottom of the oil pan. Excess debris will be included and will cause an incorrect oil analysis. Always replace the
tubing after each sampling to avoid the possibility of sample cross-contamination.
Contamination Check
* Used oil analysis can be employed to monitor engine contaminant levels which can provide evidence of system
weakness or failure such as faulty air filtration, coolant leaks, fuel dilution and wear metals that can suggest imminent
failure.
Cummins Engine Oil Recommendations
Page 10
This technique requires the comparison of the used oil analysis data to that obtained from the oil in its new
The extent of the used oil degradation from the new condition provides the indicators needed to monitor tf
The primary oil characteristics that will function as warning signals are the level of contamination (silicc
sodium, potassium) and the oil’s viscosity and flash point. General contamination check guidelines are listf
7.
l The contamination guidelines presented above are guidelines only. This does not mean values that
acceptable side of these guidelines be interpreted as indicating the oil is suitable for further servic
l The ASTM publishes testing methods in their ‘Annual Book of Standards’.
l In some circumstances, an increase in strong acid number is more applicable than TAN.
l Elemental analysis can be made using several different techniques such as Atomic Emission Spe
(AES), Atomic Absorption Spectroscopy (AAS), and Ion Coupled Plasma (ICP). These are not stand:
methods; however, most used oil analysis laboratories are capable of determining additive metal con’
by one of these methods. Sample results determined by the same laboratory using the same techniq
safely compared.
The guideline numbers presented above are representative of those which will be considered sufficient
investigation of the engine, maintenance practices, or operating procedure in order to identify the reasc
contaminant or oil property change. An oil change is also usually justified. The absolute values of the above i
with miles or hours on the engine, engine oil capacity, and the engine oil consumption rate.
Cummins Engine Oil Recommer&zi;;
0 APPENDIX A
--
Used Oil Analysis Applications
For the diesel engine operator, used oil analysis has two distinctly different applications:
Contamination Checks-used oil analysis can monitor engine oil contaminant levels and provides evidence of din
ingress, excessive fuel contamination (dilution), coolant leaks, excessive soot accumulation and abnormal wear.
General contamination check guidelines are listed in Table 7. These are only guidelines. This does not mean values
that fall on the acceptable side of these guidelines be interpreted as an indication that the oil is suitable for further use.
Used oil analysis is not a sole criteria in determining oil and filter change intervals.
Dirt ingress, usually caused by faulty air intake filtration, is determined by elevated levels of silicon in the used oil. At
times, dirt ingress occurs through the oil side of the engine from contaminated engine oil. The used oil will contain
abnormal levels of copper and lead from bearing material wear without extremely elevated levels of chromium and iron.
Excessive fuel contamination (dilution) is determined by the percent fuel in the used engine oil. This can also be
reflected in a viscosity decrease of more than a SAE grade and significantly lowered flash point compared to new oil
properties. The poor thermal stability of fuel results in oxidation of the fuel at oil sump temperatures. Subsequent
accumulation of elevated levels of lead in the used oil can occur from the interaction of the deteriorated fuel with bearing
and bushing materials.
Coolant contamination is identified from abnormal levels of the corrosion inhibitor in the coolant leaking into the oil.
m This results in elevated levels of sodium, potassium, boron and silicon in the used oil. Sodium and potassiumzontents
will depend on which is used for the corrosion inhibitor. Additionally, glycol components from antifreeze can be present
in the oil. Elevated levels of glycol components are not always present with coolant leaks because these components
can react with certain additive components in the oil, become volatile and boil off at sump temperatures. Deteriorated
glycol, which forms at oil sump temperatures, reacts with bearing and bushing materials to form elevated levels of lead
in the oil.
Excessive soot contamination of engine oil is identified as weight percent soot, and is measured by thermogravimetric
or infrared analysis. Soot is captured in the oil and harmlessly suspended until active additive components become
,.: depleted. It then agglomerates into larger particles. Valve and injector train wear occurs at an accelerated rate, resulting
in an increased soot generation rate and further accelerated wear. Valve and injector train wear result in elevated levels
of iron in the used oil. Unresolved, excessive soot accumulation and wear create sludge in the engine.
