Cummins QSB5.9-44 Operation and Maintenance Manual

Operation and Maintenance Manual Industrial B3.9, B4.5, and B5.9 Series Engines Cummins Customer Assistance Center 1-800-DIESELS TM ( 1-800-343-7357) APPLICABLE ONLY IN U.S.A. AND CANADA

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 at 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 and System Identification .................................................................................................................... E Operating Instructions ...................................................................................................................................... 1 Maintenance Guidelines .................................................................................................................................... 2 Maintenance Procedures at Daily Interval ...................................................................................................... 3 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 Adjustment, Repair, and Replacement ............................................................................................................ A System Diagrams .............................................................................................................................................. D Service Literature .............................................................................................................................................. L Service Assistance ............................................................................................................................................ S Troubleshooting Symptoms ............................................................................................................................. TS Maintenance Specifications .............................................................................................................................. V Warranty ............................................................................................................................................................. W Back .................................................................................................................................................................... back

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. 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 • 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): • Model • Serial Number • Part Number • Oil Type • Sea Water Pump - Model - Part Number

B3.9, B4.5, B5.9 Industrial 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-15 General Information...................................................................................................................................................i-15 General Cleaning Instructions ..................................................................................................................................i-10 Abrasive Pads and Abrasive Paper...........................................................................................................................i-10 Definition of Clean......................................................................................................................................................i-10 Fuel System...............................................................................................................................................................i-13 Gasket Surfaces........................................................................................................................................................ i-11 Plastic Bead Cleaning................................................................................................................................................i-12 Solvent and Acid Cleaning.........................................................................................................................................i-11 Steam Cleaning......................................................................................................................................................... i-12 General Repair Instructions ........................................................................................................................................i-8 General Information.....................................................................................................................................................i-8 Welding on a Vehicle with an Electronic Controlled Fuel System................................................................................i-9 General Safety Instructions ........................................................................................................................................i-6 Important Safety Notice...............................................................................................................................................i-6 How to Use the Manual ................................................................................................................................................i-3 General Information.....................................................................................................................................................i-3 Illustrations ...................................................................................................................................................................i-5 General Information.....................................................................................................................................................i-5 Symbols ........................................................................................................................................................................ i-4 General Information.....................................................................................................................................................i-4 To the Owner and Operator .........................................................................................................................................i-1 General Information.....................................................................................................................................................i-1 Downloaded from www.Manualslib.com manuals search engine

B3.9, B4.5, B5.9 Industrial Page i-b Section i - Introduction This Page Left Intentionally Blank Downloaded from www.Manualslib.com manuals search engine

B3.9, B4.5, B5.9 Industrial To the Owner and Operator Section i - Introduction 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). CAUTION 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. Downloaded from www.Manualslib.com manuals search engine

About the Manual B3.9, B4.5, B5.9 Industrial Page i-2 Section i - Introduction 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. Downloaded from www.Manualslib.com manuals search engine

B3.9, B4.5, B5.9 Industrial How to Use the Manual Section i - Introduction 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). Downloaded from www.Manualslib.com manuals search engine

Cummins QSB5.9-44 Operation and Maintenance Manual

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