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LeeBoy Cummins B3.9 & B5.9 Engine Manuals

1. Fuel ite SE Geesen chen o AE a a EE RE eu M cecal SE E ys cs dts t o A eode dcin i MEET SSC D Limming C stomersAssistance Center amp 3 siplri 800 DIESELS 1 800 343 7357 iiis NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 15 COLUMBUS INDIANA POSTAGE WILL BE PAID BY ADDRESSEE Cummins Engine Company Inc Product Registration Dept CAC PO Box3005 M C 91200 Columbus IN 47202 3005 hilullidibilibiahiblubilulnbnthillull Cummins Customized Parts Catalog Cummins is pleased to announce the availability of a parts catalog compiled specifically for you Unlike the generic versions of parts catalogs that support general high volume parts content Cummins Customized catalogs contains only the new factory parts that were used to build your engine The catalog cover as well as the content is customized with you in mind You can use it in your shop at your worksite or as a coffee table book in your RV or boat The cover contains your name company name address and telephone number Your name and engine model identification even appears on the catalog spine Everybody will know that Cummins created a catalog specifically for you This new catalog was designed to provide you with the exact information you nee
2. B3 9 and B5 9 Series Engines Page i b Section i Introduction THIS PAGE LEFT INTENTIONALLY BLANK B3 9 and 85 9 Series Engines To the Owner and Operator Sectioni 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 B recommendations outlined in Maintenance Guidelines Section 2 Keep records of regularly scheduled maintenance Use the correct fuel oil and coolant in your engine as specified in Maintenance Specifications Section V Cummins Engine Company Inc uses the latest technology and the highest quality componentsto produce its engines Cummins recommends using only genuine Cummins 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 inthe Service Assistance Section S About the Manual B3 9 and 85 9 Series Engines Page i 2 Section i Introduction About the Manual General Information E This manual contains information needed to operate and maintain your engine correctly as recommended by Cummins Engine Company Inc Additional service literature Gan be ordered from your local C mmins Distributor For problems th literature orders cont
3. LR A TS Maintenance Specifications rici Aet W leen 7 Lesser ERE Important Reference Numbers Control Parts List CPL Fuel Pump Part Number Filter Part Numbers e Lubricatina Oil Filter l Air Cleaner Element e Coolant e Remote Gas 9 04 refno Part Name Part Number Part Number f I Ciuich or Marine Gear i e Model e Part Number e Sea Water Pump applicable Part Number 83 9 and 85 9 Series Engines Sectiqn i Introduction Page i a Section i Introduction Section Contents About the Manual General Information e iomie crimina accen cna icai ois Acronyms and Abbreviations General Information eese enne nn nna General Safety Instructions Important Safety Notice How to Use the Manual P General Information ec seesse esee rennen rene rnm nnnm urnam ennnen na WLS TRATIONS doe ecco ocn cecinere EE General Information eene aus Symbols 5 s General Information esee nennen nennen e re To the Owner and Operator General Information
4. Troubleshooting Procedures and Techniques nimes General ienem n eat Troubleshooting Symptoms Charts serre Alternator Not Charging or Insufficient Charging ms Coolant ContaminatlOn s sss eene netten nnne nnnm ntn tn nnnm annnm tn nnar EE Coolant Loss mm ge Coolant Temperature Above W sse Coolant Temperature is Below Normal P PERE E e eEeee Engine Difficultto Start or Will Not Start Exhaust Smoke ME Engine Difficultto Start or Will Not Start No Exhaust Smoke Engine Noise Excessive mms Engine Power Output Low Engine Runs Rough at Idle Warm Engine Engine Runs Rough or Misfires Engine Speed Surges at Low or High idle Engine Starts But Will Not Keep Running Engine Vibration Excessive Engine Will Not Crank or Cranks Slowly Engine Will Not Reach Rated Speed RPM Engine Will Not Shut OF Exhaust Smoke Excessive Under Load Wale M Fuel or Lubricating Oil Leaking From Exhaust Manifold Soeresed tage ees E a era General InfOrtridtiOr se suscacercesarsaccrsceetsescteceesnseaenaceracrssncsovarseradsocseecssevesseserseies Lubricating Oil Contaminated rennes Lubricating Oil LOSS mens 83 9 and 85 9 t Engines Page TS b 1TS j Symptoms Page Lubricating Oil Pressure High eer t5 37 Lubricating Oil Pressure LOW inc cepa ecce nonae atr
5. Continued Carrection Check injection timing Refer to Section A inspect the return overflow valve Replace if necessary Refer to the OEM service manual With the key system an short out the harness at thi temperature switch If it engages troubleshoot the sensor or check for air In the coolant system Remove the sensor and make sure at ambient conditions the sensar is open and at the correct tennpekatisnareShets 1 93 F closes Replace if neces Sary Troubleshooting Symptoms Charts Page TS 41 83 9 and 85 9 Series Engines Section TS Troubleshooting Symptoms Smoke White Excessive Continued Correction Correction Cause UP EE D EI Inspectthe injectors Replacethe injectors as necessary Pad Section Cause Referto Section A Injector is malfunctioning KSB is malfunctioning Bosch VE only Sneck to ae if an eiiam sealing washer is installe under injector Remove any Refer to the OEM service Injector sealing washier not additional sealing washer manual Only one is required Refer to the OEM service manual f Coolant flow through the radiator s not correct Remove the fuel pum e Referta Section A Cali T brate the fuel pump Fuel in ection pump is malfunctioning Remeve injectorand install the roper sealing washer OK efer to Section A Contact a Cummins Authorized Repair Facility Injector sealing w
6. OK Fuel transfer pump mal E 83 9 and B5 9 Series Engines Section TS Troubleshooting Symptoms Engine Difficult to Start or Will Not Start No Exhaust Smoke Cause Correction Inspectthe fuel transfer 4 pump Replace if nees sary Refer to Section A vaty oa the Ki return ling is plumbed to the bottom of i 1 tha fe tank Fuel pump overflow valve i malfunctioning is not correct Continued Throttle linkage adjustment Check the overflow valve Replaoe f necessary Refer to the OEM service manual Check throttle linkage adjustment Refer to the OEM service manual B3 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 13 Engine Difficult to Start or Will Not Start No Exhaust Smoke Continued Cause PM Fuel injection pump is malfunctioning OK a Fuel injection pump timing is not correct EEN OK Contact a Cummins Authorized Repair Facility Correction Perform the fuel injection pump test Refer to the OEM service manual Put the engine at top dead center Check and adjust the fuel timing Refer to the OEM service manual ee leet Symptoms Charts 83 9 and B5 9 Series Engines Page TS 14 Section TS Troubleshooting Symptoms i i i t Engine Noise Excessive Cause t Correction Cause l Correction das le Check and adjust th
7. Torque Value 8 Nem 71 in Ib Fill A CAUTION A Duringfilling air must be vented from the engine cool ing passages Opentheengineventpetcock Make sure to open the petcock on the aftercooler for aftercooled engines The system mustbefilled slowly to prevent air locks Wait 2to3 minutes te allow air to bevented then add coolant to bring the level to the bottom of the radiator filler neck Failure to do so will cause entrap ment of air in cooling system and will cause engine to overheat Fill the coolant system with a prernixture of 50 percent water and 50 percent ethylene glycol type antifreeze Charge Air Cooler CAC Page A 80 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Charge Air Cooler CAC Leak Test SE i NOTE The long term integrity of the charge air cooler system is the responsibility of the vehicle and component manufacturers however the following symptoms can be cheoked by any Cummins Authorized Repair Location To check the charge air cooler for crackedtubes or header remove the inlet and outlet hoses from the cooler Remove the charge air cooler Install a cap over the outlet side d the cooler Install a pressure gauge and a shop air supply line to the inlet side of the cooler 83 9 and 85 9 Series Engines Air Intake Manifold Section A Adjustment Repair and Replacement Page A 81 Pressure Test Apply 276 kPa 40 psi of air pressureto t
8. Lubricating oll is contami nated with coolant or fuel rr Fuel lift pump is malfunc tioning tree OK Eds Werer me tusi injection uel iniection pump is pump Check the calibra Referto iho OEM EES malfunctioning tion of the fuel injection 1 pump Refer to Section A Lo LI OK e Contaci is cummins i uthorize Refer tg a Cummins Repair Facility Authorized Repair Faclllty Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Herer to Section B3 9 and 85 9 Series Engines Section TS Troubleshooting Sympfoms Cause gt Lubricating oil leak exter nal ME Lubricating oil level is above spetification Lubricating oil does not meet specifications for operating conditions mended in Section V of the Troubleshooting Symptoms Charts Page TS 35 Lubricating Oil Loss Correction Cause Correction Inspect the engine for external oil leaks Tighten the capscrews pipe plugs Check the lubricatingoil Lubricatingoil cooler is cooler for coglant ieaks and leaking cracks Referto the OEM service manual and fittings Replace gaskets if necessary Refei to the OEM service manual Air compressor is pumping Check the air lines for lubricating oil into the air carbon buildup and TP MA to system lubricating gj Pefer a Check the oil level Verify the
9. Warple Way London w3 788 England Telephone 01 743 3111 AC Delco Components Groua Civic Offices Central Milton Keynes MK9 3EL England Telephone 01908 66001 C E Niehoff amp Co 2021 Lee Street Evanston IL 60202 Telephone 708 866 6030 Delco Remy America 2401 Columbus Avenue RO Box 2439 Anderson IN 46018 Telephone 317 646 3528 Leece Neville Corp 400 Main Street Arcade NY 14009 Telephone 716 492 1700 Auxiliary Brakes The Jacobs ManufacturingCompany Vehicle Equipment Division 22 East Dudley Town Road Bloomfield CT 06002 Telephone 203 243 1441 H B3 9 and 9 Series Engines Gi M Component Manufacturers Belts De x Rubber Sr f Street St kp Cheshire SK4 1RV Eiga t Telephone C51 T 3 Belling Ltd HA Box 77 Wig Li bin W XQ England Telephone 01942 59221 Dayco Mfg Belt Technical Center 1955 Enterprize Rochester Hills MI 48309 Telephone 810 853 8300 Gates Rubber Company Dons Brosdway Goodyear Tire and Rubber Company Industrial Products Div 2601 Fortune Circle East Indianapolis IN 46241 Telephone 317 898 4170 83 9 and 85 9 Series Engines Section M Component Manufacturers Component Manufacturers Addresses General information Component Manufacturers Addresses Page M 1 NOTE The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines Suppliers ca
10. 2 3 4 5 6 7 Turbocharger wastegate actuator Oii Hill Front engine lifti bracket Water outlet Lubricating oil filter Lubricating oil cooler Water inlet Engine Diagrams a Page E 33 8 Water heater return 112 inch NPTF 9 Oil drain 10 Provision for oi immersion heater 11 Starter motor solenoid 12 Fuel injection nozzles Engine Diagrams 83 9 and B5 9 Series Engines Page E 34 Section E Engine Identification 13 2 12 11 3 10 9 4 5 8 6 7 0090027 Front View 83 9 and 85 9 Series Engines Section E Engine Identification oc BB DD a Turbocharger air outlet Engine air inlet Fuel pump drive cover Air compressor air outlet Front gear cover Fan drive belt Vibration damper Engine Diagrams Page E 35 8 Water inlet Water pump 10 Fan pulley 12 13 Alternator Automatic belt tensioner Turbocharger air inlet Engine Diagrams B3 9 and B5 9 Series Engines Page E 36 c E E gine Identification NOTES B3 9 and B5 9 Series Engines Section 1 Operating Instructions Page l a Section 1 Operating Instructions Section Contents Page Cold Weather Operation dia ee adi ct crc Eat ERROR ER die tace Sae RR ia coda issu 1 8 Operating Aids eee ee ee 1 8 llegro EELER Set 1 9 WINTCIFFONTS E 1 9 Cold Weather Starting Aids 1 10 Ether SE Aids 1 11 GIG ATS cates Te 1 12 1 10 Engi
11. 580 Lepihe 110Kress Street Dorval Quebec H8H 1G2 PO BOX 98 Telephone 514 631 5000 Regina SK S4P 225 FAX 514 631 0104 Telephone 306 721 9710 FAX 306 721 2962 Quebec City Branch a Cummins Diesel Saskatoon Branch of Winnipeg Branch of Cummins Americas Inc Cummins Mid Canada Ltd 2575 Dalton Street 3001 Faithful Avenue Ste Foy Quebec GI P 3S7 P O Box 7679 Telephone 418 653 841 1 Saskatoon SK S7K 4R4 Canada FAX 418 653 5844 Telephone 306 933 4022 FAX 242 1722 Val D Or Branch 306 Curnmins Eastern Canada Inc 1025 Rue Del Val D Or Quebec 59P 4P6 Telephone 819 825 0993 FAX 818 825 8488 Saskatchewan Lloydminster Branchof Winnipeg Cummins Mid Canada Ltd 4005 52nd Lloydminster SK 89V 0Y9 Telephone 305 825 2062 FAX 305 825 6702 Service Assistance Page S 21 Service asistance Page S 22 T Branches Gepps Cross Cummins Engine Company Pty Ltd PO BX 108 Blair Athol 5084 South Australia Australia Location 45 49 Cavan Road Gepps Gross 5094 Telephone 81 8 8262 5211 Dosra Cummins Engine Company Pty Lld P O Box 124 Darra 4076 Queensland Australia Location 33 Kimberley Street Darra 4076 Australia Telephone 61 7 8375 3277 Distributors and Branches Australia Bunbury Cummins Engine Company Pty Ltd PO Box 1751 Bunbury WA 6230 Australia Location 11 Dryanda Court Picton WA 6230 T
12. Bore Stroke Displacement Engine Weight any Less Flywheel and Electric Com ponents Firing Order Valve Clearances Intake Exhaust Compression Ratio Rotation Viewed from the Front of the Engine Aspiration Naturally Aspirated 102mm 4 02 in 120 mm 4 72 in 3 9 liters 238 in3 308 kg 679 Ib 1 3 4 2 0 25 mm 0 010 in 0 51 mm 0 020 in 18 6 1 Clockwise X 102 mm 4 02 in 120 mm 4 72 in 3 9 liters 238 in 320 kg 705 Ib 1 3 4 2 0 25 mm 0 010 in 0 51 mm 0 020 in 17 51 clockwise 102 mm 4 02 in 120 mm 4 72 in 3 9 liters 238 in 329 kg 725 Ib 1 3 4 2 0 25 mm 0 010 in 0 51 mm 0 020 in 16 51 Clockwise Specifications B5 9 S Page E 8 t Engines 1 E Engine Identification 483 9 4BT3 9 48TA3 9 Turbocharged X X Aftercooled X B3 8 and B5 9 Series Engines Section E Engine Identification General 6B Engine Data nonautomotive Bore Stroke Displacement Engine Weight dry Less ywheel and E Ee Com ponents Firing Order Valve Clearances Intake Exhaust Compression Ratio Rotation Viewed from the Front of the Engine Aspiration Naturally Aspirated Turbocharged Aftercooled 685 9 102 mm 4 02 in 120 mm 4 72 in 5 88 liters 359 in 388 kg 855 Ib 1 5 3 6 2 4 0 25 mm 0 010 in 0 51 mm 0 020 in 18 5 1 Clockwise X 6BT5 9 102 mm 4 02 in 120 mm 4 72 in
13. This warranty coverage is provided r five years or 160 935 km 100 000 miles or 3 000 hours of engine operation whichever first occurs from the date of delivery of the engine to the first user Where a Warrantable Condition exists Cummins will repair your engine at no cost to you including diagnosis parts and labor 83 9 and 85 9 Series Engines California Emission Control System Warranty E Highwa Section W Warranty Page W 3 Owner s Warranty Responsibilities LE As the engine owner you are responsible for the performance of the required maintenance listed in your Cummins Operation and MaintenanceManual Cummins recommendsthat you retain all receipts covering maintenance on your engine but Cummins cannot denv warrantv solely for the lack of receipts or for vour failure to substantiate the performance of all scheduled maintenance You are responsible for presentingyour engine to a Cummins dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time notto exceed 30 days Asthe engine owner you should also be awarethat Cummins may deny you warranty coverageif your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications If you have any questions regarding your warranty rights and responsibilities you should contact Cummins Customer Relation Department at 1 800 343 7357 or the California Air Resources Board at 9528 Telstar Avenue El Mo
14. Winterfrontscanbeused on avehicleequipped with charge air cooling CAC but must be designed to cover part of the frontal area of the cooling system A minimum of 387 cm 80 in of frontal area must be left open to allow airflowfor the CAC to function correctly Shutters installations of charge air cooler GAC engines with shut ters also require an intake manifoldair temperature switch to open the shutters to prevent excessive intake manifold temperatures This prevents engine damage due to high intake manifold temperatures as a result of blocked airflow across the CAC Cold Weather Operation age 1 9 Cold Weather Starting Aids 83 9and B5 9 Series Engines Page 1 10 Section 1 Operating Instructions Cold Weather Starting Aids With Mechanical or Electrical Metering Equipment Ether e Set the throttle at half speed Disengage the driven unit or ifequipped put the transmission in neutral Activate the switch to open the fuel pump shutoffvalve While cranking the engine inject metered amounts of starting fluid e Engine oil pressure must be indicated on the gauge within 30 seconds after starting 83 9 and B 9 Series Engines Cold Weather Starting Aids Section 1 Operating Instructions Page 1 11 Ether Starting Aids A WARNING A Because of the potential for an explosion do not use volatile cold starting alds in undergroundmine or tunnel operations Ask the local U S Bureau of Mines inspector for inst
15. Y I RN ipg9csua Air Intake System Overview 83 9 and B5 9 Series Engines Page A 74 Section A Adjustment Repair and Replacement Air Intake System Overview die General Information Air System Repair Summary Component to be Tools Preparatory Steps Replaced Air Crossover Tubing 8 mm socket screwdriver torque wrench Intake Manifold Cover and 10 mm socket R i pressure fuel lines disconnect d Gasket S aid if used and air crossover tubing Aftercooler Gasket 8 mm and 10 mm sockets 2 J t ll gaid if used 1 cross H 3 drain coolant Turbocharger and Gasket 10 mm 15 mm 16 mm 5 4 nt and exhaust piping and remove and7 16 inch wrenches crossover tubing Exhaust Manifold and 15 mm socket Dis x ct intake am exhaust piping t e tir Gasket x ube ai 1 re the turbocharger Removal of some cnassis parts is i necessary to gain access to some engi comp its 3c 16 EQuipma t r and precautions for removing chassis parts B3 9 and B5 9 Series Engines Air Crossover Section A Adjustment Repair and Replacement Page A 75 Air Crossover Remove 8 mm or Screwdriver D Loosen the hose clamps and position the hose so the crossover tube can be removed Install 8 mm or Screwdriver Use new hose and clamps as required to install the cross over tube Torque Value 8 Nem 71 in Ib Aftercooler 83 9 and B5 9 Series Engines Page A 76 Section Adjustment Repair and Replacement Af
16. Amarillo Branch Cummins Southern Plains Ine 5224 Interstate 40 Expressway East PO Box 31570 Amarillo TX 79120 1570 Telephone 806 373 3793 24 hours FAX 806 372 8547 Dallas Branch Cummins Southern Plains Inc 3707 Irving Boulevard Dallas TX 75247 Telephone 214 631 6400 24 hours FAX 214 631 2322 El Paso Branch of Phoenix Cummins Southwest Inc 14383 Gateway West El Paso TX 79927 Telephone 915 852 4200 FAX 915 852 3295 Fort Worth Branch Cummins Southern Plains Inc 3250 North Freeway Fort Worth TX 76111 Teleohone 817 624 2107 24 hours FAX 817 624 3296 B3 9 and B5 9 Series Engines tic 1S Service Assista Houston Branch Cummins Southern Plains Inc 4750 Homestead Road PO Box 1367 Houston TX 77251 1367 Telephone 713 875 7421 24 hours FAX 713 875 1515 Mesquite Branch Cummins Southern Plains Inc 2615 Big Town Blvd Mesquite TX 75150 Telephone 214 321 5555 24 hours FAX 214 328 2732 Odessa Branch Cummins Southern Plains inc 1210 South Grandview RO Box 633 Odessa TX 79760 0633 Telephone 915 332 9121 24 hours FAX 915 333 4655 San Antonio Branch Cummins Southern Plains Inc 6226 Pan Am Expressway North PO Box 18385 San Antonio TX 78218 0385 Telephone 512 655 5420 24 hours FAX 512 655 3865 B3 9 and B5 9 Series Engines Section S Service Assistance Houston Onan Branch South
17. Antifreeze must be usedin any climate for both freezing and boiling protection Cummins recom mends a 50 percent concentration level 40 percent to 60 percent range of ethylene glycol or propylene glycol in most climates Antifreeze at 68 percent concentration provides the maximum freezing protection and must never be exceeded under any condition Antifreeze protection decreases above 68 percent Antifreeze Protection Ethylene Glycol Propylene Glycol 40 23 C 9 F 40 21 C 6 F 50 37 C 35 F 5096 33 C 27 F 60 54 C 65 F 60 49 C 56 F 68 71 C 96 F 68 63 C 81 F Concentration Testing Antifreeze concentration must be checked using a refractometer such as Fleetguard Part No CC2800 Floatingball type ofdensity testers or hydrometersare notaccurateenouahfor use with heavv dutv diesel cooling systems 83 9 and 85 9 Series Engines Engine Component Ke Values Section V Maintenance Specifications 29 Engine Component Torque Values General Information Component Wrench Size Toraue Va Aftercooler Mounting 10 mm 24 18 Aftercooler Water Hose Clamp 8 mm 5 44 Alternator Link Delco 10 15 SI 13mm 24 18 Alternator Link Delco 20 27 SI 314 in 43 32 Alternator Mtg Bolt 10 15 Si 15mm 43 32 Alternator Mtg 27 SI 18mm 77 57 Alternator Support Upper 10 mm 24 18 Belt Tensioner Flat Bracket Allen 5 mm 24 18 Belt Tensioner Mounting 15mm 43 32 Crankshaft Damper and Pul
18. eere S ENRICO ERN EE 2 2 53 9 and B5 9 Series Engines Page 2 b Section 2 Maintenance Guidelines THIS PAGE LEFT INTENTIONALLY BLANK 83 9 and 65 9 Series Engines Maintenance Guidelines Overview Section 2 Maintenance Guidelines Page 2 1 Maintenance Guidelines Overview General Information Cummins Engine Company Inc recommends that the engine be maintained according to the Maintenance Schedule in this section If the engine is operating in ambient temperatures consistently below 18 C 0 F or above 38 C 100 F perform maintenance at shorter intervals Shorter maintenance intervals are also required ifthe engine is operated in an abnormally dusty environment or if frequent stops are made See your Cummins Authorized Repair Location for recommended intervals If your engine is equippedwith a component or an accessory not manufactured by Cummins Engine Company InG referto the component manufacturer s maintenancerecommendations Suppliers addresses and telephone numbers are provided in Component Manufacturers Section M Use the chart provided at the end df this section as a convenient way to keep a record of maintenance performed Tool Requirements B3 9 and B5 9 Series Engines Page 2 Section 2 Maintenance Guidelines Tool Requirements General Information Inthe text a symbol followed by the wrench size or tool description is usedto identify the tooling requiredto perform each step More than one too
19. system Refer to the OEM service manual OK Ke em Check the transmission oil Vetere entrer cler and torque converter leaking Marine kael cooledt 7 SE cogant bake engine only SE manual l OK Troubleshooting Symptoms Ch arts Page TS 6 i i I Cause Correction S Check the shutter opeta tion Repair or replace the Radiator shutters are stuck open or opening early shutters if necessary Refer to the OEM service manual Coolant Temperature is Below Normal OK Check the fan dive and controls Refer to the OEM service manual Fan drive or fan controls are malfunctioning With the key system en short cut the harness at the temperature switch If it engages tmubleshwt the sensor or check for alr In the ecolant system Remove the sensor and Temperature switch failed make sure at ambient conditions tha eensor is open and at the correct temperature 91 C 193 F make sure the sensor closes Replace if neces sary B3 9 and B5 9 Series Engines Section TS Troubleshooting Symptoms Correction Cause Check or replace the temperature gauge Refer Temperature gauge malfunction to the OEM service manual OK T Check the thermostat for the correct part number and for correct operation Refer lo fhe OEM service manual Thermostat is not correct or is malfunctioning OK
20. D is E pea F ENS lt lt Sg Saf Es 4 ie Bes S a 28 P AR ne feBitmc 17mm X Disconnectthe drain line fitting from the injection pump B3 9 and B5 9 Series Engines Fuel Manifold Drain Section A Adjustment Repair and Replacement Page A 33 Inline Pumps 10 mm LN Remove the drain line banjo capscrew from the fuel filter head Removethe capscrewfrom the bracketon the intake Ge cover 10 mm Remove the banjo capscrews from the injectors kb d pus x fi9wama Fuel Manifold Drain Page A 34 fs9ftha T B3 9 and B 9 Series i 3 i A Adjustment Repair an 3 install Rotary Pumps 0g r NOTE Use new seals and sealing washers Assemble the drain line and fuel drain manifold in the reverse order of removal Torque Value Banjo Fitting Screw 15Nem 133 in Ib Torque Value Banjo Fitting 8 N m BO in Ib Torque Value Clamp Screw 24 Nem 18 ft lb B3 9 and 85 9 Series Er Section A Adjustment r and Replacement Inline Pumps 10mm NOTE Use new seals and sealing washers Assemble the drain line and drain manifold in the reverse order of removal Torque Value Banjo Fitting Screw 15 Nem 133 in Ib Torque Value Banjo Fitting 9 Nem BO in Ib Torque Value Bracket Capscrew 24 Nem 18 ft lb Fuel Manifold Drain Page A 35 ft9wama Injector B3 9 and 85 9 Series Engines Page A 36 Section A Adjustment Repair and Re
21. Operating the Engine General Information A CAUTION A Continuous operation with a low coolant temperature below 60 C 140 F or a high coolant temperature above 100 C 212 F can damage the engine Monitor the oil pressure and coolant temperature gauges frequently Referto LubricatingOil System Specifications and Cooling System Specifications in Section V for rec ommended operating pressures and temperatures Shut offthe engine H any pressureortemperature does not meet the specifications Operating the Engine Page 1 15 Operating the Engine Page 1 16 gt eg amp gasm 83 9 and 85 9 Series Engines Section 1 Operating Instructions If anoverheating conditionstarts to occur reducethe power output of the engine by releasing the throttle pedal pres sure or shifting the transmissionto a ower gear or both untilthe temperature returnstothe normaloperating range Ifthe engine temperature does not return to normal shut off the engine and refer to Troubleshooting Symptoms Section TS or contact a Cummins Authorized Repair Location 83 9 and B59 Series Engines Section 1 Operating Instructions Most failures give an early warning Look and listen for changes in performance sound of engine appearance that can indicateservice or engine repair is needed Some changes to look for are as follows Engine misfires a Vibration e Unusual engine noises e Sudden changes in engine operatin
22. Section 1 of this manual provides all of the necessary information required for proper engine operation Check the oil pressure indicator temperature indicator warning lights and other gauges daily fo make sure they are operational Avoid exposure of your engine to corrosive chemicals Operating Instructions Overview Page 1 1 Operating Instructlons Overview Page 1 2 B3 8 and 85 9 Series Engines Section 1 Operating Instructions A WARNING A DO NOT OPERATE A DIESEL ENGINE WHE THERE ARE OR CAN BE COMBUSTIBLE VAPORS These pors can be sucked through the air intake system and cause engine acceleration and overspeeding that can result in a fiio a splosi r a i t ive t dama le Numerous safety de ice n dili il as air intake shutoff devices bi n it k of fersp 23 liig wl uit gine di 1 its pr bg might operate in a combustible environment his due to a fuel spill or gas leak Remember Cum his no way of knowing the use you have for your eni jine THE EQUIPMENT OWNER AND OPERATOR ARE RE SPONSIBLE FOR SAFE OPERATION IN A HOSTILE EN VIRONMENT CONSULT YOUR CUMMINS AUTHORIZEL REPAIR LOCATION FOR FURTHER INFORMATION 83 9 and B5 9 Series Engines Normal Starting Procedure Section 1 Operating Instructions Page 1 3 Normal Starting Procedure General information A CAUTION A D prevent damageto the starting motor do not engage the starting motor for more than 30 seconds Wait 2 minutes between each
23. all business costs and other losses resulting from a Warrantable Failure CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES United States lnciudas American Samoa the Commonwealth of Northern Mariana islands Guam Puerto Rico and the U S Virgin Islands 83 9 and 85 9 Series Engines Cummins Warran Section W Warranty Page W 1 Off Highway Engines United States and Canada Coverage Products Warranted This warranty appliesto new Engines sold by Cummins and deliveredto the first user on or after April 1 1999 that are used in industrial off highway applicationsin the United States and Canada except for Engines used in marine generator drive and certain defense applications for which different warranty coverage is provided Base Engine Warranty This warranty covers any failures of the Engine under normal use and service which result from a defect in material or factory workmanship Warrantable Failures Coveragebegitiswith thesaleofthe Engineby Cummins Coveragecontinuesfortwo years or 2 000 hoursofoperation whichever occurs first from the date of delivery of the Engineto the first user or from the date the unit is first leased rented or loaned or when the Engine has been operated for 50 hours whichever occurs first If the 2 000 hour limit is exceeded during the first year Coverage continues until the end of the first year Extended Major Components Warranty The Extended Major Components Warra
24. een DEPENDENT IPIE V 12 Fuel System seen GEESS EE tva va aeu Eua da cuu tut e NEN i ca V 14 83 9 and 85 9 Series Engines Section V Maintenance Specifications Page V b Page General Specifications 3 22 nn AAA NEAN NANPA NEE AEN ANE nent en en ennuis V 1 Lubricating Oil System ees V 5 83 9 and B5 9 Series Engines Section V Maintenance Specifications Specifications General Specifications General 4B Engine Data nonautomotive 102mm 4 02n Bore Stroke Displacement Engine Weight dry Less Flywheel and Elodie Com ponents Firing Order Valve Clearances intake Exhaust Compression Ratio Rotation Viewed from the Front of the Engine Aspiration Naturally Aspirated 483 9 102 mm 4 02 in 120 mm 4 72 in 3 9 liters 238 in 308kg 6791b 1 3 4 2 0 25 mm 0 010 in 0 5L mm 0 020 in 18 51 Clockwise X 48T3 9 120 mm 4 72 in 3 iters 238 in 320 kg 705 Ib 1 3 4 2 0 25mm 0 010 in 0 51 mm 0 020 in 17 5 Clockwise specifications Page V 1 4BTA3 9 102 mm 4 02 in 120 mm 4 72 in 3 9 liters 238 in 329 kg 725 b 1 3 4 2 0 25mm 0 010 in 0 51 mm 0 020 in 16 5 1 Clockwise Specifications age v 2 Turbocharged Aftercooled 483 9 83 9 and 85 9 Series Engines Section V Maintenance Specifications 46T3 9 X 4BTA3 9 X X 83 9 and B5 8 Series Engines Section V Maint
25. 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 resultingfrom what Cummins determines to be abuse or neglect including but not limited to operation without adequate coolants or lubricants overfueling overspeeding lack of maintenance of lubricating cooling or intake systems improper storage starting warm up run in or shutdown practices unauthorized modificationsof the Engine Cumminsis also not responsiblefor failures caused by incorrect oil or fuel or by water dirt or other contaminants in the fuel or oil Cummins Warranty B3 9 and 85 9 Series Engines Page W 4 Sectlon W Warranty This warranty does not apply to accessories suppiied by Cummins which bear the name of another company This category includes but is not limited to alternators starters fans air conditioning compressors clutches filters transmissions torque converters vacuum pumps engine exhaust brakes power steering pumps non Cummins fan drives and air compressors Failures resulting in excessive oil consumptionare covered for the duration of the coverage or 100 000 miles 160 935 kilometers or MOO hours from the date of delivery of the Engine to the first user whichever of the three occurs first Beforea claim for excessive oil consumption will be considered Owner must submit adequate documentationto show tha
26. in line pump 17 9 1 Rotation Viewed from the Clockwise Clockwise Front d the Engine Aspiration Turbocharged X X X Charge Air Cooled X 83 9 1B5 Series Engines Section V 1 a Specifications Lubricating Oil System 48 Lubrication System Data nonautomotive 483 9 Lubricating Oil Pressure at Idle minimum allowable 69 kPa 10 psi Lubricating Oil Pressure at Rated minimum allowable 207 kPa 90 psi Regulating Valve Opening Pressure 449 kPa 65 psi LubricatingOil Capacity Standard Pan Only 95 liters 10 qt Total System 10 9liters 11 5 qt Low to High 0 9liter 1 qt 4BT3 9 69 kPa 10 psi 207 kPa 30 psi 449 kPa 65 psi 9 5 liters 10 qt 11 liters 111 6 at 0 9 liter 1 at Specifications Page V 5 4BTA3 9 69 kPa 10 psi 207 kPa 30psi 449 kPa 65 psi 9 5 liters 10 qt 11 liters 11 6 qt 0 9 liter 1 qt Specifications B3 9 and B5 9 Series Engines Page V 6 Section V Maintenance specifications 6B Lubrication System Data nonautomotive 685 9 6BT5 9 6BTA5 9 ee Se 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi rale ie E 207 kPa 30 psi 207 kPa 30 psi 207 kPa 30 psi Regulating Valve Opening 449 kPa 65 psi Pressure 65 psi 449 kPa 65 psi 449 kPa 65 psi Lubricating Oil Capacity Standard Pan Only 142 liters 15 qt 14 2 liters 15 qt 14 2 liters 15 at Total System 16 3 liters 17 2 qt 16 4 liters 17 3 qt 164 liters 17 3 qt Low
27. smemteurmmremesteuen Axe CG MP A 75 Air Intake Manio Fee ee A 81 Ciean A 82 ICONES P ETE H P A B3 Preparatory essere nnn nnne nnnm tnn nnn nen E A 81 Pressure E EE A 85 Bue VE A 82 Temperature Differential Test EU M UE E D E A 85 VU 1 ee ieee A 84 Air Intake System Overview sss TENES Ee A 74 General Information sese eech ssa cua ERG n E VER REN A 74 Alternator A 112 Install A 113 Remove A 112 Belt Tensioner Automatic cccccssisscscessiscvscvsssecvscvesecssceessecesoussussesssvssecvessarsecvessersncvestesvscvvitecvscerdsttesisrenteresenensers A 4 MR B3 9 and B5 9 Series Engines dh Section A pos Repair and Replacement dh avaa fie Tu il wi Page A b AE D H poi REMOVE Re auld Charge Air Cooler Ge E A 80 Leak Test us nnn NE Pressure Test sois iat Timing Adang Syste KSB Temperature Switch nstall Remove DEI DOT ABA Zo EE EE Preparatory dips cies du da CY E OR RENE S EE Remove Cooling System i 2 dE General Information i Drive Belt Cooling Fan mace ee IV UE SC le UC El
28. 10 0 10 20 30 40 80 can be used for easier starting and providing sufficientoll je s 22 4 14 32 50 68 86 104 122 flow at ambient temperatures below 5 C 23 F However continuous use of low viscosity oils can decrease engine life due to wear Refer to the accompanying chart AllSemsons Winter Conditions Arctic Conditions C 40 30 20 10 0 10 20 39 40 50 F 40 22 4 14 32 80 6B 86 10 122 oi80bda A CAUTION A i A six cylinder oil filter can be used on a four cylinder engine Do not use a four cylinder oil filter on a six cylinder engine Use of a four cylinder oil filter on a six cylinder engine will result in engine damage Oil Filters A LF 3345 Standard Four Cylinder Applications B LF 3349 Standard Six Cylinder Applications a B3 9 and 5 9 Series Engines Arctic Operation Section V Maintenance Specifications Page V 27 Arctic Operation Preparatory A CAUTION A The use of a synthetic based 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 23 C 10 F andthere are no provisions to keep the engine warm when it is not in operation use a synthetic CE SG engine oil with adequate low temperature properties such as 5W 30 The oil supplier must be responsible for meeting the performance s
29. 24 VDC Starter AT5CCA 475CCA 475CCA Maximum Allowable Resistance of Starting Circuit With 12 VDC Starter Ohms 0 0012 0 0012 0 0012 With 24 VDC Starter Ohms 0 0020 0 0020 0 0020 Typical light accessoriesinclude alternator small steering pump and disengaged clutch Typical heavy accessories include hydraulic pump and torque converter B3 9 and 85 9 Series Engines Section E Engine Identification Electrical System Data automotive Minimum Recommended Battery Capacity 18 C 0 F With Light Accessories 12 VDC Starter 24 VDC Starter With Heavy Accessories 12 VDC Starter 24 VDC Starter Maximum Allowable Resistance of Starting Circuit i With 12 VDC Starter Ohms With 24 VDC Starter Ohms Typical light accessories include alternator small steering pump and disengaged clutch Typical heavy accessories include hydraulic pump and torque converter 83 9 625CCA 400CCA 800CCA 400CCA 0 0012 0 0020 Specifications 85 9 EOOCCA 400CCA 950CCA 475CCA 0 0012 0 0020 Page E 25 Specifications 63 9 and 65 9 Series Engines Page E 26 Section E Engine Identification Batteries Specific Gravity 1 260 to 1 280 1 230 to 1 250 1 200 to 1 220 1 120 to 1 190 HO to 1 190 B3 9 and 85 9 Series Engines Engine Diagrams Section E Engine Identification Page E 27 Engine Diagrams Engine Views The following illustrations show the locations of the major
30. 472 0306 Service Assistance Page S 12 Industrial Power Branch Cummins Gateway Inc 3256 E Outer Road Scott city MO 63788 Telephone 573 335 9399 FAX 573 335 7082 Montana Billings Branch of Denver Cummins Rocky Mountain Inc 5151 Midland Road Billings MT 59101 Telephone 406 245 4194 FAX 406 245 7923 Great Falls Branch of Denver Cummins Rocky Mountain inc 415 Vaughn Road Great Fails MT 59404 Telephone 406 452 8561 FAX 406 452 9911 Missouia Branch of Seattle Cummins Northwest Inc 4950 North Reserve Street Missouia MT 59802 1498 Telephone 406 728 1300 FAX 406 728 8523 Nebraska Omaha Distributor and Branch Cummins Great Plains Diesel Inc 5515 Center Street PO Box 6068 Omaha NE 68106 Telephone 402 551 7678 24Hoors FAX 402 551 1952 1 Kearney Branch Cummins Great Plains Diesel Inc 515 Central Avenue Kearney NE 68847 Telephone 308 234 1994 FAX 308 234 5776 Nevada Elko Branch of Salt Lake City Cummins Intermountain Inc 5370 East Idaho Street Elko NV 89801 Telephone 775 738 6405 FAX 775 738 1719 Las Vegas Branch of Salt Lake City Cummins intermountain Inc 2750 Losee Road North Les Vegas NV 89030 Telephone 702 399 2339 FAX 702 399 7457 B3 9 and B5 9 Series Engines Section S Service Assistance Sparks Branch of Salt Lake City Cummins Intermountain Inc 150 Glendale Avenue
31. 5 88 liters 359 in 399 kg 880 Ib 1 5 3 6 2 4 0 25mm 0 010 in 0 51 mm 10 020 in 17 5 1 Clockwise Speci calor Page E 9 6BTA5 9 102 mm 4 02 in 120 mm 4 72 in 5 88 liters 359 in 411 kg 906 Ib 1 5 3 6 2 4 0 25 mm 0 010 in 0 51 mm 0 020 in 16 5 1 Clockwise Specifications Page E 10 General Engine Data automotive Bore Stroke Displacement Engine eat dry Less A atei ana Electric Components Firing Order Valve Clearances Intake Exhaust Compression Ratio Rotation Viewed from the Front of the Engine Aspiration Turbocharged Charge Air Cooled B3 9 102 mm 4 02 in 120 mm 4 72 in 3 9 liters 238 in 308 to 329 kg 679 to 725 Ib 1 3 4 2 0 25 mm 0 010 in 0 51 mm 0 020 in rotary pump 17 8 1 Clockwise 83 9 and B5 9 Series Engines Section E Engine Identification 85 9 102 mm 4 02 in 120mm 14 72 in 5 9 liters 360 inf 388 to 411 kg 855 to 906 Ib 1 5 3 6 2 4 0 25mm 0 010 in 0 51 mm 0 020 in in line pump 17 8 1 Cbckw ise B3 9 and 85 9Series Engines Specifications Section E Engine Identification Page E 11 Fuel System 4B Fuel System Data nonautomotive Distributor Type Fuel Injection 483 9 4BT3 9 4BTA3 9 Pumps Maximum Allowable Restriction lo de EE Pump Must 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg ot Excee T Maximum Allowable Return Line 518 mm Delt A inHg 518 mm
32. 9 and B5 9 Series Engines Page W 34 Section W Warranty CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES THESE WARRANTIES AND THE EMISSION WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRAN TIES MADE BY CUMMINS IN REGARD TO THESE ENGINES CUMMINS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty gives you specific legal rights and you may also have other rights which vary from state to state Emission Warranty Products Warranted This emissionwarranty applies to new Engines marketed by Cummins that are used inthe United States in vehicles designed for transporting persons or property on a street or highway This warranty applies to Enginesdeliveredto 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 conformatithe time of sale by Cummins with all U S Federal emission regulations applicable at the time of manufactureand that itis free from defects in materialor factory workmanship which would causeit notto meet these regulations within the longer of the following periods A Five years or 100 000 miles 160 935 kilometers of operation whichever occurs first as measured from the date of delivery of the Engine to the ultimate purchaser or B The Base Engine Warranty If the vehicle in which the Engine is ins
33. Ae A e igs A 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Piston Style Lift Pump 14 mm 17 mm 20 mm Install the fuel line to the lift pump and filter head Use two wrenches to tighten the connection to the lift pump T rque Value 24 Nem 18 ft lb Injection Pump Supply Line Replacement 17 mm Remove the bleed screw banjo fitting 83 9 and 85 9 Series Engines Fuel Supp EN yv age A Section A Adjustment Repair and Replacement 14 mm 16mm and 24 mm Remove the supply line Bosch injection pump K NOTE Replace the seals 1 in the fittings if the line is disassembled O DP f amp gftmt 14 mm 16 mm 19 mm and 24 mm Remove the supply line Lucas CAV injection pump The y Lucas CAV pump has two fittings for the supply line Replace fitting sealing washers 1 and ferrules 2 each RI time they are removed Torque Value 32 Nem 24 ft lb NOTE Replace the seals in the fittings if the line is oS disassembled fs9sema Fuel Filter 3 E and 85 9 Series Engines Page A 22 Section A Adjustme Re r and Replacement R 17 mm Engines rated at 2500 rpm and above require additional fuel line support Install as illustrated C Torque Value 24 Nem 18 pb DS q j Fuel Filter Adapter Preparatory e Clean debris Remove fuel filters B3 9 and B5 9 Series Engines Fuel Lift us Section A Adjustment Repair and Re