Abnormal wear causes abnormal accumulation of wear metals in the used oil. Condemnation limits are not possible
except for engines in an application operating at one site on a single engine oil. The wear metal content of an oil sample
depends on the engine, the load factor, the capacity of the lubricating system, the miles or hours on the oil, the engine
oil consumption rate and so on. Engines with large oil capacities result in lower wear metal levels than engines with
low oil capacities because the particles are suspended in a larger volume of oil. Low oil consumption engines exhibit
higher wear metal levels than high oil consumption engines because of the absence of dilution by new oil between
oil changes. Engine oil consumption rate can change the wear metal content of the used oil by a factor of two and mask
doubling wear rates which can indicate an imminent failure. Wear rates are unknown unless the engine oil consumption
is known. Wear metal levels vary nearly linearly with the miles or hours on an oil sample. Doubling the miles or hours
0 on an oil sample nearly doubles the wear metal content of a used oil sample. Wear metal content of a used oil sample
is almost meaningless information without the engine oil consumption rate, the miles or hours on the oil sample, and
a new oil analysis.
Abnormal wear which can indicate that there’s a problem usually only involves elevated levels of one or two metals.
Detection of elevated levels of a wear metal is best performed by comparing the levels in the used oil sample to the
levels in previous oil samples from the same engine. Engine components containing copper and lead can become
chemically active with a change in the additive chemicals in the oil, that is switching to a different brand of oil. This
often results in dramatically increased levels, often ten times, of copper or lead in used oil. Increased levels from this
source is not reason for excessive concern. These components will become passive again after a few oil changes with
different oil. Wear metal levels will then slowly decline back into the normal range for the engine.
Never disassemble an engine based solely on used oil analysis. Perform additional troubleshooting to determine if a
problem exists. If a problem is suspected based on oil analysis, cut open the full flow oil filter and look for wear metal
particles that are trapped by the filter and easily visible.
Evaluating Operating and Maintenance Intervals
Cummins Engine Company, Inc. does not recommend that oil analysis be used to determine maintenance intervals.
Oil analysis only permits maintenance intervals to be estimated. Engines must be operated at the estimated interval
for 805,000 to 1 ,I 27,000 km [500,00 to 700,000 mij or 10,000 to 15,000 hours to determine if the estimated maintenance
interval based on oil analysis was correct. If the interval is estimated correctly, the engine will remain in an acceptable
condition for it operating environment. If an extended maintenance interval is guessed incorrectly, up to 50 percent
of the potential engine life to rebuild can be sacrificed for the longer maintenance interval.
Cummins Engine Oil Recommendations
Page 12
The use of oil analysis to estimate maintenance intervals is complicated, time consuming and expensive
expensive, several hundred dollars per engine, to create baseline data upon which to estimate a maintenanc
This is due to the need to analyze samples by more detailed and expensive analytical procedures than ths
for contamination monitoring. Good record keeping on oil consumption is required during the baseline periol
oil consumption data is necessary to convert the ppm of metals in the used oil into wear rates. Often oil COI
rates increase by two to four times toward the end of a long maintenance interval.
For example, an engine with 3220 km [2,000 mi] per quart oil consumption during the first 8050 km [5,OOC
interval can consume oil at 805 km [500 mi] per quart with 32,200 km [20,000 mi] on the oil. Slow accumuiatil
metals can reflect increased oil consumption, not low wear rates because of dilution by more new oil. LOW 1
on engines operating toward the end of the maintenance interval are required to prevent a large loss in en!
overhaul.
Many used oil testing procedures were developed from quality control tests for new engine oil. In new engine
test reflect chemically active additives in the oil. They make sure that each time the oil is blended it contains t
amount of additives.
When these test procedures are applied to contaminated and deteriorated used oil, the data will not be m
Additives make a different chemical form in used oil.
