Service Manual

Chapter 6 - Engine
Engine ................................................................................................................................................................ 6-3
1 Technical data .................................................................................................................................. 6-3
2 Cooling system ................................................................................................................................ 6-5
2.1 Cooling schematic .................................................................................................................. 6-5
2.2 Function.................................................................................................................................. 6-7
2.3 Coolant capacity ..................................................................................................................... 6-7
2.4 Cleaning system and changing antifreeze.............................................................................. 6-8
2.5 Antifreeze and corrosion protection of coolant ....................................................................... 6-12
3 Fuel system ...................................................................................................................................... 6-14
3.1 Fuel schematic ....................................................................................................................... 6-14
3.2 Fuel capacity .......................................................................................................................... 6-14
3.3 To drain condensation ............................................................................................................ 6-14
3.4 Fuel filter change .................................................................................................................... 6-17
3.5 Bleeding procedure ................................................................................................................ 6-18

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6 Engine

6.0.1 Technical data

Type4 Cycle; 60° V 12 Cylinder Diesel
AspirationTurbocharged and Aftercooled
Bore x Strokeln.xin. (mmxmm)6.25 (159) x 7.48 (190)
Displacementln.3 (litre)2746 (45)
Compression Ratio14.5:1 at 1800 RPM
Firing order1R-6L-5R-2L-3R-4L
6R-1L-2R-5L-4R-3L
Dry weight estimatedLb. (kg)12,815 (5813)
Wet weight estimatedLb. (kg)13,499 (6123)
Valves and injector settings
Intake valve adjustmentln. (mm)0.014 (0.36)
Intake valve limitsln. (mm)0.011 to 0.017 (0.28 to 0.43)
Exhaust valve adjustmentln. (mm)0.032 (0.81)
Exhaust valve limitsln. (mm)0.029 to 0.035 (0.74 to 0.89)
Injector outer base circle method adjustment in engineln-lb. (Nm)168 (19)
EXHAUST SYSTEM
Maximum allowable backpressure (at 1500 hp and less)ln. Hg (mm Hg)3 (75)
Max. allowable backpressure (at greater than 1500 hp)ln. Hg (mm Hg)2 (51)
Exhaust pipe size normally acceptableln. (mm)5.5 (139,5)
AIR INTAKE SYSTEM
Maximum allowable intake air restriction with heavy duty air cleaner
Clean elementIn. H2O (mm H2O)15 (380)
Dirty elementln. H2O (mm H2O)25 (635)
COOLING SYSTEM (estimates only)
Coolant capacity - Engine onlyU.S. Gal. (litre)28 (105)
Standard modulating thermostat range°F (°C)185 to 207 (85 to 97)
Standard LTA thermostat range°F (°C)115 to 135 (46 to 57)
Maximum allowable top tank temperature°F (°C)212 (100)
Minimum recommended top tank temperature°F (°C)160 (71)
Maximum deaeration timeMin25
Min. allow. drawdown or 20% of system capacityU.S. Gal. (litre)7 (26)
Minimum allowable pressure capPSI (kPa)11 (76)
LUBRICATION SYSTEM
Oil pressure@ Minimum low idlePSI (kPa)25 (172)

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@ Maximum rated RPMPSI (kPa)65 (448)

@ Minimum low idlePSI (kPa)20 (138)
Minimum oil pressure@ Maximum rated RPMPSI (kPa)40 (276)
Oil flow rated speed (1900 RPM)US GPM (l/min)210 (795)
Maximum allowable oil temperature°F (°C)248 (120)
Oil pan capacityU.S. Gal. (litre)75 (284)
Oil filter capacity (for one filter)U.S. Gal. (litre)0.70 (2.65)
Eliminator oil filter capacity (optional)U.S. Gal. (litre)4.8 (18)
Fleetguard centrifuge oil filter capacity (optinal)U.S. Gal. (litre)0.26 (1)
FUEL SYSTEM
Engine idle speedRPM700±25
Max. allow. fuel inlet restrictionWith clean fuel filterIn. Hg (mm Hg)4 (100)
at rated powerWith dirty fuel filterIn. Hg (mm Hg)8 (203)
Max. allow. fuel drain valve restric.Before check valvesIn. Hg (mm Hg)10 (254)
After check valvesIn. Hg (mm Hg)9 (228)
Min. allow. tank vent capability with 6 in.H 2O (152 mm H2O)
or less back pressureFt3/hr (l/hr)15 (425)
ELECTRICAL SYSTEM
Min. recommended battery capacityCold soak at 0°F (-18°C) or above24 Volt
Engine only (De-clutched load)Cold cranking amperes CCA1800
Reserve capacity min640
Maximum allowable resistance of starting circuitOhms0.002

6.0.2 Cooling system

The engine cooling system consists in two circuits :
• The principal water circuit, which cools the engine.
• The Low Temperature Aftercooling (LTA) circuit, which cools the air after its passage threw the turbo and
before its admission in the intake ports.

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6.0.2.1 Cooling schematic

1 Top tank 6a Bypass for principal circuit

2a Make up line for the principal circuit 6b Bypass for LTA circuit

2b Make up line for the LTA circuit 7a Coolant return to principal radiator

3a Principal water pump 7b Coolant return to LTA radiator

3b LTA water pump 8 LTA supply

4a Principal radiator 9 LTA core return

4b LTA radiator 12 Thermostat housing

5a Coolant supply from principal radiator 13 Coolant filters

5b Coolant supply from LTA radiator

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6.0.2.2 Function
For a detailed description of the engine cooling system flow, see Cummins Operation and Maintenance Ma-
nual.