34. BO in Ib Turbocharger Page A 93 Turbocharger 83 9 and 85 9 Series Engines Page A 94 Section A Adjustment Repair and Replacement A CAUTION A To prevent bearing damage new turbochargers must be prelubricated before start up Pour 50to 60 cc 3 to 4 oz of clean lubricating engine oil into the oil supply fitting Rotatethe turbine wheel to allow the oil to enter the bearing housing Installthe exhaust outlet connection Do not tighten the two mounting capscrews until the band clamp has been tightened Torque Value Band Clamp 8 Nem 71 in Ib Torque Value Capscrews 43 Nem 32 ft lb p e xs9cona B39 and 65 9 Series Engines E Turbocharger Section A Adjustment Repair and Replacement Page A 95 A CAUTION A When installing the oll supply line be sure the line is not indirect contact with theturbine housingor the line will burn during operation 16mm Installthe oil supply line Torque Value 35 Nem 26 ft lb Ifequippedwith awastegateturbocharger installthe intake manifold pressure supply line from the boost capsule Exhaust Manifold Dry B3 9 and B5 9 Series Engines Page A 96 Section A Adjustment Repair and Replacement V Test install the air crossover tube inlet and exhaust piping Operate the engine and check for leaks Exhaust Manifold Dry Preparatory e Remove the air crossover tube e Disconnect the air intake and exhaust piping e Remove the turbo
35. Clearance 0 508mm 0 020 in 14 mm Wrench Flat Blade Screwdriver Four Cylinder Engine Adjustment Locate top dead center T DC for cylinder No 1 Setonly valves indicatedby the arrows E exhaust intake Do not set valves that are not Indicated Holding the locknut steady with the wrench adjust the valve clearance with the screwdriver or Allen wrench Tighten the locknut and measure the valve lash again Torque Value 24 Nem 18 ft Ib Overhead Set Page 6 5 83 9 and 85 9 Serles Engines Maintenance Procedures at 38 000 km 24 000 mi A CAUTION A To avoid engine or pin damage be sure the timing pin is disengaged Markthe vibration damper and rotate the crankshaft 360 degrees 14 mm Wrench Flat Blade Screwdriver or 5 mm Allen Wrench Adjust the valves as indicated in the illustration Torque Value 24 Nem 18 ft lb Set onlyvalves indicatedby the arrows E exhaust intake Do not set valves that are not indicated d WI n i Ter E h ta l SS D 3 Overhead Set Page 6 6 dagshwa B3 9 and 85 9 Series Engines Maintenance Procedures at 380100 km 24 000 mi 14 mm Wrench Flat Blade Screwdriver Six Cylinder Engine Valve Adjustment Locate top dead center TDC for cylinder No 1 Set only the valves indicatedby the arrows in the illustra tion E exhaust intake Holding the locknut steady with the wrench adjust the valve clearance with the s
36. E ZE Z ou Qd EE won D ifs Hoop i ris b SEE jdn p NS Mr deae z RU n 7 Page Instail ANERE NEE dE EEN HIT IT AD ELE SE EXER erc OTT TTT ebe T mH ele SN SERM embed eo hee ete SES nn A 43 Preparatory AN PU ee enn ns MEE NEUE Ad D SR dee Deeds AAi ha nai e un ne stan Remove een B MIRAMUR LU IE s m BEE A 42 Fuel upp LINCS EM Cr EMERICUS iens A 18 Install e 2 A A 19 Pre E lente 4 E A 18 Remove Y WE EES DEEN n ee Ee HER CEN S E A 18 Fuel System Dares DOTE En General Information Sa mn Injector Clean E i beni Install sien tiic sit er bui Ree o Aer A 37 Preparatory TTT E RE Remove A A 36 Injector Supply Lines High eng E A26 Install EE A 29 Preparatory ccceceeuceeeeres PENN E EAEI EEEE EE vai E EEEE EAEE EEEE AE ELETEDET A 26 REMOVE E A26 Lubricating Oil Cooler sent eere e E Er GENEE Pressure feet NE LIE A 106 Remove ccaeeesecaseres Zeen SE A 104 isicing O oil Pressure e Regulator Main Rite H A 100 Clean Ee iaia Au A 101 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement lf NEE Preparatory EE ele UE Lubricating Oil System Overview enr General Information Starting Al TE it UR g F
37. Gaskets Socket and Torque Wrench SE Oil Pressure Regulator Main Rifle B3 9 and 85 9 Series Engines Page A 100 Section A Adjustment Repair and Replacement Lubricating Oil Pressure Regulator Main Rifle Preparatory Clean debris Remove 19 mm Remove the plug and regulator valve 83 9 and B5 9 Series Engines Lubricating Oil Pressure Regulator Main Rifle Section A Adjustment Repair and Replacement Page A 101 Clean Clean and inspect the regulator valve Clean and inspect the regulator valve bore NOTE In order to regulate the oilpressure the valve must move freely in the bore IcSbrea SS neu 83 9 and 85 9 Series Engines EROS Pressure Regulator Main Rifle Section A Adjustment Repair and Replacement ap Install Install a new sealing o ring on the threaded plug and lu bricate with clean lubricating engine oil install the pres sure regulator assembly Torque Value 80 Nem 59 ft lb B3 9 and B6 9 Series Engines Section A Adjustment Repair and Replacement Lubricating Oil Cooler Preparatory A WARNING A Coolant is toxic Keep away from children and pets If not reused dispose of In accordance with local envi ronmental regulations A WARNING A Some state and federal agencies have determinedthat used engine oil can be carciaogenic and cause repro ductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil
38. Location 7 Andrews Road Penrith 2750 Telephone 81 2 4729 1313 Queanbevan Cummins Engine Company Pty Ltd PO Box 527 Queanbeyan 2620 New South Wales Australia Location 15 27 Bayldon Road Queanbeyan 2620 Telephone 61 2 6297 3433 FAX 81 2 6297 6709 Regency Park Cummins Engine Company Pty Ltd FO Box2147 Regency Park SA 5942 Australia Location 11 Manton Street Hindmarsh SA 5942 Australia Telephone 61 8 83463832 FAX 61 8 8340 2045 Swan Hill f Cummins Engine Company d Lid PO Box 1264 Swan Hill 3585 Victoria Australia Location 5 McAllister Road Swan Hill 3585 Telephone 81 3 5992 1541 Tamworth Cummins Engine Company Pty Ltd PO Box 677 Tamworth 2320 New South Wales Australia Location Lot 65 Gunnedah Road Tamworth 2340 Telephone 81 2 6765 5455 Townsviile Cumrgins Engine Company Pty Ltd PO Box 7339 Garbutt Business Centre QLD4814 Australia Location 704 710 Ingham Road Townsville QLD 4814 Telephone 61 7 4774 7733 FAX 61 7 4774 7640 83 9 and 85 9 Series Engines Section S Service Assistance I Welshpool Cummins Engine Company Pty Ltd P Box 52 Welshpool 6986 Western Australia Australia Location 50 Kewdale Road Welshpaol 6106 Telephone 61 8 9458 5911 Wetherill Park Cummins Engine Company Pty Ltd Private Bag 150 Wetherill Park NSW 2164 Australia Location 492 494 Victoria Street
39. Lubrication System Data nonautomotive Lubricating Oil Pressure at Idle minimum allowable Lubricating Oil Pressure at Rated minimum allowable md Regulating Valve Opening Pressure Lubricating Oil Capacity Standard Pan Only Total System Low to High 6B5 9 69 kPa 10 psi 207 kPa 30psi 449 kPa 65psi 14 2liters 15qt 16 3 liters 17 2 qt 1 9liters 2 qt 6BT5 9 69 kPa 10 psi 207 kPa 30psi 449 kPa 65psi 14 2liters 15ct 16 4liters 17 3 qt 1 9 lifers 2 qt 6BTA5 9 69 kPa 10 psi 207kPa 30psi 449 kPa 65psi 14 2liters 15 qt 16 4 liters 17 3 gt 1 9liters 2 qt 83 9 and 85 9 Series Engines Specifications TUM Page E 16 Section E Engine Identification Lubrication System Data automotive B3 9 B5 9 LubricatingOil Pressure at Idle minimum allowable 69 kPa 10 psi 69 kPa 10 psi Lubricating Cil Pressure at Rated minimum allowable 207 kPa 30 psi 207 kFa 30 psi Regulating Valve Opening Pressure 449 kPa 65 psi 449 kPa 65 psi Lubricating Oil Capacity Standard Pan Only 9 5 liters 10 qt 142 liters 15qt Total System Liters U S qt 11 liters 11 6 qt 16 4 liters 17 3 qt 0 9 liter 1 qt 1 9 liters 2 qt Low to High 83 9 and 85 9 Series Engines Section E Engine Identification Cooling System 48 Cooling System Data nonautomotive 483 9 4BT3 9 Coolant Capacity engine only 7 liters 174 at 7 lite
40. Measure the total carbon deposit thickness inside the air discharge line as shown If the total carbon deposit X 4 X exceeds 2 mm 11 16in clean and inspectthe cylinder head the valve assembly and the discharge line Replace if necessary Contact the Cummins Authorized Repair Lo cation for procedures 83 9 and 85 9 Series Engines Air Compressor Maintenance Procedures at 77 000 km 48 000 mil E Page 7 11 If the total carbon deposit exceeds specifications continue checking the air discharge line connections up to the first tank until total carbon deposit is less than 2 mm 1 18 in Clean or replace any lines or connections that exceed this specification v Inspect any air driers splitter valves pressure relief valves and alcohol injectorsforcarbon deposits or malfunctioning O parts Inspect for air leaks Maintain and repair the parts according to the manufacturer s specifications gt ii Compressor B3 9 and B5 9 Series Engines CENT a 7 12 Maintenance Pro zedures at 77 GGG km 4t mij NOTES B3 9 and E Series E gines Section A x Repair and Replacement Page A a Section A Adjustment Repair and Replacement Section Contents Page Aoo eT aE EEA E EESE V EEEE EOSS asta EE E EEEE E sun EEEE euer A 76 Clean Sege RU ado acea AP HER KE SE eege A 70 EE RS E ee i EE A 79 Hang ecc ea MU I n Re UN A 76 PAIEMENT RII Ut Ms A 75 cl eee c UQaurdd A 75 Remove n l
41. New Savannah Road Augusta GA 30901 3891 Telephone 706 722 8825 FAX 706 722 1553 Savannah Branch Cummins South Inc 8 Interchange Court Savannah GA 31401 1627 Telephone 912 232 5565 FAX 912 232 5145 Hawaii Kapolei Distributor Cummins Hawali Diesel Power Inc 91 230 Kalaeloa Blvd Kapolei HI 96707 Telephone 808 682 8110 FAX 808 682 8477 Idaho Boise Branch of Salt Lake City Cummins Intermountain Ine 2851 Federal Way City Boise ID 83705 Telephone 208 3365000 FAX 208 338 6436 Pocatello Branch of Salt Lake City Cummins Intermountain Inc 14299 Highway 30 West Pocatello ID 83201 Telephone 208 234 1661 FAX 208 234 1662 Illinois Chicago Distributor Cummins Northern Illinois Inc 7145 Santa Fe Drive Hodgkins IL 60525 Telephone 708 579 9222 FAX 708 352 7547 Bloomington Normal Branch of Indianapolis Cummins Mid States Power Inc at US SL N and 1 55 414W Northtown Road Bloomington Normal IL 61761 Telephone 309 4524454 FAX 309 452 1642 Service Assistance Page S 7 Onan Branch z Cummins Onan Northern Illinois 8745 W 82nd Place Justin IL 60458 Telephone 708 563 7070 FAX 708 563 7095 Harrisburg Branch of St Louis Cummins Gateway Inc Highway 45 North Harrisburg IL 62946 Telephone 618 273 4138 FAX 618 273 4531 Rock Island Branch of Omaha Cummins Great Plains Diesel Inc 7820 42nd
42. Sparks NV 89431 Telephone 775 331 4983 FAX 775 331 7429 New Jersey Newark Branch of Bronx Cummins Metropower inc 41 85 Ooremus Ave Newark NJ 07105 Telephone 973 491 0100 FAX 973 578 8873 New Mexico Albuquerque Branch of Phoenix Cummins Southwest Inc 1921 Broadway N E Albuquerque NM 87102 Telephone 505 247 2441 FAX 805 842 0436 Farmington Branch of Phoenix Cummins Southwest Inc 1101 North Troy King Road Farmington NM 87401 Telephone 505 327 7331 FAX 505 326 2948 B3 9 and B5 9 Series Engines Section S Service Assistance New York Bronx Distributor Cummins Metropower Inc 890 Zerega Avenue Bronx NY 10473 Telephone 718 892 2400 FAX 718 892 0055 Albany Branch of Boston Cummins Norlheast Inc 101 Railroad Avenue Albany NY 12205 Telephone 518 459 1710 FAX 518 459 7815 Buffalo Branch of Boston Cummins Northeast Inc 480 Lawrence Bell Dr Williamsville NY 14221 7090 Telephone 716 631 3211 FAX 716 626 0799 Syracuse Branch of Boston Cummins Northeast inc 29 Eastern Avenue Syracuse NY 13211 Telephone 315 437 2751 FAX 315 497 8141 North Carolina Charlotte Distributor Curnmins Atlantic Inc 11101 Nations Ford Road 28273 P O Box 240729 Charlotte NC 28224 0729 Telephone 704 588 1240 FAX 704 587 4870 Charlotte Branch Curnmins Atlantic Ine 3700 North Interstate 85 Charlotte N
43. Warranty On Highway 83 9 and 85 9 Series Engines Page W 36 Section W Warranty California Emission Control System Warranty On Highway Products Warranted This Emission ControlSystem Warranty applies to heavy duty diesel engines hereafter engines certified with the California Air Resources Board beginning with the year 1991 marketed by Cummins and registered in Californiafor use in automotive on highway applications Your Warranty Rights and Obligations The California Air Resources Board and Cummins Engine Company inc are pleased to explain the emission control system warranty on your 1992 and subseguent model year heavy duty diesel engine In California new motor vehicle engines must be designed built and equipped to mest the State s stringent anti smog standards Cummins must warrantthe emission control system on your heavy duty diesel enginefor the periods of time listed below providedthere has been no abuse neglect or improper maintenance of your heavy duty diesel engine Your emissioncontrol system may include parts such as the fuel injectionsystem and engine electronic control module Aiso included may be hoses connectors and other emission related assemblies Ifan emission relatedpart on your engine is foundto have a defect in material or factory workmanship Warrantable Condition the part will be repaired or replaced by Cummins This is your emission control system defects warranty Manufacturer s Warranty Coverage
44. Wetherill Park NSW 2164 Australia Telephone 61 2 8816 5300 FAX 61 2 8616 5309 Wodonsa Cummins Engine Company Pty Ltd PO Box 174 Wodonga 3690 Victoria Australia Location 9 11 McKoy Street Wodonga 3690 Telephone 81 2 6024 3655 B3 9 and B5 9 Series Engines Section S Service Assistance Auckland Cummins Diesel Sales amp Service NZ Lid Service Assistance Pages 25 Distributors and Branches New Zealand Christchurch Palmerston North Cummins Diesel Engines Cummins Diesel Engines P O Box 16 149 PO Box 9024 Hornby Christchurch New Zealand Palmerston North New Zealand Location Lacation Private Bag 92804 Penrose Auckland New Zealand Location 440 Church Street Penrose Telephone 64 9 579 0085 Branches Auckland Cummins Diesel Engines Private Bag 92804 Penrose Auckland New Zealand Location 440 Church Street Penrose Telephone 64 9 579 0085 35 Parkhouse Road Sockburn Christchurch Telephone 64 3 348 8170 Mt Maunaanui Cummins Diesel Engines P O Box 4005 Mt Maunganui New Zealand Location 101 Totara Street Mt Maunganui Telephone 64 7 575 0545 852 860 Tremaine Avenue Telephone 64 6 356 2209 Service Assistance B3 9 and B5 9 Series Engines Page S 26 Section S Service Assistance NOTES B3 9 and B5 9 Series Engines Section TS Troubleshooting Symptoms Page TS a Section TS Troubleshooting Symptoms Section Contents
45. ZE PO Box 1340 Grafvansoden Strasse 59 D7070 Schwaebisch Gmuend Germany Telephone 7070 7171 31510 In Line Connectors Pioneer Standard Electronics Inc 5440 Neiman Parkway Solon OH 44139 Telephone 216 349 1300 83 9 and 85 9 Series Engines Section M Component Manufacturers Filters Fleetguard International Corp Cavalry Hill Industrial Park Weedon Northampton NN7 4TD England Telephone 0132741313 Fleetguard Ine 1200 Flestguard Road Cookeville TN 38502 Telephone 1 800 22 Filters 1 800 223 4583 Flexplates Corrugated Packing and Sheet Metal Hamsterley Newcastle Upon Tyne England Telephone 01207 560 505 Allison Transmissiart Division of General Motors Corporation PO Box 894 Indianapolis IN 46206 0894 Telephone 317 242 5000 Midwest Mfg Co 23500 Southfield Road Suite 122 Southfield MI 48076 Telephone 313 642 5355 Wohlert Corporation 708 East Grand River Avenue PRO Box 20217 Lansing Mi 48901 Telephone 517 485 3750 Fuel Coolers Hayden inc 1531 Pamorta Road PO Box 848 Corona C 91718 0848 Telephone 909 736 2665 Fuel Pumps Robert Bosch Corp Automotive Group 2800 South 25th Ave Broadview tL 60153 Fuel Warmers Fieetguard Inc 1200 Fleetguard Road Cookeville TN 38502 Telephone 615 526 9551 Gauges ALS Dyffon Industrial Estate Ystrad Mynach Hengoed Mid Glamorgan CF8 7XD England Telephone
46. adjust the high speed adjusted correctly nue top 0 screw Refer to Section A Continued Troubleshooting Symptoms Charts 83 9 and 85 9 Series Engines Page TS 28 Section TS Troubleshooting Symptoms Engine Will Not Reach Rated Speed RPM Continued H i Cause Correction Cause Correction Make Surg Ee Ge lever i Is IN the poslilon Fuel shutoff lever mechan Repl amp ce if necessary Refer cal engaged to the OEM service manual OK S Contact a Cummins Authorized Repair Facility EA Remove the fuel pump Fuel njeclionpump iS Refer to Section Ko malfunctioning brate the fuel pump Measure and correct if above specification Inspect the tust transfer Fuel tr nsf opingp mal pump Replace if neces sary Refer lo Section A Troubleshooting Symptoms Charts Page TS 29 83 9 and 85 9 Series Engines Section TS Troubleshooting Symptoms Engine Will Not Shut Off Cause Correction Check the fuelif fuel connections and fuel filters for leaks using the combus Correction tibie gas detector service tool Refer to the OEM Fuel leak service manual Cause Check for loose wires and verify that the fuel shutoff valve is functioning Check to be sure manual shutoff lever is in the run wosition OK KI Fuel shutoff electrical or manual not open l Refer to the OEM service f manual p ll Contact a Cummins Authorized Inspect th
47. and make the Engine available for repair by such facility Exceptfor Enginesdisabledby a Warrantable Failure duringthe first year from the date of delivery of the Engine to the first user Owner must also deliver the Engine to the repair facility Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory Owner is responsible for communication expenses meals lodging and similar costs incurred as a result of a War rantable Failure 83 9 and 85 9 Series Engines s Cummins Warranty Section W Warranty d Page W 33 Owner is responsible for non Engine repairs and for downtime expenses passenger delays fines all applicable taxes all business costs and other losses resulting from a Warrantable Failure Limitations T 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 overfuelinig 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 responsiblefor failures caused by incorrect oil or fuel or by water dirt or other contaminants in the fuel or oil This warranty does not apply to accessories which bear the name of another company This category includes butis not limited to alter
48. any failures of the Engine which result under normal use and service from a defectin material or factory workmanship Warrantable Failure This coverage begins with the sale of the engine by Cummins and ends two years 2 years or 50 000 miles 80 468 kilometers for 4B whichever occurs first from thedateof delivery ofthe Engine to the first user Additional coverage is outlined in the Emission Warranty section These warranties are made to all Owners inthe chain of distribution and Coverage continues toall subsequent Owners until the end of the periods of Coverage Cummins Responsibilities Cumminswill pay for ail parts and labor neededto repairthe damagetothe Engine resulting from aWarrantable Failure Cummins will pay for the lubricating oil antifreeze filter elements belts hoses and other maintenance items that are not reusable due to the Warrantable Failure Cummins will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure 3381264 Cummins Warranty B39 and B5 9 Series Engines Page W 2 Section W Warranty Cummins will pay reasonable costs for towing a vehicle disabled by a Warrantable Failure to the nearest authorized repair station for the first year from the date of delivery of the Engine to the first user or the duration of the warranty whichever occurs first In lieu of tre e expense Cumminswill pay reasonable costs for mechanicsto travelto and from the loc
49. couvertes Les pannes de bagues st roulement de paliers ne sont pas garanties Cette couverture prend effet a la date d expiration de la garantie de base du moteur et se termine trois ans ou 10000 heures d utilisation apr s ia date de livraison du moteur au premier utiiisateur cu a compter de la date laquelle le moteur est mis en location de courte ou longue duree ou en pr t pour ia premiere fois ou encore lorsque ie moteur 33813221 Cummins Warranty 839 and B5 9 Series Engines Page W 20 Section W Warranty a t utilis pendant 50 heures suivant lequel de ces termes intervient en premier Produits de consommation La garantie sur ies produits de consommation aux tats Unis est LIMITEE CUMMINS N EST PAS RESPONSABLE DES DOMMAGES INDIRECTS OU INDUITS Aux tats Unis toute garantie implicite applicable aux produits de consommation vient ch ance l expiration des garanties expresses applicables au produit Certains Etats d Am rique r futent l exclusion des deteriorationsprovoqu es par des dommages indirects ou induits ou tes limitationsde dur e de garanties implicites Ces garanties s appliquent tous les propri taires du circuit de distribution et la couverture s applique tous las proprietairesult rieurs jusqu la fin de la p riode de couverture Responsabilites Cummins Pendant la garantie de base du moteur Cummins r glera tous les frais des pieces d tach es et de la main d oeuvre necessaires a la
50. damages or imitations on how long an implied warranty lasts so the limitations or exclusions herein may not apply to you THESE WARRANTIES ARE MADE TO ALL OWNERS IN THE CHAIN OF DISTRIBUTION AND COVERAGE CON TINUES TO ALL SUBSEQUENT OWNERS UNTIL THE END OF THE PERIODS OF COVERAGE Cummins Responsibilities During The Base Engine Warranty Cumminswill payfor all parts and labor neededto repairthe damage to the Engine resultingfrom a Warrantable Failure Cummins will pay for the lubricating oil antifreeze filter elements belts hoses and other maintenance items that are not reusable due to the Warrantable Failure Cummins will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure Cummins will pay reasonable costs for towing a vehicle disabled by a Warrantable Failure to the nearest authorized repair location when necessaryto make the repair for the first 2 years from the date of delivery of the Engine to the first user Inlieu oftowing expenses Cummins will pay reasonablecostsfor mechanicsto travelto andfrom the location of the vehicle including meals mileage and lodging when the repair is performed at the site of the failure During The Extended Major Components Warranty Cummins will pay for the repair or at its option replacement of the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered Part D Cum
51. des concessionnaires moteur tout terrain Cummins agr Cummins Warranty 83 9 and B5 9 Series Engines Page W 22 Section W Warranty Le propri taire supporte les fraisde communication de repas d hebergement et d autres frais simiiairesoccasionn s par une panne sous garantie Le pmprietaire est responsable des r parations autres que celles du moteur des d penses de temps mort des dommages au chargement des amendes de toutes les taxes en vigueur de tous les co ts commerciaux et de toute autre d pense resultant d une panne sous garantie Limites Cummins deciinetoute responsabiiiteen cas de pannesou de deteriorations resuitanr de ce que Cummins considere comme un abus ou une n gligence de la part du proprietaire notamment at non limitativement une utilisation sans les lubrifiantsou lestiquides de refroidissementappropri s surremplissage de carburant vitesse tmp lev e negligence d entretien des syst mes d admission de refroidissementou de lubrification mauvaises conditions d entreposage pratiquesinappropri es de d marrage de chauffage de rodage ou d arr t modificationsnon homologueesdu moteur Cummins n est egalement pas responsable des pannes provoquees par l utilisationd une huile d un carburant ou d une eau non appropri s ainsi que des pannes provoquees par la presence de d p ts dans le carburant ou dans l huile Pour les g n rateurs de courant et les pompes a incendie unites conditionnees cette gara
52. e Drain the coolant e Remove the oil filter Lubricating Oil Cooler age A 103 Lubricating Oil 1 B3 9 and 86 9 Series Engines Page A 104 Section A Adjustment Repair and Replacement Clean EE Clean all debris from around the oil Gooier Remove Al 16mm Removethe turbocharger oil supply line from the oil filter Ri head B3 9 and 65 9 Series Engines Lubricating Oil Cooler Section A Adjustment Repair and Replacement age A 105 Remove the oil cooler cover element and gaskets Clean the sealing surfaces Lubricating Oii Cooler B3 9 and B5 9 Series Engines Page A 1 Section A Adjustment Repair and Replacement i Pressure Test i Prgssurizethe element to 690 kPa 100 psi to check it for Ic8etsa install Wl 10mm Assemble the oil cooler gasket element cooler cover gas SD ket and cooler cover to the cylinder block NOTE Be sure to remove the shipping plugs A from the new cooler element Torque Value 24 Nem 18 ft lb 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement 16 mm Connect the turbocharger oil supply line Torque Value 35 Nem 26 ft Ib Install a new oil filter Follow the manufacturer sinstructions for tightening Lubricating Oil Cooler Page A 107 Irgetnb Lubricating Oil Cooler 83 9 anc E Series Engines Page A 10 Section A Adjustment Repai Replacement Fill A CAUTION A The
53. equipped finger tighten the capscrews for the support bracket RIP DROLE BL MEN i EE PE A WEP Tighten the mounting nuts ey x pe A Tighten the capscrews for the rear support bracket Torque Value Mounting Nuts 44 N m 32 itb Torque Value Support Bracket 14Nem 124 in Ib B3 9 and 85 9 Series Engines Fuel Injection Pumps In Line Section A Adjustment Repair and Replacement Page A 69 22 mm A Pump 30 mm P Pump Vd Install the fuel injection pump retaining nut and washer Torque Value 10to 15 Nem 89 to 133 in lbj Disengage the engine timing pin Fuel Injection Pumps In Line Page A 70 ouo V ONA KU KM gcanuha B3 9 and B5 3 i Engines A Adjustment Repair and 24 mm Remove the fuel pump timing pin plug Reverse the posi lion of the pinand install the pin plug and sealingwasher Torque Value 24 Nem 18 ft lb 22 mm or 27 mm Tighten the fuel pump drive nut Torque Value P7160 Pump 178N m 191 ft lb Torque Value A Pump 95 Nem 70 ft lb Torque Value EPQ Pump 127 Nem 94 ft lb Install the gear cover access cap hand tight 83 9 and B5 9 Series Engines Fuel Injection Pumps In Line Page A 71 Section A Adjustment Repair and Replacement 10 mm Installthe fuel pump mounting bracket capscrews finger tight Install support mounting capscrews finger tight Make sure alignmentis correct and tighten capscrews Torque Value
54. external engine components filters and other service and maintenance points Some external components will be at different locations for different engine models NOTE The illustrations are only a reference to show a typical engine Engine Diagrams 83 9 and B5 9 Series Engines Page E 28 Section E Engine Identification 1 e A a N zl UO 00900280 Side View 83 9 and 85 9 Series Engines Section E Engine Identification Intake air preheater optional Fuelfilter water separator Water heater 3 4 inch NPTF Fuelinlet connection 114 inch NPTF Magnetic pickup location 3 4 16UNF Fuel Eft pump Dipstick Oil pressure 118 inch NPTF DJ o om P cw gt 9 Engine dataplate 10 Air compressor 11 Air compressor intake 12 In line fuel injection pump 13 High pressure fuel lines 14 Engine air inlet Engine Diagrams Page E 29 B3 9 and B5 9 Series Engines Section E Engine Identification Engine Diagrams 30 Page E 00900270 Rear View 83 9 85 9 Series Engines Engine Diagrams c Ex Li Page E 31 1 Turbocharger exhaust outlet 5 Fuel return connection 2 Clutch mounting plate 6 Rear engine lifting bracket 3 Flywheel housing 4 Flywheelflexplate 83 9 and 85 9 Series Engines Section E Engine Identification Engine Diagrams Page E 32 L 00900278 Turbocharger Side View 83 9 185 9 i Engines Section E Identification
55. hu ae p m a Coolant Level Inspect DCN EUM sucha erodes E Drive Belts Inspect a sonocareen reg DT e Fan Cooling Inspect k Date TE e Fuel Water Separator Drain caves RA ES OREL S quand Eeler dated Shanes 3 2 e Lubricating OM Level Check kA EE haie kditniid enden 3 3 Every 10 000 km 6000 ml 250 Hours or 3 Months Maintenance Check Air Cleaner dl 3IflSpect aiue anra set REECH 4 11 Air Intake Pipi inspect mm 22s cam fasses E EAT Meis diesen d qeu carla 47 gt Charge Air Congr Check Gorrect oe ee RONDA 4 8 Lubricating Oil and Filters Change inner deseen teer tn sn aco tado da cds 48 Every 19 000 km 12 000 mi 500 Hours or 6 Months Maintenance Check e Cooling System Antifreeze Check SE SEEUEE Ee Lueden 59 Fuel Filter spin on type Replace keen EE 5 2 e Fuel Supply Lines Vent TROP m 5 4 e Injector Supply Lines high pressure Vent 5 7 B3 9 and B5 9 Series Engines Page References for Maintenance Instructions Section 2 Maintenance Guidelines Page 2 9 Every 38 000 km 24 000 mi 1000 Hours or 1 Year Maintenance Check e Drive Belt Test icit teintes a e Seueri cer ER ER HERREN Uno ee e E 6 8 Drive Beit and Tensioner Inspect is rennen enean aser nap Een 6 8 Overhead Set Measure mm vun IT EE E V I Bera 6 2 Every 77 000 km 48 000 mi 2000 Hours or 2 Years M
56. in Hg 100 mm Hg 4 in Hg 100 mm rig 4 in Hg EE Return Line S SE 518 mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hei 518 mm Hg 20 4 in Hg Maximum rip Allowa a pressure 35 kPa 5 psi 35 kPa 5 psi 35 kPa 5 psi Maximum Inlet Ge to the Injection Pump Must Not Exceed 70 kPa 10 psi 70 kPa 10 psi 70 kPa 10 psi In Line Type Fuel Injection Pumps Maximum Inlet Restriction to the Fuel Transfer Pump Must Not 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg 100 mm Hg 4 In Hg Exceed Fuel Transfer Pump Minimum 172kPa 25 psi High 172kPa 28 psi High 172kPa 25 ale High Output Pressure Flow and 90 kPa 13 psi Flow and 90 kPa 13 psi Flow and 90 kPa 13 psi Low Flow amp Rated rpm Low Flow amp Ratedrpm Low Flow Rated rpm Fuel Filter Restriction maximum GE Are 35 kPa 5 psi 35 kPa 5 psi 35 kPa 5 psi Fuel Pump Gallery Pressure 140 Pid p psi amp Ho kPa 20 psi 140 kPa 20 psi Rated rpm Rated rpm Fuel Return Maximum Restriction 518 mm Hg 20 4 in Ho 518 mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hg The low flow fuel transfer pump will have 82 7 kPa 12 psi 83 9 and 85 9 Series Engines Specifications Section V Maintenance Specifications Page V 15 6B Fuel System Data nonautomotive Distributor Type Fuel Injection 685 9 6BT5 9 6BTA5 9 Pumps Maximum Allowable Restriction to the Fuel Transfer Pump Must 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg Not Exceed Maximum Allow
57. injection Pumps Maximum Inlet Restrictionto the Fuel Transfer Pump Must Not Exceed Fuel Transfer Pump Minimum Output Pressure Fuel Filter R striction maximum pressure drop across filters Fuel Pressure Gallery Pressure Fuel Return Maximum Restriction 83 9 and 85 9 Series Engines Section V Maintenance Specifications 83 9 100 mm Hg 4 in Hg 518 mm Hg 20 4 in Hg 35 kPa I5 psi 70 kPa 10 psi B3 9 100mm Hg 4 in Hg 175 kPa 25 psi Rated rpm 35 kPa 5 psi 140 kPa 20 psi Rated rpm 518 mm Hg 20 4 in Hg 85 9 100 mm Hg 4 in Hg 518 mm Hg 120 4 in Hg 35 kPa I5 nsi 70 kPa 10 psi 85 9 100 mm Hg in Hg 175 kPa 25 psi Rated rpm 35 kPa 5 psi 140 kFa 20 psi Rated rom 518 mm Hg 20 4 in Hg 83 9 and 85 9 Series Engines Specifications Section V Maintenance Specifications Page V 17 Electrical System 48 Electrical System Data nonautomotive 483 9 4873 9 48TA3 9 Minimum Recommended Battery Capacity 18 C 0 F With Liaht Accessories 12 VDC Starter 625CCA 625CCA 625CCA 24 VDC Starter 312CCA 400CCA 400C CA With Heavy Accessories 12 VDC Starter BOOCCA BOOCCA BOOCCA 24 VDC Starter 400CCA 400CCA 400CCA Maximum Allowable Resistance of Starting Circuit With 12 VDC Starter Ohms 0 0012 0 0012 0 0012 With 24 VDC Starter Ohms 0 0020 0 0020 0 0020 Typical light accessories include alternator small steering pump and disengaged clutch oS Typical heavy accessori
58. marketed by Cummins that are used in the United States in vehicles designed for transporting persons or property on a street or highway This warranty appliesto Engines deliveredto the ultimate purchaser on or after January I 1998 Coverage Cummins warrants to the ultimate purchaser and each subsequent purchaser that the Enginei is d ser buiit and equipped so as to conformat the time d sale by Cumminswith all US Federal emission regulations applicable at the time of manufacture and that it is free from defectsin material or factory workmanship which would cause it not to meet these regulations within the longer of the following periods A Five years or 100 000 miles 160 935 kilometers of operation whichever occurs first as measured from the date of delivery of the Engine to the ultimate purchaser or B The Base Engine Warranty Ifthe 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 defectsin materialor factory workmanship are not covered by this warranty 83 9 and 85 9 Series Engines Cummins Warrant Section W Warranty Page W 2 Cummins is not responsiblefor failures or damage resultingfrom what Cummins determinesto be abuse or neglect including but not limited to operation without adequate coolants or lubricants overfueiing overspeeding lack of maintenance of lubricating cooling
59. of Memphis Cummins Mid South Inc Hwy 90 East FO BOX 1229 Amelia LA 70340 Telephone 504 631 0576 FAX 504 631 0081 New Orleans Branch of Memphis Cumming Mid South Inc 110 E Airline Highway Kenner LA 70062 Telephone 504 468 3535 FAX 504 465 3408 Maine Bangor Branch of Boston Cummins Norlheast Inc 221 Hammond Street Bangor ME 04401 Telephone 207 941 1061 FAX 207 945 3170 Scarborough Branch of Boston Cummins Northeast Inc 10 Gibson Road Scarborough ME 04074 Telephone 207 883 8155 FAX 207 883 5526 Service Assistance Maryland Baltimore distributor Cummins Power Systems Inc 1907 Parkwood Drive MD 21061 Telephone 410 590 8700 FAX 410 590 8723 Massachusetts Boston Distributor Cummins Northeast Inc 100 Allied Drive Dedham MA 02026 Telephone 781 329 1750 FAX 781 329 4428 Springfield Branch Cummins Northeast Inc 177 Rocus Street Springfield MA 01104 Telephone 413 737 2659 FAX 413 731 1082 Page S 9 Service Assistance Page S 10 Mexico Tijuana Branch of Los Angeles Distribuidora Cummins De Baja Blvd 3ra Oeste No 17523 Fracc Industrial Garita de Otay C P 22400 Tijuana Baia California Mexico Telephone 011 52 66 238433 FAX 011 52 66 238649 Michigan Detroit Novi Distributor Cummins Michigan Inc 41216 Vincenti Court Novi MI 48375 Telephone 248 478 9700 FAX 248 478 1570
60. of the three occurs first Before a claim for excessive oil consumption will be considered Owner must submit adequate documentation to show that consumption exceeds Cumrnins published standards Failures of belts and hoses supplied by Cummins are not covered beyondthe first 12 monthsfromthe date of delivery of the Engine to the first user or the expiration of the applicable Base Warranty whichever occurs first Parts usedto 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 Warranty B3 9 and 65 9 Series Engines Page W 28 Section W Warranty CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES THESE WARRANTIES AND THE EMISSION WARRANTY SET FORTHHEREINAFTER ARE THE SOLE WARRAN TIES MADE BY CUMMINS IN REGARD TO THESE ENGINES CUMMINS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty gives you specific legaf rights and you may also have other rights which vary from state to state Emission Warranty Products Warranted This emission warranty applies to new Engines
61. or intake systems improper storage starting warm up run in or shutdown practices unauthorizedmodificationsof 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 Cumminsis not responsiblefor non Engine repairs downtime expenses cargo damage fines all applicabletaxes all business costs or other losses resulting from a Warrantable Failure CUMMINS IS NOT RESPONSIBLEFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES A recreational vehicle for this warranty is defined as a Class A Motorhome which is a vehicular unit built on a self propelledmotor vehicle chassis primarily designed or alteredto providetemporary living quartersfor recreational travel or camping use The living unit has been entirely constructedon a bare specially designedmotor vehicle chassis IncludesAmerican Samoa the Commonwealthof Northern Mariana Islands Guam Puerto Rico andthe U S Virgin Islands Cummins Warranty 83 9and 85 9 Series Engines Page W 30 Section W Warranty United States and Canada Diesel Engine Schoo Bus Coverage Products Warranted This warranty applies to new diesel Engines sold by Cummins Engine Company Ine hereafter Cummins and delivered to the first user on or after September 15 1996 that are used in school bus applications in the United States or Canada Base Engine Warranty The Base Engine Warranty covers any fail
62. sae A09 General Information An e pjsbiesee ci iA 108 Engine Component Torque Values V 29 General Information wn V 29 Engine Diagrams ET Er 4 E27 Engine Views diia etiem S E27 Cummins Engine Nomenclature T d vad oe E3 Engine Dataplate us E4 Fuel degt Pump Dataplate E4 Bosch Er E4 e S BS Sianadyne deg ES Engine Operating Range id sess 1 14 General Information pet m t 14 Engine Shutdown m General Information dir vrseentk anadah 7 6 ee ZA CLLLLLLE ED vas Manca yh nh eee A 3 e EEN Install Ar98 Preparatory A 96 Remove A97 Fan Cooling E 2 OB Maintenance Check inner 38 Fan Spacer and Pulley A5 Install A 6 REMOVE science coe een si A 5 Flow Diagram Air Intake System s een D 14 General Informat bn D 14 Flow Diagram Compressed Air System D 26 General Informaton RT D 26 Flow Diagram Cooling System D 12 General Informatbn D 12 Flow Diagram Exhaust System D 20 General Information D 20 Flow Diagram Fuel System D General Information D 2 Flow Diagram Lubricating Oil System e D 6 General InforMatiON annee D 8 Fuel Filter Adapter A 22 NC A 22 Remove A 23 Fuel Filter Spin On Type E ie ten Oe Install ses 5 2 Rem
63. sized for each application Bending the lines is not acceptable and can cause fuel leaks 17mm Install the fuel lines in reverse order of removal Torque Value Line Fittings 24Nem 18 ft lb Torque Value Support Clamp 6 Nem 53 in Ib Torque Value Support Bracket 24 Nem 18 ft lb Injector Supply Lines High Pressure Page A 29 Z d H pz X c S ES e AE ME Pas Injector Supply Lines High Pressure A 30 B3 9 and 85 9 Series Engines Section A r Adjustment Repair and Replapement Inline Pumps 19mm Install the lines in reverse order of removal Torque Value Line Fittings 24 Nem 18 ft lb Torque Value Support Clamp 6 Nem 52 in Ib Torque Value Support Bracket 24 Nem 18 ft lb NOTE If removed reinstallthe support clamp in the origi nal position and make sure the lines do not contact each other or another component Install a protective cover on the injectors and fuel delivery valves to preventthe entry of dirt into the system B3 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Fuel Manifold Drain Preparatory e Clean debris Remove Rotary Pumps 10mm Remove the capscrew from the hold down clamp Fuel Manifold Drain Page A 31 Fuel Manifold Drain 83 9 and 85 9 Series Engines Page A 32 Section A Adjustment Repair and Replacement ad Mi 10 mm RE A Remove the banjo fitting screws and washers y S
64. system mustbefilled slowly to prevent air locks Be sureto open the aftercooler to allow airto escape asthe system is filled Fillthe coolant system and OC engine to cheek r IS ubricating oil system Operate Y g j j Stop the engine and check tne coolant and oil level dech O ayy Mhe 83 9 and 85 9 Series Engines Electrical Equipment Overview Section A Adjustment Repair and Replacement Page A 109 Electrical Equipment Overview General Information Electrical System Repair Summary A WARNING A Batteries can emit explosive gases To avoid injury always ventilate the compartment before servicing the page To avoid arcing remove the negative battery cable first and attach the negative battery cable ast A WARNING A Acid is extremely dangerous and can damagethe machinery and can also cause serious burns Always provide a strong tank of soda water as aneutrallzing agent when servicing the batteries Wear goggles and protective clothing to avoid serious burns Component to Be Re Tools Preparatory Steps placed Starting Motor Ratchet 17 mm socket Disconnect ground cable to battery 14 mm wrench and torque wrench Alternator Ratchet 8 mm 14 mm and Disconnect ground cable to battery and remove 16 mm socket torque drive belt wrench and 1 2 drive breaker bar Starting Motor 83 9 and B5 9 Series Engines Page A 110 Section A Adjustment Repair and Replacement Re Start
65. the dipstick calibration and oil pan capacity Fiii the System to the specified level Referto Section 3 Check for excessive blowby Referto the OEM service manual Change e ol and filters Use the oil type recom engine operation and Continued maintenance manual B3 9 and B5 9 Series Engines Section TS Troubleshooting Symptoms Troubleshooting Symptoms Charts Page TS 36 T l Lubricating if Loss Continued Correction Check the turbocharger for oil seals and for leaks Referto Section A Turbocharger oil seal is leaking Contact a Cummins or Repair Facility B3 9 and 85 9 Series Engines Section TS Troubleshooting Symptoms Lubricating Oil Pressure High Cause Cause Lubricating oil pressure sensor or gauge is mai functioning or is not in the correct location Lubricatingoti does not eiii onditio s Correction Check the oil pre 331 3 witch or gauge foi co e operation and location 1efer to the OEM service manual Al Allow the engine to warm to operating temperature If the engine will not reach Operating temperature refer to the Coolant Temperature Below Normal symptom tree Change the oil and filter Use the oil type recom nended in Section V of the I engine operation and maintenance manuai Troubleshooting Symptoms Charts Page TS 37 Correction Check the oil
66. the fuel drain line Remove the throttle shutoff linkage Remove the fuel injection pump top cover e Disassemble the fuel injection pump top cover B3 9 and 65 9 Series Engines Fuel Shutoff Valve Section A Adjustment Repair and Replacement Page A 43 Install 5 16 Inch Install new insulating tubes onto the terminals on the ter minal studs of the new solenoid Install the valve into the cover Torque Value 14N m 124 in Ib j 5 16 Inch Install the cover and gasket onto the fuel injection pump NOTE Extreme care must be taken in assembling the cover to the fuel injection pump to make sure the shutoff arm is in proper contact with the linkage hook tab installthe cover to the pump ata downward angle from the driveshaft end of the fuel injection pump then slide the cover horizontally into position Torque Value 5Nem 44 in ib Fuel Shutoff Valve 83 9 and 85 9 Series Engines Page A 44 Section A Adjustment Repair and Replacement a F1 Inline Pumps CG ii SYNCHRO f n P f ua dci d zm D LI ROVK Governor Shutoff Solenoid pi gu d T nox Th TE 10 mm SC E LT OK 29 u m CS SH Remove the hitch pin clip mounting capserews and the lt gt PT fuel shutoff solenoid e I rx Install the new sdlenoid in reverse order of removal and ud TR D connectthe wires Make sure the part number and cable y EL tie block is facing away from the engine Vg Torque Value 10 Nem 8
