Cummins Engine QSM11 Industrial Operation Maintenance Manual

P/N QSM11CUMMINSENG Shop Manual Copyright DOOSAN 2006 DOOSAN reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold. It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment. This documentation may include attachments and optional equipment not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Shop Manual P/N QSM11CUMMINSENG QSM11 Cummins

QSM11CUMMINSENG Page 1 QSM11 Cummins Engine QSM11CUMMINSENG QSM11 CUMMINS ENGINEQSM11CUMMINSENG QSM11 Cummins Engine Edition 1

QSM11CUMMINSENG QSM11 Cummins Engine Page 2 MEMO

QSM11CUMMINSENG Page 3 QSM11 Cummins Engine Table of Contents QSM11 Cummins Engine Safety Precautions ................................................ 7 Applicable Models ................................................. 7 QSM11 Engine ..................................................... 8 Important Reference Numbers ........................................ 9 Introduction ......................................................... 10 To the Owner and Operator ........................................... 10 About the Manual ........................................................... 10 How to Use the Manual ................................................. 11 Illustrations..................................................................... 11 General Safety Instructions ........................................... 12 General Repair Instructions ........................................... 15 General Cleaning Instructions ....................................... 17 Acronyms and Abbreviations ......................................... 25 Engine Identification ........................................... 26 Engine Data Plate .......................................................... 26 ECM Data Plate ............................................................. 27 Cummins Engine Nomenclature .................................... 27 Fuel Injection Pump Data Plate ..................................... 27 Engine Diagrams ........................................................... 28 Engine Specification ...................................................... 30 Operating Instructions......................................... 32 Operating Instructions - Overview ................................. 32 Normal Starting Procedure ............................................ 33 Cold Weather Starting ................................................... 35 Starting Procedure After Extended Shutdown or Oil Change................................................ 36 Operating the Engine ..................................................... 36 Engine Operating Range ............................................... 38 Engine Shutdown........................................................... 39 Electronic Controlled Fuel System................................. 39 Fuel System Description ................................................ 44 Programmable Features ................................................ 45

QSM11CUMMINSENG QSM11 Cummins Engine Page 4 Electromagnetic Interference (EMI) ............................... 50 Maintenance Guidelines ..................................... 52 Maintenance Guidelines - Overview.............................. 52 Tool Requirements ........................................................ 52 Maintenance Schedule .................................................. 53 Maintenance Procedures at Daily Interval .......... 55 Daily Maintenance Procedures - Overview ................... 55 Fuel-Water Separator .................................................... 56 Lubricating Oil Level ...................................................... 57 Coolant Level ................................................................. 57 Cooling System Hoses .................................................. 58 Fan, Cooling .................................................................. 59 Drive Belts ..................................................................... 60 Crankcase Breather Tube .............................................. 61 Charge-Air Piping .......................................................... 61 Air Cleaner Restriction .................................................. 62 Maintenance Procedures at 500 Hours or 6 Months......................................................... 63 Maintenance Procedures - Overview ............................ 63 Fuel Filter (Spin-on Type) .............................................. 63 Lubricating Oil and Filters.............................................. 65 Lubricating Oil Filter (Spin-on)....................................... 67 Coolant Filter ................................................................. 68 Supplemental Coolant Additive (SCA) and Antifreeze Concentration ........................................ 71 Engine Wiring Harness ................................................. 72 Maintenance Procedures at 1,500 Hours ........... 73 Maintenance Procedures - Overview ............................ 73 Overhead Set ................................................................ 73 Maintenance Procedures at 2,000 Hours or 1 Year....... 80 Maintenance Procedures - Overview ............................ 80 Air Cleaner Restriction .................................................. 80 Air Leaks, Air Intake and Exhaust Systems................... 81 Batteries ........................................................................ 83

QSM11CUMMINSENG Page 5 QSM11 Cummins Engine Engine Mounts .............................................................. 84 Engine Steam Cleaning................................................. 84 Turbocharger ................................................................. 85 Water Pump................................................................... 86 Vibration Damper, Viscous ............................................ 87 Fan Drive Idler Pulley Assembly .................................... 88 Turbocharger ................................................................. 88 Cooling System ............................................................. 89 Adjustment, Repair and Replacement ................ 96 Fuel Shutoff Valve ......................................................... 96 Belt Tensioner, Automatic (Alternator) ......................... 100 Water Pump................................................................. 102 Coolant Thermostat ..................................................... 111 Turbocharger ............................................................... 114 Check for Correct Component ..................................... 115 Refrigerant Compressor Drive..................................... 115 Starting Motor .............................................................. 117 Engine Storage - Long Term ....................................... 118 System Diagrams ............................................. 119 System Diagrams - Overview ...................................... 119 Fuel System ................................................................ 120 Lubricating Oil System ................................................ 121 Cooling System ........................................................... 122 Flow Diagram, Air Intake System ................................ 124 Service Literature ............................................. 127 Additional Service Literature ....................................... 127 Service Literature Ordering Location........................... 127 Cummins Customized Parts Catalog .......................... 128 Component Manufacturers ............................... 130 Service Assistance ........................................... 135 Routine Service and Parts........................................... 135 Emergency and Technical Service .............................. 135 Problem Solving .......................................................... 135 Division and Regional Offices - Locations ................... 137

QSM11CUMMINSENG QSM11 Cummins Engine Page 6 Distributors and Branches - United States .................. 138 Distributors and Branches - Canada ........................... 153 Distributors and Branches - Australia .......................... 156 Distributors and Branches - New Zealand ................... 159 Regional Offices - International - Locations ................ 160 Distributors - International - Locations......................... 167 Troubleshooting Symptoms .............................. 183 Troubleshooting Procedures and Techniques.............. 183 Troubleshooting Symptoms Charts ............................. 183 Maintenance Specifications .............................. 223 General Engine ........................................................... 223 Fuel System ................................................................ 223 Lubricating Oil System ................................................ 224 Cooling System ........................................................... 224 Air Intake System ........................................................ 225 Exhaust System .......................................................... 225 Electrical System......................................................... 225 Cummins/Fleetguard® Filter Specifications ................ 226 Fuel Recommendations and Specifications ................ 227 Lubricating Oil Recommendations and Specifications .............................................................. 228 After Market Oil Additive Usage .................................. 230 Coolant Recommendations and Specifications ........... 230 Cooling System Sealing Additives ............................... 232 Cooling System Soluble Oils ....................................... 232 Supplemental Coolant Additive (SCA)......................... 232 Testing SCA Concentration Level CC-2602 Test Kit .... 233 Test Intervals ............................................................... 234 Coolant Replacement Requirements .......................... 234 Drive Belt Tension ....................................................... 235 Engine Component Torque Values .............................. 235 Cap Screw Markings and Torque Values..................... 236

QSM11CUMMINSENG Page 7 QSM11 Cummins Engine SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DL500 5001 and Up

QSM11CUMMINSENG QSM11 Cummins Engine Page 8 QSM11 ENGINE Figure 1

Cummins Engine QSM11 Industrial Operation Maintenance Manual

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