CUMMINS QSB4.5 Engine Operation & Maintenance Manual

Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins Authorized Repair Locations and component manufacturers. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the'new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins Inc. reserves the right to make changes ait any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. NOTE: 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 Introduction ........... ' ..................................... i Engine Identification ..................................................................................... Industrial Features .................. ......... ............................................................ :..... FB Operating Instructions ............................................................................. Maintenance Guidelines .................... ...:............ 2 Maintenance Procedures at Daily Interval ................................................................. Maintenance Procedures at 250 hours or 3 months ................................ 4 Maintenance Procedures at 500 hours or 6 months ................ 5 Maintenance Procedures at 1000 Hours or 1 Year ....................... 6 Maintenance Procedures at 2000 Hours or 2 Years ................................ 7 Maintenance Procedures at 5000 hours or 4 years ..................... 8 Adjustment, Repair, and Replacement .................................................................. System Diagrams ............................................................................................................................. D Service Literature ........................................................................... Component Manufacturers....................................................................................... Service Assistance ............................................................................ Troubleshooting Symptoms.................................................................................... Maintenance Specifications................................................................................... Warranty ........................................................ ....................... .................... ..;................... W

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. i Name Number Number Engine Model Engine Serial Number (ESN) ' Control Parts List (CPL) Fuel Pump Part Number Electronic Control Module (ECM) Electronic Control Module Serial Numbers (ECM) Filter Part Numbers: • Air Cleaner Element • Lubricating Oil I • Fuel • Fuel-Water Separator • Coolant / ■ • Crankcase Ventilation • Cummins Particulate Filter Governor Control Module (GCM) (if applicable) Belt Part Numbers: • ■ • • Clutch or Marine Gear (if applicable): l ■ ...................................... I • Model • Serial Number • Part Number • Oil Type • Sea Water Pump - Model f - Part Number

QSB Series Section i - Introduction Page i-a Section i - Introduction Section Contents , Page About the Manual ............. .. ................. ................. . ..................................... ..i-2 General Information.. ! ...... ..................................... ....i-2 Acronyms and Abbreviations ............. ............. .................. ....... ......... ......................................... ...i-13 General Information.................. ............................................................................... ......... .............. ...................i-13 General Cleaning Instructions ...................................... ..' . ......i-9 Abrasive Pads and Abrasive Paper......................... ................i-9 Definition of Clean................................... .........i-9 Gasket Surfaces ..................................................... ...i-10 Plastic Bead Cleaning.............. .................................. ................................... .......................... ............. ...... ........ ..i-11 Solvent and Acid Cleaning........................... i-10 Steam Cleaning.... .......................................... ............. .......................... .................. .............. ........ .......... ....i-11 General Repair Instructions .................................................... i-8 General Information...................... ...i-8 Welding on a Vehicle with an Electronic Controlled Fuel System ................................................ ...i-8 General Safety Instructions ....... i-6 Important Safety Notice ................. '.....i-6 How to Use the Manual .......................... ,.....i-3 General Information. ....... i-3 Illustrations .............. j-5 General Information. ............................ i-5 Symbols ............................. : ................... ,.i-4 General Information..................... ' ....................... ....i-4 To the Owner and Operator .............. i-1 General Information..................................... i-1

Page i-b This Page Left Intentionally Blank QSB Series Section i - Introduction

QSB Series Section i - introduction To the Owner and Operator Page i-1 To the Owner and Operator General Information Preventive maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines (Section 2). Keep records of regularly scheduled maintenance. Use the correct fuel, lubricating oil, and coolant in your engine as specified in Maintenance Specifications (Section V). Blending engine oil with fuel is prohibited for engines with an aftertreatment system. Cummins Inc. uses the latest technology and the highest quality components to produce its engines. Cummins Inc. recommends using genuine Cummins new parts and ReCon® exchange parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. If you have a problem that can not be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the Service Assistance (Section S). Product coverage, warranty limitations and owner responsibilities are available in Warranty (Section W). A cautionA Disconnect both the positive ( + ) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine mounted components is not recommended.

About the Manual General Information This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Inc. For additional service literature and ordering locations, refer to Service Literature (Section L). This manual does not cover vehicle, vessel, or equipment maintenance procedures. Consult the original vehicle, vessel, or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to Symbols in this section for a complete listing of symbols and their definitions. Each section of the manual is preceded by a Section Contents to aid in locating information. About the Manual QSB Series Page i-2 Section i - Introduction

QSB Series Section i - Introduction How to Use the Manual Page i-3 How to Use the Manual General Information This manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenance schedule, that states the required intervals and maintenance checks, is located in Maintenance Guidelines (Section 2). Locate the interval at which you are performing maintenance; then follow the steps given in that section for all the procedures to be performed. Keep a record of all the checks and inspections made. A maintenance record form is located in Maintenance Guidelines (Section 2). Engine troubleshooting procedures for your engine are located in Troubleshooting Symptoms (Section TS). Specifications for your engine are located in Maintenance Specifications (Section V).

Symbols Page i-4 General Information QSB Series Section i - Introduction 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: A A WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION - Minor personal injury can g'awSKStesr structions are not followed. Indicates a REMOVAL or DISASSEMBLY step. indicates an INSTALLATION or ASSEM- BLY step. INSPECTION is required. CLEAN the part or assembly. m rf\ PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE Cftil be given!.>»1 S J i! < *,~ * TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT. Refer to another location in this manual Pr information. iditional The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the compo* nent. ____

CUMMINS QSB4.5 Engine Operation & Maintenance Manual

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