67. to 80 mm and 90 to 95 mm Clean the area around the fuel filter head Remove the filters Clean the gasket surface of the filter head Replace the o ring Install Fillthe newfilter s with clean fuel and lubricatethe o ring seal with clean lubricating oil standard filter usedassecondaryfilter indual filter applications e Fuel waterseparator usedas primaryfilter in dual filter applications Fuel water separator used in single filter applica tions 83 9 and 85 9 Series Engines Fuel Filter Spin On Type Maintenance Procedures at 19 000 km 12 000 mi Page 5 3 A CAUTION A SD Mechanical overtighteningwill distort threads filter l ement seal or filter can Instail the filter as specified by the filter manufacturer ligethe Fuel Supply Lines Page 5 4 B3 9 and B5 9 Series Engines Maintenance Proceduresat 19 000 km 12 000 mi Fuel Supp Lines vent pu e MO Controlledventingis provided attheinjection pumpthrough the fuel drain manifold Small amounts d air introducedby changing the filters or injection pump supply line will be vented autdmatically if the fuel filter Is changed in accor dance with the instructions No manual bleeding is re quired NOTE Manual bleeding is required if e The fuel filter is nbt filled prior to installation e Injection pump is replaced e High pressurefuel line connections are loosenedor lines replaced e Initial engine start up or sta
68. to High 1 9 liters 2 qt 1 9 liters 2 qt 19 liters 2 qt 83 9 and 85 9 Series Engines Section V Maintenance Specifications Lubrication System Data automotive Lubricating Oil Pressure at dle minimum allowable Lubricating Oil Pressure at Rated minimum allowabie Regulating Valve Opening Pressure LubricatingOll Capacity Standard Pan Only Total System Liters U S at Low to High B3 9 69 kPa 10 psi 207 kPa 30 psi 449 kPa 65psi 9 5 liters 10 qt 11 liters 11 6 qt 0 9 liter 1 qt Specifications Page V 7 B5 9 69 kPa 10 psi 207 kPa 30 psi 449 kPa 65psi 14 2 liters 15ai 16 4 liters 17 8 qt 1 8 liters 2 ai Specifications 83 9 and B5 9 Series Engines Page V 8 Section V Maintenance Specifications l Cooling System 48 Cooling System Data nonautomotive 4B3 9 4BT3 9 4BTA3 9 Coolant Capacity engine only 7 liters 7 4 qt 7 liters 7 4 qt 97 liters 10 2 qt Standard Modulating Thermo Start 83 C 181 F Fully Start 83 C 181 F Fully Start 83 C 1812F Fully stat Range Open 95 C 203 F Open 95 C 203 F Open 98 C 203 F Pressure Cap 104 C 220 F Systems 103 kPa 15 psi 103kPa 15 psi 103 kPa 15 psi 99 C 210 F Systems 48 kPa 7 psi 48 kPa 7 psi 48 kPa 7 psi 6B Cooling System Data nonautomotive 685 9 eBT5 9 6BTA5 9 Coolant Capacity engine only 10 5 liters 11 1 gt 10 5 liters 11 1 o 14 5 liters 115 3 qt Standa
69. 0 p86 A E bt ESN
70. 0 570 420 1100 820 570 420 1 14 800 590 650 480 1200 890 650 480 g 04 cap t 83 9 and 95 9 Series Engines Section W Warranty Page W a Section W Warranty Section Contents Page All Bus Categories Worldwide Except U S Canada Diesel Powered School Buses een W 7 B5 9 amp C8 3 Engines United States and Canada Recreational Vehicle ss W 25 B iSB Engines United States and Canada Automotive eere nennen entrent nnne We California Emission Control System Warranty On Highway Piette Mte ARE ONE Ss W 36 Moteurs tout terrain Etats Unis et Canada TES EE ET A AG RE LIL W 19 Off Highway Engines United States and Canada emen cernes W 13 United States and Canada Diesel Engine School Bus mx ageet EH Ree PTET W 30 83 9 and 85 9 Series Engines Page W b Section W Warranty THIS PAGE LEFT INTENTIONALLY BLANK 83 9 and 85 9 Series Engines Cummins Warrant Section W Warranty Page W B ISB Engines United States and Canada Automotive Coverage Products Warranted This warranty applies to new B and ISB s ries diesel Engines sold by Cummins and delivered to the first user on or after October 1 1996 that are usedin automotive on highway applicationsinthe United States or Canadawith three exceptions Cummins provides different warranty coverage for engines used in fire apparatus truck and crash truck bus and coach and recreational vehicle applications Base Engine Warranty This warranty covers
71. 01443 812791 Grasslin U K Ltd Vale Rise Tonbridge Kent TNS 1TB England Telephone 01732 359888 Icknield Instruments Ltd Jubilee Road Letchworth Herts England Telephone 04628 5581 Superb ot and Gauge Co 21 Prinoip Street Birmingham 84 61E Enaland Telephone 021 359 4876 Component Manufacturers Addresses Page M 5 Component Manufacturers Addresses Page M 4 Electronic Switches Cutler Hammer Products Eaton Corporation 4201 N 27th Street Milwaukee WI 53216 Telephone 414 449 6600 Engine Protection Controls Flight Systems Headquarters Hempt Road P O Box 25 Mechanicsburg PA 17055 Telephone 717 697 0333 The Nason Company 2610 Blue Ridge Bivd West Union SC 29696 Telephone 803 638 9521 Teddington Industria Equipment Windmill Road Sunburn on Thames Middlesex TW16 7HF England Telephone 09327 85500 Fan Clutches Kysor Cooling Systems N A 6040 West 62nd Street Indianapolis IN 46278 Telephone 317 328 3330 Holset EngineeringCo Ltd RO Box A9 Turnbridae Huddersfield West Yorkshire England HD6 7RD Telephone 01484 22244 Harton Industries inc P Q Box 9455 Minneapolis MN 55440 Telephone 812 378 6410 Rockford Clutch Company 1200 Windsor Road P O Box 2908 Rockford IL 61132 2908 Telephone 815 633 7460 Fans Truflo Ltd Westwood Road Birmingham B6 7JF England Telephone 021 557 4101 Hayes Albion Corporation J
72. 11900052 B3 9 and 85 9 Series Engines Flow Diagram Exhaust System Section D System Diagrams Page D 21 1 Wastegate closed 2 Wastegate open 5 Turbocharger exhaust inlet 6 Turbocharger exhaust outlet 3 Exhaust valve 4 Exhaust manifold 33 9 and B5 9 Series Engines Section D S stem Diagrams Flow Diagram Exhaust System Page D 22 Naturally Aspirated Engine a S B3 9 and B5 9 Series Engines Flow Diagram ast System Section D System Diagrams Page D 23 1 Exhaust valve 2 Exhaust manifold Flow Diagram Exhaust System 83 9 and 85 9 Series Engines Page D 24 Section D System Diagrams Turbocharged Engine 11400064 B3 9 and B5 9 Series Engines Section D System Diagrams 1 Exhaust valve 2 Exhaust manifold 3 Turbocharger exhaust inlet Flow Diagram Exhaust System 4 Turbocharger exhaust outlet Page D 25 Flow Diagram Compressed Air System B3 9 and B5 9 Series Engines Page D 26 Section D System Diagrams Flow Diagram Compressed Air System General Information 12900074 ESR 83 9 and 85 9 Series Engines Section D System Diagrams 19 oO P QN gt Compressor Compressor intake E Type unloader Reservoir line Governor Discharge line Splitter valve line Flow Diagram Compressed Air System Page D 27 8 Economy valve line 9 Air dryer 10 Check valve built into dryer 11 Reservoir wet tank 12 Check valve 13
73. 24 Nem 18 ft Ib Fuel injection Pumps in Line A 72 83 9 and 85 9 Series Engines Section Adjustment Repair and Replacement A CAUTION If a replacement or repaired pump was installed be sure to fill the governor housingwith clean lubricating engine oil before starting the engine Failure to do so will result in damage to the governor fly weights Remove the access plug andfill the governor housingwith clean lubricatingengineoi using specifications inthe table below Cil Capacity RQVK Governor 750 mi 0 71 qt RQV Governor 750 ml 0 71 qt RSV Governor 450 mi 0 48 qt Bosch RSV H Governor 500 mi 0 53 qt Denso install the access plug Torque Value 28 Nem 21 ft lb B39 and B5 9 Series Engines Section A Adjustment Repair and Replacement Fuel Pump Adjust Idle Speed Adjustment RQVK Governor 10 mm Screwdriver and Tachometer Idle adjustment forthe RQVK governor requires setting of the idle adjustment screw Loosenthe locknut and turn the screw counterclockwise to raisethe rpm clockwise to decrease idle speed untilthe dataplate specifiedidle speed is attained with normal idle operation accesspry loads i e transmission hydraulic air conditioning Tighten the lock screw RSV Governor Idle adjustment for industrial engines requires the setting of boththe low idle screw 1 and the bumper spring screw 2 AA JB Fuel Pum Page A 7 s Ng ns S L ES E o
74. 5 359 3744 B3 9 and B5 9 Series Engines Section S Service Assistance Wyoming Cummins Rocky Mountain Inc 2700 Hwy 14 amp 18 North PO Box 1207 82717 Gillette WY 82718 Telephone 307 682 9611 FAX 307 682 8242 Gillette Branch of Denver Rock Springs Branch of Salt Lake City Cummins Intermountain Inc 2000 Foothill Blvd PO Box 1634 Rock Springs WY 82901 Telephone 307 362 5168 FAX 307 362 5171 83 9 and 85 9 Series Engines Section S Service Assistance Alberta Edmonton Distributor and Branch Cummins Alberta 11751 181 Street Edmonton AB TES 2K5 Telephone 780 455 2151 AX 780 454 9512 Calgary Branch Cummins Alberta 4887 35th Street SE Calgary Alberta T2B 3H6 Canada Telephone 403 569 1122 FAX 403 569 0027 Grande Prairie Cummins Alberla Grande Praire RR2 Site 9 Box 22 Sexsmith AB CN TOH 3CO Telephone 780 568 3359 AX 780 568 2263 Hinton Branch Cummins Alberta 135 Veats Avenue Hinton Alberta T7V 188 Canada Telephone 780 8655111 AX 780 8655714 Lethbridge Branch Cummins Alberta 24th S et Nor EC Ab borta T HaTe Canada Telephone 403 329 6144 FAX 403 320 5383 British Columbia Vancouver Distributor Cummins British Columbia 18452 96th Avenue Surrey B C Canada VAN 3P8 Telephone 604 882 FAX 604 882 5080 Kamloops Branch Cummins British Columbia 976 Lavai Crescent Kamloops BC Ca
75. 5 New Engine Break in Oils rA V 29 Lubricating Oil System Overview s A99 General information amener ADO Maintenance Guidelines Overview c General Information 24 Maintenance Procedures Overview en 4 General Information ssesrrarennne is 4 Maintenance Record Form ws 2 10 General Information Maintenance Schedule se 23 General Information Moteurs tout terrain Etats Unis et Canada wu Normal Starting Procedure eOppanipinne 1 3 General Information ps etm i e 1 3 ff Hidhway Engines United States and Vd Canada Japan ek Operating Leila Kaos mnQ dy General information Operating the Engine General information Overhead Set Adjust Page References for Maintenance Instruotions 3 General Information PUTET TEE Sealants aig V 24 General information eienarnmentieeioiesn V 24 Service Assistance m 4 Distributors and Branches Australla Aussen Ann S 22 Distributors and Branches Canada usnisa 8 19 Distributors and Branches New Zealand u M Distributorsand Branches United SE Division and Regional Offices Emergency and Technical Service i i Problem Solving je Routine Service and Paris A Service Literature ipod Locatlon General Information VE ee Specifications m Air Intake System Batteries Specific Gravity Cooling System Electrical System Exhaust System Fuel System Side General Specif
76. 57 e ncludesail 50 states Bermuda PuertoHico Virgin Islands and the Bahamas Outside of North America contact you Regional Office Telephone numbersand addressesarelisted in the International Directory 9 02 svc assist frt Service Assistance 83 9 and 85 9 Series Engines Page 2 Section S Service Assistance Problem Solving Normally any problem that arises with the sale service or repair ofyour engine can be handled by a Cummins Authorized Repair Location in your area Refer to the telephone directory yellow pages for the one nearestyou If the problem has not been handled satisfactorily follow the steps outlined below 1 If the disagreementis with a Dealer talk to the Cummins Distributor with whom he has his service agreement 2 Ifthe disagreement is with a Distributor call the nearest Cummins Division or Regional Office however most probiems are soived below ine Division or Regionalaffice ievel Telephone numbers and addresses are iisied in this section Before calling write down the following information a Engine model and serial number b Type and make of equipment c Tal kilometers miles or hours of operation d Warranty start date e Nature d prablem f Summary ofthe current problem arranged in the order of occurrence g Name and location of the Cummins Distributor or Dealer 3 Ifaproblemcan not be resolved satisfactorily throughyour Cummins Authorized Repair Locationor Division Office wri
77. 83 9 and 85 9 Series Engines Section D System Diagrams Flow Diagram Lubricating Oil System Page D 8 Lubricationfor the Turbocharger 07300188 B3 9 and 85 9 Series Engines Flow Diagram Lubricating Oil System Section D System Diagrams Page D 9 1 Oil supply 2 Oil drain Flow Diagram Lubricating Oil System 83 9 and 85 9 Series Engines Page D 10 Section D System Diagrams l Lubrication for ihe Power Componenis PER E m BAIC E E d SE BED 3 07900167 83 9 and B5 9 Series Engines Section D System Diagrams 1 To valve train 2 Main oil rifle 3 From oil cooler 4 Rod journal 5 To rod bearing Flow Diagram Lubricating Oil System Page D 11 6 Crankshaft main journal 7 From main oil rifle 8 To camshaft 9 To piston cooling nozzle Flow Diagram Cooling System B3 9 and E5 9 Series Engines Page D 12 Section D System Diagrams Flow Diagram Cooling System General Information 08900138 B3 9 and B5 9 Series Engines Section D System Diagrams Sections A and B 1 Coolant inlet 2 Pump impeller 3 Coolant flow past oil cooler 4 Coolant flow past cylinder head 5 Coolant to cylinder head Flow Diagram Vd xm Page D 13 Sections C and D 1 Coolant flow from the cylinder head 2 Coolant to the thermostat housing 3 Coolant flow past injector 4 Thermostat 5 Coolant bypass passage 6 Coolant flow to pump inlet 7 Bypass closed 8 Cool
78. 9 Series Engines Page A 4 Section A Adjustment Repair and Replacement Belt Tensioner Automatic Remove 3 8 Inch Square Drive Liftbelttensioner to relievetension in the belt and remove the belt NOTE The bolt tonsionor is spring loaded and must be pivoted away from the drive belt Pivoting in the wrong direction can result in damage to the belt tensioner 13 mm Remove the belt tensioner 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Install 3 8 Inch Square Drive 15 mm Wrench install the belt tensioner and tighten the capscrew Torque Value 43 Nem 32 ft lb Liftand holdthe tensioner Installthe drive belt and release the tensioner Service Tip If difficulty is experienced installingthe drive beit for example the belt seemstoo short positionthe belt over the grooved pulleys first then while holdingthe ten sioner up slide the belt over the water pump pulley Fan Spacer and Pulley Remove 3 8 Inch Square Drive Lift belttensioner to relievetension inthe beit and remove the belt NOTE The belt tensioner is spring loaded and must be pivoted away from the drive belt Pivoting in the wrong direction can result in damage to the belt tensioner Fan Spacer and Pull Page ey A 5 Fan Spacer and Pulley 83 9and B5 9 Series Engines Page A 6 Section A Adjustment Repair and Replacement Ho t og 13 mm A Remove the four capsorews fan and space E In
79. 9 in Ib SA ROMIE Pm 10mm 16mm Adjust the solenoid linkage as necessary so thatthe plunger is magnetically held in with the shutoff lever inthe absolute full run position Turn the large hexontheendoflheplunger to make adjustments 83 9 and 85 9 Series Engines Cold Start Timing Advance System KSB Temperature Switch Section A Adjustment Repair and Replacement Page A 45 Cold Start Timing Advance System KSB Temperature Switch Remove 27mm Disconnect the KSB 1 wiring harness 2 from the switch 3 Instali T30 TORX 12 mm Replace the KSB and wiririg harness Torque Value KS8 Mounting Nuts 9 Nem BO in Ib US ai 5 X j ei 7 8 iv9hma Fuel Injection Pump Rotary Page A 46 B3 9 and B59 Series Engines Section A Adjustment Repair and Replacement Fuel Injection Pump Rotary Preparatory e Remove ail fuel lines Remove control linkage e Remove fuel shutoff solenoid A CAUTION A A diesel engine can nottoleratedirtorwi rinthe el system A tiny piece of dirt or a few drops of water in the injection system can stop the engine Clean all externalsurfaces of the injection pump including allline connections and fittings that are to bedisconnected Clean the area around the injection pump gear cover to prevent dirt from entering the crankcase 83 9 and 85 9 Series Engines Fuel Injection Pump Rotary Section A Adjustment Repair and R
80. Alfowable Intake Restriction at Rated Speed and Loaded with Dirty Air Filter Element 83 9 635 mm HO 25 in H 0 Specifications Page V 11 85 9 635 mm H O 25 in HO Specifications 83 9 and 85 9 Series Engines Page V 12 Section V Maintenance Specifications Exhaust System 48 Exhaust System Data nonautomotive 4B3 9 4BT3 9 4BTA3 9 Maximum Allowable Exhaust Re T Se at Rated Speed and 76 2 mm Hg 3 0 in Hg 76 2 mm Hg 3 0 in Hg 76 2 mm Hg 3 0 in Hg Loade 68 Exhaust System Data nonautomotive 6B5 9 6BT5 9 6BTA5 9 Maximum Allowable Exhaust Re pee at Rated Speed 2nd 76 2mm Hg 3 0 in Hg 76 2mm Hg 3 0 in Hg 76 2 mm Hg 3 0 in Hg oa 83 9 and B5 8 Series Engines Specifications Section V Maintenance Specifications Page V 13 Exhaust System Data automotive D B3 9 85 9 eae Aan SS p estriction at Rated Speed an Loaded 1991 to 1993 EPA certi 114 3mm Hg 4 5 in Hg 114 3mm Hg 4 5 in Hg fied Maximum Allowable Exhaust Restriction at Rated Speed and 152 4 mm Hg 6 in Hg with oxidation ROM 1994 to 1998 EPA certi catalyst ied 152 4mm Hg 6 in Hg with oxidation e catalyst Specifications 83 9 and 65 9 Serles Engines Page V 14 Section V Maintenance Specifications Fuel System 48 Fuel System Data nonautomotive Distributor Type Fuel Injection 483 9 46T3 9 4BTA3 9 Pumps Maximum Allowable Restriction POR FER m to the Fuel Transfer Pump Must 100 mm Hg j
81. Aluminum mm Nem ft lb Nem ft lb Nem ft lb Nem ft lb Nem ft lb Nem ft lb 6 9 ug 5 7 4 13 10 7 4 14 9 7 4 7 14 9 11 7 18 14 11 7 23 18 11 7 8 23 17 18 14 33 25 18 14 40 29 18 14 10 45 33 30 25 65 50 30 25 70 50 30 25 12 80 60 55 40 115 85 55 40 125 95 55 40 14 125 90 90 65 180 133 90 65 195 145 90 65 18 195 140 140 100 280 200 140 100 290 210 140 100 18 280 200 180 135 390 285 180 135 400 290 180 135 20 400 290 550 400 g 03 cap m Capscrew Markings and Torque Values B3 9 and B5 9 Series Engines Page V 34 Section V Maintenance Specifications Capscrew Markings and Torque Values U S Customary Cpe ELEA e Capscrew Torque Grade 5 Capscrew e rew To Gra Capscrew Body Size Cast tron Aluminum Castiren A um hum Nem ft lb Nem ft lb Nem ft lb Nem ft lb 1 4 20 9 7 8 6 15 11 8 6 1 4 28 12 9 9 7 18 13 9 7 5 46 18 20 15 16 12 30 22 16 12 BG 24 23 17 19 14 33 24 19 14 3 8 16 40 30 25 20 55 40 25 20 3 8 24 40 30 35 25 60 45 35 25 7146 14 60 45 45 35 90 65 45 35 7 16 20 65 50 55 40 95 70 55 40 1 2 13 95 70 75 55 130 95 75 55 112 20 100 75 60 60 150 110 60 60 9 16 12 135 100 110 60 180 140 110 80 9H6 16 150 110 115 85 210 155 115 85 5 8 11 160 135 150 110 255 190 150 110 518 18 210 155 160 120 290 218 160 120 34 10 325 240 255 190 460 340 255 190 3 4 16 385 270 265 210 515 380 285 210 716 9 490 360 380 280 745 550 380 280 7 8 14 530 390 420 310 825 610 420 310 1 8 720 53
82. Blissfield Michigan Diesel Fuel Systems Inc Subsidiary of Cummins Michigan Inc 211 N Jipson Street Blissfield MI 49228 Telephone 517 486 4324 FAX 517 4863614 Dearborn Branch Cummins Michigan Inc 3760 Wyoming Avenue Dearborn MI 48120 Telephone 313 8456200 FAX 313 843 6070 Grand Rapids Branch Cummins Michigan Inc 3715 Clay Avenue SW Grand Rapids MI 49508 Telephone 616 538 2250 FAX 616 538 3830 Grand Rapids Branch Standby Power Inc 7880 Expressway Drive SW Grand Rapids MI 49548 Telephone 616 281 2211 FAX 616 281 3177 Iron Mountain Branch of De Pere Cummins Great Lakes Inc 1901 Stevenson Avenue iron Mountain MI 49801 Telephone 906 774 2424 800 236 2424 FAX 906 774 1190 B3 9 and B5 9 Series Engines Section S Service Assistance Novi Branch Cummins Michigan Inc 25100 Novi Road Novi Mi 48375 Telephone 248 380 4300 FAX 248 380 0910 Power Products Branch of Detrolt Cummins Michigan Inc 41326 Vincenti Ct Novi Mi 40375 Telephone 248 426 9300 FAX 248 473 8560 Saginaw Branch Cummins Michigan Inc 722 N Outer Drive Saginaw MI 48605 Telephone 517 752 5200 FAX 517 752 4194 Standby Power Branch of Detroit Cummins Michigan Inc 12130 Dixie Redford MI 1 239 Telephone 31 53 FAX 313 538 3966 B3 9 and B5 9 Series Engines Section S Service Assistance Minnesota St Paul Distributor Cummins North C
83. C 28206 Telephone 704 596 7690 FAX 704 596 3038 Greensboro Branch Curnmins Atlantic Inc 513 Preddy Boulevard 27406 PO Box 22066 Greensboro NC 27420 2066 Telephone 336 275 4531 FAX 336 275 8304 Wilson Branch Cummins Atlantic Inc 1514 Cargill Avenue 27893 RO Box 1177 Wilson NC 27894 1117 Telephone 252 237 9111 FAX 252 237 9132 Service Assistance Page S 13 North Dakota Fargo Branch of St Paul Cummins North Central Inc 3801 34th Ave SW Fargo ND 58104 Telephone 701 282 2466 FAX 701 277 5399 Grand Forks Branch of St Cummins North Central Inc 4728 Gateway Drive Grand Forks ND 58201 Telephone 701 775 8197 FAX 701 775 4833 Minot Branch of St Paul Cummins North Central Inc 1501 20th Avenue S E Minot ND 58702 Telephone 701 852 3585 FAX 701 852 3588 Ohio Paul Lei Columbus Distributor and Branch Cummins Interstate Power Inc 4000 Lyman Drive Hilliard Columbus OH 43026 Telephone 614 771 1000 FAX 614 771 0769 Service Assistance Page S 14 Columbus Distributor Cummins Interstate Power Inc 2297 Southwest Bldv Suite K Grove City CH 43123 Telephone 614 771 1000 FAX 614 527 2576 Cincinnati Branch Cummins Interstate Power Inc 10470 Evendale Drive Cincinnati OH 45241 l Telephone 513 563 6670 FAX 513 563 0594 Cleveland Branch Cummins interstate Power inc 7585 Northfield Road C
84. CA 90640 Telephone 323 728 8111 FAX 823 889 7422 Bloomington Branch Cummins Cal Pacific Inc 3061 S Riverside Avenue Bloomington CA 92377 Telephone 809 877 0433 FAX 909 877 3787 San Diego Branch Cummins Cal Pacific Inc 310 N Johnson Avenue Et Caion CA 92020 Telephone 619 583 3093 FAX 619 593 0600 Ventura Branch Cummins Cal Pasific Inc 3958 Transoort Si Ventura CA 93003 Telephone 805 644 7281 FAX B05 644 7284 Colorado Denver Distributor Cummins Rocky Mountain Inc 5100 East 58th Avenue Commerce City CO 80022 Telephone 303 287 0201 FAX 303 288 7080 Denver Onanlindustrial Branch Cummins Rocky Mountain Inc 5100 East 58th Ave Commerce City CO 80022 Telephone 303 286 7697 FAX 303 287 4837 Service Assistance Page S 6 Durango Branch Cummins Rocky Mountain Inc 13595 County Road 213 Durango CO 81301 Telephone 970 259 7470 FAX 970 259 7482 Grand Junction Branch Cummins Rocky Mountain Inc 2880 U S Hignway amp amp 50 PO Bex 339 Grand Junction CO 81501 Telephone 303 242 5776 FAX 303 243 5495 Connecticut Rocky Hill Branch of Bronx Cummins Metropower inc 914 Cromwell Ave Rocky Hill CT 06067 Telephone 860 529 7474 FAX 860 529 7524 Florida Tampa Distributor Cummins Southeastern Power Inc Corporate Office 5421 N 59th Street Tampa FL 33610 Telephone 813 621 7202 FAX 813 621 8250 Ft Myer
85. CS Pump le Eege Pleasure Boat eeler 8 S Z O 1 Or whichever occurs first If the application accumulates high hours and low mileage the change interval is determined bv hours B3 9 and B5 9 Series Engines Maintenance Schedule Section 2 Maintenance Guidelines Page 2 7 Arctic Operation A CAUTION A The use of a synthetic base oil does not justify extended oll change intervals Extended oil change intervals can decrease engine life due to factors such as corrosion deposits and wear If an engine is operatedin ambienttemperaturesconsistently below 23 C 10 F and there are no provisionsto keep the engine warm when itis not in operation use asyntheticCE SF or higher API classification engine oil with adequate low temperature properties such as 5W 20 or 5W 30 The oil supplier is responsible for meeting the performance service specifications represented with its product e Ee B3 9 and BS 9 Serles Engines Page References for Maintenance Instructions Page 248 H TRUE i un Section 2i OI Zeep e Guidelines ie i i il i M o Page References for Maintenance Instructions Qu dM pe AER ET ME CH General Information ft ee EK dpi beider o hipiai nep s 8 For your convenience listed below are the page numbers that contain speci instructions for parmi th the main tenance checks listed in the maintenance schedule i g pd Daily or Refueling Maintenance Check e a age
86. Contact a Cummins Authorized Repair Facility 83 9 and 65 9 Series Engines Section TS Troubleshooting Symptoms Coolant Temperature Above Normal Cause Coolant tevel is below specification Radiator fins are d or obstructed with debris Cooling system hose is collapsed restricted or leaking pe OK Lubricatingoil level is below specification OK Correction Inspect the enaine and cooling system for external coolant leaks Repair If necessary Add coolant Referio Section 7 inspect the radiator fins Clean and repair the fins as necessary Refer ta the OEM service manual Inspect the radiator hoses Refer to Sectlon A ee i Check the oll level Verify the dipstick calibration and the oil pan capacity Fill the system to the specified level Refer to Section 3 Troubleshooting Symptoms Charts Cause Fan shroud is damaged or missing or the air recircu lation baffles gf p maged Fan drive belt is loose tight or not in alignment ft Fan drive or fan controls are rnalfunctloning OK La Radiator cap is not corr is malfunctioning or n low pressure rating Continued Page TS 7 Correction inspect the shroud and the recirculationbaffles Repair replace or install if neces sary Refer to the OEM service manual Check the fan drive belt Refer to Section A Check the fan drive and controls Refer
87. Engines Page A 90 Section A Adjustment Repair and Replacement TS Install a new gasket and apply anti seize compoundto the AU mounting studs 15 mm A Install the turbocharger and a new gasket a A Torque Value 43 Nem 32 ft lb tab tb gkha B3 9 and 85 9 Series Engines Turbocharger Section A Adjustment Repair and Replacement Page A 91 13mm Jf required bendthelockplatesbackandloosentheturbine housing capscrews Position the bearing housingto install the turbocharger drain tube 13 mm Installthe hose and clamps on the turbochargerdrain tube loosely Install the drain tube and gasket on the turbo charger Torque Value 24 Nem 18 ft ib tb9hona Turbocharger j B3 9 and B5 9 Series Engines Page A 92 Section A Adjustment Repair and Replacement Screwdriver Position the turbocharger drain hose to connect the drain tubes tighten the clamps 13 mm Punch Hammer If loosened tighten the turbine housing capscrews Bend the lockpletes onto the flats to prevent loosening Torque Value 20 N m 15 ft lb tb9hema 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement 10 mm If required loosen the compressor housing and position the housing to align with the crossover tube Torque Value 9 Nem BO in Ib SA 11 mm Plastic Hammer Wn d Tighten the band clamp Tap around the clamp with a plastic hammer and tighten again Torque Value 9 Nem
88. Excessive Under Load Continued Cause Correction Cause Correction Monitor the turbocharger Check the AFC for leaks boost pressure with an Repair any leaks found if SE Airduel AFO contro Is D manual leaking o obstructed tlltings for SE Refer to the OEMservice manual Turbocharger is malfunc tinning OK Altow the engina to warm to T operating e If Contact a Cummins the engine Will not reach Authorized Engine is cold operating temperature refer Repair Facility Below Normal symptom 4 DEI Fuel injection pump ls Remove the oe d malfunctioning Refer to Section Cali brate the fuel pump Troubleshooting Symptoms Charts Page TS 32 G NE Fi Cause Correction Chack for added loading from malfunctioning accessories or driven units brakes dragging and other changes in vehicle loading L Operate the engine from a temporary tank cf good quay No 2 diesel fuel Ciean and flush vehicle s fuel system Fill fuel system with a good quality No 2 diesel fuel 5 Fuel quality is poor Bleedthe fuel system and check for leaks Refer to Air in the fual system Section 5 OK B3 ind B5 9 SeriesEngines Section TS 1 ubleshooting Sympioms Knock SES Correction Put the engine at tob dead center Check and adjust the fuel timing Refer to Section A Fuel Injection pump timing 18 not co
89. Hg 20 4 in Hg 518 mm Hg 20 4 in Hg Maximum Allowable Pressure Drop across Fuel Filter 35 kPa 5 psi 35kPa 5 psi 35 kPa 5 psi Maximum Inlet Pressureto the Injection Pump Must Not Exceed 70 kPa 10 psi 70 kPa 10 psi 70 kPa 10 psi In Line Type Fuel Injection Pumps Maximum Inlet Restriction to the Be LUE Pump Must Not 100 mm Hg 4 in Hg 100mm Hg 4 in Hg 100 mm Hg 4 in Hg xcee Fuel Transfer Pump Minimum 172kPa 25 ps High 172KPa 25 pail Hion 172 kPa 25 psi High Output Pressure Flow and 90 kPa 13 psi Flow and 90 kPa 13 psi Flow and 90 kPa 13 psi Low Flow amp Rated rom Low Flow Rated rpm Low Flow e Rated rpm Fuel Filter Restriction maximum e AP pressure drop across filters 35 kPa 5 psi 35 kPa 5 psi 35 kPa 5 psi Fuel Pump Gallery Pressure 140kPa 20 psi 140kPa 20 psi 140kPa 20 psi Rated rpm Rated rpm Rated rom Fuel Return Maximum Restriction 518 mm Hg 20 4 inHg 518mm Hg 20 4 inHg 518mm Hg 20 4 in Hg The low flow fuel transfer pump will have 82 7 kPa 12 psi Specifications 53 9 and B5 9 Series Engines Page E 12 Section E Engine Identification 68 Fuel System Data nonautomotive Distributor Type Fuel Injection 685 9 6BT5 9 6BTA5 9 Pumps Se TO eee Maximum Allowable Restriction to the Fuel Transfer Pump Must 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg Not Exceed Maximum kiiowabie Return Line Maximum Allowable Press
90. M er Si ERN TAERREEE Tnm M Prelubrication Systems M Radiators M Throttle Assemblies M Is is 1 300017 EROTICA M NINNNIN AD 83 9 and B5 9 Series Engines Section M Component Manufacturers Section M Component HERE H Section Contents Component Manufacturers Addresses Air Compressors Air Cylinders Air Heaters Air Starting Motors Alternstors ssena Pee Auxiliary Brakes i Seat BOltS issus tortues Catalytic Converters Clutches Coolant Heaters Coolant Level Switches Drive Plates Electric Starting Motors Electronic Switches Engine Protection Controls 5 Fan Clutches TTT reer rere een beara nae wks szasgzgzggggggg C35 CO CO C3 CO PO PO PO cas 1 gt Ne NOE Mi ip Se eee pe M 4 zz AS Fans M 4 Fault Lamps Cn n e Ra ee Hu RER CECI TLC aat en an ui ela b pauu CEE ip Ian e e M 4 Filters nue cutus M 5 Flexplates me M 5 Fuel Coolers vs a M5 Fuel Pumps asie M Fuel Warmers M 5 Gauges een rcp aise Ces Seen AEAT M 5 General Information R MA 83 9 and 85 9 Series Engines Section S Service Assistance Page S a Section S Service Assistance Section Contents Page SIE Seet Reese ee El GE A E EES aie ST a Distributors and Branches Australia ns
91. Minute Society of Automotive Engineers Supplemental Coolant Additive Step Timing Control Variable Speed Vehicle Speed Sensor 83 9 and B5 9 Series Engines Section E Engine Identification Page E a Section E Engine Identification Section Contents Page dore B Tcu ca E 27 Engine Views int eitar anne eseu EE E 27 Engine Identification sus SR A SI e eene E 1 ummins Engine ida SEET Eeer EE ee eee EE E 3 Engine Dataplate EEN E T Fuel Injection Pump Dataplate HUH XR p E 4 Boechg s pec M EEN E 4 CAV Ee E 5 Stanadyne pen E 5 PS POGIICAU EET EC Em m E 7 Air Intake System E 19 Batteries Specific E 26 Cooling System E 17 Electrical System E 23 Exhaust System E21 Fuel System E GE ee eh yis B uS A EE 1 E44 83 9 and 85 9 Series Engines Page E b Section E Engine Identlfication THIS PAGE LEFT INTENTIONALLY BLANK t 83 9 and 85 9 Series Engines Section E Engine Identification Engine Identification Engine Dataplate The engine dataplate shows specific information aboutthe engine The engine serial number ESN and control parts list CPL provide information for ordering parts and for service needs The engine dataplate must not be changed unless approved by Cummins Engine Company Inc Engine Identification Page E 1 83 9 and B5 9 Series Engines Engine Identification can Sectio
92. ROMM OVO EE Tool Requirements General Information Turbocharger iL Install sis nee S lt EE OH Water TT E eege Ee ier Install MERE Ee ee Preparatory pec D Em e R mmereg M Gelee ege B3 9 and 85 9 Series Engines Page A f Section A Adjustment Repair and Replacement THIS PAGE LEFT INTENTIONALLY BLANK 83 9and BS5 9 Series Engines Section A Adjustment Repair and Replacement Tool Requirements General Information Tool Requirements Repair Tools Required Sockets Wrenches 10 mm 8mm 12 mm 10mm 13 mm 13 mm 15 mm 15 mm 17mm 17mm open end 18mm 19mm 19mm 22mm 22mm 24mm 27mm Tool Requirements Page A 1 Other Allen wrench 8 mm Breaker bar 112 in sq drive Flat screwdriver Ratchet 3 8 in sq drive Ratchet 1 2 in sq drive Filter wrenches 75to 80 mm and 90 to 95 mm Drill motor 1 4 in Drill bit 3 mm Slide hammer Flat chisel T bar puiler 75mm Sheet metal screw No 10 Torque wrench Pliers Engine barring gear Part No 3824591 H Cooling System 83 9 and 85 9 Series Engines Page A 2 Section A Adjustment Repair and Replacement Cooling System General Information A WARNING A Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with loc
93. SC 29483 Telephone 843 851 9819 FAX 843 875 4338 Service Assistance Page S 15 Columbia Branch of Charlotte Cummins Atlantic Inc 1233 Bluff Road 29201 PO Box 13543 Columbia SC 29201 3543 Telephone 803 799 2410 FAX 803 779 3427 South Dakota Sioux Falls Branch of Omaha Cummins Great Plains Diesel Inc 701 East S i Street North Sioux Falls SD 57104 Telephone 605 336 1715 FAX 605 336 1746 Tennessee Memphis Distributor amp Distribution Center Cummins Mid South Inc 666 Riverside Drive Memphis TN 38703 Telephone 901 577 0666 FAX 901 522 8758 Chattanooga Branch of Atlanta Cummins South Inc 1509 East 26th Street Chattanooga TN 37407 1095 Teleohone 618 629 1447 FAX 615 629 1494 Service Assistance Page S 16 Knoxville Branch of Louisville Cummins Cumberland Ino 1211 Ault Road Knoxville TN 37914 Telephone 423 5230446 FAX 423 523 0343 Memphis Branch Cummins Mid South Inc 1784 E Brooks Road Memphis TN 38118 Telephone Sales Admin 901 345 7424 Parts 801 345 1784 Service 901 345 6185 FAX 901 346 4735 Nashville Branch of Louisville Cummins Cumberland Inc 706 Spence Lane Nashville TN 37217 Telephone 615 3664341 FAX 615 366 5693 Texas Arlington Distributor Cummins Southern Plains inc 600 N Watson Road Arlington TX 76004 3027 Telephone 817 640 6801 FAX 817 640 6852
94. Secondary pressure line Flow Diagram Compressed Air System 83 9 and B5 9 Series Engines Page D 28 Section D System Diagrams 4 200 o 12900076 B3 9 and B5 9 Series Engines Flow Diagram Compressed Air System Section E Sy item Diagrams Page D 29 Compressor 5 Governor 6 Discharge line 1 2 3 Unloaderline 7 Reservoir wet tank 4 Reservoir line Fiow Diagram Compressed Air System 83 9 and B5 9 Series Engines Page D 30 Section D System Diagrams NOTES B3 9 and 85 9 Serles Engines Section L Service Literature Page L a Section L Service Literature Section Contents t Page Additional Service ET L 1 Gereral uui e L 1 Service Literature Ordering Location since nnno nennen nnne nn rona rni therein rasare natn L 2 General Information GEES ET KEE E E Em Les L 2 83 9 and B5 9 Series Engines Page L b Section L Service Literature THIS PAGE LEFT INTENTIONALLY BLANK _B3 9 and BS Series Engines Additional Service Literature Section L Literature Page L 1 Additional 1 Literature General Information The following publications can be purchased by contacting a Cummins Distributor or by calling 1 800 DIESELS B 343 7357 Bulletin No Title of Publication 3666087 B Series Troubleshooting and Repair Manual 3666017 B Series Engine Shop Manual 3810234 B Series Alternate Repair Manual 3810326 4B Se
95. Street West Rock Island IL 61204 Telephone 309 787 4300 FAX 309 787 4397 Onan Branch Cummins Gateway Inc 1 Extra Mile Drive Collinsville IL 62234 Telephone 618 345 0123 FAX 314 531 6604 Service Assistance Page S 8 Indiana Indianapolis Distributor Cummins Mid States Power Inc P O Box 42917 3762 West Morris Street Indianapolis IN 46242 0917 Telephone 317 243 7979 FAX 317 240 1925 Evansville Branch of Louisville Cumrnins Cumbedand Inc 7901 Highway 41 North Evansville IN 47711 Telephone 812 867 4400 FAX 812 421 3282 Ft Wayne Branch Cummins Mid States Power Inc 3415 Coliseum Blvd West At Jet 1 69 amp 30 33 Ft Wayne IN 46808 Telephone 219 482 3601 FAX 219 484 8930 Gary Branch of Chicago Cummins Northern Illinois Inc 1440 Texas Street Gary IN 48402 Telephone 219 885 5591 FAX 219 883 4817 Indianapolis Branch Cummins Mid States Power Inc F O Box 42917 3621 West Morris Street Indianapolis IN 48242 0917 Telephone 317 244 7251 AX 317 240 1215 Onsn Branch Mid States Power Inc 4301 W Marris Street P O Box 42917 Indianapoiis IN 46240 0917 Telephone 317 240 1967 AX 317 240 1975 iowa Cedar Rapids Branch of Omaha Cummins Great Plains Diesel Inc 625 33rd Avenue SW Cedar Rapids IA 52406 Telephone 819 366 7537 24 hours FAX 819 366 7562 Des Moines Branch of Omaha Cummins Grea
96. TS 24 an Section TS Troubleshooting Symptoms Engine Starts But Will Not Keep Running Cause Correction Cause E Correction Check and adjust the low Idle speed is set too low forl Fuel filter or fuel suction Replace the fuel filter accessorles idle screw Geet to Section Ime is restricted Refer to Sectlon 5 OK Ka D Full eu line or passag Check the fuel supply line Disengage engine criven restriction between the fue or passage for sharp bands MAU pump and he injectors or restriction OK Y Check for correct solenoid Verify by operating the operation herer to Section Fuel contaminated engine with clean fuel from a temporary tank Fust shutoff lever mechani cal partially engaged Bleed the fuel system and Air inthe fuel system check for leaks Refer to Fuel injection timing is not correct Check he fuel pump timing Refer to Section A Contact a Cummins Authorized Repair Facility 83 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 25 Engine Vibration Excessive Cause Correction Cause Correction Refer to the Engine Runs Engine not running Glean and replace the Rough or Misfires symptom Alternataddmeageg worn or Iii alternator Referto the smoothly tree OEM service manual OK f Contact a Cummins inspect the engine mounts Authorized Engi
97. Tighten the pump lock screw GE Torque Value 13Nem 115 in lb WY NOTE Be sure to disengage the timing pin CWN S bo9piba 83 9 and 85 9 Series Engines e EH Pump Rotary 56 Section A SES Repair and Replacement Page A K de II Install the injection sine support bracket Finger tighten OT Ge A TEM SO all capscrews before final tightening DO he Ge DE qr B f BD I IS Za gt g S rt lt KG amp Pad ep m De Sa f Z N lax 9 fs9suhb Tighten the capscrews Torque Value 24 Nem 18 ft lb NOTE Tighten the bracket to block mounting capscrews 1 before tightening the bracket to injection pump cap screw 2 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement 22 mm Tighten the drive gear mounting nut Torque Value Bosch 65 Nem 48 ft lb Torque Value Stanadyne 65 Nem 48 ft lb Install the access cap 8 mm Install the solenoid wiring and all fuel lines Fuel Injection Rump R age otar A 5 Fuel Injection Pump Rotary Page A 58 83 9 and BS 9 Series Engines Section A Adjustment Repair and Replaaement NOTE When connectingthe cable rod to the control lever adjust the length so the lever has stop to stop movement pH i NOTE Similarly adjust the length of the cable rod to the mechanical shutdown lever so there is a stop to stop movement B3 9 and 85 9 Series Engines Hot ap Rotary Section A Adjustmen
98. able Return Line Restriction 518 mm Hg 20 4 inHg 518mm Hg 20 4 in Hg 518 mm Hg 1204 in Hg Maximum Allowable Pressure Droo across Fus Filter 35 kPa 5 psi 35 kPa 5 psi 35 kPa 5 psi Maximum Inlet Pressure to the Injection Pump Must Not Exceed 70 kPa 10 psi 70 kPa 10 psi 70 kPa 10 psi E In Line Type Fuel Injection Pumps Maximum Inlet Restrictionto the EU rds Pump Must Not 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg xcee Fuel Transfer Pump Minimum 172kPa 25psi High 172kPa 2 psf High 172 Em psi High Output Pressure Flow and 90 kPa 13 psi Flow and 90 kPa 13 psi Flow and 90 kPa 13psi Low Flow amp Ratedrpm Low Flow Ratedrpm Low Flow Rated rpm Fuel Filter Restriction maximum pressure drop across filters 35 kFa 5 psi 35 kPa 5 psi 35 kPa 5 psi Fuel Pump Gallery Pressure 140 kPa 20 psi amp 140kPa 20 psi amp 140kPa Lei Rated rpm Rated rpm Rated rpm Fuel Return Maximum Restriction 518 mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hg The low flow fuel transfer pump will have 82 7 kPa 12 psi Specifications Page V 16 Fuel System Data automotive Distributor Type Fuel Injection Pumps Maximum Inlet Restrictionto the Fuel Trans fer Pump Must Not Exceed Maximum Allowable Return Line Restriction Maximum Allowable Pressure Drop across Fuel Fiiter Maximum inlet Pressure to th Injection Pump Must Not Exceed In Line Type Fuel
99. ackson Manufacturing Piant 1999 Wildwood Avenue Jackson Mi 49202 Telephone 517 782 9421 83 9 and 85 9 Series Engines Section M Component Manufacturers Engineered Cooling Systems Inc 201 W Carmel Drive Carmel IN 46032 Telephone 317 8463438 Brookside Corporation PO Box 30 MeCordsville IN 46055 Telephone 317 335 2014 TCF Agrovent Company 9100 Purdue Rd Suite 101 Indianapolis IN 46268 1190 Telephone 317 872 0030 Kysor Cadillac 1100 Wright Street Cadillac MI 49601 Telephone 616 775 4681 Schwitzer 6040 West 62nd Street PO Box 80 B Indianapolis IN 46206 Telephone 317 328 3010 Fault Lamps Cutler Hammer Products Eaton Corporation 4201 N 27th Street Milwaukee WI 53216 Telephone 414 449 6600 83 9 and 85 9 Series Engines Section M Component Manufacturers Catalytic Converters Donaldson Company Inc 1400 West 94th Street PO Box 1299 Minneapolis MN 55440 Telephone 612 887 3835 Nelson Division Exhaust andFlitration Systems 1801 US Highway 51 FO Box 428 Stoughton WI 53589 Telephone 808 873 4200 Walker Manufacturing 3901 Willis Road P O Box 157 Grass Lake Mi 49240 Telephone b17 522 5500 Coolant Level Switches Robertshaw Contmls Company P O Box 400 Knoxville TN 37901 Telephone 216 885 1773 Clutches Twin Disc International S A Chaussee de Namur Niveiles Belguim Telephone 087 224841 Twin Disc Incorporated 1328 Racin
100. act 800 DIESELS 343 7357 f USA ic 1 This manual does not cover vehicle or equipment maintenance procedures Consult the vehicle or original equipment manufacture OEM for 4 x nance recomm sndations ith candU S customary values are listed iri this manual The metric value isl 1fi t fall d th U S customary in icke Numerous illustrations and symbols are used totic in ig the meaningof the text Referto Sy Section fc i t fisting of symbols dtt i definitions Each s ig ded by a ctio Contents to aid in locating information quickly B3 9 and B5 9 Series Engines How to Use the Manual Section i Introduction Page i 3 How to Use the Manual General Information Thismanual isorganizedaccordingtointervalsabwhichmaintenanceonyourengineisto be performed A maintenance chart table that gives required intervals and checks to be made is located in Section 2 Locatethe interval at which you are performing maintenance then follow the steps given in that Sectionfor all the proceduresto be performed In addition the procedures completed under previous maintenance intervals must also be performed Keep a record of ail the checks and inspections made A record form for recording the date or hours at which maintenance checks were performedis located in Section 2 Referto SectionTS for a guide to troubleshootingyour engine Followthe directionsgiven in that section to locate and correct engine problems Referto SectionV for specifications r