Commercially available oil testing techniques do not measure depletion of all the chemical additives in
determine when these additives stop protecting engine parts from wear and deposits. Low wear metal leve
oil samples can reflect high oil consumption rates and dilution with new oil added to replace that consumed.
metal levels in used oil samples can also reflect additional contamination and wear debris. Engine oil operate
this saturation point often drops contamination and wear debris out as sludge. This results in declining wear m
at increasing kilometers [miles] or hours on the oil.This does not mean that wear rates are decreasing and oil
is improving. It means that oil analysis becomes meaningless after the engine oil is excessively contamin
The values listed in Table 7 are guidelines only. The absolute value of these numbers will vary with the si
Cummins Engine Oil Recomr
Appendix B
Duty Cycle Method Example:
The following example demonstrates the use of the duty cycle method in determining the recommendec
interval. Consult your Operation and Maintenance manual for the chart that applies to your specific engi
the following tables for the given example. This is an example for a heavy duty engine.
zoo
2,500
6
!25
3,700
Average fuel consumption Average fuel consumption is Average fuel consumt
is less than 5.5 mpg between 5.5 and 6.5 mpg above 6.5 mpg
a* Light Duty
I--
Miles 16,000
Months
Hours :50
Fuel Gallon- 3,000
Averaoe fuel consumotion Averaa_e fuel consumption is Average fuel consumf
I is lessthan 5.5 mpg ’ between 5.5 and 6.5 mpg above 6.5 mpg
l the truck is not operated off highway or in dusty conditions, and the fuel used contains less than 0.05 Pe
The following illustrates how the table is used.
Cummins Engine Oil Recommendations
Page 14
2. Next select the correct duty cycle based on the operating conditions of the engine. In this example, the fuel
consumption is between 5.5 and 6.5 miles per gallon and WW is less than 80,000 lb. Therefore, follow the
recommendations for Normal Duty.
3. The recommended oil change intervals for these conditions are 16,000 miles, six months, 400 operating hours,
or 3,000 fuel gallons, whichever comes first.
A CAUTION A
A sharp increase in engine component wear will occur if the oil drain interval is extended beyond the recom-
mended limits as determined by the duty cycle methods. Extended oil drain intervals will deplete the oil additives
package.
Chart Method Example:
The following example demonstrates the use of the chart method in determining the recommended oil change interval.
Consult the Operation and Maintenance manual for the chart that applies to the specific engine. The chart below is
used for the example given. This is an example for the high horsepower engine.
Assume that the total lubrication oil system capability equals 129 liters [34 U.S. gallons]. This can be determined by ‘-*
adding the high level of the oil in the oil pan plus the capacity of the full flow and by-pass filters. Also assume that
accurate fuel and oil consumption records have determined that the average fuel consumption equals 114 fiters [30
U.S. gallons] per hour and average oil consumption equals 4 hours per U.S. quart. The charts need to be applied in
the following order:
1. Select the chart entitled Lubricating Oil System Capacity 129 liters [34 U.S. gallons].
2. The left vertical axis of the chart represents fuel consumption in U.S. gallons per hour. Determine the location of
114 liters [30 gallons] on the left vertical axis and draw a line from left to right across the chart, parallel with the 0
bottom of the chart, until it intersects with the curve marked 4 (4 hours per quart).
3. From the intersection point on curve 4, draw a line perpendicular to the bottom of the chart. The number across
the bottom of the chart represents the oil change interval in hours,
4. In this case, the perpendicular line intersects the horizontal axis at 376. Using this process, the total Oil capacity,
oil consumption, and fuel consumption of the engine indicate that an oil change interval or 375 hours is recom-
mended.
A sharp increase in engine component wear will occur if the oil drain interval is extended beyond the recom-
mended limits as determined by the chart method. Extended oil drain intervals will deplete the oil additive
package.
Model 36000
Powershift Transmission
3-4-6 Speed
Short Drop