101. ad gasket Is gasket Refer to the OEM debris mixture of antifreeze and saking service manual water Refer to Section 7 OK Contact a Cummins Authorized Repalr Facility OK Check th jransmission oil Transmission oil cooler or cooler and torque conve torque converter cooler s DCH iJ Marine Res cooled engine only cooler for coo ant leaks Refer to the OEM service Check the lubricatingeli cooler for coolant leaks and cracks Refer to Section A Lubricatingeil cooler is leaking 63 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 5 Coolant Loss Cause Correction Cause Correction ee i Drain and flush the cooling B Air compressor cylinder Inspect tne alr compressor Coolant is rusty and has system Fill with corr ct head is cracked or porous cylinder head and gasket debris mixture of antifreeze and or has a leaking gasket Refer to the OEM service water Refer to Section 7 nonmarineengines only manual Inspect the angine and its Check the lubricating oil Lubricating oil cooler is CD MA up oil f j cooler for oleae Refer to gasket tappet cover oi ection A cooler or drain cock leaks i OK v Contact a Cummins g Authorized Check for combustion Repair Facility Combustion gases are gases in the cooling entering the cooling systaml
102. ada Inc 50 Simmonds Drive Dartmouth Nova Scotia B3B 1R3 Telephone 902 468 7938 FAX 902 468 5177 Parts 802 488 58 Ontario Toronto Distributor Cummins Ontario Inc 7175 Pacific Circle Mississauga ON L5T 2A5 Telephone 805 795 0050 FAX 905 795 0021 Kenora Branch of Winnipeg Cummins Mid Canada Ltd Highway 17 East PO Box 8 Kenora Ontario DON 3X1 Telephone 807 548 1941 FAX 807 548 8302 Ottawa Branch Cummins Ontario Inc 3189 Swansea Crescent Ottawa Ontario K1G 3W5 Telephone 613 736 1146 FAX 613 736 1 202 i B3 9 and B5 9 Series Engines Section S Service Assistance Thunder Bay Branch Cummins Ontario Inc 1400 W Walsh Street Thunder Bay Ontario P7E 4X4 Telephone 807 577 7561 FAX 807 577 1727 Whitby Branch Cummins Ontario Inc 1311 Hopkins Street Whitby Ontario LIN 2C2 Canada Telephone 905 668 6886 FAX 905 668 1375 Quebec Montreal Distributor Cummins Eastern Canada Inc 7200 Trans Canada Highway Pointe Claire Quebec HBR 1C2 Telephone 514 685 8410 FAX 514 695 8917 Montreal Branch Cummins Eastern Canada Inc 7200 Trans Canada Highway Pointe Claire Quebec H9R 1Ce2 Canada Telephone 514 695 8410 Sales 514 695 4555 Parts 514 694 5880 FAX 514 695 8917 B3 9 and BS 9 Series Engines Section S Service Assistance Dorval Onan Branch Regina Branch of Winnipeg Cummins Eastern Canada Inc Cummins Mid Canada Ltd
103. aileghan Street Hexham New South Wales Australia Telephone 61 2 4964 8466 FAX 61 2 49644616 Kalgoorlie Cummins Engine Company Pty Ltd PO Box 706 Kalgoorlie 6430 Western Australia Australia Location 16 Atbara Street Kalgoorlie 6430 Telephone 614 9021 2588 Karratha Cummins Engine Company Pty Lid FO Box 377 Karratha WA 6714 Australia Location 1490 Lamberl Road Karratha WA 6714 Australia Telephone 61 8 9144 4646 FAX 81 8 9143 1507 Laverton Cummins Engine Company Pty Ltd Locked Bag 1 Laverton Victoria 3028 Australia Location 195 Boundary Road Laverton North Victoria 3028 Australia Telephone 61 3 9360 0800 FAX 613 9360 0438 Service Assistance Page S 23 Leeton Cummins Engine Company Ply Ltd P O BOX 775 Leeton NSW 2705 Australia Location 29 Brady Way Leeton NSW 2705 Australia Telephone 81 2 6953 3077 FAX 61 2 6953 3109 Mackay Cummins Engine Company Pty Ltd PO Box 842 Mackay 4740 Queensland Australia Location 4 Presto Avenue Mackay 4746 Telephone 61 7 4955 1222 Mount Gambier Cummins Engine Company Pty Ltd P O Box 2219 Mount Gambier 5290 South Australia Australia Location 2 Avey Road Mount Gambier 5290 Telephone 61 87 25 6422 Service Assistance Page 5 24 Penrith Cummins Engine Company Pty Ltd P O Box 132 TEES Cambridae Park 2747 New South Wales Australia
104. aintenance Check Air Compressor INSPEC eonim rre ri eicere EE duce Aa p eae AE AREE 7 9 Cooling System Drain Flush Fill nn nennen nnn nnm aesneacsneacsnsosensocenenrenensenensenensanensseress 7 2 e Vibration Damper Inspect E ue 7 8 Cooolant and Antifreeze Change accessi enean rmn erste tire ree nahe res WII 7 2 Maintenance Record Form 83 9 and B5 9 Series Engines Page 2 10 Section 2 Maintenance SES Maintenance Record Form General Information Maintenance Record Equipment Name Number g 02 h malnt Page 2 11 Maintenance Record Form B3 9 and B5 9 Series Engines Section 2 Maintenance Guidelines Maintenance Record Form B3 9 and B5 9 Series Engines Page 2 12 Section 2 Maintenance Guidelines NOTES 1 5 9 Series jii es ic rocedures at Daily Interval Page 3 a Section 3 Maintenance Procedures at Daily Interval Section Contents N m Page Coolant Level RE 3 4 Maintenance Check code deeg EEE geen diese Ee 3 4 Daily Maintenance Procedures Overvlew cccsccccscessceeceeseeseseeseesenseceeseesesseseesenseseeseesenseseesensenseseesensesees 3 General Information se ae rc HOMI UT 3 Drive CN 3 Maintenance Check 5 nn ete are nets nna kAa nanna S Nusia K Kakik 5 Ee MK T DE 3 7 Fan Goller ee enee das die TET ett eaten eme eee 3 8 Maintenance Check i 3 8 Fuel Water Separator 3 2 Maintenance Check 3 2 Lubricati
105. al envi ronmental regulations A WARNING A Do not remove the pressure cap from a hot engine Wait untilthe coolant temperature is below 50 C 122 F before removing the pressure cap Heated coolant spray or steam can cause personal injury Components to Tools Preparatory Steps Be Replaced Drive belt Breaker bar 3 8 in sq drive Belt tensioner Ratchet Remove drive belt 3 8 in sq drive 13 mm socket and torque wrench Fan hub 13 mm socket wrench Remove drive belt and fan pulley Water pump 10 rnmsocket wrench Drain coolant and remove drive belt Thermostat 10 mm 18 mm and 19 mm Drain coolant remove drive belt loosen alternator socketlwrench link remove alternator mounting capscrew remove thermostat housing 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Drive Belt Cooling Fan Remove 3 8 Inch Square Drive Liftthe tensioner to remove the drive belt NOTE The belt tensioner is spring loaded and must be pivoted away from the drive belt Pivoting in the wrong direction can result in damage to the belt tensioner Install A CAUTION A Applying excessive force in the opposite direction of windup or afterthetensioner hasbeen wound up to the positive stop can cause the tensioner arm to break 3 8 Inch Square Drive Lift and holdthe belttensioner Installthe drive belt release the tensioner Drive Belt Cooling Fan Page A 3 Belt Tensloner Automatic B3 9 and B5
106. ant flow back to radiator Flow Diagram Air Intake System 83 9 and 85 9 Series Engines Page D 14 Section D System Diagrams Flow Diagram Air intake System General information 10200253 B3 9 and 85 9 Series Engines Section D System Diagrams 1 Intake air inlet to turbocharger 2 Turbocharger air to charge air cooler 3 Charge air cooler 4 Intake manifold 5 Intake valve Flow Air Intake System Page D 15 Flow Diagram Air Intake System 83 9 B5 9 Series Engines Page D 16 Section D System Diagrams Turbocharged Aftercooled Water Jacket Engine ee aile Sor E E e ee E nik SEPT E Zeng E 1090025 B3 9 and 85 9 Series Engines Section D System Diagrams 1 Intake air inlet to turbocharger 2 Air to intake manifold 3 Intake manifold 4 Intake valve Flow Diagram Air Intake System Page D 17 Flow Diagram Air Intake System 83 9 and 9 Series Eng r Page D 18 Section D System Diagrams Naturally Aspiraied Engine 3 DG EE de AS gas H gt Dall Ei i P EEN SS A 10900254 83 9 and B5 9 Series Engines Flow Diagram Air k S Section D System Diagrams Fig D 19 1 Intake air inlet 3 Intake valve 2 Intake manifold Flow Diagram Exhaust System 83 9 and B5 9 Series Engines Page D 20 Section D System Diagrams Flow Diagram Exhaust System General information Turbocharged with Wastegate
107. asher not correct po Troubleshooting Symptoms Charts 83 9 and 85 9 Series Engines Page TS 42 Section TS Troubleshooting Symptoms NOTES 83 9and 35 9 Series Engines Section V Maintenance Specifications Page V a Section V Maintenance Specifications Section Contents Page Arctic Operation ma Dese Seege in she E di te Ee ua Rc dne RE V 27 PCP AN ALON Sac sccas can ER RM STE EE OO Re EE TRE Ten V 27 i eda Markings and Torque EI V 32 apscrew Markings and Torque Values MetriC siennes V 33 Capscrew Markings and Torque Values U S Omar LEE AEE De v 34 General Information m TEE V 32 Coolant Recommendations and Specifications V 28 Preparatory sissiiseaccssansesesseccssatiarsscseaccaies d EE EE V 28 Engine Component Torque Values ege deer v 29 eneral Information Rennes EE AE ET N E ES E E S EE 54 NEE Fuel Recommendations and Specifications mn esses Koseng iioi TEE TT EE v 20 Fuel Recommendation EIS v 20 Lubricating Oil Recommendations and Specifications ENEE V 25 New Engine Break in Oils 7 reet MINER V 25 LIII V 24 ELCH Rue Ee EE V 24 Re len NEE V T Air Intake System Sege A E EAE ET m se V 10 Cooling BEE V 8 Ste EE V 17 Exhaust System
108. at of anti seize compound to the threads of the injector hold down nut fignuwa Assemble the injector and new copper washer ah a Use only one copper washer air NOTE A light coat of clean lubricating engine oil between the washer and injector can help to keep the washer from falling during Installation fi9waaa a u o9 UeN 6 enjeA enbioy pjojueu Uep jen eui iejsuy wu QL iu rel WeN 09 enjeA andio sinu ejzzou 10199fu1 eut ue Jopafu eui juano oj peeu eui Ul YOJOU OW SL 8 ZZOU eu jo epis out uo uoisnijoud aux emie QU persu unu P iueureoejdeH pue d y ueunsnipy V uonoes soeuiBua sees 6 Sd pue Gta moe me ewemgy 0t v aed 1039e u B3 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement 17 mm inistall the high pressure fuel lines Torque Value 24 Nem 18 ft lb Fuel Shutoff Valve Preparatory e Label and disconnect wiring Fuel Shutoff Valve Page A 41 Fuel Shutoff Valve Page A 42 ivOvaea ip8cvmc 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Clean Rotary Pumps 22 mm CAV 24 mm Bosch Clean around the valve Remove the valve NOTE Be careful notio dropihe piston and spring when removing the valve Replace the valve and connect the electrical wire Torque Value 43 Nem 32 ft lb Remove Remove the electrical wiring e Remove
109. ation of the vehicle including SC mileage B3 9 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W and lodging when the repair is performed at the site of the failure Owner Responsibilities Owner is responsible for the operation and maintenance of the Engine as specified in the applicable Cummins Operation and Maintenance Manual Owner is also responsiblefor providing proof that all recommended maintenance 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 Engine available for repair by such facility Exceptfor Engines disabled by a Warrantabte Failure duringthe first year fromthe date of delivery of the Engine to the first user or the duration of the warranty whichever occurs first Owner must also deliver the Engineto the repair facility Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure Owner is responsible for communication expenses meals lodging and similar costs incurred as a result of a War rantable Failure Owner is responsiblefor non Enginerepairs and for downtime
110. attemptto start electrical start ing motors only e Disengage the driven unit or if equipped put the transmission in neutral With the throttle in the idle position turn the key to the ON position and wait for the WAIT TO START lamp to go out then turn the key to the START position If the engine does not start after three attempts check the fuel supply system Absence of blue or white exhaust smoke during cranking indicates no fuel is being delivered Normal Starting Procedure Page 1 4 3 to 5 minutes cispovt2 B3 9 and B5 9 Series Engines Section 1 Operating Instructions The engine must have adequate oli pressure within 15 seconds after starting lithe WARNING lampindicatinglow oil pressure has not gone out or there is no cli pressure indicated on a gauge within 15 seconds shut Offtheengine immediately to avoid engine damage Confirm the correct oil level in the oil pan idlethe engine 3to 5 minutes before operatingwith a load 83 9 and B5 9 Series Engines Section 1 Operating Instructions Increase the engine speed rpm slowly to provide ad equate lubricationto the bearings and to allow the oil pres sure to stabilize A CAUTION A me i Do notoperate engine at lowidle for long periods more than 10 minutes Operating engine for long periods at lowidlecandamage engine becausecombustioncham ber temperatures will decrease and the fuel will not completely burn This will cause carbon t
111. aulic pump and torque converter Fuel Recommendations and Specifications B3 9 and B5 9 Series Engines Page V 20 Section V Maintenance Specifications Fuel Recommendations and Specifications Fuel Recommendations A WARNING A Do not mix gasoline alcohol or gasohol with diesel fuel This mixture can cause explosion A CAUTION A Because of precise tolerances of diesel injection systems it is extremely important fhaf the fuel be kept clean and free of dirt or water Dirt or water in the system can cause severe damageto both the injection pump and the injection nozzles A CAUTION A Do not use diesel fuel blended with lubricatingoil inengines equipped with a catalytic converter including 1994 model year and beyond Damage to legally required emission control can result Use ASTM No 2D fuel with a minimum cetane number of 40 No 2 diesel fuel gives the best economy and performance under most operating conditions Fuels with cetane numbers higher than 40 can be required in higher altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke At operating temperatures below 0 G 32 F use a blend of No 1 D and No 2 D fuels also known as winterized No 2 D NOTE No 1 D fuel can be used however fuel economy will suffer Uselow sulfur content fuel having a cloud pointthat is atleast 10 degrees belowthe lowest expectedfuel temperature Cloud point is the temperature at which wax crystals begin to form i
112. automotive 463 9 Maximum Allowable Intake Restriction at Rated Speed 508 mm H 0 and Loaded with Dirty Air 20 in H20 Filter Element 6B Air Intake System nonautomotive 665 9 Maximum Allowable Intake R striction at Rated Speed and 508 mm HO Loaded with Dirty Air Filter Ele 20 in HO ment 46T3 9 635 mm 4 0 25in HO eBT5 9 635mm HO 25in H Specifications Page E 19 4BTA3 9 635mm H O 25in HO eBTA5 9 635 mm H O 25in H20 Specifications 93 9 and B5 9 Series Engines Page E 20 Section E Engine Identification Air Intake System Data automotive 83 9 65 9 Maximum Allowable Intake Restriction eh Di 635 mm H 0 635 mm HO at Rated Speed and Loaded with Dirty i Air Filter Element 25 in HO 25 in HI 83 9 and 85 9 Series Engines Specifications Section E Engine Identification Page E 21 Exhaust System 48 Exhaust System Data nonautomotive 483 9 4BT3 9 4BTA3 9 Maximum Allowable Exhaust Re B striction at Rated Speed and 76 2 mm Hg 3 0 inHg 76 2mm Hg 3 0 in Hg 76 2 mm Hg 3 0 in Hg Loaded 6B Exhaust System Data nonautomotive 6B5 9 6BT5 9 6BTAS 9 Maximum Allowable Exhaust Re eee at Rated Speed and 76 2 mm Hg 3 0 in Hg 76 2 mm Hg 3 0 in Hg 76 2 mm Hg 8 0 in Hd oa Specifications Page E 22 B3 9 and 85 9 Series Engines Section E Engine Identification Exhaust System Data automotive B3 9 B5 9 Maximum Allowable Exhaust Restr
113. below 7 G 45 F the system will operate as follows Engine Starting Cycle E aos 1 Tum the ignition key to the RUN position When the key is in this position the WAIT TO START light will be illuminated for approximately 25 seconds Do not crank the engine until the WAIT TO START light shuts off NOTE The controller is rest each time the ignition is turned off andthe cycle will start over 2 When the WAIT TO START lamp goesout the preheat cycle is complete Depress the accelerator pedai and crank the engine Crank the starter as soon as the WAIT TO START lamp goes out 3 Postheat Cycle Postheating occurs as the grid heater elements are cycled for a while with the engine running Postheating helps warm the engine up faster and eliminates white smoke Postheating is determined by the engine ambient air temperature upon start up 83 9 and B5 9 Series Engines Starting Procedure After Extended Shutdown or Oil Change Section 1 Operating Instructions Page 1 13 Starting Procedure After Extended Shutdown or Oil Change General Information Complete the following steps after each oil change or after the engine has been shut down for more than 30 days to make sure the engine receives the correct oil flow through the lubricating oil system 1 Disconnect the electrical wire from the fuel pump solenoid 2 Rotatethe crankshaft usingthe starting motor until oil pressure appears on the gauge or the warning lamp goes E out 3 Conne
114. blies replaced during Scheduled Maintenance of the engine as specifiedin Cummins Operation and Maintenance Manuals THIS WARRANTY TOGETHER WITH THE EXPRESSCOMMERCIAL WARRANTIES ARE THE SOLEWARRANTIES MADE BY CUMMINS THERE ARE NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE California Emission Control System Warranty On Highway B3 9 and 85 9 Series Engines Page W 40 Section W Warranty NOTES About the Manual cocotte ge tH General Information sessen e i 2 Acronyms and Abbreviations i i 8 General Information 4 essences L Additional Service Literature L 1 General Information is L 1 Aftercooler sea A 76 Clean A 78 Fil A 79 Install en A 78 Preparatory A 76 Remove e us n A76 Alr Cleaner R vee 411 Maintenance Check e 4 11 Air Compressor 7 9 inspect sus 7 9 Air Crossover A75 install vee A5 Remove sesssruse A 75 Air Intake Manifold sessssssseeaeenennennna enn A 81 SEET A 82 Install A83 Preparatory A Lees ABT Pressure Test Bee A 85 Remove ns AB2 Temperature Differential Test A 85 N t a creans ies D A 84 Air Intake Pipingssmsamaannenennnnnnnnenne b rennen 4 7 Inspect for REUSE 4 7 Air Intake System Overview A 74 General Information A 74 Ail Bus Categories Worldwide ee U S Canada Di
115. by a Warrantable Failure of the defective Covered Part Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items replaced during repair of a Warrantable Failure m 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 Operationand MaintenanceManual Owner is also responsiblefor providing proof that all recommended maintenance has been performed Beforethe expiration d the applicable warranty Owner mustnotify a Cummins distributor authorized dealer or other repair location approved by Cummins of any Warrantable Failure and make the Engine available for repair by such facility Locations inthe United States and Canadaare listed in the Cummins Off Highway Authorized Dealer Directory Owner is responsible for communication expenses meals lodging and similar costs incurred as a result of a War rantable Failure Owner is responsible for non Engine repairs downtime expenses cargo damage fines all applicable taxes all business costs and otherlosses resulting from a Warrantable Failure Cummins Warranty 83 9 and 85 9 Series Engines Page W 16 2 MM Section W Warranty E E 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 a
116. charger ifused 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Remove 15 mm 13 mm Remove the exhaust manifold Clean Clean the sealing surfaces Exhaust Manifold pry Page A 9 xm9bdeb Exhaust Manifold Dry Page A 98 amp K amp G Si a e900sa D B3 9 and 85 9 Series Englnes Section A Adjustment Repair and Replacement Install 15 mm 13 mm Apply anti seize compound on exhaust manifold bolt threads install the exhaust manifold and new gaskets Follow the tightening sequence shown in the illustration Then follow the same sequence and tighten to the same torque values Torque Value 43 Nem 32 ft ibj Install the parts previously removed Operate the engine and check for leaks 83 9 1B5 Series Engines Lubricating Oil System Overview Section A Repair and Replacement Page A 99 Lubricating Oil System Overview General Information Lubricating System Repair Summary A WARNING A Some state and federal agencies have determined that used engine oil can be carcinogenic and cause repro ductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil Component to Be Replaced Tools Preparatory Steps Oil Pressure Regulator Valve Ratchet 19 mm Socket and Clean debris and or Spring Torque Wrench Oil Cooler Element and or 16 mm Wrench Ratchet 10 mm Drain coolant Remove the oil filter
117. crewdriver or Allen wrench Tighten the locknut and measure the valve lash again Torque Value 24 Nem 18 ft lb A CAUTION A To avoid engine or pin damage be sure timing pin is disengaged Mark the pulley and rotate the crankshaft 360 degrees 83 9 and B5 9 Series Engines Overhead Set Maintenance Procedures at 38 000 km 24 000 ml Page 6 7 Adjust the valves as indicatedin the illustration Set only the valves indicatedby the arrows in the illustra tion E exhaust intake Do not set valves that are not indicated Torque Value 24 Nem 18 ft lb 15 mm Installthe rocker lever covers and tighten the capscrews Torque Value 24 Nem 18 ft lb Drive Belts Page 6 8 83 9 and B5 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mil Drive belts Test Drive Belt and Tensioner Inspection Check the location d the drive belt on the belt tensioner pulley The belt must be centered on cr centeredclose to the middle of the pulley Belts aligned either too far for ward or backward can cause belt wear belt roll offfailures or increase uneven tensioner wear Check the belt deflection at the longest span of the belt The deflection must be checked at the center 1 of the span The maximumdeflection allowed in the beltis 9 5 to 12 7 mm 3 8 to 1 2 in 63 9 and B5 9 Series Engines Drive Belts Maintenance Procedures at 38 000 km 24 000 mi Page 8 9 Belt Tensioner Gauge Par
118. ct operation Refer to the OEM service manual Check foi the specified boost pressure Inspect the turbocharger Replace if necessary iru to Section 1 ubleshooting Symptoms Charts B3 9 and 85 9 Series Engines F je TS 18 Section TS Troubleshooting Symptoms Engine Power Output Low Continued l Cause Correction Adjust i Makesure the pushro are not benl or ke leversnot severel worn Refer to ly worn action 6 1 Valve lash excessive In pt e ste Repa ei lo as eces3a lefi og A Remove the fuel injection Fuel infection pump is pump Check the calibra malfunctioning tion of the fuel injection pump Refer to Section A ne OK Contact a Cummins Authorized Repair Facility Troubleshooting Symptoms Charts 63 9 and 65 9 Series Engines Page TS 19 Section TS Troubleshooting Symptoms Engine Runs Rough at Idle Warm Engine ee Correction Cause Correction Idle speed Check and adjust the low gt Fuel injection pump timing Check and adjust the is set too low fo c idle screw ra Section is incorrect date injection pump timing accessories efer to Section A OK Inspect the injectors injector is malfunctioning deer r Bleed the fuel system and check for leaks Refer to Section 5 Air in the fuel system Check the overflow valve Replace if necessary Refer Check the en ine mounts Engine mounts are worn Refer to the OEM ser
119. ct the cold starting BS aid if used Vent A WARNING A Do not mix gasoline alcohol or gasohol with diesel fuel This mixture can cause explosion Install and bleed the high pressure fuel lines c7 wmftaa 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Pressure Test Pressure Gauge Part No ST 1273 Installthe pressure gauge Part No ST 1273 to the fitting in the turbocharger outlet Install another pressure gauge Part No ST 1273 in the intake manifold Operate the engine at rated rpm and load Record the readings on the two gauges If the differential pressure is greater than 21 kPa 3 psi Check the charge air cooler for plugging Clean or replace if necessary Temperature Differential Test Install a temperature gauge in the intake manifold Lock the fan drive in the ON mode to prevent erratic test results This can be done by installing a jumper across the temperature switch or supplying shop air to the fan Refer to the fan drive manufacturerfor lockup procedure NOTE Some trucks have a manual switch that will lock on the fan Air Intake Manifold Page A 85 ra V ENA SW a E igo D D D D D e A Turbocharger 83 9 and 85 9 Series Engines Page A 86 Section A Adjustment Repair and Replacement Operatethe engine at rate rpm and load Recordthe intake manifold temperature Measurethe ambient temperature at least 2 feet in front o
120. ct the electrical wire to the fuel pump solenoid valve 4 Start the engine refer to normal starting procedures in this section 5 Refer to fuel system bleeding section 5 for instructionto vent fuel system Engine Operating Range Page 1 14 83 9 and 85 9 Series Engines Section 1 Operating Instructions Engine Operating Range General Information A CAUTION A Do not operate the engine at excessive full throttle op eration below peak torque rpm refer to engine data plate for peak torque rpm for more than 30 seconds This condiiion will shorten engine life to overhaul can cause serious engine damage andisconsidered driver abuse Cummins engtnes are designedto operate successfully at full throttle under transient conditions down to peak torque engine speed This is consistent with recommended op erating practices Operation of the englhe below peak torque rpm can occur during gear shifting due to the differenceof ratios between transmission gears but engine operation must not be sustained for more than 30 seconds at full throttle below peak torque rpm 83 9 and 85 9 Series Engines Section 1 Operating Instructions A CAUTION A Do not operate the engine beyond high idle speed un der any circumstances Operating the engine beyond highidlespeed can causesevereengine damage When descending a steep grade use a combination of trans mission gears and engine or service brakes to control the vehicle and engine speed
121. d to order parts for your engine This will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins Parts Microfilm System Additional Features of the Customized Catalog include Engine Configuration Data Table of Contents Separate Option and Parts Indexes Service Kits when applicable ReCon Part Numbers when applicable Automotive Recreational Vehicle Bus and Industrial 53 9 and 55 9 Series Engines G Operation and Maintenance Manual 00900282 Copyright 2000 Bulletin No 3810205 14 Cummins Engine Company Inc Printed 3 00 All rights reserved Foreword Thi manual contains information for the correct operation and maintenance of your Cummins engine Italso includes important safety information engine and systems specifications troubleshooting cuide lines n 1 li i of Cummins I ap Lc s d component manufacturers Read and Safety instructions Refer to the WARNING in th Gene a afety Instructions in Section i P llnsar nwau AHU MTU a Introducti this tt the equipment Ifthe i is d or sold give the manualt th new owner The oe specifications and recommended maintenance guidelines in this manuale based on inform n in effect at the time of printing Cummins Engine Company i u reserves ihe righi to make changes at any time without obli Je ie Ify find differences between your engine and the information in this manual ontac yourl Cummi
122. dequatecoolants or lubricants overfualing 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 oil or fuel or by water dirt or other contaminants in the fuel or oif For power units and fire pumps package units this warranty applies to accessories except for clutches and filters supplied by Cummins which bear the name of another company Except for power units and fire pumps this warranty does not apply to accessories which bear the name of another company Such non warrantedaccessories include but are not limitedto alternators starters fans air conditioning compressors clutches filters transmissions torque converters steering pumps and non Cummins fan drives engine compression brakes and air compressors Cummins Compusave units are covered by a separate warranty Beforea claim for excessive cil consumption will be considered Owner must submit adequate documentation to show that consumption exceeds Cummins published standards Failures of belts and hoses supplied by Cummins are not coveredbeyondthe 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 resulti
123. e the battery and replace if necessary Refer to the OEM service manual Repair Facility Battery charge is low 83 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms 7 Page TS 27 Engine Will Not Reach Rated Speed RPM Cause Correction x Cause Correction Vehicle speed is too low for Reduice the engine load Air fuel tube leaking Tighten the fittings repair adequate cooling with high Increase the engine fan wastegate diaphragm plumbing replace waste engine load rpm by downshifting ruptured or wastegate gate diaphragm Refer to plumbing damaged the OEM service manual OK _ t Check throtile llnkage Throttle linkage adjustment adjustment Refer to the la not correct Inspect the air cooler for internal and external EM Service manual Charge air cooler restricteq restriction Replace the if equipped 7 restricted cooler if neces sary Referto Section A Compare the tachometer reading with a handheld ichometer or an electronic service tool reading Calibrate or replace the tachometer as necessary Refer to the OEM service manual Tachometer is not cali brated or Is malfunctioning Check the flow through the filter to locate the source of Fuel supply is not aa P equate the restriction Refer to Section 5 OK gt Loosen the locknut and High speed screw is not
124. e dini ERS urson n prenne di neenon x Catalytic Converters regen AM Clutches sn ro C Coolant Heaters est imn Coolant Level Switches Drive Plates 4 ia Waddell scht GO Electric Starting Motors Electronic Switches pepe taper intente genito Engine Protection Controls eagace adetpenguleeea cce sadenlanid det doce Fan Olutches uiasica ein suis M Fans noe TE TD Fault Lamps Meed pedet duni Filters s Fiexplates Fuel Coolers Fuel Pumps Fuel Warmers Gauges General Information Governors KENE Eed Heat Sleeve Eieren See Hydraulic and Power Steering re Seen In Line Connectors Se D ie Oil Healers 1 TE Kalender Prelubrication Systems sistens Radiators m dat s Throttle Assemblies E daeh er Torque Converters Coolant Level Maintenance Check Coolant Recommendations and Specifications Preparatory ss Coolant Thermostat Wack EE m vele voile adr dalles sue A 14 Artan iae t dera t i A0 be eee A 12 Cooling System IT Z Dram see CETTE 72 Fill Flush General Information sise E avisada A2 Maintenance Check E Daily Maintenance Procedures Overview insane General Information Drive Bell Cooling Fan Install shee TTT sns 3 Remove AS Drive Belis EM Maintenance Check i se 37 Test etn shine BB Electrical Equipment Overview
125. e Street Racine Wi 53403 Telephone 414 634 1981 Coolant Heaters Fleetguard Inc 1200 Fleetguard Road Ceokeville TN 38502 Telephone 615 526 9551 Drive Plates Detroit Diesel Allison Division of General Motors Corporation PQ BOX 894 Indianapolis IN 48206 0894 Telephone 317 242 5000 Electric Starting Motors Butec Electrics Cleveland Road Leyland PR51X8 England Telephone 01744 21663 Component Manufacturers Addresses Page M 3 CAV Electrical Equipment PO Box 36 Warple Way London w3 SS England Telephone 013 743 3114 AG Baloo components Group Civic Offices Central Milton Keynes MK9 3EL England Telephone 0908 66001 Delco Hemy America 2401 Columbus Avenue PO Box 2439 Anderson IN 46018 Telephon i 317 646 3528 Leece Neville Carp 400 Main Street Arcade NY 14009 Telephone 716 492 1700 Nippondenso Inc 2477 Denso Drive PO Box 5133 Southfield MI 48086 Telephone 313 350 7500 Component Manufacturers Addresses Page M 2 StartMaster Air Starting Systems A Division Sycon Corporation 9595 Cheney Avenue P O Box 49i Marion OH 43302 Telephone 614 382 5771 Alternators RobertBosch Ltd PO Box 98 Broadwater Park North Orbital Road Denham Uxbridae Middlesex UD9 5HG England Telephone 01895 833633 Butec Electrics Cleveland Road Leyland PR5 1XB England Telephone 01744 21663 CAV Electrical Equipment PO Box36
126. e air intake ducts Repair Facility Engine running on fumes ocate and isolate the E source of ihe fumes Make drawn into the air intake repairs as needed Refer tothe OEM service manual nt OK Troubleshooting Symptoms Charts Page TS 30 ji i i Exhaust Smoke 3 Correction Cause Engine is being lugged down Use lower gear system Completely bleed air from the fuel system Refer to the OEM service i Check the air filter for restrictions Refer to Section 4 Putthe engine at top dead center Check and adjust 1 the fuel timing Referto the OEM service manual Fuel injection pump timing is not correct Eds Excessive Under Load 83 9 and 85 9 Series Engines Section TSi Troubleshooting Symptoms Cause i 1 i intake or exhaust leak T QK Injector sealing washer not Sen correct Continued 1 i Correction 73 Check intake and exhaust Systems for loose or damaged piping connec tions and or missing pipe plugs Check ele Ai and exhaust manifol mounting SCH to Section Check to see if an extra sealing washer is installed under injector Remove any additional sealing washer Only one is required Refer to Section A Inspect the Injectors Replace the injectors as necessary artes to Section B3 9 and B5 9 Series j Troubleshooting Symptoms Charts Section TS T 4 Symptoms Page TS 31 Exhaust Smoke
127. e drive ibrati Drive belt is loose tight or Vibration damper is Inspect the vibration not in alignment HAS Delt as Greg deed to damag damper Refer lo Section 7 OK E Ke 1 Contacta Cummins inspect tho air intake and Authorized exhaust systems for air Repair Facility Air intake or exhaust leaks e leaks Refer to the OEM service manual Adjust vaives Make sure the push rods are not bent Valve lash excessive set Or rocker lavers not severely worn Refer lo ection 6 Turbocharger noise 83 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 15 Engine Power Output Low Cause Correction Cause Correction i 5 7 valide speed is too iew ior pente engine en ae ne intake and adeguate coojing w ghj increase the engine fan exhaust systems for engine load rpm by dovnshiftino Intake and exhauat system restrictions inspect the intake air filter and replace as necessary Lubricating oii level is Check the cil level Add or above or below specifica drainoil if necessary tion Refer to Section 1 Air fuel tubs leaking Tightenthe fittings repair wastegate diaphragm plumblng replace waste ruptured or wastegate gale diaphragm Refer to plumbing damaged the OEM service manual Check the fugl pump Throttle linkage adj stment throttle linkage adjustment Is not correct rr Referto the GEM service manual Ins
128. e for the Bosch in line pump is located on the side of the injection pump The dataplate provides information for fuel pump calibration 83 9 and 85 9 Series Engines Engine Identification Section E Engine Identification Page E 5 CAV The injection pump dataplate for the Lucas DPA pump is located on the side of the injection pump The dataplate provides information for fuel pump calibration ip8plgb Stanadyne The injection pump dataplate for the Stanadyne DB4 is located on the side of the injection pump The dataplate provides informationfor the fuel pump calibration zi s H ES Engine Identification 83 9 and B5 9 Series Engines Page E 6 Section E Engine ldentification Denso Dataplate The Denso fuel injection pump dataplate contains the fol lowing information S A Fuel Injection pump part number B Denso serial number B A i D Ms re er Q W lt e CS ASIE NES RS C Cummins part number Qt imag at TIR Y a 441611 ae pbs o SE D Fuel injection pump bar code e 2391744948 D The Cummins part number for the fuel pump governor combination is located on the governor dataplate S R V425 tIQ0AOC ISO BR CDC NO 390 6541 Made in USA E 5 9 Serf Engines S E Engine Identification Specifications General Specifications General 48 Engine Data nonautomotive 483 9 4BT3 9 Specifications Page E 7 4BTA3 9
129. e ofthe Engin to the ultimate purchaser cr B The Base Ei ne Warranty If the vehicle in F the Engine is Ik ii i 3 ii th stateof California a separate California Emission a y also applies f Limitations Failures other than those resulting from defects in Y or workmanshlp are not covered by it warranty Cummins is not re ible foi failures or damage resulting from what Cummins determines tobe abuse 9 neg incl din 3 but not d t cperation without adequate CC art or lubricants overfueling verspeed 1g lac of t a f ir Of or ike systen improper storage ring wnt run in o1 sh J vn eu d m atit of the Engine Cummins is als t ible for failures caused by incorrect Cummins Warranty 83 9 and 85 9 Series Engines Page W 18 Section W Warranty fuel or by water diri of other contaminanis 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 IncludesAmerican Samoa the Commonwealthof Northern Mariana Islands Guam Puerto Rico andthe U S Virgin Islands Alternators starters and fans ARE covered for the duration of the base engine warranty on B3 3 engines B3 9 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W 1 Moteurs tout terrain Etats Unis et Canada Garantie Produits garantis Lapr sente garant
130. e with clean lubricating oil to the proper level NOTE Total system capacity assumes lubricating oil pan plus lubricating oil filter Some applications use a slightly different lubricating oil pan capacity and all lubricating oil quantities must be adjusted accordingly Contact your local Cummins Dis tributor if you have any questions Four Six Cylinder Cylinder Pan Capacity 9 5 liters 10 qt 14 2 liters 15 qt Total system 10 2 liters 10 8 q 15 1 liters 16 qti Capacity NOTE Some 6B applicationsuse a reducedcapacity pan 10 4iters 11 gts and some haveincreasedcapacity of 16 liters 17qt Fill quantities must be adjusted accordingly 83 9 and 85 9 Series Engines E Air intake Pipin Maintenance Procedures at 10 000 km 6000 mi Page 4 Operate the engine and check for leaks at the filters and oil drain plug Air Intake Piping Inspect for Reuse inspectthe intake piping for cracked hoses loose clamps or punctures that can allow dirt and debris to enter the engine Tighten or replace parts as necessaryto make sure the air intake system does not leak Charge Air Cooler CAC Page 4 8 cag0 se 83 9 and 85 9 Series Engines Maintenance Procedures at 10 000 km 6000 mil Charge Air Cooler CAC Inspect for Reuse Sg Ifthe engine experiences a turbocharger failure or any e other occasion where oil or debris is put into the charge air cooler the charge air cooler must be cleaned lt
131. ead each row of blocks from top to bottom Follow the arrows through the chart to identify corrective action A WARNING A Troubieshooting presenis the risk of equipment damage personai injury or deaih Troubieshooting must be performed by trained experienced technicians l g 03 t00 002 0m 83 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 3 Alternator Not Charging ar Insufficient Charging Cause Correctlon Cause Correctlon Battery cables or connec Test the alternator output tions are loose broken or check tie battery cables Alternator is malfunctioning Refer to the OEM service corroded and connections Refer to manual reel cessive the OEM service manual OK Contact a Cummins Authorized Check the alternator belt Repair Facility tension Check sin Alternator belt is loose or belt wrap and repair if missing necessary Replace belt or belt tensioner or both Refer to Seciion A Make sure the drive pulley loose on the water pump is tight on the shaft Refer sna to th QpgMervice Alternator drive pulley is Troubleshooting Symptoms Charts B3 9 and B5 9 Series Engines Page TS 4 Section TS Troubleshooting Symptoms Coolant Contamination Cause Correction Cause Correction rain an flush the cooling gt Check the cylinder head Coolant is rusty and has system Fill with correct Cylinder he
132. ecommended by Cummins Engine Compary Inc for your engine Specifications and torque values for each engine system are given in that section e Symbols Page i 4 Symbols General Information 83 9 and 85 9 Series Engines Section i introduction 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 parsonat injury of extensive property damage can result if the warning instructions are not followad P CAUTION Minor personal injury can result or a part an assembly or Me en gine can be damagad d Me caution in structions am not followed D Indicates a AEMOVAL or DISASSEMBLY step Indicatas an INSTALLATION or ASSEM BLY step INSPECTION is required CLEAN the pan or assembly HO amp p g 0 half sym e a PORE PERFORMa mechanical or time MEASUREMENT LUBR CATE the part or assembly indicates that a WRENCH or TOOL ZE wiil be given TIGHTEN to a specific torque PERFORY an electrical MEASUREMENT Refer to another locationin this manual of another publication for additional information The component weighs 23 kg BD Ib ar more TO avoid persona injury use a hoist or get assistance Jo Dt the compo nant E B3 9 and B5 9 Series Engines Section i Introduction Illustrations General Information Some of the illustrations throughou
133. ection 3 Maintenance Procedures at Daily Interval Lubricating Oil Level Maintenance Check The vehicle must be level when checking the oil level to make sure the measurement is correct Shut off the engine for an accurate reading Never operate the engine with the oil level belowthe L low mark or above the H high mark Wait atleast 10 minutes after shutting af the engine to check the oil level This allows time for the oil to drain into the oil pan Refer to LubricatingOil Recommendations Specifications in Section V for oil recommendations Low Mark to High Mark Oil Capacity Four Cylinder 0 95 liter itat Six Cylinder 1 89 liters 2 at Lubricating Oil Level Page 3 3 oigo0sb Coolant Level Page 3 4 e B3 9 and 5 9 Series Engines Section 3 Maintenance Procedures at Daily Interval Coolant Level Maintenance Check A WARNING amp DO not remove a pressure cap from a hot engine Wait until the coolant temperature is below 50 C 122 F before removing the pressure cap Heated coolant spray r Sto m can cause personal injury Never use a sealing additiveto 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 83 9 and 5 9 Series Engines Section 3 Maintenance Procedures at Daily Interval A CAUTION A Do not addcold coolant to a hot engine Engine cast
134. ectrical Equipment Overview nn General Information Exhaust Manifold Diy ELT C e Install ger Preparatory mss ia T egene rege eege ee waits B3 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Page A c Fan Spacer and Pulley sterne PT Zug LEE PRE E E EENEG tere nz ue A Fuel Fiter TE miis er Iz Wo n EE Bizue At T Fuel Injection Pump Rotary nn ssinnnennnnnnnnnnnennnnnennnnnnnnnnnnennt install csc svcsctisvascaccewscessieveundecsenessnc CE cU ero PT PArATONY Ane e RE ek EEN Fuel Injection Pumps In Line lcu EE Pr paratOry PR REMOVE seess onte ri ha DT Fuel Lift Pump Clean lastall sise css Preparatory Fuel Manifold Drain icio um ur com or cuan nnn tuum enne rante nn iamiam animu ama Eoi doi inde Install GE eege E duro EE M cu m P OOO Fuel TT BEE ore Euel Shu toff EVINRRE TERRI CIENT EM Clean P cence teg SARs dus po d B3 9 and B5 9 Series Engines r Page Ad TANT DE red A iser Repair and een D ooh He rr D
135. elephone 61 8 9725 6777 FAX 61 8 97256444 Cairns Cummins Engine Company Pty Itd FO Box 7189 Cairns Mail Centre 4870 Queensland Australia Location Liberty Street Cairns 4870 Telephone 81 7 9352999 Campbellfield Oummiris Engine Company Pty Ltd Private Bag 9 Campbel field 3061 Victoria Australia Location 1788 1800 Hume Highway Campbellfield 3061 Telephone 613 9357 9200 B3 9 and B5 9 Series Engines Section S Service Assistance D i H Dandenong Cummins Engine Company Pty Ltd Lot 7 Greens Road Dandenong 3175 Victoria Australfa Telephone 613 9708 8088 Darwin Cummins Engine Company Pty Ltd PO Box 37587 n Winnellie 0821 Northern Territory Australia Location Lot 1758 Graffin Crescent Winnellie 0821 Telephone 61 8 8947 0766 Devonport Cummins Engine Company Pty Ltd PO Box 72E Tasmania Australia Location 2 Matthews Way Devonport 7310 Telephone 61 3 6424 8800 B3 9 and 85 9 Series Engines Section S Service Assistance Emerald Cummins Engine Company Ply Ltd P O Box 668 Emerald 4720 Queensland Australia Location Capricorn Highway Emerald 4720 Telephone 81 7 4982 4022 Grafton Cummins Engine Company Pty Ltd FO BX 18 South Grafton 2461 New South Wales Australia Location 18 20 Induna Street South Grafton 2461 Telephone 61 2 6642 3655 Hexham Cummins Engine Company Pty Ltd 21 G
136. elp you in troubleshooting service and general maintenance of your engine Flow Diagram Fuel System Page D 2 Flow Diagram Fuel System General Information 83 9 and 85 9 Series Section D System gil re B3 9 and 85 9 Series Engines Section D System Diagrams Fuel from supply tank Prefilter or screen Fuel lift pump Fuel water separator Fuel filter Low pressure fuel line yog fF WPM a Turbocharger boost control line Flow Diagram Fuel System Page D 3 Bosch P7100 Injection pump Bosch rotary injection pump 10 11 12 13 Fuel drain manifold High pressure line Bosch 17 mm closed nozzle hole type injectors Fuel return to supply tank Flow Diagram Fuel System B3 9 and 85 9 Series Engines Page D 4 Section D System Diagrams Hydraulic Cold Start Injection Advance Rotary Pumps Only 83 9 and 85 9 Series Engines Flow Diagram Fuel System Section D System Diagrams Page D 5 1 KSB valve 3 Temperature switch 2 Wiring harness Flow Diagram Lubricating Oil System B3 9 and 85 9 Series Engines Page D 6 Section D System Diagrams Flow Diagram Lubricating Oil System General Information 07900189 83 9 and B5 9 Series Engines Flow Diagram Lubricating Oil En Section D System Diagrams Page D 7 1 Gerotor lubricating oil pump 4 Full flow filter 2 Pressure regulating valve 5 Filter bypass valve 3 Lubricating oil cooler
137. enance Specifications General 6B Englne Data nonautomotive Bore Stroke Displacement Engine Weight dry Less Flywheelantd Electric Com ponents Firing Order Valve Clearances Intake Exhaust Compression Ratio Rotation Viewed from the Front of the Engine Aspiration Y Naturally Aspirated Turbocharged Aftercooled 685 9 102 mm 14 02 in 120 mm 472 in 5 88 liters 359 in 388 kg 855 Ib 1 5 3 6 2 4 0 25 mm 0 010 in 0 51 mm 0 020 in 18 5 1 Clockwise X 6815 9 102 mm 4 02 in 120mm 4 72 in 5 88 liters 359 in 399 kg 880 Ib 1 5 3 6 2 4 0 25 mm 0 010 in 0 51 mm 0 020 in 17 51 Clockwise Specifications Page V 3 6BTA5 9 102 mm 4 02 in 120mm 4 72 in 5 88 liters 359 in 411 kg 906 Ib 1 5 8 6 2 4 0 25 mm 0 010 in 0 51 mm 0 020 in 16 5 1 Clockwise Specifications 83 9 and 85 9 Series Engines Page V 4 Section U Maintenance Specifications General Engine Data automotive B3 9 B5 9 Bore 102mm 4 02 in 102 mm 4 02 in Stroke 120 mm 4 72 in 120mm 472 in Displacement 3 9 liters 238 in 5 9 liters 360 In Engine Weight dry Less 308 to 329 kg 879 to 725 Ib 388 to 411 kg 855 to 906 Ib Flywieet and Electric Components Firing Order 1 3 4 2 1 5 3 6 2 4 Valve Clearances Intake 0 25 mm 0 010 in 0 25 mm 0 010 in Exhaust 0 51 mm 0 020 in 0 51 mm 0 020 in Compression Ratio rotary pump 17 6 1
138. entral Inc 3030 Centre Pointe Drive Suite 500 Roseville MN 55113 Telephone 651 636 1000 FAX 651 638 2442 Duluth Branch Cummins Diesel Sales Inc 3115 Truck Center Drive Duluth MN 55806 1786 Telephone 218 628 3641 FAX 218 628 0488 St Paul Branch Cummins North Central Inc 2690 Cleveland Ave North St Paul MN 55113 Telephone 651 636 1000 FAX 651 638 2497 Mississippi Jackson Branch of Memphis Cummins Mid South inc 325 New Highway 49 South Jackson MS 392884224 Telephone Admin 601 932 7016 Parts 601 932 2720 Service 601 939 1800 FAX 601 932 7399 Missouri Kansas City Distributorand Branch Cummins Mid America Inc 8201 NE Parvin Road Kansas City MO 64161 Telephone 816 414 8200 FAX 816 414 8299 Joplin Branch Cummins Mid America Inc 3507 East 20th Street Joplin MO 64801 Telephone 417 623 1661 FAX 417 623 1817 Service Assistance Springfield Branch Cummins Mid America Inc 3637 East Kearney Springfield MO 65803 Telephone 417 862 0777 FAX 417 862 4429 t Louis Distributor Cummins Gateway Inc 7210 Hall Street St Louis MO 63147 Telephone 314 389 5400 FAX 314 389 9671 Columbia Branch Cummins Gateway Inc 5221 Highway 763 North Columbia MO 65202 Telephone 314 449 3711 FAX 314 449 3712 Sikeston Branch Cummins Gateway Inc 101 Keystone Drive Sikeston MO 63801 Telephone 314 472 0303 FAX 314
139. eplacement age A 47 Remove A CAUTION A To prevent damage to the timing pin be sure to disen gage the pin after locating top dead center Locate top dead center for cylinder No 1 Push the top dead center pin into the hole in the camshaft gear while slowly barring the engine 14 mm Loosenthe CAV injectionpump lock screw and positionthe X special lock washer Tighten the lock screw against the driveshaft Torque Value 7 Nem 62 in Ib Small Openline Showing fs9loue a Fuel Injection Pump Rotary page A 40 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement i i 3 8 Inch d Loosen us StanadyneDB4 fuel injection pump lockscrew ahd position the special washer Tighten the lock screw until contact is made with the fuel injection pump driveshaft Torque Value 12 Nem 106 in Ib 10 mm The special washer on the Bosch injection pump mustbe removed so the lock screw can be tightened against the driveshaft Tighten the lock screw Torque Value 30 Nem 22 ft lb B3 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Fuel Injection SA Rotar 22 mm Remove the gear cover access cap Remove the nut and washer from the fuel pump shaft N mae gc8cama 75 mm T Bar Puller Pull the fuel pump drive gear loose from the shaft is9gema F Fuel Injection Pump Rotary B3 9 and B5 9 Series Engines Page A 50 Section A Adj
140. er may elect to have maintenance replacement ar repair of the emission control parts performed by a facility other than a Cummins distributor an authorized dealer or a repair location approvedby Cummins and may elect to use parts other than new genuine Cummins or Cummins approved rebuilt parts and assemblies for such Maintenance replacement or repair however thecostof suchserviceorparts and subsequent failures resuitingfromsuchserviceorpartswiii notbe covered under this emission control system warranty except for Emergency Repairs as described below Cummins Responsibilities The warranty coverage begins when the engine is delivered to the ultimate purchaser Repairs and service will be performed by any Cummins distributor authorized dealer or other repair location approved by Cummins using new genuine Cummins or Cummins approved rebuilt parts and assemblies Cummins will repair any oftheem ission cpntrol parts found by Cumminstobe defectivewithoutcharge fot parts or labor includingdiagnosis which results in determination that there has been a failure of a warranted emission control part Emergency Repairs In the case of an emergency where a Cummins distributor authorized dealer or other repair location approved by Cummins is not available repairs may be performed by any available repair location or by any individual using any replacement parts A part not being available within 30 days or a repair not being complete within 30 days consti
141. ern Plains Power A Division of Cummins Southern Plains 1155 West Loop North Houston TX 77055 Telephone 713 958 0020 FAX 713 956 0266 Utah Salt Lake City Distributor Cummins Intermountain Inc 1030 South 300 West Salt Lake City UT 84101 Telephone 801 355 6500 FAX 801 524 1351 Vernal Branch Cummins Intermountain Inc 1435 East 335 South Vernal UT 84078 Telephone 435 7885732 FAX 435 789 2852 Virginia Cloverdale Branch of Charlotte Cummins Atlantic Inc 263 Simmons Drive Cloverdale VA 24077 Telephone 540 966 3169 FAX 540 966 3749 Richmond Branch of Charlotte Cummins Atlantic Inc 3900 Deepwater Terminal Road Richmond VA 23234 Telephone 804 232 7891 FAX 804 232 7428 Tidewater Branch of Charlotte Cummins Atlantic Inc Atlantic Power Generation 3729 Holland Blvd Chesapeake VA 23323 Telephone 757 485 4848 FAX 757 485 5085 Washington Seattle Distributor Cummins Northwest Inc 811 SW Grady Way 98055 2044 P O Box 9811 Renton WA 98057 9811 Telephone 425 235 3400 FAX 425 235 8202 Chehalis Branch Cummins Northwest Inc 926 N W Maryland Chehalis WA 98532 0339 Telephone 360 748 8841 FAX 860 748 8843 Service Assistance Page S 17 Spokane Branch Cummins Northwest Inc 11194 W Westbdw Blvd Spokane WA 99204 Telephone 509 455 4411 FAX 509 624 4681 Tacoma Branch Cummins Northwest Inc 3701 Pacific High
142. ervice specifications Additional information regarding lubricating oil availability throughout the world is available in the EMA Lubricating E Oils Data Book for Heavy Duty Automotive and Industrial Engines The data book can be ordered from the Engine Manufacturers Association One Illinois Center 111 East Wacker Drive Chicago iL U S A 60601 The telephone number is 312 644 6610 Coolant Recommendations and Specifications 83 9 and 85 9 Series Engines Page V 28 Section V Maintenance Specifications Coolant Recommendations and Specifications Preparatory Heavy duty diesel engines require a balanced coolant mixture of water and antifreeze Drain and replacethe mixture every 2 years 320 000 km 200 000 mi or 6000 hours of operation whichever comes first to eliminate buildup of harmful chemicals e Antifreeze is essential in any climate It broadens the operating temperature range by lowering the coolant freezing point by raising its boiling point Do no use more than 50 percent antiireeze in the mixture unless additional freeze protection is required Never use more than 68 percent antifreeze under any condition e Usesoftwater inthecoolant mixture Contaminants in hard water neutralize thecorrosion inhibitor components Water must not exceed 300 ppm hardness or contain more than 100 ppm of either chloride or sulfate e Specifications Use low silicate antifreeze that meets ASTM4985 test GM6038M spec criteria Concentration
143. es include hydraulic pump and torque converter Specifications Page V 18 EB Electrical System Data nonautomotire 685 9 Minimum Recommended Battery Capacity 18 C O F With Light Accessories 12 VDC Starter BOOGCA 24 VDC Starter 400CCA With Heavy Accessories 12 VDC Starter 950CCA 24 VDC Starter 475CCA Maximum Allowable Resistance of Starting Circuit With 12 VDC Starter Ohms 0 0012 With 24 VDC Starter Ohms 0 0020 Typical light accessories include alternator small steering pump and disengaged clutch 6BT5 9 800CCA 400CCA 950CCA A75CCA 0 0012 0 0020 Typical heavy accessories include hydraulic pump and torque converter B3 9 and B5 9 Series Engines Section V Maintenance Specifications 6BTA5 9 BOOCCA 400CCA 950CCA 475CCA 0 0012 0 0020 83 9 and 85 9 Series Engines Specifications Section V Maintenance Specifications Page V 19 Electrical System Data automotive 83 9 85 9 Minimum Recommended Battery Capacity 18 C F With Light Accessories 12 VDC Starter 825CCA 800CCA 24 VDC Starter 400CCA 400CCA With Heavy Accessories 12 VDC Starter 800CCA 950C CA 24 VDC Starter 400CCA 475CCA Maximum Allowable Resistance of Starting Circuit With 12 VDC Starter Ohms 0 0012 0 001 2 With 24 VDC Starter Ohms 0 0020 0 0020 Typical light accessories include alternator small steering pump and disengaged clutch Typical heavy accessories include hydr
144. esel Powered School Buses ln2ssleseses w7 Aiternator E EK Install sunsunssnn A 113 Remove ET S AE A 112 Index Page 1 Arctic Operation e eaat Mo Preparatory un V 27 B5 9 amp C8 3 Engines United States and Canada Recreational Vehicle ae de TTT de Belt Tensioner Automatic dee Aed Install A 5 Remote ess And B ISB Engines United States and Canada Automotive eo Wel California Emission Control System Te Capse ew Aarkings and Torque falues Capscrew Markings and Torque Val ies Metric Capscrew Markings and Torque Val ies U S Customary V 34 General Information ss V 32 Charge Air Cooler CAC M 4 9 4 8 A 80 m A 81 Cold Start Timing Advance System KSB Temperature Lui p E A 45 Install e Remove m Cold Weather Operation ins Operating Alds E ens Shutters e WinterfrontS nuren Cold Weather Starting Aids Ether Starting Aids sms nn Grid Heater Diu With Mechanical or Electrica Metering Equipment Ether ibis Component Manuiaoturers Addresses enne Air Compressors Air Cylinders Air Heaters i Air Slarting Motors mmmmmmmnmmmmmnnmnmnnnnnnne index Page 2 Alternators un cnni iiie id aee dre d UNT Brakes eee eeniritkt
145. essure to the injection Pump Must Not Exceed 70 kPa 10 psi 70 kPa 10 psi n Line Type Fuel Injection Pumps 83 9 85 9 Maximum Inlet Restrictionto the Fuel Transfer 100mm Hg 4 in Hg 100 mm Hg 4 in Hg Pump Must Not Exceed Fuel Transfer Pump Minimum Output Pressure 175kPa 25psi Ratedrpm 175kPa 28 psi Ratedrpm Fuel Filter Restriction maximum pressure drop i across filters 35 kPa 5 psi 35 Ea psi Fuel Pressure Gallery Pressure 140 kPa 20 psi Rated rpm 140 kPa 20 psi Rated rpm Fuet Return Maximum Restriction 518 mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hg Specifications Page E 14 Lubricating Oil System 48 Lubrication System Data nonautamotive Lubricating Oll Pressure amp Idle minimum allowable Lubricating Oil Pressure at Rated minimum allowable Reguiating Valve Opening Pressure Lubricating Oil Capacity Standard Pan Only Total System Low to High 4B3 9 69 kPa 10 psi 207 kPa 30psi 449 kPa 65 psi 95 liters 10 at 10 9 liters 11 5 qt 09 liter 1 qt B3 9 and 85 9 ij Engines Sectior E Engine W 4BT39 69 kPa 10 psi 207 kPa 30 psi 449 kPa 65 psi 9 5 liters 10 qt 11 liters 11 6 qt 0 9 liter 1 qt 4BTA3 9 69 kPa 10 psi 207 kPa 30 psi 449 kPa 65 psi 9 5 liters 10 qt 11 liters 11 6 qt 0 9 liter 1 qt B3 9 and BS 9 Series Engines Specifications Section E Engine Identification Page E 15 6B
146. eton Branch c Seattle Cummins Northwest Inc 223 SW 23rd Street Pendleton OR 97801 1810 Telephone 541 276 2561 FAX 541 276 2564 B3 9 and B5 9 Series Engines Section S Service Assistance Portland Branch of Seattle Cummins Northwest Inc 4711 N Basin Avenue P O Box 2710 67208 2710 Portland OR 97217 3557 Telephone 503 2840900 FAX 503 286 5938 Pennsylvania Philadelphia Distributor Cummins Power Systems Inc 2727 Ford Road Bristol PA 19007 Telephone 215 785 6005 and 609 583 0005 FAX 215 785 4085 Bristol Branch Cummins Power Systems Inc 2727 Ford Road Bristol PA 19007 Telephone 215 785 6005 and 609 563 0005 FAX 215 785 4728 Pittsburgh Branch Cummins Power Systems Inc 3 Alpha Drive Pittsburah PA 18238 2901 Telephone 412 820 8300 FAX 412 820 8308 Harrisburg Branch Cummins Power Systems Inc 4499 Lewis Road Harrisburg PA 17111 2541 Telephone 717 564 1344 FAX 717 558 8217 Puerto Rico Puerto Nuevo Branch of Tampa Cummins Diesel Power Inc 31 Calle C EI Matadero Puerto Nuevo Puerto Rico 00920 Telephone 787 793 0300 FAX 787 793 1072 South Carolina Charleston Branch of Charlotte Cummins Atlantic Inc 3028 West Montague Avenue Charleston SC 294185593 Telephone 843 554 5112 FAX 843 745 0745 Charleston Branch of Charlotte Cummins Atlantic Inc 231 Farmington Road Charleston
147. f the vehicle The maximumtemperaturedifferential must n otbegreater than 25 C 45 F if ine iemperaiurediffereniial is greaierihan 25 C 45 F check the charge air cooler for dirt and debris on the fins and clean as necessary If the problem still exists check the cooler for internal contamination or plugging Turbocharger Preparatory e Remove the air crossover tube e Disconnect the intake and exhaust piping 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Remove 10mm Remove the capscrews from the oil drain tube 16 mm Remove oil supply line Turbocharger Page A 87 Turbocharger 83 9 and B5 9 Series Engines Page A 88 Section A Adjustment Repair and Replacement If equipped with a wastegate turbocharger remove the es intake manifold pressure supply line from the boost capsule da cT C NELLE 15 mm and 11 mm Remove fhe exhaust clamp turbocharger and gasket Plug the opening with a clean shop rag to prevent foreign material from entering exhaust system to9gkha 83 9 and 85 9 Series Engines Turbocharger Section A Adjustment Repair and Replacement Page A 89 Clean Clean the sealing surface Inspect the sealing surface and mounting studs for damage Install NOTE If the turbocharger is not to be immediately re placed cover the opening to prevent any material from failing into the manifold tb900wa Turbocharger 83 9 and 85 9 Series
148. four cylinder oil filter on a six cylinder engine will result in engine damage Make sure the correct oil filter is used The filter for the six cylinder engine is longer than the filter for the four cylinder engine A Standard for four cylinder applications B Standard for six cylinder applications Lubricating Oil and Filters B3 9 165 9 Seri s Engines Page 4 4 Maintenance Prec t 10 000 km 6000 mi NOTE Fillthe filter with clean lubricating oil before Instal lation Apply a light film of lubricating oil to the gasket sealing surface before installing the filter SE A CAUTION A Mechanical overt ightening of filter can distort the threads or damage the filter element seal Instail the filter as specified by the filter manufacturer B3 9 and BS 9 Series Engines Lubricating Oil ang Filters Maintenance Procedures at 10 000 km 6000 mi Page 4 5 Clean the sealing surface Check the oil drain plug threads Install the drain plug Steel Pan Torque Value 80 Nem 59 ft lb Aluminum Pan Torque Value 60 Nem 44 ft lb If9pgsa Fill NOTE Use a high cual 15W 40 multiviscosity lubricat ing oil such as Valvoline Premium Blue or its equivalent in Cummins engines Choose the correct lubricatingoil for your operating climate as outlined in Section 2 pl800gc Lubricating Oil and Filters Page 4 6 83 9 and B5 9 Serles Engines Maintgnance Procedures at 10 000 km 6000 mi Fillthe engin
149. ft lb 3 8 Inch Square Drive Liftthe tensioner and install the belt Service Tip Ifdifficulty isexperiencedinstallingdrive belt such as the bet seemstoo short position the belt Guer je grooved pulleysfirst then while holding the tensioner up slide the belt over the water pump pulley 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Coolant Thermostat Preparatory A WARNING A Batteries can emit explosive gases To avoid personal injury always ventilate the compartment before servic nae batteries To avoid arcing removethe negative aly cable first and attach the negative battery cable last A WARNING A Coolant is toxic Keep away from children and pets if not reused dispose of in accordance with local envi ronmental regulations a Disconnect the negative battery cable a Drain 2 liters 2 iqt of coolant e Remove the radiator hose from the outlet connec tion e Remove the drive belt Coolant Thermostat Page A 11 Coolant Thermostat Page A 12 eh9csma ehScsmb 4 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Remove 14 mm 16 mm Loosen the lower alternator link capscrew O Remove the upper alternator mounting capscrew Ga Lower and remove the alternator B3 9 and B5 9 Series Engines Coolant Thermostat Section A Adjustment Repair and Replacement Page A 13 10 mm Remove the thermosta
150. g temperatures or pressures e Excessive smoke Loss of power e An increase in oil consumption An increase in fuel consumption Fuel oil or coolant leaks Operating the Engine Page 1 17 Performance 2 Sound Service Engine Appearance ej800k0s Engine Shutdown Page 1 18 B3 9 and B5 9 Series Engines Section11 Operating Instructions Engine Shutdown General Information 1 Allow the engine to idle 3to 5 minutes before shutting it offafter a full load operation This allows adequate cooldown of pistons cylinders bearings and turbo charger components 2 Turn the ignition keyswitch to the OFF position 83 9 and Engines Section2 1 t uidelines Page 2 a Section 2 Maintenance Guidelines Section Contents Page Maintenance Guidelines Overview sescenti rrr mna aa a ae d oS 2 1 General Information re P 2 1 Maintenance Record Form nn Eeer 2 10 General Information guter crar tn vent DEENEN EEN EEE eet 2 10 Maintenance Schedule rnit intra edu a ea aiaa aada iaaa a aas aaria narat 2 3 General InformatiOn eere n e e arcc MEI 2 3 Page References for Maintenance Instructions Eege Ee SE 2 8 General Information EE 2 8 Tool Requirements A EAE 2 2 General Information
151. ge 7 a Maintenance Procedures at 77 000 Kilometers 48 000 Miles 2000 Hours or 2 Years Section Contents leie ET 7 9 DEER a EE 7 9 Maintenance Procedures Overview Seeche EE EE E 7 1 General Information ken ENEE EE 7 1 Vibration pampers aC E A EE 7 8 Inspect E E 7 8 and 85 9 Series Engines Page 7 b Maintenance Dee at 77 000 km 48 000 mi THIS PAGE LEFT INTENTIONALLY BLANK B3 9 and 85 9 Series Engines Maintenance Procedures Overview Maintenance Proceduresat 77 000 km 48 000 mi Page 7 1 Maintenance Procedures Overview General Information All checks or inspections listed under daily or previous maintenance intervals must also be performedat this time in addition to those listed under this maintenance interval Cooling System Page 7 2 B3 9 and BS 9 Series Engines Maintenance Procedures at 77 000 km 48 000 mi Cooling System Drain A WARNING amp Avoid prolonged and repeated skin contact with used antifreeze Suchprolonged repeatedcontact cancause skin disorders or other bodily injury Keep out of reach c children A CAUTION A Protect the environment Handling and disposing of used antifreeze is subject to federal state and local regulations Use authorized waste disposal facilities including civic amenity sites and garages providing authorized facilities for the receipt of used antifreeze If indoubt contact your local authorities of the EPA for gu
152. gine cylinder block camshaft crankshaft connecting rods and Cummins fan clutch Covered Parts Bushing and bearing failures are not covered This coverage begins with the expiration of the Base Engine Warranty and ends three years or 300 000 miles 482 805 kilometers or 10 800 hours operation whichever occurs first from the date of delivery df the Engine to the first user Emission Warranty Additional coverage is outlined under the Emission Warranty 3301278 Cumrnins Warranty 83 9 and B5 9 Series Engines Page W 8 Section W Warranty Consumer Products This warranty on Consumer Products in the United States is a LIMITED warranty CUMMINS IS NOT d 3 FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES Any implied warranties applicable to Consumer Ic iir the L itt 1 States terminate concurrently with the expiration of the express warranties applicable to such products Some s e or countries do not allow the f incidental or consequential damages or limitations on SIE long an implied warranty las so the limitations or exclusions herein may c ly to you Those warranties are made ic all ners in the chain of disiribution and Coverage continues to iii ubs So Owners until the end of the periods of Coverage Cummins Responsibilities L ing The Base Engine War Cu mmins will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable Failure Cummins wil pay for the lubricating oi
153. gued or after consuming alcohol or drugs thatca impair your c e Some state and federal agencies in the United States of America hav determined that used engine oil can be jos d can 2 reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil e Coolant is toxic If not reused dispose of in accordance with local environmental regulations Acronyms and Abbreviations Page 8 Acronyms and Abbreviations General Information AFC Air Fuel Control API Amerioan Petroleum institute ASA Air Signal Attenuator ASTM American Society ot Testing and Materials C Celsius i CARB California Air Resources Board CLD Cubic Inch Displacement CNG Compressed Natural Gas CPL Control Farts List cSt Cant tokes ECM Electronic Control Module ECS Emission Control System EPA Environmental Protection Agency EPS Engine Position Sensor F Fahrenheit GVW Gross Vehicle Weight Hg Mercury hp Horsepower HO Water ICM ignition Control Module km l Kilometers per Liter 4 01 abbrev kPa LNG LTA MIP MPa mph mpq Nem NG OEM ppm psi PTO rpm SAE SCA STC VSS 83 9 end B5 9 Series Engines ME Section i Introduction Kiiopascal Liquid Natural Gas Low Temperature Aftercooling Mixer inlet Pressure Megapascal Miles Per Hour Miles Per Quart Newton meter Natural Gas Original Equipment Manufacturer Parts Per Million Pounds Per Square Inch Power Takeoff Revolutions Per
154. he repair except for the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered Part Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items replaced during the repair 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 Operationand Maintenance Manuals Owner is also responsiblefor providing proof that all recommendedmaintenance has been performed Beforethe expiration of the applicablewarranty Owner must notify a Cummins distributor authorized dealer or other repair location approved by Cummins of any Warrantable Failure and make the Engine available for repair by such facility Except for Engines disabled by a Warrantable Failure during the Base Engine Warranty the Owner must also deliver the Engine to the repair facility Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory Owner is responsible for communication expenses meals lodging and similar costs incurred as a result of a War rantable Failure Cummins Warranty 83 9 and B5 9 Series Engines Page W 10 Seotion W Warranty i Owner is responsible for non Engine repairs and for downtime expenses passenger delays fines cargo damage all applicable taxes all business cost and other lo
155. he cooler Ifthe pressure drop is 35 kPa B psi or less in 15 seconds the cooler is okay If the pressure drop is greater than 35 kPa 5 psi in 15 seconds the charge air cooler must be repaired or re placed Refer to the charge air cooler manufacturer for repair instructions NOTE A leak tank can be used to locate the air leak ca20Dkd Air Intake Manifold Preparatory Remove the high pressurefuel lines e Disconnect the cold starting aid if used i e Remove the air crossover tube industrial Air Intake Manifold Page A 82 10 mm B3 9 and B5 9 Series Engines Section A Adjustment Repair ard Rep on st Remove d Remove the manifold cover and gasket NOTE Plugthe opening of the air intake with a clean shop rag to prevent foreign matter from entering combustion chamber Clean Clean the sealing surface NOTE Keepthe gasket material and any other materialout of the air intake B3 9 and B5 9 Series Engines Air Intake Manifold Section A Adjustment Repair and Replacement Page A 83 Install NOTE The holesshowninthe illustration are drilled through and must be sealed by applying liquid Teflon sealant to the capscrews im9csxa 10 mm Install the cover and a new gasket Torque Value 24 Nem 18 ft lb Air Intake Manifold B3 9 and 85 9 Series Engines Page A 84 Section A Adjustment Repair and Replacement an Assemble the intake piping and conne
156. ications V 1 E7 Lubricating Oil System V 5 E 14 Starting Motor A 110 Install LEPPCECLCELELES COLLE lo raaeteareraggn us V 17 E 23 4 V 12 E 21 V 14 En Starting Procedure After Extended Shutdown or Oll Change 1 13 General Information 143 Symbols i 14 General Informatio 14 Sytem Diagrams Overview D 1 General Information D 1 To the Owner and Operator i 1 General Information dH Tool Requirements eene enne 2 2 General Informati ss EM Troubleshooting Procedures and Techniques TS General Information m TEES TS 1 roubleshooting Symptoms Charts TS 2 Alternator Not Charging or Insufficient Charging TS 3 Coolant Contamination t5 4 t5 5 Coolant Temperature Above Normal neren renes t5 7 Coolant Temperature is Below Normal t5 6 Engine Difficultto Start or Will Not Start Exhaust Smoke TS 10 Engine Difficulkio r LhMotStart No Exhaust Smoke TS 12 Engine Noise Excessive nennen TS 14 Engine Power Output Low TS 16 Engine Runs Rough at Idle Warm Engine TS 18 Engine Runs Rough or Misfires TS 21 Engine Speed Surges at Low or High ldle TS 23 Engine Starts But Will Not Keep Running TS 24 Engine Vibration Excessive 18 25 Engine Will Not Crank or Cranks Slowly TS 26 Engine Will Not Reach Rated Speed RPM TS 27 Engine W
157. iction at Rated Speed and i Loaded 1991 to 1993 EPA certi 114 3 mm Hg 4 5 in Hg 114 3 mm Hg 4 5 in Hg fied Maximum Allowable Exhaust Restriction at Rated Speed and 152 4 mm Hg 6 in Hq with oxidation 152 4 mm Hg 6 in Hg with oxidation M 1994 to 1998 EPA certi catalyst catalyst ie B3 9 and B5 9 Series Engines Section E Engine Identification Electrical System 4B Electrical System Data nonautomotive 4B3 9 4BT3 9 Minimum Recommended Battery Capacity 18 C 0 F With Light Accessories 12 VDC Starter 825CCA B25CCA 24 VDC Starter 312CCA a00CCA With Heavy Accessories 12 VDC Starter 800CCA 800CCA 24 VDC Starter A0Q0CCA 400CCA Maximum Allowable Resistance of Starting Circuit With 12 VDC Starter Ohms 0 0012 0 0012 With 24 VDC Starter Ohms 0 0020 0 0020 Typical light accessories include alternator small steering pump and disengaged clutch Typical heavy accessories include hydraulic pump and torque converter Specifications Page E 23 4BTA3 9 625CCA 400CCA 800CCA 400CCA 0 0012 0 0020 Specifications E 83 9 end B5 9 Series Engines Page E 24 Section E Engine Identification 6B Electrical System Data nonautomotive 685 9 6BT5 9 6BTA5 9 Minimum Recommended Battery Capacity 18 C 0 F With Liaht Accessories 12 VDC Starter BOOCCA B800CCA BOOCCA 24 VDC Starter 400CCA 400C CA 400CCA With Heavy Accessories 12 VDC Starter 950CCA 950CCA 950CCA
158. idance as to proper handling ofused antifreeze A WARNING A Donotremovethe pressurecap from a hot engine Wait until the coolant temperature is below 50 C 122 F before removingthe pressurecap Heatedcoolant spray or steam can cause personal injury Hu 859 le Engines int d res at 77 000 km mi A WARNING amp Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with local envi ronmental regulations Drainthe coolingsystem by openingthe drainvaive onthe radiator and removing the plug in the bottom of the water inlet A drain pan with a capacity of 19 liters 5 gall w it be adequatein most applications Check for damaged hoses and loose or damaged hose clamps Replace as required Check the radiator for leaks damage and buildupof dirt Cleanand replaceas required e Page 7 Cooling System Page Pa y 83 9 and 85 9 Series Engines Maintenance Procedures at 77 000 krn 48 000 mi Flush A CAUTON A Duringfilling air mustbevented fromthe engine cool ant passages The air vents through the jiggle pin openings to the top radiator hose and out the fill open ing Additional ventingisprovidedfor engiinesequipped with an aftercooler Open peteock during filling NOTE Adequate venting isprovidedforafill rate of 19liters 5 gal per minute A CAUTION A Do not install the radiator ap The engine is to be operated without the cap for this process Fill
159. ies applique aux nouveaux moteurs vendus par Cummins et livr s au premier utiiisateur a compter du 1er avril 1999 pour un usage dans des applications industrieiies tout terrain aux Etats Unis et au Canada l exception des moteurs utilis s dans des applications marines et d entrainement de g n rateur ainsi que dans certaines applications militaires pour iesquelies une couverture de garantie diff rente est fournie Garantie de base du moteur Lapresentegarantiecouvretoute pannedu moteur dans des conditionsnormates d utiiisation etd entretien provenant d un d faut de mat riau ou de fabrication en usine pannes couvertes La garantie prend effet dater de la vente du moteur Eiie s tend sur une p riode de deux ans ou 2 000 heures d utilisation suivant lequelde ces termes intervient en premier a compter de ladate de livraison du moteur au premier utilisateurou de la date laquelle le moteur est mis en location de courte ou longue dur e du en pr t pour la premiere fois ou encore lorsque le moteur a t utilis pendant 50 heures suivant lequel de ces termes intervient en premier En cas d une utilisation depassant 2 000 heures durant la premiere ann e la p riode de garantie s tend jusqu la fin de la premiere ann e Garantie etendue des composants principaux La Garantie prolongbe des principaux l ments couvre les pannes justifiables du bloc cylindre de l arbre a cames du vilebrequin des bielles du moteur pieces
160. ii Cepit ce naL a canc cerae Cus ue Eed t5 38 Smoke White ExcessiVe Cu Eens rn ira rrr isa neun GEES cra cr dee ee ee TS 40 B3 9 and B5 9 Series Engines Troubleshooting Procedures and Techniques Section TS Troubleshooting Symptoms Page TS 1 Troubleshooting Procedures and Techniques General Information This guide describes some typical engine operating problems their causes and some acceptable correctionsto those problems Unless noted otherwise the problems listed are those which an operator can diagnose and repair A WARNING Performing troubleshooting procedures NOT outlined in this section can result in equipment damage or personal injury or death Te haning must be performed by trained experienced technicians Consult a Cummins Authorized Repair Location for diagnosis and repair beyondthat which is outllned and for symptoms not listed section Before beginning any troubleshooting refer to General Safety Instructions in Section i of this manual Follow the suggestions below for troubleshooting e Study the complaint thoroughly before acting e Refer to the engine system diagrams Do the easiest and most logical things first e Find and correct the cause d the complaint ei Troubleshooting Symptoms Charts B3 9 and 85 9 Series Engines Page TS 2 Section TS Troubleshooting Symptoms Troubleshooting Symptoms Charts General Information Use the following charts to aid in diagnosing specific engine symptoms R
161. iles hours or months whichever occurs first Is the vehicle an on highway application If Yes Referto Table 1 If No Is the vehicle used in a construction mining or logging operation If Yes Referto Table 2 If No Is the vehicle used in an agricultural or stationary power application If Yes Referto Table 3 If No Use the following oil change interval 10 000 km 6000 mi 250 hours or 3 months whichever occurs first B3 9 and B5 8 Series Engines Maintenance Schedule Section 2 Maintenance Guidelines Page 2 5 Table 1 Use the following oil drain intervals for your Vehicle Equipment km O qmi Mixe Dumper 1 10000 6000 1 Or whichever occurs first If your application accumulates high hours and low mileage the change interval is determined by hours Note If the vehicle accumulates 12 875 km 8000 mi in a month the oil change interval will be 17 000 km 10 000 mil or 250 hours whichever occurs first Maintenance Schedule 83 9 and 3 Series Engines Page 2 6 Section 2 ii Guidelines Skidder 1 Or whichever occurs first If the application accumulates high hours and low mileage the change interval is determ ned by hours our a Vehicte Equipment Hours Months Farm Tractors o i 6 Combines QG O Irrigation Equipment BEE EG EE Ee Generator Set OT At Compressor 1 ene
162. ill Not Shut OM TS 28 Exhaust Smoke Excessive Under Load TS 30 Fuel Knock TS 32 Fuel or Lubricating Oil Leaking From Exhaust Manifold 5 33 General Information ni eene nennen Lubricating Cil Contaminated Lubricating Oil Pressure High Lubricating Oil Pressure Low Smoke White Excessive Turbocharger Clean Install Preparatory Remove Test oar eee United States and Canada Diesel Engine School Bus Vibration Damper usse tette INSPEC esee Water Pump Clean Preparatory ES REMOVE Lubricating Oil LOSS nissan E NO POSTAGE NECESSARY IF MAILED BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 15 COLUMBUS INDIANA POSTAGE W LL BE PAID BY ADDRESSEE CUMMINS ENGINE COMPANY INC MAIL CODE 41302 BOX 3005 COLUMBUS IN 20 III Do not use this form to order additional literature 1 f t to Section L L fo literatureir fo Literature Survey Form Bulletin No 3810205 14 We are always open to any suggestions or recommendations that will aid in imp 3v ng our ma U this postage paid survey form to evaluate this manual Please check the appropriate response and use Ihe space provided below to list any additional comments o le the neededinformation easy to locate in the manual Is the information easy to read Js the informa
163. illed using qt 3 that prevents the release of refrigerant gas fluorocarbons i i theat Spheis ederal lim iequire ed y u recycling refrigerant z e To avoid personal ni pn us ai get wsista gt healifing 1Konents that weigh 23 kg 50 Ib or more N sure all lifting devices such as chains hooks or slings are in good condition and are of the correct capacity Nacest hooks az positioned correctly Ah easp i rbar ver r essary The lifting hooks nt not ber le load sd e Corrosion inhibitor a component of SCA and lubricating oil contains alkali Do not get tr subst in your eyes A ilp or i contact hki D iotsy Ik iit lly In case of contact Ji d aly wash skin with soap and water 1 e of a inmed at ly flooil eyes wih large amounts of water for a minimum f 15 is CALL HYSICIAN KEEP OUT OF REACH OF CHILDREN var IM wy wlKetone are r ath t ral and tk d with saution Follow the nan ifactur instructions to provide complete safety when using these materials KEEP IT OF F EACH OF HILDREN e o avoid bur is be alert for hot pans or products that na just been ned f ad bot fluids in lines tubes and rti H ay uset thata in good condition Make sure 1unders nc ok 3 th beforepe g any service work Use L gn n 4 immi FeConf ep ci ne arts oe oe e Ah use the same fastener part number or equivalent when ola fa r Do not use a fastener of lesser y i y if replacements are necessary Do not perform any repair when fati
164. ing Motor Remove Disconnect the ground cable from the battery Identify each electrical wire with a tag indioating location eeScoma 14 mm A Remove the battery cable from the solenoid eeScomb 83 9 and 85 9 Series Engines Starting Motor Section A Adjustment Repair and Replacement Page A III 10 mm Remove the starting motor Install 10 mm Install the starting motor in the reverse order of removal Torque Value 43 Nem 32 fi Ibj stgbdma Alternator 83 9 and B5 9 Series Engines Page A 112 Section A Adjustment Repair and Replacement Alternator Remove Disconnectthe ground cable from the battery terminal Identify each electrical wire with a tag indicating location Remove the drive belt 14 mm 8 Remove the capscrew from the alternator link 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement 16mm Remove the alternator mounting screws Remove the alternator Install Positionthe alternator on the bracket and secure it with the mounting capscrews Do not tighten at this time D se Alternator Page A 113 Alternator 83 9 and 85 9 Series Engines Page A 114 Section A Adjustment Repair and Replacement Connect the alternator linkto the alternator Finger tighten the capscrews NOTE Makesure the alternator link is properly positioned for correct belt alignment eeScsma 14mm 16mm Tighten the alternator mounting ca
165. ings can be damaged Allow the engine to coolto below 50 C 122 F before adding coolant If additional coolant is added to the cooling system a 50 percent mixture d water and antifreeze must be premixed before being added to the system Since the ability of antifreeze to remove heat from the engine is not as good as water pouring antifreeze into the engine first could contribute to an overheated condition before the liquids are completely mixed Refer to Coolant Recom mendations and Specifications in Section V NOTE On applications that use a coolant recoverysystem check to make sure the coolant is at the appropriate level on the coolant recovery tank depending on engine temperature Coolant Level Page 3 5 50 PERCENT 50 PERCENT WATER WATER 50 PERCENT 50 PERCENT ANTIFREEZE ANTIFREEZE Coolant Level Page 3 6 3 and 5 9 Series Engines Section 3 Maintenance edures st Daily Interval Fillthe cooling system with coolant to the bottom of the fill neck in the radiator fill or expansion tank NOTE Some radiators have two fill necks both of which must be filled when the cooling system is drained B3 9 and 5 9 Series Engines Drive Belts Section 3 Maintenance Procedures at Dally Interval Drive Belts Maintenance Check Inspectthe beltsdaily Check the beltforintersecting cracks e Traverse across the belt width cracks are acceptable Longitudinal direction of belt length cracks that inte
166. ion Cooling system is contami nated with dirt scale or Clean the cooling system studge OK Contact a Cummins Authorized Repair Facility amp CG GE j I Troubleshooting Symptoms Charis ba and 85 9 Series Engines Page TS 10 i Section TS Troubleshooting Symptoms i E edge e Engine Difficult to Start or Will Not Start Exhaust Smoke Cause Correction Cause i Correction i T3 n Verity the correct startin i Check the flow through the Starting procedure is not s procedure Refer to Section Fuel supply is not ad filter to locate the See of Correct 1 equate the restriction Refer to the OEM service manual OK Check the engine crankiny speed with a handheld tachometer or electronic Fuel drain backup service tool If the cranking speed is slower than 150 rpm referto the OEM Service manual Verify the fuel return line 18 plumbed to the bottom of Engine cranking speed is the fuel tank too slow i LEE Sr O i Check the overflow Fuel oumn overf om valve j Replace 1necessary Refer f oning Ge to Ihe OEM service Starting aid is necessary Check for correct operation manual for cold weather or starting of cold starting aid Refer to aid is malfunctioning Section 1 Inspectthe fuel transfer Fuel transfer pump mal pump Replaceif naces Bleed the fuel system and functioning Air in the fuel system check for leaks Refer t
167. l antifreeze filter elements belts hoses and other i it that r r it reusable due to the Warrantable Failure mirins will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Wi antable Failure Cummins will pay reason gt costs for v 1 a vehicle disabled by a Warrantable Failure to the nearest authori ed r airlocation n l ftowing p C iir willpayreasonable costs for ct s tr 1 uidfron he location of the vehicle it 1 rile ar lodgit t tt il is performed at the site of the failure ig The Extended M j Components Warranty C i Willy for the repair or ati ption replacement of the defect ve Covered Part and any Covered Part damage bya antat e Failure of the detective Covered Part 83 9 and 85 9 Series Engines Cummins Warranty Section W Warranty Page W 9 Owner Responsibilities During The Base Engine Warranty Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenanceiterns replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure During The Extended Major Components Warranty Owner is responsible for the cost of all labor neededto repair the Engine includingthe labor to remove and reinstall fhe engine When Cummins elects to repair a part insteadof replacing it Owner is not responsiblefor the labor needed to repair the part Owner is responsible for the cost of all parts required for t
168. l is needed Sockets Wrenches Other Tools 19mm 19 mm Filter wrenches 75 to 80 mm and 90 to 95 mm 17mm 17mm Ratchet 1 2 inch drive 15mm 15mm Flat blade screwdriver 14mm Torque wrench 13 mm Allen wrench 6 16 inch 10mm Feeler gauges 0 25 mm and 0 51 mm Engine barring gear Part No 3824591 83 9 and 85 9 Series Engines Section 2 Maintenance Guidelines Maintenance Schedule General Information B3 9 and 85 9 Series Er 1 Maintenance Schedul Daily or Refueling Every 10 000 km 6000 mi 250 Hours or 3 Months Maintenance Schedule Page 2 3 La Every 19 000 km Every 38 000 km Every 77 000 km 48 000 12 000 mi 500 Ho 24 000 mi 1000 Hours mi 2000 Hours or 2 or 6 Months or 1 Year Years Maintenance Check Check Inspect Change Replace inspect Check Inspect Check Ins d eplace e Oil level Change lubricatingoil Coolant level e Fan e Replace lubricating oil e Drive belt filter e Fuel water separator e Inspect air cleaner e Inspect intake system e Check charge air cooler 4 t Refer to the Oil Chan nterval tables provided in 2 Initial valve lash clear e adjustment subsequen change for automotive er es or 2000 hour 2 year in 8 Heavy duty year arou intifreezethat meets the 320 000 km 200 000 mi iichever occurs first Antif 4 Service intervalis 2 y 3 or 320 000 km 200 000 5 Service intervalis every other oilchange or 19 00 e Change lub
169. leveland OH 44146 Telephone 440 4396800 FAX 440 439 7390 Strasburg Branch Cummins Interstate Power inc 777 South Woosler Avenue Strasburg OH 44680 Telephone 216 878 5511 FAX 216 878 7666 Toledo Branch Cummins Interstate Power Inc 801 illinois Avenue Maumies Toledo OH 43537 Telephone 419 893 8711 FAX 419 893 5362 Youngstown Branch Cummins interstate Power Inc 7145 Masury Road Hubbard Youngstown OH 44425 Telephone 216 534 1935 FAX 216 534 5606 Oklahoma Oklahoma City Branch of Arling ton Cummins Southern Plains Inc 5800 West Reno Oklahoma City OK 73127 Telephone 405 946 4481 24 hours FAX 405 946 3336 Tulsa Branch of Arlington Cummins Southern Plains Inc 16525 East Skelly Drive Tulsa OK 74116 Telephond 918 234 3240 FAX 918 233 2342 B3 9 and 85 9 Series Engines Section S Service Assistance Oregon Bend Branch of Seattle Cummins Northwest Inc 3500 N Highway 97 97701 5729 RO Box 309 Bend OR 97709 0309 Telephone 541 389 1900 FAX 541 389 1909 Coburg Eugene Branch of Seatile Cummins Northwest Inc 91201 Industrial Parkway Coburg OR 97401 Mailing Address PO Box 10877 Eugene OR 97440 2887 Telephone 541 687 0000 FAX 541 887 1977 Medford Branch c Seattle Cumrnins Northwest Inc 4045 Crater Lake Highway Medford OR 97504 9736 Telephone 541 779 0151 FAX 541 772 2395 Fendi
170. ley 15 mm 137 101 Crossover Clamp 5 16 in 5 44 T Bolt Type Clamp 11 mm 8 71 Exhaust Outlet Pipe V Band Clamp 7 16 in 8 7L Fan Bracket Mounting 10 mm 24 18 Fan Pulley 10mm 24 18 Engine Component Torque Values B3 9 and B5 9 Series Engines Page V 30 Section V Maintenance Specifications Component Wrench Size Torque Value Nem ft lb in Ib Fan Pulley 13 mm 43 32 B3 9 and B5 9 Serles Engines Engine Component Torque Values Section V Maintenance Specifications Page V 31 Component WrenchSizee Torque Value 10 0 Nem ft lb in Ib Fuel Filter 7510 85 mm Install as specified by filter manufacturer Fuel Filter Adapter Nut 24 mm 32 24 Lubricating Oil Filter 751085 mm 3 4 Tum after Contact Lubricating Oil Cooler Assembly 10mm 24 18 Lubricating Oil Pan Drain Plug steel 17mm 80 59 Lubricating Oil Pan Drain Plug aluminum 17 mm 55 41 Lubricating OJf Pan Heater Plug 27 mm 80 59 Lubricating Oil Pressure Regulator Plug 19mm 80 59 Starter Mounting 10 mm 43 32 Thermostat Housing 10 mm 24 18 Water Inlet Connection 15mm 43 32 Water Pump Mounting 13mm 24 18 Valve Cover 15 mm 12 f 106 Water in Fuel Sensor 19 mm Hand Tighten Top Load Filter Lid 10 mm Hand Tighten Capscrew Markings and Torque Values B3 9 and 85 9 Series Engines Page V 32 Section V Maintenance Specifications Capscrew Markings and Torque Values General information A CAUTION A When replacing capscrews always use a capscrew
171. lisationde pieces non homologuees Une nouvelle pi ce Cumminsowune piece reconditionnee homologu e utilis e pour la r paration d une pannesous garantie est alors identifi e comme la piece originale remplac e en vertu de cette garantie CUMMINS NE COUVRE PAS L USURE DES PIECES COUVERTES CUMMINS N EST PAS RESPONSABLE DES DOMMAGES INDIRECTS OU INDUITS LESPRESENTES GARANTIES SONT L ESGARANTIESEXCLUSIVESDE CUMMINS CONCERNANT CES MOTEURS CUMMINS NE CONSENT AUCUNE AUTRE GARANTIE EXPRESSE OU IMPLICITE ET AUCUNE GARANTIE DE BONNE QUALITE COMMERCIALE OU D ADAPTATION A UN USAGE SPECIFIQUE Cette garantie vous procure certains droits qui peuvent varier d un tat a l autre Garantie concernant l mission de polluants e Produits garantis Cette garantie s appiique aux nouveaux moteurs commercialises par Cummins et utilis s aux Etats Unis sur des v hicules a usageindustrieltout terrain La pr sente garanties appliqueaux moteurslivr s l acheteur final acompter du leravril 1999 pourles moteursjusqu a 750 chevaux ou compter du ler janvier 2000 pour lesmoteurs d au moins 751 chevaux Gaiantie Cumminsgarantit au dernier acheteur et achaque futur acheteurque l moteur a t con u construit et quip selon leslois am ricaines en vigueur portant sur la pollution et qu il ne comporte aucun d faut de fabrication des composants ce qui engendrerait une non conformite du moteur pendant les p riodes suivantes A cing ans ou 3 000 he
172. ll debris from around the fittings Remove WI Rotary Pumps 17 mm Oe Disconnect the fuel line s from the injector NOTE If individual lines are to be replaced remove the support clamp from the set of lines containingthe lineto be replaced B3 9 and B5 9 Series Engines Injector Supply Lines High Pressure Page A 27 Section A Adjustment Repair and Replacement 17mm Disconnectthe fuel line s from the fuel pump Install pro S tective covers onto the injectors and delivery valves to prevent entry of dirt into the system Inline Pumps 8 mm 17 mm and 19 mm Disconnectthe line s from the injectorts NOTE If individual lines are to be replaced remove the supportclamp from the set oflinescontaining the lineto be removed Injector Supply Lines High Pressure B3 9 and 85 9 Series Engines Page A 26 Section A Adjustment Repair and Replacement EI 19 mm Disconnect the line s from the fuel pump S 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Install Rotary Pumps A CAUTION A Installthe supportclamp inthe original position and to prevent damage from high frequency vibration make sure the lines havenotbeenbentor do notcontact each other or another component A CAUTION A To prevent damage to the fuel lines they must be con nectedto the injectors andfuel injection pumpina free state without forcing the connecting nuts The fuel lines are correctly
173. lso serves New Zealand Cummins Americas Regional Office Cummins Latin America 3088 N Commence Parkway MPC 14 BuildingA Miramar FL 33025 Telephone 305 621 1300 NOTE This office serves Puerto Rico and South America excluding Brazil 9 05 dem reglonal Service Assistance Page G A Alabama Birmingham Distributor Cummins Alabama Inc 2200 Pinson Highway PO Box 1147 Birmingham AL 35201 Telephone 205 841 0421 AX 205 849 5926 Mobile Branch Cummins Alabama Inc 1924 N Beltline Hwy Mobile AL 36601 1598 Telephone 334 456 2236 AX 334 452 6419 Mobile Onan Marine Branch Cummins Alabama Inc 3422 Georgia Pacific Avenue Mobile AL 36617 Telephone 334 452 6426 FAX 334 473 6657 Montgomery Branch Cummins Alabama inc 2325 West Fairview Avenue Montgomery AL 36100 Telephone 205 283 2594 AX 205 263 2594 g 18 dom distributor 9 and B5 9 Series ii S a ion S Ser ai r and Branches United States Alaska Anchorage Branch of Seattle Cummins Northwest Inc 2610 Commercial Drive Anchorage AK 99501 3095 Telephone 9971 279 7594 FAX 807 276 6340 Arizona Phoenix Distributor and Branch Cummins Southwest Inc 2239 N Black Canyon Hgwy Phoenix AZ 85009 Telephone 602 252 8021 AX 602 253 5725 Tucson Branch Cummins Southwest Inc 1912 West Prince Road Tucson AZ 85705 Telephone 520 887 7440 AX 520 887 4173 Arka
174. lure 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 usedto 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 35 NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES B3 9 and B5 9 Series Engines Cummins arany Section W Warranty Page W 11 THESE WARRANTIES AND THE EMISSION WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRAN TIES MADE BY CUMMINS IN REGARD TO THESE ENGINES CUMMINS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty givesyou specific legal rights and you may also have other rightswhichvary from state to state or country to country Emission Warranty Products Warranted This emission warranty applies to new diesel LPG compressed or liquid natural gas fueled engines marketed by Cummins that are used inthe United States in vehicles designed for transporting persons or property on a street or highway This warranty applies to Engines delivered to the ultimate purchaser on or after January 1 1999 Coverage Cummins warrants to the ultimate purchaser and each subsequent purchaser that the Engine is designed built and equipped so ag to conform at
175. mins Warranty 83 9 and 85 9 Series Engines Page W 32 Section W Warranty Owner Responsibilities During The Base Engine Warranty Owner is responsiblefor the cost of lubricatingoil antifreeze filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure During The Extended Major Components Warranty Owner is responsible for the cost of all labor neededto repair the Engine includingthe labor to remove and reinstall the Engine When Cummins elects to repair a part insteadof replacing it Owner is notresponsiblefor the labor needed to repair the part Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered Part Owner is responsible for the cost of lubricatingoil antifreeze filter elements and other maintenanceitems replaced during the repair During The Base Engine and Extended Major Components Warranties Owner is responsible for the operation and maintenahce of the Engine as specified in the applicable Cummins Operation and Maintenance Manual Owner is also responsiblefor providing proof that all recommended maintenance _ has beer 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
176. n E Engine Identification Page E 2 Have the following engine data available when communicating with a Cummins Authorized Repair Facility The information on the dataplate is mandatory when sourcing service parts 1 Engine Serial Number ESN 2 Control Parts List CPL Dot de bi ttuhtt of d annuler Jeux Soup Front Feta O der Ortu rfAlumaga D n o ip k n Speed mm Deke ct Fabrication Vesse Rater AVERTISSEMENT 18 13 QW i dub tot syl 6 mn ou Etude 83 9 and B5 9 Series Engines Section E Engine Identification Cummins Engine Nomenclature Automotive Applications The model name for automotive engines provides the fol lowing engine data B5 9 C B Engine series 5 9 Displacement Industrial Applications The model name for industrial engines provides the fol lowing engine data B3 9 C B Engine series 3 9 Displacement in liters Engine Identification Page E 3 Engine Identification Page E 4 DaOBERT BOSCH cea Lol VE A123 0 460 424 006 390 3354 2055 92 34 93579 P S6A1900320 335265 E 6518530 O 9 400 230 097 SE IA oi e A tpo0tgl 63 9 and 85 9 Series Engines Section E Engine ldentification Fuel Injection Pump Dataplate Bosch The injection pump dataplate for the Bosch VE pump is located on the side of the injection pump The dataplate provides information for fuel pump calibration Bosch In line Dataplate The injection pump dataplat
177. n be contacted direotly for any specifications not covered IN this manual Air Compressors Bendix Heavy Vehicles Systems Div oi Allied Automotive 901 Cleveland Street Elyria OH 44036 Telephone 216 329 8000 Holset Engineering Co Inc 1320 Kemper Meadow Drive Suite 500 Cincinnati OH 45240 Telephone 513 825 9600 Midland Grau Heavy Duty Systems Heavy Duly Group Headquarters 10930 N Pamona Avenue Kansas City MO 64153 Telephone 816 891 2470 Air Cylinders Bendix Lid Douglas Road Kingswood Bristol England d Telephone 0117 871881 Catching Engineering 1733 North 25th Avenue Melrose Park IL 60160 Telephone 708 344 2334 TEC Hackett Ine 8909 Rawles Avenue Indianapolis IN 48219 Telephone 317 895 3670 Air Heaters Fleetguard Inc 1200 Fleetguard Road Cookeville TN 38502 Telephone 615 526 9551 Kim Hotstart Co PO Box 11245 Spokane WA 992110245 Telephone 509 534 6171 Air Starting Motors Ingersoll Rand Chorisy New Road Horwich Bolton Lancashire England EL6 GN Telephone 01204 65544 Ingersoll Rand Engine Starting Systems 888 Industrial Drive Elmhurst IL 60126 Telephone 708 530 3875 9 04 cmp add 83 9 and 85 9 Series Engines Page M b Section M Component Manufacturers Page 3OVGI TOI S eet Weeer eebe gege ee EE VER RE RE MER EON ER SESE M6 Heat Sleeves 2 eee AM Hydraulic and Power Sisene guo LL M tt e el CN
178. n diesel fuel Theviscosityofthefuel must be kept above 1 3 centistokes to provide adequate fuel system lubrication at 40 C 104 F For a more detailed description of fuel properties referto Fuel for Cummins Engines Bulletin No 3379001 B3 9 and B59 Series Engines Fuel Recommendations and Specifications Section V Maintenance Specifications Page V 21 The following chart lists acceptable alternate fuels for midrange engines A CAUTION A Do not use diesel fuel blended with lubricating oil in engines equipped with a catalytic converter including model year 1994 and beyond Damage to legally required emission control can result NOTE Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not warrantable NOTE Wear on any midrange fuel pump componentattributedto the lack of lubricationin the fuel is not a warrantable reoair Acceptable Alternate Fuels Component Wear Durability WEE E WEE EECH WEE E EE No E EE OK OR OR o EU WT E EEN ET E E EE E ORDEN EE OK only if 5 parcent new lubricating oil is blended with these fuels to increase the lubricity to acceptable level i Fuel CB and Specifications B3 9 and B5 9 Series Engines Page V 22 Section V Maintenance Specifications Fuel Type No 1 D diesel No 2 D diesel No 1 K kerosene No 2 K kerosene Jet A Jet A 1 JP 8 Jet B JP 4 Cite No 1 Ddiesel_ No 2 Ddiesel No 1 K kerose
179. nada V2C 5P5 Telephone 250 828 2388 FAX 250 828 6713 Prince George Branch Cummins British Columbia 102 3851 18th Avenue Prince George B C V2N 1B1 Telephone 250 564 9111 FAX 250 564 5853 Service Assistance Page S 19 Distributors and Branches Canada Sparwood Branch Cummins British Columbia 731 Douglas Fir Road Sparwood B C VOB 2GO Canada Telephone 250 425 0522 AX 250 425 0323 Tumbler Ridge Branch Cummins British Columbia industrial Site Box 226 Tumbler Ridge B C Canada VOC 20 Telephone 250 2424217 FAX 250 242 4906 Manitoba Winnipeg Distributor Cummins Mid Canada Ltd 489 Oak Point Road P O Box 1860 Winnipeg MB R3C3R1 Canada Telephone 204 632 5470 FAX 204 697 0267 4 Service Assistance Page S 20 New Brunswick Fredericton Branch of Montreal Cummins Eastern Canada Ine R R 1 Doak Road FO Box 1178 Station A Fredericton New Brunswick E3B 4x2 Canada Telephone 506 451 1929 FAX 506 451 1921 Newfoundland St John s Branch of Montreal Cummins Eastern Canada Ine 122 Clyde Avenue Donovans Industrial Park Mount Pearl Newfoundland A1N 2C2 Canada i Telephone 709 747 0176 FAX 709 747 2283 Wabush Branch of Montreal Cummins Eastern Canada Inc Wabush Industrial Park Wabush Newfoundland AOR 1B0 Telephone 709 282 3626 FAX 709 282 3108 Nova Scotia Halifax Branch of Montreal Cummins Eastern Can
180. nators starters fans air conditioning compressors clutches filters transmissions torque con vertere vacuum pumps power steering pumps and air compressors Cummins branded alternators and startersare coveredfor the first two yearsfromthe date of deliveryof the Enginetothefirst user or theexpirationof the Base Engine Warranty whichever occurs first Excessive oil consumption for B series Engines is covered for the duration of the coverage or 100 000 miles 160 935 kilometers or MOO hours from the date of delivery of the Engine to the first user whichever of the three occurs first Before aclaim for excessive oil consumptionwill be considered Owner must submit adequate documentatiqnto show that consumption exceeds Cummins published standards Failures of belts and hoses supplied by Cummins are not covered beyondthe first year from the date of delivery of the Engine to the first user or the expiration of the applicable Base Warranty whichever occurs first Parts used to repair a Warrantable Faiiure 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 Warranty 83
181. nd table located in Section 2 for the recommended oil change interval based on engine application Oil Performance Recommendations 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 CE SG NOTE CC CD or CD SF engine oils can be used in areas where CE oil is not yet available butthe oil change interval must be reduced to one half the interval given in the maintenance schedule A sulfatedash limit of 1 0 mass percent is suggestedfor optimumvalve and piston depositandoil consumption control The sulfated ash must not exceed 1 85 mass percent Oil Viscosity Recommendations The use of multiviscasity lubricatingoil has been foundto improveoil consumptioncontrol and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures While 15W 40 oil is recommendedfor mostclimates refer to the accompanyingtable for oil viscosity recommendations for extreme climates Lubricating Oil Recommendations and Specifications B3 9 and B59 Series Engines Page V 26 Section V Maintenance Specifications NOTE Limited use of low viscosity oils such as 10W 30 C 40 30 20
182. ne No 2Kkerosene eA et A PP JB B3 9 and B5 9 Series Engines Section V Maintenance Specifications Fuel Filters A Standard filter used as secondary filter in dual filter applications B Fuel water separator primary filter for dual filter ap plications C Fuel water separator used in single filter applications s Fuel Recommendationsand Specifications Page V 23 Sealants 63 9 and 85 9 Series Engines Page V 24 Section V Maintenance Specifications Sealants General Information Use the sealants listed below or sealants containing equivalent properties Sealants Description Sealing Method Pine plugs Precoated Teflon or pipe sealer cup plugs Loctite 277 of 11 264 O rings No sealant required Rear camshaft expansion plug Preooated or Loctite 59 241 liquid Teflon Fuel pump studs Lactite 609 Turbocharger drain in block Loctite 277 or 11 264 Frontseal in gear cover Loctite 277 or 11 264 Rear seal in gear cover No sealant Qil pan at T joint Three Bond 1207C PIN 3823494 83 9 and 85 9 Series Engines Lubricating Oil Recommendations and Specifications Section V Maintenance Specifications Page V 25 Lubricating Oil Recommendations and Specifications New Engine Break in Oils Do not use special break in oils for new or rebuilt Cummins engines Use the same type of oil during the break in as that used in normal operation Recommended Oil Change Intervals Refer to the flowchart a
183. ne Operating Range 1 14 General Ironman sen 1 14 Engine S MUTA OW rec 1 18 ET EIN eu AN OM EE 1 18 Normal Starting ProCQure ivvisscsscedeessscsnesscessessearvanvassassovncusrvervesdersiuscusr cas VEN RON ERREUR REY HEN FEN ER RE HERE REN RN RE a RE RE 1 3 General IMfOrrMatiOn EE E T ON A V 1 3 Operating Instructions Overview smsen T c Seet TEES 1 1 GeMeral TOMA On EE 1 1 Operating the Engine scccssssssssesessssssssssss pose tteneeateateaeeecenaneneeaeeateaesoneresseeaeeeteaneeneeateaueaeeenernteneeateateanee 5 General MOP MAO EE 5 Starting Procedure After Extended Shutdown or Oil Change General Information aes Vi vn Pa En A Ea RARRRRRRRRERAHARERRRARARHAHARERRRARARHAHARERRRARRRHAHARERERARRRRRRHARERE RERERHERERHRRRERHERERHRERERHSSERERRRRERHESER CO ECC 83 9 and 85 9 Series Engines Page i b Section 1 Operating Instructions THIS PAGE LEFT INTENTIONALLY BLANK 83 9 and B5 9 Series Engines Section 1 Operating Instructions Operating Instructions Overview General Information Correct care of your engine will help result in longer life better performance and more economical operation Followthe daily maintenancechecks listedin Maintenance Guidelines Section 2 The new Cummins engine associated with this manual does not require a break in procedure
184. ne mounts are worn Replace as needed Refer Repair Facility damaged or not correct TF to the OEM service 2 manual OK Check be fan drive and ranar E controls Refer lo the OEM service manual 2 te Inspect the vibration Vibration damper malfunc damper Replace if tioning six cylinder only necessary Refer to Section 7 Troubleshooting Symptoms Charts B3 9 and 85 9 Serles Engines ju TS 26 Section TS Troubleshooting iis i i Engine Will Not Crank or Cranks Slowly Ca 1 Correction Cause Correctlon ine dri i f Check the busy supply to Engine pi Balls ale Disengage engine driven i Starter solenoid is not the starter solenold Refer gag regalving voltage E to the OEM service manual OK L d Check crankshaft or ease eae Di Fof rotation Refer to Section Check the starting circuit 8 components Referto the OEM service manual Checkthe fuses wires and connections Referto the OEM service manual and Manufacturer s wiring diagram Electrica system is open blown fuses broken wires or loose connections Remove the Starting motor and h apect for broken teeth SR e ring gear and pinion Inspect ior o broken starling moto sring Starting motor operating j but not cranking the engin i OK m battery If the battery Contact a Cummins 18 law check the elternator Authorized for proper charging Charg
185. ner has been raised to remove install the belt check the tensioner capscrew for the cor rect torque Torque Value 43 Nem 32 ft lb Fill A CAUTION A Be sureto vent theengineand aftercooler duringfilling to remove air from the coolant system or overheating will result Fillthe cooling system Operate the engine and check for leaks 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Fuel System Overview General information Fuel System Repair Summary Do not mix gasoline alcohol or gasc Components to Be Replaced Lift Pump High pressureLines Injector Fuel Drain Manifold Injectors Injection Pump Fuel Solenoid Rotary Pump Fuel Filter Head A WARNING A Tools 13 14 and 17 mmwrenches 10 mm socket 14 17 and 19 mm open end wrenches torque wrench 10 and 19 mm open end wrenches 10 and 13 mm sockets torque wrench Ratchet 24 mm deep well socket torque wrench 10 mm wrench ratchet 22 mm socket 75 mm T bar puller 8 mm capscrews 1 2 inch open end wrench flat screwdriver 13 mm socket 13 mm wrench hammer flat chisel torque wrench Bosch 24 mm wrench Lucas CAV 22 mm wrench 24 mm 75 to 80 mm and 90 to 95 mm filter wrench 4 with diesel fuel This mixture can ci Fuel System Overview Page A 17 e an explosion Preparatory Steps Clean debris Clean debris Disconnect the EE and fuel drain manifold Remove Ces line Sup
186. neto the first user In lieu of towing expenses Cummins will pay reasonable costs for mechanicsto travel to and from the location of the vehicle including meals mileage and lodging when the repair is performed at the site of the SE Owner Responsibilities During The Base Engine Warranty Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure Owner is responsible for the operation and maintenance of the Engine as specified in the applicable Cummins Operationand Maintenance Manual Owner is also rgsponsible for providing proof that ail recommended maintenance 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 Engine available for repair by such facility Exceptfor Engines disabledby a Warrantable Failure duringthe first year from the date of delivery of the Engine to the first user Owner must also deliver the Engine to the repair facility Locations inthe United States and Canada are listed inthe Cummins United States and Canada Sales and Service Directory 83 9 and B5 9 Series Engines Cummins Warranty Section W Warranty Page W 27 Owner is responsible for communication expenses meals lodging and similar costs incurred as a resul
187. ng Oil Level sssssusnssuusunununnnunnnnunnnnnunnnnnns 3 3 Maintenance Check S 3 3 83 9 and 5 9 Series Engines Page 3 b tio 3 Maintenan Proceduresat Daily Interval THIS PAGE LEFT INTENTIONALLY BLANK B3 9 and 5 9 Series Engines Daily Maintenance Procedures Overview Section 3 Maintenance Procedures at Daily Interval Page 3 1 Daily Maintenance Procedures Overview General Information Preventative maintenance begins with day to day awareness df the condition of the engine and its systems Before starting the engine check the oil and coolant levels Look for e Leaks e Loose or damaged parts e Worn or damaged belts e Any change in engine appearance Fuel Water Separator 83 9 and 5 9 Series Engines Page 3 2 Section 3 Maintenance Procedures at Daily Interval zz Fuel Water Separator Maintenance Check A CAUTION A Do not overtighten the valve Overtightening ean dam agethe threads Drain lhe water and sediment from the separator daily Shutoffthe engine Use your handto openthe drainvalve Turnthe valve counterclockwise four completeturns until the valve drops down 1 inch Drainthe filter sump of water until clear fuel is visible Pushthevalveupandturn thevaiveclockwisetoclose the drain valve NOTE If more that 2 ounces are drained refiilingthe filter is requiredto prevent hard starting Referto Section 5 for venting the low pressure fuel lines 83 9 and 59 Series Engines S
188. ng 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 WEARQUT OF COVERED PARTS CUMMINS IS NOT RESPONSIBLE FOR INCIDENTALOR CONSEQUENTIAL DAMAGES B3 9 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W 1 4 WARRANTIES SET FORTH HEREIN HF SOLE WARRANTIES MADE BY CUMMINS IN REGARD TO ENGINES CU AMIS RAKES NO O EF FIES EXPRESS OR IMP OR gt F MER r ABILITY OR SS ORA 1 t Th arrantygih you ci ega ht and you may also have other Il which vary from state 9 state Warranty Products This emission warranty applies to new Eng r ib li that u usedintheU it 1S t in vehicles 154 df bi til ffhig y This alrat applies o igi h to the tt purchaser or after April 1 1999 for engines up to 750 horsepower on or after January 1 2000 for gi 751 horsepower and over Coverage nu ants the ultimate purchaser and each e ent pt c a rthat the En jine 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 r ofi fact re r thatitis fre gt n 3 i inworkt ip or materi D dca eiti yi meetthese regulations within the longer of the following periods A Five years or 3 000 hours of operation whict sei occu fi st as measured fon 1 ate gt celv
189. nose PE MT 5 22 Distributors and Branches Canada 2 4 esses nennen nnn atn a anaa RE bunau danan NER dE aAA S 19 Distributors and Branches New Zealand Popp 5 25 Distributors and Branches United States nn eege 5 4 Division and Regional e lu 3 Emergency and Technical Service ns eerie estere rene tenete tenete 8 1 Problem Solving EE NEE EE S 2 Routine Service and ETC S 1 Page S b 83 9 and B5 9 Series Engines Section S Service Assistance THIS PAGE LEFT INTENTIONALLY BLANK B3 9 and B5 9 Series Engines Service Assistance Section S Service A Page S 1 Service Assistance Routine Service and Parts Personnelat CumminsAuthorized Repair Locationscanassistyou with the correct operation and serviceof your engine Cummins has a worldwide service network of more than 5 000 Distributors and Dealers who have been trained to providesound advice expert service and complete parts support Checkthe telephonedirectoryyellow pages or refer to the directory in this section for the nearest Cummins Authorized Repair Location Emergency and Technical Service The Cummins Customer Assistance Center provides a 24 hour toll free telephone number to aid in technical and emergency service when a Cummins Authorized Repair Location can not be reached or is unable to resolve an issue with a Cummins product If additional assistance is required call Toll Free 1 800 DIESELS 1 800 343 73
190. ns Atoi db II tit or M 1 800 DIES El S 1 800 343 7357 toll free inthe US nd C i The latest technology and the highest quality components were used to produce this engine Wh replacement parts are lid v Or using only genuine Cummins or ReCon exchange part Tr parts be identified bythe d iig d E i x 7 Dec SE o eo e EX Note Warranty information is located in Section W Makesure you are familiar with the warranty or warranties applicable to your engine 9 03 om frwd Table of Contents Introduction eeeseeeeeeen nennen nnne Engine Identification Operating Instructions Maintenance Guidelines Maintenance Procedures at Daily Interval rarer BEEEEEEEEEEREEREEERSEEEEERSERERHEEESERESEREEREE Maintenance Procedures at 10 000 Kilometers 6000 Miles 250 Hours or 3 Months Maintenance Procedures at 19 000 Kilometers 12 000 Miles 500 Hours or 6 Month Maintenance Procedures at 38 000 Kilometers 24 000 Miles 1000 Hours or 1 Year Maintenance Procedures at 77 000 Kilometers 48 000 Miles 2000 Hours or 2 Years Adjustment Repalr and Replacement System Diagrams S eer REREESREN LUTTE OTT Section Section Service Literature ss 5 1 eee nee oct sdesncervenclevivsechevendechssectauesesievdvaedstenttavesests L Component Manufacturer sine M Service Assistance j S Troubleshooting Symptoms
191. nsas Little Rock Branch of Memphis Cummins Mid South inc 6600 interstate 30 Little Rock AR 72209 Telephone Sales 501 5695600 Service 501 589 5656 Parts 501 569 5613 AX 501 585 2199 California San Leandro Distributor Cummins West Inc 14775 Wicks Blvd San Leandro CA 24577 8778 Telephone 510 351 6101 FAX 510 352 3925 Arcata Branch Cummins West Inc 4801 West End Road Arcata CA 95521 Telephone 707 822 7392 FAX 707 822 7585 B3 9 and 85 9 Series Engines Service Assistance Section S Service Assistance Page S 5 Bakersfield Branch Cummins West Inc 4601 East Brundage Lane Bakersfield CA 93307 Telephone 805 325 9404 FAX 805 861 8719 Fresno Branch Cummins West Inc 2740 Church Avenue Fresno CA 93706 Telephone 209 495 4745 FAX 209 486 7402 Redding Branch Cummins West Inc 20247 Charlann Drive Redding CA 96001 Telephone 916 222 4070 FAY 916 224 4075 Stockton Branch Cummins West Inc 41 West Yokuts Avenue Suite 131 Stockton CA 95207 Telephone 208 472 0386 FAX 209 478 2454 West Sacramento Branch Cummins West Inc 2661 Evergreen Avenue West Sacramento CA 95691 Telephone 916 371 0630 FAX 916 371 2849 Los Angeles Distributor Cummins Cal Pacificins 1939 Deere Avenue Irvine Irvine CA 92606 Telephone 949 253 6000 FAX 949 253 6080 Montebello Branch Cummins Cal Pacific Inc 1105 South Greenwood Avenue Montebello
192. nte CA 91731 A warranted part which is scheduled for replacement as required maintenance is warranted up to the first scheduled replacement point Prior to the expiration of the applicable warranty Owner must give notice of any warranted emission control failure to a Cummins distributor authorized dealer or other repair location approved by Cummins and deliver the engineto such facility for repair Repair locations are listed in Cummins United States and Canada Service Directoty Owner is responsible for incidental costs such as communication expenses meals lodging incurred by Owner or employees of Owner as a result of a Warrantable Condition Owner is responsiblefor downtime expenses cargo damage fines all applicable taxes all businesscosts and other losses resulting from a Warrantable Condition CUMMINS IS NOT RESPONSIBLE FOR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDEBUT ARE NOTLIMITED TO FINES THEFT VANDALISMOR COLLISIONS California Emission Control System Warranty On Highway 83 9and 85 9 Series Engines Page W 38 Section W Warranty Replacement Parts Cummins recommends that any service parts usedfor maintenance repair or replacement of emission control systems be new genuine Cummins or Cummins approved rebuilt parts and assemblies and that the engine be serviced by a Cummins distributor authorized dealer or the repair location approved by Cummins The own
193. ntie s applique aux aocessoires sauf pour les embrayages et filtres fournis par Cummins qui portentle nom d une autre societe Mis a partles generateurs de courant et les pompes a incendie Cummins ne garantit pas les accessoires portant le nom d une autre societe Ces accessoires comprennent les aiternateurs les d marreurs les ventilateurs les compresseurs d air conditionnes les embrayages les filtres les transmissions les convertisseurs de couple ies pompes d assistance de direction les entrainements ventilateurs d une marque differentede calle de Cummins les freins de compression moteur et les compresseurs dair Les unites Compusave Cummins sont assujetties a une garantie differente Avant qu une reclamation concernant une consommation excessive en huile soit prise en compte le proprietairedoit fournir une documentationadequate afin de pouvoir prouver que laconsommationd passe celle d finie par Cummins B3 9 and BS 9 Series Engines Cummins Warranty Section W Warranty Page W 23 Les deteriorations des courroies et flexibles fournis par Cummins ne sont pas garanties au del des 500 premieres heures ou apr s un an d utilisation suivant lequel de ces termes intervient en premier Les piecesutilis es pour la r paration d une panne sous garantie peuvent tre des pi ces Cummins neuves des pieces reconditionn es homoioguees ou des pieces r par es Cummins n est pas responsable des pannes resultant de l uti
194. nty covers Warrantable Failures of the Engine cylinder block camshaft crankshaft and connecting rods Covered Parts Bushing and bearing failures are not covered This Coverage bagins with theexpirationofthe BaseEngine Warranty and ends three years or 10 000 hoursofoperation from the date of delivery of the Engine to the first user or from the date the unit 3s first leased rented or loaned or from when the Engine has been operated for 50 hours whichever occurs first 3 3381321 Cummins Warranty 83 9 and 85 9 Series Engines Page W 14 Section W Warranty Consumer Products The warranty on Consumer Produ ts in the United States isa LIMITED warrai CUMMINS IS NOT RESPONSIBLE FOR INCIDENTALOR CONSEQUENTIAL DAMAGES Any impliedwarranties applicable to Consumer Productsin the United States terminate concurrently with the expiration of the express warranties applicable to the product In the United States some states do not allow the exclusion of incidental or consequential damages or limitationson how long an implied warranty lasts so the limitations or exclusions herein may not apply to you These warranties are madeto all Owners inthe chain ofdistribution and Coveragecontinues to subsequent Owners untilthe end of the periods of Coverage Cummins Responsibilities During The Base Engine Warranty Cummins will pay for all parts and laborneededto repairthedamageto the Engineresultingfroma Warrantable Failure Cummins
195. o Section 5 sary Refer to the OEM Service manual Continued 83 9 and 85 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 11 Engine Difficult to Start or Will Not Start Exhaust Smoke Continued Cause Correction Cause Correction Check the air intake system inspectthe injectors for restrictlon Refer to Intake air restriction is high Replace the injectors as necessary Refer to the Injector is malfunctioning E OEM service manual Section 4 OK Verify by rating the Contact a Cummins engine with clean fuel from Authorized a temporary tank Repair Facility Gheckt gt el pimp e linkage adju ae Er LL e Md is not correct Refer to the OEM service manua Valves or injectors adjusted wrong Adjust valves and injectors iubleshooting Symptoms Charts ge TS 12 Cause E Correction Starting procedure is not correct Electricalor manual fuel shutdown binds Air in the fue system verity tne correct starting j Pmeedure Relierio Section o s supoly tank Refer sonog manual Check for loose wires and verify that the solenoid is functioning Check to be sure manual shutoff lever is not binding at the injection pump Refer to the OEM service manual Bleed the fuel system and checkfor leaks Refer to Section 5
196. o Section 5 Check the overflow valve Fuel RE Zu Replace if necessary Refer 9 to the OEM sevice manual Continued Troubleshooting Symptoms Charts B3 9 and B5 9 Series Engines Page TS 22 Section TS Troubleshooting Symptoms Engine Runs Rough ac Misfires Continued Cause Correctlon Put the engine at top deao Fuel Mission pump timing center Check and adjust s not correct r 7 the altimim Refer to Section A LL OK Ka Contact a Cummins Authorized Repair Facility B3 9 and 65 9 Series Engines Troubleshootirig Symptoms Charts Section TS Troubleshooting Symptoms Page TS 23 Engine Speed Surges at Low or High Idle Cause Correction Cause Correction Leve eru Eee Fillthe su tank Refer tothe service manual Replace the malfunctioning Fuel level is low in the tank injector Refer to Section A Injector is malfunctioning Remove the fuel pue Refer to Section A Call brate the fuel pump Adjust the idle speed Refer Fuel injection pump is to Section A malfunctioning OK Contact a Cummins Authorized Bleedthe fuel system and Repair Facility check for leaks Refer to Section 5 Fuel supply line or passage Check the fuel supply line restriction between the fuell or passage for sharp bends pump and the injectors l or restriction Troubleshooting Symptoms Charte B3 9 and 85 9 Series Engines Page
197. o build up around the injector spray holes and piston rings that cancause the valves to stick To avoid damage operate the engine at a higher idle Normal Starting Procedure Page 1 5 Normal Starting Procedure Page 1 6 Parallel E Connection sb8coga Connection B3 9 and 85 9 Series Engines Section 1 Operating Instructions A WARNING A Batteries can emit explosive gases To avoid personal injury always ventilate the compartment before servic ing the batteries To avoid arcing remove the negative battery cable first and attach the negative battery cable last The accompanying illustration shows a typical parallel bat tery connection This arrangement doubles the cranking amperage A CAUTION A When using jumper cables to start the engine make sure to connect the cables in parallel Positive to positive and negative to negative When using an external electrical source to start the engine turn the disconnect switch to the OFF position Removethe key before attaching the jumper cables to prevent un intentional starter engagement This illustration shows a typical series battery connection This arrangement positive to negative doubles the voltage 83 9 and 85 9 Series Engines Normal Starting Procedure Section 1 Operating Instructions Page 1 7 Starting Procedure Matrix Starting Procedure Matrix Automotivellndustrial idie Throttle All pumps abo
198. of the same measurement and strength as the capscrew being replaced Using the wrong capscrews can result in engine damage Metric capscrews and nuis ere identified by the grade number stamped on the head of the capscrew oion ihe surface of the nuts U S Customary capscrews are identified by radial lines stamped on the head of the capscrew The following examples indicate how capscrews are identified Metric M8 1 25X 25 U S Customary 5 16 X 18 X 1 1 21 MB 1 25x ae e 12 Major thread diameter In nl Major thread diameter In inches a Distance between threads In millimeters Number of threads per inch Length In millimeters Length I Inches ed TT NOTES 1 Always usethe 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 10 convert the ft lb value to in Ib to obtain a better torque with an in lb torque wrench Example 6 ft lb equals 72 in lb g 02 nom Capscrew Markings and Torque Values 83 9 and B5 9 Series Engines age V 33 Section V Maintenance Specifications Capscrew Markings and Torque Values Metric Commercial Steel Class 8 8 10 9 12 9 Capscrew Head Markings Body Size Torque Torque Torque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron
199. ol engines Wait 2 to 3 minutes i allowarte von 3 then add mixture to bring level to the top NOTE T systemt a si fillrateof19liters I per inu B3 9 and 85 9 Series Engines Maintenance Procedures at 77 000 km 48 000 mi A CAUTION A Never use water alone for coolant Damage from cor rosioncan be the result of using water alone for cool ant Use a mixtureof 50 percent water and 50 percentethylene glycol antifreeze to fillthe cooling system Coolant Capacity engine only liters U S aal 4B3 9 4BT3 9 7 MAX 1 85 4BTA3 9 7 9 MAX 21 6B5 9 6BT5 9 9 MAX 2 38 8BTA5 9 9 9 MAX 2 61 Jacket water aftercoolersare used on the 4BTA and GBTA engines If a charge air cooler iSused the coolantcapacity isthesameasthenaturally aspirated orturbocharaed onlv engines Cooling System Page 7 7 50 PERCENT 50 PERCENT f WATER WATER 50 PERCENT 50 PERCENT ANTIFREEZE ANTIFREEZE O Vibration Damper Page 7 8 dag00sa 83 9 and 85 9 Series Engines Maintenance Procedures at 77 000 km 48 000 mi A WARNING A Do notremovethe pressure cap froma hot engine Wait until the coolant temperature is below 50 C 122 F Failure to do so can cause personal injury from heated coolant install the pressure cap Operatethe engine until itreaches a iemperature of 80 C 180 F and check for coolant leaks Check the coolant level again to make sure system js full of coolant or that the co
200. olant level has risen to the hot level in the recovery bottle on the system if equipped Vibration Damper Inspect Check the index lines A on the damper hub B and the inertiamember C Ifthe nes are morethan 1 59 mm 1 16 in out of alignment replace the damper 83 9 and B5 9 Series Engines Maintenance Procedures at 77 000 km 48 000 mi Inspect the rubber member for deterioration If pieces of rubber are missing or if the elastic member is more than 3 18 mm 1 8 in below the metal surface replace the damper NOTE Also look for forward movement of the damper ring on the hub Replace the damper if any movement is detected Air Compressor Inspect NOTE All air compressors have a small amount of lubri cating oil carryover that lubricates the piston rings and moving parts When this lubricating oil is exposed to nor mal air compressor operating temperatures over time the lubricating bil will form varnish or carbon deposits If the following inspections are not done the air compressor piston ringswill be affected by high operatingtemperatures and pressures and will not seal correctly Air Compressor Page 7 9 Mo dagrisa Air Compressor 83 9and 859 Series Engines Page 7 10 i Maintenance Procedures at 77 000 km 48 000 mi Air Compressor Discharge Inspection Drain the air system wet tank to release the system ajr pressure Remove the air discharge line from the at compressor ca900vb
201. on TS Troubleshooting Symptoms Lubricating Oil Pressure Low Continued Troubleshooting Symptoms Charts Page TS 39 Cause Lubricating oil viscosity not Lubricating oil high pressure relief valve is malfunctioning or lubricat ing pump pressure regula tor Lubricating oil filler is plugged OK ae Contact a Cummins Authorized Repair Facility Correolion Make aure the correct lubricating oil is being used Refer to Section 5 Remove end inspect the high pressure relief valve Referto the OEM service manual Change the oil and fllter Reter to Section 4 Troubleshooting Sym ptoms Charis Page TS 40 i H Cause Starting procedure is not correct Coolant temperature is below Specification Intake manifold air tempera ture is below specification Fuel rate is low fuel pressure is low intake manifold pressure is low 83 9 and 85 9 Series Engines Section TS Troubicsioodpe Symptoms Smoke White Excessive Correction Verify the correct starting procedure Refer to Section 3 1 Refer to the OEM service manual Referto the OEM servize manual Cheok the fuel pump output pressure pulsation lamper and pressure regulator Replace ihe fuel pump if necessary Cause Injection timing Incorrect E OK Fuel pump return overflow vaiveis malfunctioning Temperature switch failed
202. or the Environmental Protection Agency for guidance about proper handling and disposal of used engine oil Lubricating Oil and Filters Page 4 2 epspgma B3 9 and 85 9 Series Engines Maintenance Procedures at 10 000 km 1609 mil Lubricating Oil and Filters Drain NOTE Ifthe engine is in service the oil drain Interval of 10 000 km 6000 mi 250 hours or 3 months or approved extended interval from the table in Section 2 must be used Change the oit filters to remove the contaminants sus pended In the oil NOTE Drain the oil only when it is hot and the contami nants are in suspension A WARNING amp To avoid personal injury avoid direct contact of hot oil with your skin 17mm Operate the engine until the water temperature reaches 60 C 140 F Shut the engine off Remove the oil drain plug NOTE Use a container that can hold at least 20 liters t5 qt of oil 83 9 and 85 9 Series Engines Lubricating Oil and Filters Maintenance Procedures at 10 000 km 6000 mi Page 4 3 Remove 90 to 95 mm Filter Wrench Clean the area around the lubricating oil fitter head Re move the filter Clean the gasket surface of the filter head NOTE The o ring can stick on the filter head Make sure it is removed before installing the new filter Install A CAUTION A A six cylinder oil filter can be used on a four cylinder engine Do not use a four cylinder oil filter on a six cylinder engine Use of a
203. ot touching the tensioner must be replaced Drive Belts Page 6 11 fagblse ea200ke Drive Belts Page 6 12 B3 9 and B5 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mi With the drive belt removed check to be sure that the tensioner pulley rotates freely 83 9 and 85 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mi Measure the clearance between the tensioner spring case and the tensioner arm to verify wear out and uneven bear ing wear If the clearance exceeds 3 mm 0 12 in at any point the tensioner has failed and must be replacedas a complete assembly Experience has revealed that tension ers generally will show a larger clearance gap near the lower portion of the spring case resulting in the upper portion rubbing against the tensioner arm Always replace the belt when the tensioner is replaced Below is a breakdown of the tensioner 1 Tensioner cap 2 Tensioner arm 3 Spring case 4 Tensioner pulley 5 Clearance gap Drive Belts Page 6 13 Drive Belts Page 6 14 d MATE 83 9 and B5 9 Series Engines Maintenance Procedures al 38 000 km 24 000 mi Inspect the tensloner for evidence of the tensionsr arm contactingthetensioner cap Ifthereis evidence of thetwo areas making contact the pivot tube bushing has failed and the tensloner must be replaced 83 9 and 65 9 Series Engines Maintenance Procedures at 77 000 km 48 000 mi Pa
204. ove een Be ae eue 5 2 Fuel Injection Pump Rotary A 46 Install E A 51 Preparatory A 46 Remove seeeseern A47 Fuel Injection Pumps In Line A60 Install Lu wa ABS Preparatory A 60 Remove A 60 Fuel Lift Bump EE RM CUT Gi Fuel Pump AUS siseuscsvcaveovctenssstseoveansesacesvescourves UN Ers Recommendations and Specifications Fuel Recommendatlons Fuel Shutoff Valve Clean Fuel Supply Lines Install Preparatory Remove Fuel System Overview General Information Fuel Water Separator MaintenanceCheck General Safety Instructions Sen Important Safety Notice Di How to Use the Manual General Information lilustrations General Info mation Injector nn Clean Install Preparatory UE index Page 4 bassen asina ene GE een caries tertie Remove ateerries eeenesgiis eddie edge sidus RE RE ET TES Lubricating Oil and Fiere Lubricating O oil Cooler Clean san ve CATATTTOE Preparatory marin AR 103 Pressure Test me 106 Remove rerni A104 Lubricating Oil Level 5 Maintenance Check eege EEN miss 33 Lubricating Oil Pregsure Regulator Main Ri i He rei A 100 Clean en EE eene mens ATOT A 102 Preparatory ww A 100 Remove A 100 Lubricating OU Recommendations and Specitiations V 2
205. ow through the i filter to locate the source of the restriction Refer to Section 5 Inspect the fuel retur lir for restrictions Refer 1 OEM service man al Check the overflow vatye Replace 1rnecessary Refer to the OEM service manual B3 9 and 85 9 Series Engines Section TS Troubleshooting Symptoms Cause Fue lift pump is malfunc tioning intake manifold air temper ture is above specification Fuel temperature ig above specification n Troubleshooting Symptoms Charts Engine Power Output Low Continued Correction Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump H necessary Refer to the OEM service manual Check intake air tempera ture Refer to Section A Fill the fuel tanks Turn off or neie the fuel heaters and check the fuel cooler Refer to the OEM service manual Cause Fuel injection pump timing Is not correct OK Exhaustsystem restriction Is above sp cification OK Ke Turbocharger wastegate is malfunctioning if equipped Turbocharger is worn or malfunctioning Continued Page TS 17 Correction Putthe engine attop dead center Gheck and adjust the fuel timing Refer to the OEM service manual i rform the xida lon e eter t service manual Check the waste gate for corre
206. pegt the air cooler for internal and external Charge air cooler restricted restriction Replace the if equipped restrictedcooler ifneces sary Refer to the OEM service manual Fuel shutoff lever mechant Check or replace shutoff cal partially engaged lever in run position Continued roubleshooting Symptoma Chart age TS I Cause a Air leakhetwaen the turbocharger and the inta manifold Exhaust leaks at the H Engine Power O Correction Check for leaks in the air crossover tube charge ai air 0868 cooler connections manifoldor turbocharger Air inthe fuel system or through holes in the manifold cover and repair or replace if nacessai Refer to the OEM service manual r Check and correct any leaks in the exhaust H i manifold or turbocharger gaskets Check for a cracked exhaust manifold Refer to the OEM service manual d H Check for air in the fuel system Completely bleed air from the fuel system Refer to the OEM service manual 63 9 and 85 9 Series Engines Section I T utputjLow Continued Cause Fuel supply is not ad equate Fuel return restrictian excessive Fuel pump overltow valve i j malfunctioning Continuad diesel fuel Reter to Section KEE Symptoms t Correction Ara Einen ta temporary tanklot No 2 Check the fl
207. placement an Reversethe position of the pin so the slot of the pin will fit VA over the timing tooth in the pump y P S Be d Install and secure the pin with the access plug B3 9 dB i gines Section A n 3 Repair and Replacement A CAUTION A The fuel pump drive inside diameter and the shaft out side diameter must be clean and dry before installing the shaft into the gear A nonpetrolum based cleaner can be usedto clean the drive gear and shaft mounting surfaces Failure to do so will result in gear slippage in the retarded direction Clean the drive gear and shaft with a nonpetrolurn based cleaner NOTE If the mounting flange o ring has a colored stripe itcan not be reused Replace with a new o ring Further more do not lubricate the new type o ring Instead lubri cate the seating area of the gear housing Lubricate the mounting flange of the fuel injection pump with clean lubricating engine oil NOTE The P7100 fuel injection pump driveshaft has a provision for a Woodruff key however it is not requiredfor the P7100 drive gear Fuel Injection Pumps In Line Page A 67 Fuel Injection Pumps In Line 83 9 and B5 9 Series Engines Page A 68 Section A Adjustment Repair and Replacement e ide fhe pump shaft through the drive gear and position tHE pimp flange onto the mounting studs Push the pump forward until themounting flangeando ring are properly fitted into the gear housing bore If
208. placement i I Injector i Preparatory Thoroughly clean around the injectors Disconnectthe high pressure fuel lines e Disconnect the fuel drain manifold Remove TEM 16 mm and 24 mm Box Wrenches A CAUTION A The Injector must not rotate inthe bore of the cylinder head This will damage the cylinder head Removethe injectors NOTE Hold the injector body with a 16 mm wrench while loosening the hold down nut with a 24 rnm end wrench 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Clean Injector Bore Brush Part No 3822509 Clean the injector nozzle bore using service tool No 3822509 Install Remove the injector hold down nut and apply a coat of anti seize compound to injector surface A Avoid getting anti seize compound in the fuel drain hole B Injector Page A 37 tigboea ANTI SEIZE LUBRICANT fl9numa Injector B3 9 and 85 9 Series Engines Page A30 Section A Adjustment Repair and Replacement Eh Install the hold down nut on the injector body Boia ss ti9nuha an Install a new O ring into the recessed groove on the top of OS the hold down nut Make sure the O ring 3s not cut or twisted when installing Bosch and Stanadyne NOTE CAV injectors retain the O ring inside the hold down nut ligorna B3 9 and 85 9 Series Engines Injector Section A Adjustment Repair and Replacement Page A 39 Apply a light co
209. placement Page A 2 Remove n 24 mm K Removethe retaining nut filter head adapter and sealing washers Oe Installin reverse order of removal Torque Value 32 Nem 24 ft lb px 1s a e l fl numa Fuel Lift Pump Preparatory Clean debris from around the lift pump Disconnectthe fuel supply lines Fuel Lift Pump 83 9 and 85 9 Series Engines Page A 24 T i Section er Adjustment Repair and Replacement i H Clean Piston Style Clean the mounting surface on the cylinder block Diaphragm Style 10 mm Remove the lift pump Clean the mounting surface on the cylinder block dp9bkea B3 9 and 85 9 Series Engines Fuel Lift Pump Section A Adjustment Repair and Replacement Page A 25 Install Diaphragm Style 10 mm Installthe lift pump and a new gasket Torque Value 24 Nem 18 ft Ib Connectthe fuel lines dp9gkha 1 Piston Style GE A CAUTION A IY Alternately tighten the mounting capscrews AS the capscrewsare tightened the fuel transfer pump plunger Q is pushed into the pump Failure to tighten the cap i SC evenly can result in the plunger being bent or roken Install the pump Torque Value 24 Nem H8 ft lb Connect the fuel lines i Injector Supply Lines High Pressure B3 9 and 85 9 Series Engines Page A 26 d i Section A Adjustment Repair and Replacement PO at al eel I injector Supply Lines High Pressure Preparatory Clean a
210. ply line and return line Remove the AFC air line oil line s fuel shutoff solenoid and control linkage Label and disconnect wiring Clean debris B3 9 and B5 9 Series Engines Fuel Supply Lines Page A 18 Section A Adjustment Repair and Replacement ST Fuel Supply Lines Preparatory Low Pressure Fuel Line Thoroughly clean all fittings and components before re moval Makesure that the debris water steam or cleaning solution does not reach the inside of the fuel system FT ry ey 4 2 E ES EUN i Ee N W pe AA PEN n E SE dr n PDD IAN MI Remove Diaphragm Style Lift Pump 14 mm 17 mm Sy Disconnect the fuel line from the lift pump and filter head Usetwo wrenchesto disconnectthe linefrom the lift pump B3 9 and B59 Series Engines Fuel SET Lines Section A Adjustment Repair and Replacement ge A 19 Piston Style Lift Pump 14 mm 17 mm 20 mm Disconnect the fue line from the lift pump and filter head Use iw wrenches to disconnect the line from the lift pump Install Diaphragm Style Lift Pump 14 mm 17 mm Installthe fuel line to the lift pump and liter head Use two wrenches to tighten the connection to the lift pump Torque Value 24 Nem 18 ft IbT a NOTE Do not overtightenthe connection Fuel leaks can result from overtightening ft9hdha Fuel Supply Lines Page A 20 EAE NC EI A ic ENDS mee DES LN ER
211. pressure Refer to the OEM service manual Lubricatirg oil pressure is above specification OK 3 Contact a Cummins Authorized Repair Facility l Troubleshooting Symptoms Charts B3 9 and 85 9 Series Engines l Section TS Troubleshooting Symptoms Page TS 38 i i GERS e i Lubricating Oil Pressure Low Cause Correction Cause Correction Lubricatingoil level is lo Kee CT d E buts DS ubricating oi islow J lubricating oil Refer to Lubricating oil is diluted dipstick rain caps or oi Section 3 with water T caps Cre Oe eer Pe OK manual Check the oil pressure yitch or gauge for corre operation and location Refer to the OEM service manual Lubricating ol pressure sensor or gauge is mal functioning or is not in the correct location Changeh e oil and filters Use the oil type recom mended In Section V of the engine operation and maintenance manual Lubricating cil does net maet specifications for operating conditions SE heoil Reter to Got Vie di ection 4 Ifthe oil be EE diluted comes diluted again contact an Authorized Cumas anal Facility l Lubricating oil leak exter Inspectthe engine for externaloil leaks Tighten the capsorews pipe plugs and fillings Replace gaskets ifnecessary Refer to the OEM service manual nal Continued 83 9 and 85 9 Series Engines Secti
212. ps In Line 83 9 and B5 9 Series Engines Page meee el Section A Adjustment Repair and Replacement 30 mm P Pump LA Removethe gear cover access cap Remove the nut and washer from the fuel pump shaft 75 mm T Bar Ed Pull the fuel pump drive gear loose from the shaft B3 9 and 85 9 Series Engines Fuel Injection Pumps In Line Section A Adjustment Repair and Replacement Page A 63 15mm Remove the four mounting nuts Remove the fuel pump h tall Engine Barring Tool Part No 3824591 Make sure theenginehascylinder No 1 attopdeadcenter The barring gear inserts into the flywheel housing and engages the flywheel ring gear The engine can then be rotated by hand using a 112 inch ratchet or breaker bar Fuel Injection Pumps In Line Page A 64 RI B3 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Injection Pump Timing The injection pump also has a timing pin located in the governor housing to positionthe pump shaftto correspond with top dead center for cylinder No 1 24 mm Remove the access plug 83 9 and 65 9 Series Engines Fuel Injection Pumps In Line Section A Adjustment Repair and Replacement Page A 65 Remove the timing pin If the timing tooth is not aligned with the timing pin hole rotate the pump shaft until thefiming tooth aligns Fuel Injection Pumps In Line 83 9 and 85 9 Series Engines Page Ne RA p Section A Adjustment Repair and Re
213. pscrews Torque Value A 24 Nem 18 ft lb Torque Value B 43 Nem 82 ft lb D eh9csha B3 9 and B5 9 Series Engines Section D System Diagrams Page D a Section D System Diagrams Section Contents Flow Diagram Air intake System General Information o ee Flow Diagram Compressed Air System General Information Flow Diagram Cooling System General NOrmal eee c Flow Diagram Exhaust System uooczios eI Ete aae aa act SE ER ER enar Pe PUR ERN ee een RENT deae EUR General Information esee sesenta nnn nnne Flow Diagram Fuel System General Information Flow Diagram Lubricating Oil System General Information nn System Diagrams Overview nn G n ral Info MAO BEE 83 9 and 85 9 Series Engines Page D b Section D System Diagrams THIS PAGE LEFT INTENTIONALLY BLANK B3 9 and B5 9 Series Engines System Diagrams Overview Section D System Diagrams Page D 1 System Diagrams Overview General Information The following drawings show the flow through the engine systems Although parts can change between different applications and installations the flow remains the same The systems shown are Fuel System Lubricating Oil System Coolant System e Intake Air System e Exhaust System e Compressed Air System Knowledge of the engine systems can h
214. que Vaiue 15 to 20 Nem 133 io 177 in lb A CAUTION A The pump shaft must be unlocked after installation to prevent pump damage 13mm If reinstallingthe removed pump installthe pump onto the engine Rotatethe pumpto alignthe scribe marks Tighten the three mountitig nuts Torque Value 24 Nem 18 ft lb 83 9 and 85 9 Series Engines Fuel Injection Pump Rotary Section A Adjustment Repair and Replacement Page A 53 13 mm If installing a new or rebuilt pump without scribe marks take up the gear lash by rotating the pump against the direction of drive rotation Tighten pump retaining nuts Torque Value 24 N m 18 ft Ib If a new or rebuilt pump is being installed permanently an mark the injection pump flange to matchthe mark on the Os gear housing j Fuel Injection Pump Rotary 83 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement 14 mm h Loosenthe CAV pump lock screw and positionthe special washer behind the lock screw head Tighten the pump lock screw Torque Value 20 Nem 15 ft lb 3 8 Inch Loosenthe Stanadyne DB4fuel injection pump lock screw and position the special washer behind the lock screw Tighten the lock screw B3 9 and B5 9 Series Er i Fuel Injection num Rotar Section A Adjustment t and Replacement age A 5 10mm NOTE On the Bosch pump the special washer is wired is to the pump and must be installed under the lock screw
215. r Reuse eege ee ARE 47 Charge Air Cooler CAC M 4 a Eileen DEE DEER Ee 4 9 Inspect for REUSE ns denses 4 8 Lubricating OFF and He CC 4 2 re EE 4 2 cM EE REI NEUE 4 5 j Bene cake sz CE 4 3 R MOVe ns c M 4 3 Maintenance Procedures Overview nes cessere m a re nk ER RR RR A ERR RI ER a 8 4 1 General Information rara aa eoo aie ui cierra eu cran rn Eege da de ace EN ERE a EE ERN RE RNA ERR CER KR Ea EE RE RE EUREN 4 1 83 9 and B5 9 Series Engines Page 4 b Maintenance Proceduresat 10 000 km 6000 mi THIS PAGE LEFT INTENTIONALLY BLANK 83 9 and B5 9 Series Engines Maintenance Procedures Overview Maintenance Procedures at 10 000 km 8000 mi Page 4 1 Maintenance Procedures Overview General Information A WARNING A Some state and federal agencies have determined that used engine oil can be carcinogenic and cause repro ductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil Protect the environment Handling and disposal of used engine oil is subject to federal state and local laws and regulations Use authorized waste disposal facilities including civic amenity site and garages providing authorized facilities for receipt of used oil If in doubt contact state and environmentalauthorities
216. ranty on Consumer Productsinthe United States is a LIMITED warranty CUMMINS IS NOT RESPONSIBLE FORINCIDENTALOR CONSEQUENTIAL DAMAGES Any impliedwarranties applicableto Consumer Productsinthe United States terminate concurrently with the expiration of the express warranties applicable to such products Inthe United States some states do not allow the exclusion incidental or consequential damages or limitations on how Jong an implied warranty lasts so the limitations or exclusions herein may not apply to you These warranties are made to all Owners inthe chain of distribution and Coveragecontinues to all subsequent Owners until the end of the periods of Coverage 3381327 Cummins Warranty B3 9 and 65 9 Series Engihes Page W 26 Section W RUD Cummins Responsibilities During The Base Engine Warranty Cumminswill payforall parts and labor needed to repairthedamage to the Engineresulting from a Warrantable Failure Cummins will pay for the lubricating oil antifreeze filter elements belts hoses and other maintenance items that are not reusable due to the Warrantable Failure Cummins will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure Cummins will pay reasonable costs for towing a vehicle disabled by a Warrantable Failure to the nearest authorized repair location when necessary to make the repair for the first year from the date of delivery of the Engi
217. rd Modulating Thermostat Start 83 C 181 F Fully Start83 C 1819F Fully Stan 83 C 1 81 F Fully Range Open 85 C 203 F Open 85 C 2039F Open 95 C 203 F Pressure Cap 104 C 220 F Systems 103 kPa 15 psi 103 kPa 15 psi 103kPa 15 psi 99 C 210 F Systems 48 kPa 7 psi 48 kPa 7 psi 48 kPa 7 psi B3 9 and 85 9 Series Engines Section V Maintenance Specifications Cooling System Data automotive Coolant Capacity engine only Standard Modulating Thermostat Range Pressure Cap 104 C 220 F Systems 99 C 210 F Systems B3 9 7 liters 7 4 qt Start 83 C 181 F 103 kPa 15 psi 48 kPa 7 psi Specifications Page V 9 B59 10 5 liters 11 1 qt Fully Open 95 C 203 F 103 kPa 15 psi 48 kPa 7 psi Specifications 83 9 and B5 9 Series Engines Page V 10 Section V Maintenance Specifications Air Intake System 4B Air intake System nonautomotive 4653 9 4BT3 9 4BTA3 9 Maximum Allowable Intake Restriction at Rated Speed 508 mm H 0 635 mm HO 635 mm HO and Loaded with Dirty Air 20 in H 25 in H 6 25 in H Filter Element 6B Air Intake System nonautomotive 685 9 6BT5 9 6BTA5 9 Maximum Allowable Intake Re striction at Rated Speed and 508 mm H O 635 mm ec 635mm HO Loaded with Dirty Air Filter Ele 20 in H 6 25 in HOI 25 in H ment 83 9 and 85 9 Series Engines Section V Maintenance Specifications Air Intake System Data automotive Maximum
218. re beginningany repair work Disconnectthe air starting motor if equipped to preventaccidental engine starting Put a Do Not Operate tag in the operators compartment or on the controls Use ONLY the proper engine barring techniques for manually rotating the engine Do not attemptto rotatethe 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 e 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 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 pressureoil or fuel can cause personal 9 03 safety 83 9 and 85 9 Series Engines General Safety Instructions Section i Introduction Page i 7 injury e To on nt suffocationand frostbite wear protective sl tt C LY iscon 3 tfi u liquid refrige it fr lines in a well ated area To protect the environment 3 id ofrige in sy n nustleprop y e If and f
219. reparation du produit endommag en raison d une panne justifiable Cummins prend en charge l huile l antigel les cartouches de filtre ainsi que d autres piecesou fournitures d entretien non r utilisables en raison d une panne sous garantie Cummins paie la majeure partie des frais de deplacement des m caniciens ce qui comprend les frais de repas les frais kllom triques et lesfraisd hebergement dansle cas o une reparationdoit tre effectu e sur leslieuxdelapanne Cummins prend en charge une partie des frais de main d oeuvre lorsqu il est n cessaire de d poser et de remonter le moteur lors d une panne sous garantie Pendant la garantie etendue des principaux composants Cummins r glera la reparation ou s il pr f re le remplacement de la pi ce couverte d fectueuse et de toute piece couverte endommag e par une panne justifiable de la piece couverte d fectueuse 83 9 and 85 9 Series Engines Cummins Warranty Section W Warranty Page W 21 Responsabilit s du proprietaire Pendant la garantie de base du moteur Lepropri taire doit r gler l huile de graissage l antigel les l ments filtrants et lesautresarticlesd entretien remplac s au cours des reparations effectuees dans le cadre de lagarantie a moins que ces articles ne puissent plus tre utilis s en raison d une panne justifiable Pendant la garantie etendue des principaux composants Le proprietaireest responsable de tous les frais de la main d oeuvre n ces
220. rge air cooler has been thoroughly cleaned of all oil and debris with solvent wash the charge air cooler internally with not soapy water to remove the remaining solvent Rinse thoroughly with clean water Blow compressed air into the charge air cooler in the op positedirection of normalairtlow untilthe charge air cooler is dry internally Referto the vehicle manufacturer s instructions for instal lation procedures B3 9 and 85 9 Series Engines Maintenance Procedures at 10 000 km 6000 mi Air Cleaner Restriction Maintenance Check Maximumintake air restrictionis 635 mm 25 0 in of water for turbocharged engines Naturally aspiratedengines have a maximum restriction of 510 mm 20 0 in of water Turbocharged engines must be operated at a rated rom and full load to check maximum intake air restriction Re placethe air cleaner element when the restriction reaches the maximum allowable limit or clean according to the manufacturer s recommendations NOTE Follow the manufacturer sinstructionswhen clean ing or replacingthe air cleaner element Checktheair cleaner service indicator if equipped Change the filter element when the red indicator flag 2 is at the raised position in the window 1 After the air cleaner has beenServiced pushthe button 3 to resetthe service indicator NOTE Never operate the engine without an air cleaner Intake air must be filtered to prevent dirt and debris from entering the engine and ca
221. ricatingoil Change lubricating oil e Change lubricating oil e eplace lubricating oil filter e Replace fuel filter 5 Inspect air cleaner e Replace lubricatingoil e Replace lubricating oil filter filter e Replace fuel filter 6 Replace fuel filter 5 Adjust valve lash clear Change antifreeze e Inspect air Intake sys anca 2 e Inspect air cleaner tem e inspect air cleaner Check charge air cooler e Check antifreeze 3 Inspect intake system 4 e Check charge air Check oharge air e Inspect Intake system cooler 4 cooler 4 Inspect fan hub e Check antifreeze 3 e Inspect belt tensi nar inspect fan hub e Check belt tension e Inspect belt tensio Inspect damper Check helt tensinn 15 secuon to f nd the spec ir o i change interval for ing ual applications rilustmants ta he nerfarmiJ at 77 000 km 48 000 m lr t rvals or every 8th oil vals for industrial engines ical composition of GM6038 A must be used The change interval is 2 years or 2ze is essential for freeze o srheat and corrosionprotection i whichever occurs first m 12 000 mi 500 hours or 6 months whichever occurs first LI Maintenance Schedule _B3 9 and B5 9 Series Engines Page 2 4 E Section 2 Maintenance Guidelines Lubricating Off Drainllnterval Refer to the following flowchart to determine the maximum recommended oil change and filter change intervals in kilometers m
222. ries Standard Repair Times 3810305 6B Series Standard Repair Times 3666025 Specifications Manual Service Literature Orderlng Location Page L 2 Service Literature Ordering Location General Information Region United States and Canada UK Europe Mid East Africa and Eastern European Countries South and Central America excluding Brazil and Mexico Brazil and Mexico Far East excludin Australia and New Zealand GD loc 83 9 and 85 9 Series Engines Section L Service Literature Ordering Location Cummins Distributors Or Contact 1 800 DIESELS C 800 343 7357 Cummins Engine Co Ltd Roval Oak Wav South Daventry Northants NN 11 5NU England Cummins Americas Inc 16086 NW 52nd Avenue Hialeah FL 33104 Cummins Engine Co Inc international Parts Order Dept MC 40931 Box 3005 Columbus IN 47202 3005 Cummins Diesel Sales Corp Literature Center 8 Tanjong Penjuru Jurong industrial Estate Singapore B3 9 an d 85 9 Series Engines Service Literature Ordering Location Section L Service Literature Page L 3 Region Ordering Location lit and New Zealand Cummins Diesel Australia Maroondah Highway P O B 139 Ringwood 3134 Victoria Australia Obtain current price information from your local Cummins Distributor Component Manufacturers Addresses 83 9 and B5 9 Series Engines Page M 8 Section M Component Manufacturers NOTES 83 9 and B5 9 Series Engines Componen
223. rrect R I Inspect the injectors and Injectors worn or maltunc replace any malfunctioning tioning eT injectors Refer to Section H OR Contact a Cummins Authorized Repair Facility B3 9 and B5 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 33 Fuel or Lubricating Oil Leaking From Exhaust Manifold C Correction Cause Correctlori Check the air intake system Check the turbocharger for oil seals and for leaks Turbocharger oil seal is Intake air restriction is high for restriction Refer to Section 4 leaking Refer to Section A OK OK 3 Contact a Cummins Injector needle Inspect the injectors Authorized sticking Replace if necessary Refer Repair Facility to Section A OK L Rem wv T3 Jrbocha gel Turbocharger dra n line s drail 2 d check for restr ctad ft restriction Clean or replace the drain IIne Troubleshooting Symptoms Charts Page TS 34 i d cause lubricating ail OK Lubricating ail sludge Is excessive OK w Check for coolant in the oil Coolant is leaking into the 1 83 9 and 85 9 Series Engines Section Es Troubleshooting Symptoms i Lubricating Oil Contaminated Correction Cause Correction Inspect the injectors njgctor needle valve slicking Replace leie e Refer Refer to the Lubricating Oil Contaminated symptom
224. rs 174 qt Standard la 1c Thermo Start83 C 1 F Fully Start gt 181 F ly stat Rangi Open 95 C 203 Open 5 203 F Pressure Cap 104 C 220 F Systems 103kPa 15 psi 99 C 210 F Systems 48 kPa 7 psi 6B Cooling System Data nonautomotive 103kPa 15 psi 48 kPa 7 psi 685 9 10 5 liters 11 1 qt 6BT5 9 gt _ Coolant Capacity engine only 10 5 liters 11 1 qt Standard Modulating Thermostat Range Open 85 C 203 F Open 95 C 20 Pressure Cap 104 C 220 F Systems 103 kPa 15 psi 99 C 210 F Systems 48 kPa 7 psi 103 kPa 15 psi 48 kPa 7 psi Specifications Page E 17 4BTA3 9 9 7 liters 10 2 qt Start 181 F Fully Open 3 C C3 F 103 kPa 15 psi 48 kPa 7 psi 6BTA5 9 145 liters 15 3 qt Start 83 C 181 F Fully Start83 C 181 Kai Start 83 C Dart Fully Open 95 C 203 F 103 kPa 15 psi 48 kPa 7 psi Specifications Page E 18 Cooling System Data automotive Coolant Capacity engine only Standard Modulating Thermostat Range Pressure Cap 104 C 220 F Systems 99 C 210 F Systems B3 9 7 liters 7 4 qt Start 83 C 181 F 103 kPa 15 psi 48 kPa 7 psi 83 9 and B5 9 Series Engines Section E Engine Identification B5 9 10 5liters 11 1 qt Fully Open 85 C 203 F 103kPa 15psi 48 kPa 7 psi 63 9 and B5 9 Series Engines Section E Engine identification Air IntakeSystem 4B Air Intake System non
225. rsect with transverse cracks are notacceptable Replacethe belt if it is frayed or has pieces of material missing Refer to SectionAfor belt adjustment and replacementprocedures Belt damage can be caused by Incorrecttension fafbisa e Incorrect size or length Pulley misalignment e Incorrect installation e Severe operating environment Oil or grease on the side of belts Fan Cooling B3 9 and 5 9 Series Engines Page 3 8 Section 3 Maintenance Procedures at Dally Interval O Fan Cooling Maintenance Check 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 end cause personal injury or property damage NOTE Rotate the crankshaft by using the engine barring gear An inspectionof the coolingfan is requireddaily Check for cracks loose rivets and bent or loose blades Check the fan to make sure it is securely mounted Tighten the cap screws if necessary Replace any fan that is damaged 83 9 and 85 9 Series Engines Maintenance Procedures at 10 000 km 6000 mi Page 4 a Maintenance Procedures at 10 000 Kilometers 6000 Miles 250 Hours or 3 Months Section Contents Page Air Cleaner Restriction INE TE MMC TM ccm 4 11 Maintenance Check eene eege SE 4 11 Ludlcc3unq 4 7 Inspect fo
226. rt up after an extended period of no engine operation Vehicle fuel tank has run empty 83 9 and 85 9 Series Engines Fuel Supply Lines Maintenance Proceduresat 19 000 km 12 000 mi Page 5 5 Low Pressure Lines and Fuel Filter s 8 mm Open the vent screw Operate the priming button on the lift pump until the fuel flowing from the fitting is air free Tighten the bleed screw Torque Value 9 N m 80 in Ib Fuel su Page 5 pply Lines ip9lvva B3 9 and B5 9 Serles Engines Maintenance Pmcedures at 19 000 km 12 000 mi Injection Pump Venting 8 mm Bleed the Lucas CAV pump at the location shown in the illustration Airlfuel can be pumped from this location with the hand lever on the lift pump if the fuel solenoid valve is energized 83 9 and B5 9 Series Engines Maintenance Procedures at 19 000 km 12 000 mi A WARNING amp It is necessary to put the engine in the RUN position Becausetheenginecanstart be sure to follow all of the safety precautions Use normal engine starting proce dure A CAUTION A When using the starting motor to vent the system do not engage itfor more than 30 seconds at atime Walt 2 minutes between engagements Air can vented from both pumps through the fuel drain manifold line by operating the starting motor Injector Supply Lines High Pressure Vent A WARNING amp While ge injectors keep hands and body parts away from the injector nozzle F
227. ructions A WARNING A Stein ishighly flammable and explosive Keep flames sparks and arcing switches away from starting uid A WARNING A Do not breathe starting Huid fumes Startingtiuid fumes can be hazardous to your health A CAUTION A Do not use excessive amounts of starting fluid when starting an engine The use of too much starting fluid will cause damage to the engine e Spray starting fluid into the air cleaner intake while another person cranks the engine Cold Weather Starting Aids 83 9and B5 9 Series Engines Page 1 12 Section 1 Operating Instructions Grid Heater A WARNING A 8 To avoid personal injury and property damage never use sta ting fluid if the grid heater option is used Starting fluid which contains ether can cause an exp a A grid heateris available that improves cold weather starting characteristicsby heatingthe intake air It is available for B Series automotiveratings with an in lineinjection fuel pump andindustrial jacket water aftercooled with a Bosoh in iineinjecilon pump it can also serve to reduce White smoke iiit isenergized during cold ambienttemperatures while the engine is at idle Theelectricgrid heateroperatesinapreheatandpostheat mode The length of heateron timeisafunction f the engine temperature beet Miren Ifthe engine ambientair temperature is greater than 7 C 45 F the electric grid air heater system will not be activated ifthe engine ambient air temperature is
228. s Branch Cummins Southeastern Power Inc 2671 Edison Avenue Ft Myers FL 33902 Telephone 941 337 1211 FAX 941 337 5374 Jacksonville Branch Cummins Southeastem Power Inc 755 Pickettville Rd Jacksonville FL 32220 Telephone 804 378 1902 FAX 904 378 1904 Hialeah Miami Branch Cummins Southeastern Power Inc 9900 N W 77th Avenue Hialeah Gardens FL 33016 Telephone 305 821 4200 FAX 305 557 2992 Ocala Branch Cummins Southeastern Power 321 Southwest 52nd Ave Ocala FL 34474 1892 Telephone 352 861 1122 FAX 352 861 1130 B3 9 and B5 9 Series Engines Section S Service Assistance Orlando Branch Cummins Southeastern Power inc 4020 North Orange Blossom Trail Orlando FL 32810 Telephone 407 288 2080 FAX 407 290 8727 Tampa Branch Cummins Southeastern Power Inc 5912 E Hillsborough Avenue Tampa FL 33610 Telephone 813 626 1101 FAX 813 628 4183 Georgia Atlanta Distributor Cummins South Inc 5125 Georgia highway 85 College Park GA 30349 Telephone 404 763 0151 FAX 404 786 2132 Albany Branch Cummins South Inc 1915W Oakridge Drive Albany GA 31707 4938 Telephone 912 888 6210 FAX 912 883 1670 B3 9 and B5 9 Series Engines Section S Service Assistance Atlanta Branch Cummins South Inc 100 University Avenue S Ww Atlanta GA 30315 2202 Telephone 404 527 7800 FAX 404 527 7832 Augusta Branch Cummins South Inc 1255
229. saire a lar paration du moteur v compris lesfraisde main d oeuvre pour d monter et r installer le moteur Lorsque Cumminschoisit der parer une pieceplut t que de la remplacer le proprietairen est pas responsable de la main d oeuvre n cessaire a ia reparation de la piece Le proprietaire supporte les frais occasionn s parle remplacement des piecesexcept pour la piece d fectueuse sous garantie et toute piece garantie dont la deterioration a t provoqu e par une panne sous garantie de la piece defectueuse sous garantie Le proprietairesupporteles frais de remplacement de l huile de l antigel des cartouches de filtre ainsi que des autres pieces ou fournitures lors d une reparation en raison d une panne sous garantie PENDANT LA P RIODE DE GARANTIE DE BASE DU MOTEUR ET DE GARANTIE ETENDUE DES COMPOSANTS PRINCIPAUX Le proprietaire est responsable de l utilisation et de l entretien du moteur comme il est sp cifi dans le manuel d utilisation et d entretien Cummins Le proprietaire doit galement pouvoir prouver que tous les travaux d entretien recommand s ont t effectu s Avant la date d expiration de la garantie en vigueur Ie proprietaire doit avertir un concessionnaire Cummins un concessionnaireagr ou un autre site de reparation homologue de toute panne sous garantie et pouvoir confier le moteur afin qu il puisse tre r par Les sites de reparation aux Etats Unisainsi qu au Canada sont num r s dans le repertoire
230. sses resulting from a BEE 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 overspeeding lack of maintenance of lubricating cooling or intake systemes improper storage starting warm up run in or shutdown practices unauthorized modifications cf the Engine Cummins is also not responsiblefor fallures caused by incorrect oil or fuel or by water dirt or other contaminants in the fuel or oil This warranty does not apply to accessorieswhich bearthe name of another company Such non warrantedaccessories include but are not limited to alternators starters fans air conditioning compressors clutches filters transmissions torque converters vacuum pumps power steering pumps and air compressors Excessive oil consumption for B series engines is covered for the duration of the coverage or 100 000 miles 160 935 kilometers or 7000 hours from the date d delivery of the Engine to the first user whichever of the three occurs first Before a claimfor excessive ail consumption Will be considered Owner must submitadequate dooumentation to show that consumption exceeds Cummins published standards Failures of belts and hoses supplied by Cummins are coveredfor the first year from the date of delivery of the Engine to the first user Parts used to repair a Warrantable Fai
231. stall M 3 8 Inch Square Drive an Lift the tensioner and install the belt Service Tip If difficulty is experienced installingthe drive belt the belt seems too short position the belt over the grooved pulleys first then while holdingthe tensioner up slide the belt over the water pump pulley 17800012 B3 9 and B5 9 Series Engines Water Pump Section A Adjustment Repair and Replacement Page A 7 10 mm 13mm ES install the four capscrews fan and spacer 10 mm Wrench Torque Value 24 Nem 18 TO 13 mm Wrench Torque Value 43 Nem 32 ft Ibi VAS as Water Pump Preparatory A WARNING it is toxic Keep away from children and pets If not D a dispose c in cordance with loc envi niali d ti Drain the coolant Water Pump 83 9 and B5 9 Series Engines Page A 8 Section A Adjustment Repair and Replacement Remove Remove the drive belt 13 mm Remove the two capscrews and water pump 83 9 and 85 9 Series Engines Water Pump Section A Adjustment Repair and Replacement Page A 9 Clean Clean the sealing surface on the cylinder block Clean o ring sealing surface on the water pump housing INI Install the o ring onto the water pump housing C IN VAS wpSrina Water Pump Page A 10 83 9 and 85 9 Series Engines Section A Adjustment Repaiq and Replacement Install to UE SE a ee 10 mm Install the water putnp Torque Value 24 Nem 18
232. t Repair and Replacement Page A 59 Bleed all air from the fuel system If necessary adjust the idle speed Fuel Injection Pumps In Line 83 9 and 85 9 Series Engines Page A 60 Section A Adjustment Repair and Replacement Fuel Injection Pumps In Line Preparatory e Clean debris e Remove all fuel lines e Remove control linkage Remove fuel shutoff solenoid e Remove AFC air line Remove oil line s Remove A CAUTION A A diesel engine can nottolerate dirt or water inthe fuel system A tiny piece of dirt or a few drops of water In the injection system can stop the unit Cleanall externalsurfaces ofthe injection pump including alllineconnectionsandfittingsthatareto bedisconnected Clean the area around the injection pump gear cover to prevent dirt from entering the crankcase B3 9 and B5 9 Series Engines Section A Adjustment Repair and Replacement Engine Barring Gear 1 2 Inch Ratchet or Breaker Bar Locate top dead center for cylinder No 1 Push the top dead center pin into the hole in the camshaft gear while slowly barring the engine NOTE Besuretodisengagethe pinafterlocating top dead center The barring gear inserts into the flywheel housing and engages the flywheel ring gear The engine can then be rotated by hand using a 1 2 inch ratchet or breaker bar 10 mm Remove the fuel pump mounting bracket Fuel Injection Pumps In Line Page A 61 Fuel Injection Pum
233. t des amerides de toutes les taxes en vigueur de tous les co ts commerciaux et de toute autre d pense resultant d une panne sous garantie CUMMINS N EST PAS RESPONSABLE DES DOMMAGES INDIRECTS OU INDUITS Doivent tre pris en compte l archipelam ricain Samoa le Commonwealth des les Marianadu nord les les Guam Porto Rico et les tles am ricaines Vierges Les alternateurs les demarreurs et les ventilateurs SONT couverts pendant la dur e de la garantie debase des moteurs B3 3 B3 9 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W 2 85 9 amp C8 3 Engines United States and Canada Recreational Vehicle Coverage Products Warranted This warranty applies to new B5 9 and C8 3 series diesel Enginessold by Cummins Engine Company Inc hereafter Cummins anddeliveredtothefirst user on or after March 15 1998 thatareused inrecreationalvehicie applications in the United States or Canada Base Engine Warranty The Base Engine Warranty covers any failures d the Engine whichresult under normal use and service fromadefect in material or factory workmanship Warraritable Failure This coverage begins with the sale ofthe Engine by Cummins and continues for seven years or 150 000 miles 241 400 kilometers whichever occurs first from the date of delivery of the Engine to the first user Emission Warranty Additional coverage is outlined in the Emission Warranty on the back page Consumer Products This war
234. t Manufacturers Addresses SectionM Component Manufacturers Page M 7 Deutsch The G amp O Manufacturing Company Twin Disc Incorporated Industrial Products Division 37140 Industrial Avenue Hemet CA 92343 Telephone 714 929 1200 Oil Heaters Fleetguard Inc 1200 Fleeiquard Road Cookeville TN 38502 Telephone 615 525 8551 Kim Hotstart Co PO Box 11245 Spokane WA 99211 0245 Telephone 509 534 6171 Prelubrication Systems RPM Industries Inc Suite 109 55 Hickory Street Washington PA 15301 Telephone 412 228 5130 Radiators JB Radiator Specialties Inc PO Box 292087 Sacramento CA 95829 2087 Telephone 916 381 4791 100 Gando Drive PO Box 1204 New Haveni CT 06505 1204 Telephone 203 562 5121 Young Radiator Company 2825 Four Mile Road Racine WI 53404 Telephone 910 271 2307 LandM Radiator Inc 1414 East 37th Street Hibbing MN 55746 Telephone 218 263 8993 Throttle Assemblies Williams Controls Inc 14100 SW 72nd Avenue Porttand OR 97224 Telephone 503 684 8600 Torque Converters Twin Disc international S A Chaussee de Namur Nivelles Belgium Telephone 067 224941 1328 Racine Street Racine WI 53403 1758 Telephone 414 684 1981 RockfordPowertraln Inc Off Highway Systems 1200 Windsor Road P O Box 2908 Rockford L 51139 2908 Telephone 815 633 7460 Modine Mfg Co 1500 DeKoven Avenue Racine WI 53401 Telephone 414 636 1640 Componen
235. t Manufacturers Addresses Page M 6 Kabi Electrical and Plastics Cranborne Road Patters Bar Herts ENG 3JP England Telephone 01707 53444 Datcon Instruments PO Box 128 East Petersburg PA 17520 Tele hr 717 56 5713 Rochester Gauges Inc 11616 Harry Hines Bivd PO Box 29242 Dallas TX 75229 Telephone 214 241 21 61 Governors Woodward Governors Lid PO Box 15 663 664 Aiax Avenue Slough Bucks SL1 4DD Eng land Telephone 01753 26835 Woodward Governor Co PO Box 1519 Fort Collins CO 80522 Telephone 303 482 5811 800 5232831 Barber Colman Co 1354 Clifford Avenue Loves Park iL 61132 Telephone 815 637 3000 United Technologies Diesel Systems 1000 Jorie Blvd Suite 111 Oak Brook IL 69521 Telephone 312 325 2020 Heat Sleeves Bentley Harris ManufacturingGo 100 Bentley Harris Way Gordonville TN 38563 Telephone 313 348 5779 Hydraulic and Power Steer ing Pumps Hobourn Automotive Temple Farm Works Priory Road Strood Rochester Kent England ME2 2BD Telephone 01634 71773 83 9 and 85 9 Series Engines Section M Component Manufactureis Honeywell Control Systems Ltd Honeywell House Charles Square Bracknell Berks RG12 ER Telephone 01344 4245 Sundstrand Hydratec Ltd Cheney Manor Trading Estate Swindon Wiltshire SN2 2PZ England Telephone 01793 30101 Sperry Vickers BO Box 302 Troy MI 48084 Telephone 313 280 3000
236. t No ST 1293 Use the Cummins belttensioner gauge Part No ST 1293 to measure the tension in the drive belt fagtoga Check the tensioner arm pulley arid stops for cracks If r sacks are oticed tt tersionern 1 kb 4 Drive Belts Page 6 10 83 9 and B6 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mi With the belt on verify that neither tensioner arm slops are in contact with the spring casing stop If either stop is touching the drive belt must be replaced After replacingthe belt if the tensioner arm stops are still incontactwith the spring casing stop replacethe tensioner 3 8 Inch Breaker Bar Extension Remove the drive belt and check torque of the tensioner capscrew Torque Value 43 Nem 32 ft lb After checking the torque use a 3 8 Inch breaker bar with an extension to rotate the tensioner slowly away from the area of belt contact Ifthe arm rotates with any roughness or hesitancy replace the tensioner B3 9 and B5 9 Series Engines Maintenance Procedures at 38 km 24 000 mi 1 the belt for gt Transverse 1 belt width cracks are acceptable 3 gil di a ofthe belt length cracks that intersect with transverse cracks are it acceptable If the belt is frayed or has any piec ol material missing the belt is unacceptable and needs to be laced With the belt removed verify that the tensioner arm stop is in contact with the spring case stop If these two are n
237. t Plains Diesel inc 1680 N E 51st Avenue PO Box B Des Moines IA 50313 Telephone 515 262 9591 Parts 515 262 9744 FAX 515 262 0626 B3 9 and 65 9 Series Engines Section S Service Assistance Des Moines Branch of Omaha Midwestern Power Products Division of Cummins Great Plains Die se Inc 5194 N E 17th Street Des Moines IA 50313 Telephone 515 264 1650 AX 515 264 1651 Kansas Colby Branchof Kansas City Mis souri Cummins Mid America LLC 1880 South Range Colby KS 67701 Telephone 785 462 3945 FAX 785 462 3070 Garden City Citv Missouri Cummins Mid America Inc 1285 Acraway Garden City ke 67846 Telephone 31 6 275 2277 FAX 316 275 2533 Branch of Kansas B3 9 and B5 9 Series Engines Section Service Assistance Wichita Branch of Kansas City Missouri Cummins Mid America Inc 5101 North Broadway Wichita KS 67201 Telephone 316 838 0875 FAX 316 838 0704 Kentucky Louisville Distributor Cummins Cumberland Inc Corporate Office 2301 Nelsonville Parkwav Louisville KY 40223 Telephone 502 254 3363 FAX 502 254 9272 Hazard Branch Cummins Cumberland Inc Highway 15 South PO BOX 510 Hazard KY 41701 Telephone 606 436 5718 FAX 606 436 5038 Louisville Branch Cummins Cumberland Inc 9820 Bluegrass Parkway Loulsville KY 40299 Telephone 502 491 4263 FAX 502 499 0896 Louisiana Morgan City Branch
238. t consumption exceeds Cummins published standards Failuresof belts and hoses supplied by Cumrninsare covered duringthe first year irom the date of delivery ofthe Engine to the first user or the duration of the warranty 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 resultingfrom the use of parts not approved by Cummins A new Cummins or Cummins approved rebuilt part usedto repair a Warrantable Failure assumesthe 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 THIS WARRANTY AND THE EMISSION WARRANTY SET FORTH HEREINAFTERARE THE SOLE WARRANTIES MADE BY CUMMINS IN REGARD TO THESE ENGINES CUMMINS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty gives you specific legal rights and you may also have other rights which vary from state to state 83 9 and B5 9 Series Engines Cummins Warranty Section W Warranty Page W 5 Emission Warranty Products Warranted This emission warranty applies to new B and ISB series diesel Engines marketed by Cummins that are used in the United States invehicles designed for transportingpersons or property on a street or highway This warrant
239. t housing lifting bracket thermo stat and thermostat seal Clean Clean the gasket surfaces NOTE Do not let any debris fall into the thermostat cavity when cleaning gasket surfaces Coolant Thermostat Page A 14 thghsha B3 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Install A CAUTION A Always use the correct thermostat and never operate the engine without athermostat An incorrect thermo stat can cause the engine to overheat or runtoo cold The engine will overheat if operated without amp thermo stat because the coolant flows backto the inlet of the water pump instead of through the radiator for cooling Assemble the removed parts in the reverse order of re moval Make sure the gasket is aligned with the capscrew holes Install the capscrews and finger tighten The notched end ofthe rubber thermostat seal points away from the cylinder head 83 9 and 85 9 Series Engines Coolant Thermostat Section A Adjustment Repair and Replacement Page A 15 10mm Tighten the capscrews Torque Value 24 Nem 18 ft lb th9csoa 14 mm 16mm Positionthe alternator and install the mounting capscrews S Torque Value A 24Nem 18 ft lb as Ze Torque Value B 43 Nem 82 ft lb i pe Bf Coolant Thermostat Page A 16 83 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement 13 mm Install the drive belt NOTE After the tensio
240. t of a War rantable Failure Owner is responsible for non Engine repairs and for downtime expenses passenger delays 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 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 Cumminsis also not responsible for failures caused by incorrect oil or fuel or by water dirt or other contaminants in the fuel or oil This warranty does not apply to accessories which bear the name of another company This category includes but is not limited to alternators starters fans air conditioning compressors clutches filters transmissions torque con verters vacuum pumps power steering pumps and air compressors Cummins branded alternators and starters are coveredforthefirsttwoyearsfrom the date of delivery of the Engine to the first user or the expiration of the Base Engine Warranty whichever occurs first Excessive oil consumption for B series Engines is coveredfor the duration of the coverage or 150 000 miles 241 400 km or 10 000 hours from the date of delivery of the Engineto the first user whichever
241. t or other contaminants in the fuel or oil Cummins Is not responsible for non Engine repairs downtime expenses cargo damage fines all applicable taxes all business costs or other losses resulting from a Warrantable Failure Cummins Warranty B3 9 and 85 9 Series Engines Page W 6 Section W Warranty CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES United States includesAmerican Samoa the Commonwealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands 83 9 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W All Bus Categories Worldwide Except U S Canada Diesel Powered School Buses Coverage Products Warranted This warranty applies to new diesel LPG compressed or liquid natural gas fueled engines sold by Cummins and deliveredto the first user onor afterJanuary 1 1999 that are usedin all bus categoriesworldwide exceptU S Canada diesel powered school buses Base Engine Warranty The Base Engine Warranty covers any failures of the Engine which result under normal use and service from a defect in material or factory workmanship Warrantable Failure This coverage begins with the sale ofthe engine by Cummins and continues for two years from the date of delivery ofthe Engine to the first user Extended Major Components Warranty The Extended Major Components Warranty applies to ail except B and ISB series Engines and covers Warrantable Failures f the en
242. t the initial 38 000 km 124 000 mi adjustment Subsequent adjustments are to be performed at 77 000 km 48 000 mi Overhead Set Page 6 2 B3 9 and B5 9 Series Engines Maintenance Procedures at 36 000 km 24 000 mi Overhead Set Adjust Remove 15 mm Removethe valve cover 1 2 Inch Drive Engine Barring Tool Part No 3824591 Locate top dead center TDC for cylinder No 1 by barring the crankshaft slowly while pressing on the engine timing pin Barringthe engine is recommendedfrom the flywheel on the rear of the engine 83 9 and B5 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mi When the timing pin engages in the hole in the camshaft gear cylinder No 1 is at TDC on the compression stroke A caution A To avoid engine or timing pin damage you must dis engage the timing pin after locating top dead center Overhead Set Page 6 3 Camshaft Gear Engine Timing Pin Overhead Set Page 6 4 K O W 83 9 and 85 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mi Feeler Gauge NOTE The clearance is correct when some resistance S felt when the feeler gauge is slipped between the valve stem and the rocker lever NOTE Caution must be used when setting the exhaust valve lash on marinedylinder heads with rotators The top of the valve stem is slightly recessed belowthe top of the valve rotator Intake Clearance 0 254 mm 0 010 in Exhaust
243. t this manual are ge neric and will not look exactly likethe engine or parts used in your application The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition The illustrations are intended to show repair or replace ment procedures The procedure will be the same for all applications although the illustration can differ Illustrations Page i 5 General Safety Instructions B3 9 and 85 9 Series Engines Page i 6 TE Section i Introduction General Safety Instructions Important Safety Notice WARNING Improper praatices or carelessness can cause burns cuts mutilation asphyxiation or other bodily injury or eat Read and undersiand ali oithe saieiy precautions and warnings before periorming any repair This list contains tne general safety precautions that must be followed to provide personal safety Special safety precautions are included in the procedures when they apply 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 Rotating parts can cause cuts mutilation or strangulation Do not weari loose fitting or torn clothing Remove ail jewelry when working Disconnectthe battery negative cable first and discharge any capacitors befo
244. talledis registered in the state of California a separate California Emission Warranty also applies Limitations Failures otherthan those resultingfrom defects in material or factory workmanship are not coveredby this warranty Cummins is not responsible for failures or damage resulting from what Cummins determinesto be abuse or neglect including but not limited to operation without adequate coolants or lubricants overfueling overspeeding lack of B39 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W 3 maintenance of lubricating cooling or intake systems improper storage starting warm up run in or shutdown practices unauthorized modificationsof the Engine Cummins is also not responsible for failures caused by incorrect oil or fuel of by water dirt or other contaminants in the fuel or oil Cummins is not responsible for non Engine repairs downtime expenses cargo damage fines ail applicabletaxes all business costs or other losses resulting from a Warrantable Failure CUMMINS B NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES A vehicle usedto transportstudents to and from school and school related events Vehicle must have warning lights and the words SCHOOL BUS written on the front and rear roof caps IncludesAmerican Samoa the Commonwealth of Northern Marianalslands Guam PuertoRico andthe US Virgin Islands g auto carb California Emission Control System
245. te to Cummins Customer Assistance Center 41403 Cummins Engine Company Ine Box 3005 Columbus IN 47202 3005 83 9 and 85 9 Series Engines Section S Service Assistance Division and Regional Offices Service Assistance Page 3 NOTE The following list contains offices in U S Canada Australia New Zealand and Puerto Rico United States Southern Division Office Cummins Engine Company 425 Franklin Roa 1 S W Suite 500 Marietta GA 30067 Telephone 770 423 1108 FAX 770 499 8240 Plains Regional Office Cummins Engine Company Inc 1901 Central Drive Suite 356 Bedford TX 76021 Telephone 817 267 3172 FAX N A Canada Canadian Division Office Cummins Diesel of Canada Ltd 5575 North Service Road Burlington Ontario L726M1 Telephone 905 331 5944 FAX 905 331 0276 Western Canada Regional Office Cummins Diesel of Canada Ltd 18452 88th Avenue Surrey B C V3T 4W2 Telephone 604 882 5727 FAX 604 882 9110 Eastern Canada Regional Office Cummins Diesel of Canada Ltd 7200 Trans Canada Hwy Pt Cuaire Quebec HER 106 Telephone 514 695 2402 FAX 514 695 8917 Central Canada Regional Office Cummins Diesel of Canada Ltd 4887 35th Street SE Calgary Alberta T2B 3C6 FAX 403 569 9974 Australia Regional Office Cummins Engine Company Pty Ltd 2 Caribbean Drive Scoresby Victoria 3179 Australia Telephone 61 3 9785 3222 FAX 61 3 9763 0078 NOTE This office a
246. tercooler Preparatory A WARNING Coolant is toxic Keep away from children and pets If not reused dispose of in accordance with local envi ronmental regulations Disconnect the cold starting aid it used Remove the air crossover tube Remove the high pressure fuel lines e Drain 2 liters 2 1 qt of coolant Remove 8mm Removethe coolant supply tube 1 and the coolant return B3 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement Remove the high pressure fuel lines 10 mm Remove the aftercooler housing and gasket Plug the opening with a clean shop rag to prevent foreign material from entering the air intake Aftercooler Page A 77 H9fima at9hsma Aftercooler Page A 78 E E ee ad Pa C QC imB okea a GE Le 2 at9 cexa B3 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement 5 og NN Clean Clean the sealing surface 4 NOTE Keep the gasket material and any other materialout of the air intake install 10 mm NOTE The holes shown in the illustration are drilled through Apply liquid Teflon sealant to the capscrews Install the aftercooler housing and a new gasket Torque Value 24 Nem 18 ft lb 83 9 and 85 9 Series Engines Aftercooler Section A Adjustment Repair and Replacement Page A 79 8 mm Installthe coofant supply tube 1 and coolant return tube 2 Install the air crossover tube 3
247. the system with a mixture of sodium carbonate and water or commercially available equivalent NOTE Use0 5kg 1 0 Ib of sodium carbonateforevery23 liters 6 0 gal of water B3 9 and B5 9 Series Engines Ge age 7 Maintenance Procedures at 77 000 km 48 000 mi A WARNING A Coolant is toxic Keep away from children and pets If not reused dis of in accordance with local envi 2 tal eg Cr ra 3 eI 15 wiht coolant tte teltpeatu gt E 80 C 1752F Shut the engine off and drain the cooling system Fill the cooling system with clean water NOTE Be sure to vent the engine and aftercooler for com plete filling NOTE Do not installthe radiator cap or the new coolant filter Cooling System Page 7 6 83 9 and 85 9 Series Engines Maintenance Procedures at 77 000 km 48 000 mi A WARNING amp Coolant is toxic Keep away from children and pets If not reused dispose of in acoordance wlth local envi ronmental regulations Operate the enginefor5 minuteswith the coolant reaching the temperature above 80 C 176 F Shut the engine off and drain the cooling system NOTE If the water being drained is still dirty the system must be flushed again until the water is clean Fill A CAUTION A The system must be filled properly to prevent air locks During filling air must be vented from the engine cool i t passages Be st e to open the petcock on the af t cooler for f gt sc
248. the time of sale by Cummins with ail US Federal emission regulations applicable at the time of manufacture and that it isfree from defectsin materialor factory workmanshipwhich would cause itnotto meet these regulations within the longer of the following periods A Five years or 100 000 miles 160 935 kilometers of operation whichever occurs first as measured from the date ot delivery of the Engine to the ultimate purchaser or B The Base Engine Warranty Ifthe vehicle in which the Engine is installed is registeredin the state of California a separate California Emission Warranty also applies Limitations Failures other than those resulting from defects in materialor factory workmanship are not covered by this warranty LI Cummins is not responsiblefor failures or damage resulting from what Cummins determinesto be abuse or neglect including but not limited to operation without adequate coolants or lubricants overfueling overspeeding lack of Cummins Warranty 63 9 and 65 9 Series Engines Page W 12 Section W Warranty maintenance of lubricating cooling or intake systems improper storage starting warm up run in or shutdown practices unauthorized modifications of the Engine Cumminsis also not responsible for failures caused by incorrect oil orrfuel or by water dirt or other contaminants in the fuel or oil Cummins is not responsible for non Engine repairs downtime expenses cargo damage fines all applicabletaxes
249. tion easy to understand Does the information sufficiently cove t16 subject Are subjects in the Index specific enough to locate in the manual Are the important points sufficiently emp si d Are the illustrations easy to understand Does the text support the operation Dh illustrated Do you use the Table of Cort at dE tion Content Do you use the Index III Hl Please provide comments on any response s marked No in this survey and on any suggestions you feel could improve our manuals LLL Name Company Street Address City D State Province Country o Zip fPostal Code Do not use this form to order additional literature Refer to Section L Service Literature for literature information rh or ENP EH Dieselengine exhau to the State of Calif other reproductive h CALIFORNIA Proposition 65 Warning Dieselengine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Cummins Engine Company Inc Box 3005 Columbus Indiana U S A 47202 Registered Office Cummins Engine Company Ltd 46 50 Coombe Road New Malden Surrey KT3 4QL England Cummins Customer Assistance Center 1 800 DIESELS 1 800 343 7357 APPLICABLE ONLY IN U S A AND CANADA Copyright 2000 Cummins Engine Company Ine Bulletin No 3810205 14 Printed n U S A 3 0
250. to the OEM service manual Check the radiator pressure cap Refer to the OEM service manual 1 iubleshooting Symptoms Charts F ge TS 8 Coolant Temperatur Lause i are Temperature gauge malfunction Thermostat is not correct or fs malfunctioning m Correction inspect the radiator shutt rs Repair or replace if necessary Refer to the manufacturer s instructions Check the shutterstat setting Referto the OEM service manual Check or replace the temperature gauge Refer to the OEM service manual Check the thermostat for the correct Dart number and for correct operation Refer to the OEM service manual 83 9 and 85 9 Series Engines Section TS Troubleshooting Symptoms ybove Normal Continued Fuel pump is malfunction ing Vers Correction Cause Test the fuel pump on a fuel pump test stand Replace the fuel pump If necessary Reduce the engine load Increase the engine fan rpm by downshifting Vehicle speed is too low fo adequate cooling with high engine load Check the water pump for correct operation Replace the water pump lf neces sary Water pump is malfunctio ing E Inspect and bleed the cooling system Continued B3 9 and 65 9 Series Engines Troubleshooting Symptoms Charts Section TS Troubleshooting Symptoms Page TS 9 Coolant Temperature Above Normal Continued Cause Correct
251. tutes an emergency Cummins will reimbursethe Owner for expenses including diagnosis notto exceedthe manufacturer s suggested retail pricefor all warranted parts replaced and labor charges based on the manufacturer s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate Replaced parts and paid invoices must be presented at a Cummins authorized repair facility as a condition of reimbursement for emergency repairs not performed by a Cummins distributor authorized dealer or other repair location approved by Cummins B39 and B5 9 Series Engines California Emission Control System Warranty n Mu Section W Warranty Page W Warranty Limitations Cummins is not responsiblefor failures or damage resultingfrom what Cummins determines to be abuse or neglect including but not limited to operation without adequate coolants or lubricants overfueling overspeeding lack of maintenance of cooling lubricating or intake systems improper storage starting warm up run in or shutdown practices unauthorized modificationsto the engine Cummins is also not responsiblefor Se caused by incorrect oil or fuel or by water dirt or other contaminants in the fuel or oil Cummins is not responsible for failures resulting from improper repair or the use of parts which are not genuine Cummins or Cummins approved parts Cummins is not responsiblefor the material and labor costs of emission control parts and assem
252. uel coming from the injector is under extreme pressure and can cause se rious injury by penetrating the skin 17mm 19mm Venting is accomplished by looseningone or morefittings atthe injectors and cranking the engineto allow entrapped air to bleed from the lines Injector Supply Lines High Pressure Page 5 IpStbva 83 9 and 85 9 Serles Engines Maintenance Procedures at 19 000 km 12 000 mi A WARNING amp Do not bleed the fuel system ona hot engine this can cause fuel to spill onto a hot exhaust manifold which can cause fire Startthe engine and vent one line at atime untilthe engine runs smoothly Tighten the line fittings Torque Value 30 Nem 22ft Ib Injector Supply Lines High Pressure Page 5 8 B3 9 and 85 9 Series Engines Maintenance Procedures at 19 000 km 12 000 mi Cooling System Maintenance Check A CAUTION A Overconcentration of antifreeze or use of high silicate antifreeze can cause damage to the engine Refractometer Part No C2800 Check the antifreeze concentration Use a mixture of 50 percentwater and 50 percent ethylene glycol or propyiene glycol baseantifreezeto protectihe engine to 32 C f 25 F year around The Fleetguard refractometer Part No C2800 providesa reliable easy to read and accurate measurement of freez ing point protection and glycol antifreeze concentration Antifreeze is essential in every climate Use of antifree
253. ure j Drop across Fuel Filter 35 kPa 5 psi 35 kPa i 5 psi 35 KPa 5 psl Maximum Intet Pressure to the Injection Pump Must Not Exceed RFID pel 70 Pa 10 psi 70 kPa 10 psi In Line Type Fuel Injection Pumps Maximum Inlet Restriction to the Fuel Transfer Pump Must Not 100 mm Hg 4 m Hg 100 mm Hg 4 in Hg 100 mm Hg 4 in Hg Exceed Fuel Transfer Pump Minimum 172kPa 25pslj High 172kPa 25psi High 172 kPa eps High Output Pressure Flow and 90 kPa 13psi F ow and 90 kPa 13 psi Flow and 90 kPa 13 psi Low Flow Rated wm Low Flow Rated rpm Low Flow Rated rpm Fuel Filter Restriction maximum f pressure drop across filters 35 kPa 5 psi 35 kPa 5 psi 35 kPa 5 pel Fuel Pump Gallery Pressure 140 kPa 20 psi 140 kPa 20 psi 140 kPa 20 psi Rated rpm Rated rprn Rated rpm Fuel Return Maximum Restriction 518 mm Hg 20 4 inHg 518mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hgj The low flowfuel transfer pump will have 82 7 kPa 12 psi 83 9 and 85 9 Series Engines Specifications Section E Engine Identification Page E 13 Fuel System Data automotive Distributor Type Fuel iniection Pumps B3 9 B5 9 Maximum inlet Restrictionto the Fuel Trans fer Pump Must Not Exceed 100 mm Hg 4 in Hg 100 mm Fig 4 d Ho Maximum Allowable Return Line Restriction 518 mm Hg 20 4 in Hg 518 mm Hg 20 4 in Hg B Maximum Allowable Pressure Drop across i Ever Eiler H 35 kPa 5 psi 35 kPa 5 psi Maximum inlet Pr
254. ures D Cummins Warranty 83 9 and B5 8 Series Engines Page W 24 Section W Warranty d utilisation suivantlequel de ces termes intervient en premier et a dater de la livraison du moteur l acqu reur final ou B la garantie de base des moteurs Si fe v hicule muni du moteur Cummins est enregistr dans l Etat de Callfornie une autre garantie du syst me antipollution s applique egalement Limites Lea pannes autres que celles resultant d un d faut de mat riaux ou de main d oe vre ne sont pad garanties Cummins decline toute responsabiliteen cas de pannesou de deteriorations resultant de ce que Cummins considere comme un abus ou une negligencede la part du proprietaire notamment et non fimitativement une utiiisation sans les lubrifiants ou lesliquides de refroidissernentappropri s surremplissage de carburant vitesse trop lev e negligence d entretien des syst mes d admission de refroidissementou de lubrification mauvaises conditions d entreposage pratiquesinappropri es de d marrage de chauffage de rodage ou d arr t modificationsnonhomoliogu es du moteur Cummins n est galement pas responsable des pannes provoquees par l utilisation d une huile d un carburant ou d une eau non appropri s ainsi que des pannes provoquees par la presence de depbts dans le carburant ou dans l huile Cummins n est pas responsable des reparations auires que celles du moteur des d penses de temps mort des dommages au chargemen
255. ures ofthe Enginewhich result under normal use and service from a defect in materialor factory workmanship Warrantable Failure This coverage begins with the sale ofthe Engineby Cummins and continues for five years or 100 000 miles 160 935 kilometers whichever occurs first from the date of delivery of the Engine to the first user Extended Major Components Warranty The Extended Major Components Warranty applies to all except B and SB series Engines and covers Warrantable Failures of the engine cylinder block camshaft crankshaft connecting rods and Cummins fan clutch Covered Parts Bushing and bearing failures are not covered This coverage begins with the expiration of the Base Engine Warranty and ends three years or 300 000 miles 482 805 kilometers whichever occurs first from the date of delivery of the Engineto the first user Emission Warranty Additional coverage is outlined in the Emission Warranty on the back page 3381329 B3 9 and B5 9 Series Engines Cummins Warranty Section W Warranty Page W 31 Consumer Products This warranty on Consumer Products in the United States is a LIMITED warranty CUMMINS IS NOT RESPONSIBLE FOR INCIDENTALOR CONSEQUENTIALDAMAGES Any impliedwarranties applicableto Consumer Productsin the United States terminate concurrently with the expiration of the express warranties applicable to such products In the United States some states do not allow the exclusion of incidental or consequential
256. using premature wear Air Cleaner Restriction Page 4 11 acgetma agsiaga Air Cleaner Restriction 83 9 and 85 9 Series Engines Page 4 12 Maintenance Procedures at 10 000 km 6000 mi NOTES B3 9 and 85 9 Series Engines Maintenance rocedures at 19 000 km m Page 5a Maintenance Procedures at 19 000 Kilometers 12 000 Miles 500 Hours or 6 Months Section Contents Cooling System iis Les Check stall ue Fu 1 apply Liries i eee e ced adet acted m PACE its 5 4 EE SE wen Supply Lines High BE ue deen ETT sie E chatons 5 7 rm EE OP Maintenance Procedures Overview m HN EO 5 1 E General Information esee eee nnam nannten rena Were Er REY da cave PEE XE ae 5 1 83 9 and 85 9 Series Engines Page 5 b Maintenance Procedures at 19 000 km 12 000 mi THIS PAGE LEFT INTENTIONALLY BLANK 83 9 and 85 9 Series Engines Maintenance Procedures Overview Maintenance Procedures at 19 000 km 12 000 mi Page 5 1 Maintenance Procedures Overview General Information All checks or inspections listed under daily or previous maintenanceintervals must also be performed at this time in addition to those listed under this maintenance interval Fuel Filter Spin On Type Page 8 2 2S L es 83 9and 85 9 Series Engihes Maintenance Procedures at 19 000 km 12 000 imi Fuel Filter Spin On Type Remove 75
257. ustment Repair and Replacement A CAUTION A Do notremovethe control lever The lever is indexed to the shaft during pump calibration Removal of the lever will alter the fuel pump calibration and affect engine performance 13 mm NOTE Do not drop the drive gear key when removing the pump Od Remove the three mounting nuts Remove the fuel pump REN S B3 9 and 35 9 Series Engines Section A Adjustment Repair and Replacement Install Makesure the engine has cylinder No 1 at top dead center The keyway inthe shaft of new reconditionedpumpswill be locked in a position corresponding to the keyway in the drive gear when cylinder No 1 is at top dead centeron the compression stroke After verifying that cylinder No 1 is at top dead center install the pump Make sure the key does not fall into the gear housing E f Attach the pump by finger tightening the three mounting nuts The pump must be free to move in the slots Fuel Injection pump R age otar A 5 Fuel Injection Pump Rotary Page A 52 fs9nuhb B3 9 and 85 9 Series Engines Section A Adjustment Repair and Replacement 22 mm CAV Stanadyne 24 mm Bosch Attach the pump driveshaft nut and spring washer The pump can rotate slightly due to gear helix and clearahce This isacceptableprovidedthe pumpisfreetomoveonthe flange slots and the crankshaft does not move NOTE Do not overtighten This is not the final torque Tor
258. ve 18 C 60 F X after 5 seconds see Note Automotive Industrial Full Throttle All pumps below 16 C 60 F X Note 1 Full throttle on the VE pump makes sure there is sufficient start fuel delivery and helps keep the engine operating once started The in line pumps with RQV and RQV K governors require full throttle to position and hold the rack In the stari fuel position NOTE Full throttle is applied after engaging the starter Disengage the driven unit or if equipped put the transmission in neutral positionthe fuel shutoff electrical switch or mechanism control to the RUN position ki Cold Weather Operation 83 9and B5 9 Series Engines Page 1 8 Section 1 Operating Instructions Cold Weather Operation Operating Aids Use the following chart as a referencefor required cold weather starting aids Operation in ambient temperatures below 0 C 32 F will possibly require special consideration be given to engine starting At temporatures below 09 C 32 F1 operate the engine at moderate speeds for 5 minutes hefore full loads ac applied OIL PANAND STARTING AIDS BLOCKHEATERS BATTERY CAPACITY UNAIDED UNAIDED ANDARD oc Je p oem a ee UE Mir Te SUGGESTED SUGGESTED 120 HH tor EA a 7 Le XTRA CAPACITY 18 C DF REQUIRED SUGGESTED See Wate T MEME rr IM EXTRA CAPACITY REQUIRED REQUIRED 180 200 V 3 83 9 and 85 9 Series Engines Section 1 Operating Instructions Winterfronts
259. vice Fuel p overilow valve mali aliunctioning to the OEMservice Po manusi damaged or not correct manual OK OK gt Continued Fuel transfer pump mak pump Replat if neces functioning sary Refer to Section A OK EEN Symptoms Charts 83 9 and B5 9 Series Engines Page TS 20 Section TS Troubleshooting Symptoms Engine Runs Rough at Idie Warm Engine Continued Cause Correction Remove the fuel injection Fuel injection pump is pump Check the calibra malfunctioning r tion of the fuel injection pump Refer to Section A l OK Contact a Cummins Authorized Repair Facility B3 9an 859 i E r Troubleshooting Symptoms Charts Section TS bh do yl Page TS 21 Engine Runs Rough or Misfires Cause Correction Cause Correction Verify by operating the Check the fuel liit pump for Fuel contaminated engine with clean fuel from correct operation Check Fuel lift pump is maifunc eee the pump output pressure a temporary tank tinning Replace the fuel lift pump H necessary Feler to Section Bleed the fuel system and Air in the fuel system f check for leaks Referlo Section 5 Adjust valves Make sure the push rods are not bent or rocker levers not severely worn Refer to ection 6 Check the fuel lines fuel connections and fuel filters Fuel leak for leaks Refer to Section Repipcetitzeinipettossas f necessary Refer t
260. way East Tacoma WA 98424 1135 Telephone 253 922 2191 FAX 253 922 2379 Yakima Branch Cummins Morthwest Inc 1905 East Central Avenue 88901 3609 PO Box 9129 Yakima WA 98809 0128 Telephone 509 248 9033 FAX 509 248 9035 West Virginia Charleston Branch of Louisville Cummins Cumberland Inc 3100 MacCorkle Ave SW PO Box 8456 South Charleston WV 25303 Telephone 304 744 6373 FAX 304 744 8605 Service Assistance Page S 18 Falrmont Branch of Louisville Cummins Cumberland Inc South Fairmount Exit 1 79 145 Middletown Road Fairmont WV 26554 Telephone 304 367 0196 FAX 344 367 1077 Wisconsin DePere Distributor Cummins Great Lakes Inc Coroorate Office 875 Lawrence Drive PO Box 5070 DePere WI 54115 5070 Telephone 820 337 1991 FAX 920 337 9746 Chippewa Falls Branch Cummins Great Lakes Inc 2030 St Highway 53 Chippewa Falls WI 54729 Telephone 715 720 0680 FAX 715 720 0685 DePere Branch Cummins Great Lakes Inc 939 Lawrence Drive P O Box 5070 DePere WI 54115 5070 Telephone E 336 8831 800 236 1191 FAX 920 336 8954 Milwaukee Branch Cummins Great Lakes Inc 9401 South 13th Street P O Box D Oak Creek WI 53154 Telephone 414 768 7400 800 472 8283 FAX 414 7659441 Wausau Branch Cummins Great Lakes Inc 4703 Rib Mountain Drive Wausau Wi 54401 Telephone 715 359 6886 800 236 3744 FAX 71
261. will pay for the lubricating oil antifreeze filter elements and other maintenance items that are not reusable due to the Warrantable Failure Cummins will pay reasonable costs for mechanicsto travelto and from the equipment site moldin meals mileage and lodging when the repair is performed at the site of the failure Cumminswiil pay reasonablelabor costs for Engine removal and reinstallationwhen necessary to repair a Warrantable Failure During The Extended Major Components Warranty Cummins will pay for the repair or at its option replacement of the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered part B3 9 and B5 9 Series Engines Cummins Warrant Section W Warranty Page W 1 Owner s Responsibilities During The Base Engine Warranty j Owner is responsible for the cost of lubricatingoil antifreeze filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure During The Extended Major Components Warranty Owner is responsible for the cost of all labor needed to repair the Engine including the labor to remove and reinstall the Engine When Cummins elects to repair a part instead of replacing it Owner is not responsiblefor the labor needed to repair the part Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and any Covered Part damaged
262. x Removethechargeaircoolerfrornthevehicle Refertothe gt vehicle manfacturer s instructions Inspect the charge air cooler for cracks holes or damage Inspectthe tubes fins andwelds for tears breaks or other damage lt ZA Refer to Section A for the leak check procedure 83 9 and B5 9 Series Engines enance Procedures at 10 Ok mi Clean A WARNING 4 1 ng st lents acht or alkaline materials for use Wear goggles and it 1 tti baoil r sonal injury i iallan maniifantriiear c racnmmandationce far rg S a TET A CAUTION A Do not use causti cleaners to clean the charge air coc Damage to ie charge air cooler will ul Flush the cliarge a cooler internally with solvent in the opposite direction of normal rfk ak th ck 3 er cooler in llic ly tag on the end tanks with a rubber mallet to disicig t ape 1 leb is Corinue ih shir until all d bris or oil is removed Charge Air Cooler CAC Page 4 9 caB gea Charge Air Cooler CAC Page 4 10 gt 83 9and 859 Series Engines Maintenance Procedures at 10 000 km 6000 mi A WARNING When using solvents acids or alkaline materials for cleaning follow manufacturer s recommendations for use Wear goggles and protective clothing to avoid per sonal injury A WARNING A Wear appropriate eye and face protection when using compressed air Flying debris anddirt can cause bodily injury After the cha
263. y applies to Engines delivered to the ultimate purchaser on or after October 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 Cumminswith all U S Federal emission regulations applicable at the time of manufacture and that it is free from defects in materialor factory workmanship which would cause it notto meet these regulations within the longer of the following periods A Five years or 100 000 miles 160 935 kilometers of operation whichever occurs first as measured from the date of delivery of the Engine to the ultimate purchaser or B 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 material or factory workmanship are not covered by this warranty Cummins is n t responsible for failures or damage resuiting from what Cummins determinesto be abusenr neglect including but not limited to operation without adequate coolants 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 oil or fuel or by water dir
264. zebroadensthe operatingtemperature range by lowering the coolant freezing point and by raising its boiling point The corrosion inhibitors also protect the cooling system componentsfrom corrosion and providelonger component life Cooling System Page 5 9 Cooling System 13 9 and B5 9 Serles E Page 5 10 Maintenance P res at 000 km 40 mi NOTES 83 9 and 85 9 Series Engines Maintenance Procedures at 38 000 km 24 000 mi Page 6 a Maintenance Procedures at 38 000 Kilometers 24 000 Miles 1000 Hours or 1 Year Section Contents Page Drive Belts FREE Eee rerba REC 8 8 EE 6 8 Maintenance Procedures Overview Ve 64 G n ral Information AEE e reete e ra cr e Morin Perte esee crees ena veta ze aires dur ce ooa erue Fi Re ed ones 6 1 Overhead Set tsb dree ENEE laide Pa EE 6 2 PCY USE EE 6 2 83 9 and 85 9 Series Engines Page 6 b Maintenance Procedures at 38 000 km 24 000 mi THIS PAGE LEFT INTENTIONALLY BLANK B3 9 and B5 9 Serles Engines Maintenance Procedures Overview Maintenance Procedures at 38 000 km 24 000 mi Page 6 1 Maintenance Procedures Overview General Information All checks or inspections listed under daily or previous maintenance intervals must also be performedat this time in addition to those listed under this maintenance interval The proceduresgiven in this sectionforvalve lash adjustmentare to be performeda

LeeBoy Cummins B3.9 & B5.9 Engine Manuals

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LeeBoy Cummins B3.9 &amp; B5.9 Engine Manuals

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LeeBoy Cummins B3.9 & B5.9 Engine Manuals