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Principal circuit
The flow coming from the water pump goes threw the V-centre of the engine.
The coolant is distributed in the two banks : it cools the cylinders and goes up to the cylinders heads.
The coolant is then driven to the thermostat.
• The engine is cold
The coolant goes to the thermostats. As the thermostats are closed, the coolant is driven, threw the by-
pass pipe, to the suction side of the water pump.
• The engine temperature is increasing
The thermostat gets partially opened and a part of the coolant goes to the by-pass, the other part is driven
to the radiator in order to be cooled.
• The engine is hot
The thermostats are wide opened and all the coolant is driven to the radiator in order to be cooled.

Low Temperature Aftercooling (LTA) circuit

• The engine is cold
The coolant goes to the LTA thermostats. As the thermostats are closed, the coolant is driven, threw the
by-pass pipe, to the suction side of the LTA pump.
• The engine temperature is increasing
The thermostat gets partially opened and a part of the coolant goes to the by-pass, the other part is driven
to the LTA radiator in order to be cooled.
• The engine is hot
The LTA thermostats are wide opened and all the coolant is driven to the radiator in order to be cooled.

6.0.2.3 Coolant capacity

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Cooling capacity
Engine L (US gal.) 130 (34.3)

Total L (US gal.) 342 (90.2)

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6.0.2.4 Cleaning system and changing antifreeze

Caution!
Do not use caustic cleaners in the cooling system. Aluminium components will be damaged.

Warning!
Wait until the temperature is below 50°C (120°F) before removing the coolant system pressure cap.
At or near operating temperature, the engine coolant system is hot and under pressure.

Avoid contact with coolant and components containing coolant, since it could cause severe burns.
Check the coolant level only after the cap 6 is cool enough to touch. When cold, the coolant level should not
drop below the bottom end of the filler neck under the cap 6 of the expansion tank 7.

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To drain the coolant

Push the lever 1 all the way backward to open the heater water supply.

Open the coolant shut off valves 5 for the cab heater on the Diesel engine.

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The radiators are fitted with a drain valve 9 situated at the bottom.
To drain the coolant, first remove teh cap of the drain valve and screw the drain hose delivered with the ma-
chine onto the drain valve and drain the coolant in a suitable container (remove the coolant pressure cap).
Remove the drain hose and reinstall the cap of the drain valve.
Do not allow the cooling system to dry out.
Do not remove the coolant filter.

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To clean the cooling circuit

Immediately add 3,8 liters (1 US gallon) of Fleetguard RESTORE, RESTORE PLUS (or equivalent) for each
38 to 57 liters (10 to 15 gallons) of cooling system capacity, and fill the system with plain water.

Caution!
Fleetguard RESTORE contains antifreeze. Do not allow the cooling system to freeze during the
cleaning operation.

Be sure that the coolant shut off valves 5 are open and that the lever 2 is pushed all the way backward to open
the heater water supply. The blower does not have to be on.
Run the engine at high idle and add water until the coolant level will no longer drop.
Operate the engine at normal operating temperatures (at least 85°C (185°F)) for 1 to 1,5 hours.
Shut the engine off, and drain the cooling system.
Fill the cooling system with clean water to flush the cooling system.
Operate the engine at high idle for 5 minutes with the coolant temperature above 85°C (185°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.

To refill the cooling circuit

Fill the cooling circuit with a new heavy-duty coolant and SCA (see Cummins Operation and Maintenance Ma-
nual page V-17).
Open the cap on the surge tank on top of the powerpack.
Add the coolant until it reaches the middle range of the indicator.
Run the engine at high idle and add coolant until the coolant level will no longer drop. It should reach the middle
range of the indicator.

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Note!
If the heater will not run normally after the coolant change, it is possible that air is collected in the
heat exchanger. In this case the heater exchanger must be vented :
– run the engine and be sure that the coolant shut off valves for the cab heater on the Diesel engine
are open and that the lever is pushed all the way backward.
– Unscrew the vent screw 10 on the heat exchanger under the cab until coolant comes out, than
retighten the screw.

6.0.2.5 Antifreeze and corrosion protection of coolant

The proper antifreeze and corrosion protection must be maintened all year long.
The excavator is delivered from the factory with a cooling system protection to -36°C (-34°F) (this corresponds
to approx. 50% antifreeze).
Supplemental Coolant Additives are used to prevent liner pitting and scale deposits in the cooling system. The
SCA concentration in the cooling circuit must be constantly maintained.
Normally, changing the coolant filters regularly is sufficient to maintain the proper concentration.
However, check the SCA concentration level whenever coolant is added to the cooling system between the
filter changes. Use Fleetguard coolant test kit CC2602, to check the concentration level. Instructions are inclu-
ded with the test kit.

Caution!
Under-concentration of coolant additives can result in liner pitting and system corrosion. Over-con-
centration can result in water pump leakage.

The recommended concentration level of supplemental coolant additives is 1,5 units per US gallon of coolant.
The additive level must never drop below 1,2 units or exceed 3 units per gallon of coolant.
See Cummins Operation and Maintenance Manual for details.

Coolant filters
The filter contains a paste, which ensures the SCA concentration in the cooling circuit.
Use the correct fleetguard coolant filter to maintain the correct SCA concentration in the system. The correct
service coolant filter to be used is determined by the total cooling system capacity and other operationel factors
(See Cummins Operation and Maintenance Manual - section V).
Maintain the correct concentration by changing the service coolant filter at the intervals specified in maintenan-
ce schedule and Cummins Operation and Maintenance Manual.

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To change the coolant filters

• Turn the valve 1 on the filter head to the OFF position to prevent water loss.
• Unscrew and remove the filter elements.
• Clean the area around the filter head and the gasket surface on the filter head.
• Lightly oil the seal rings on the new filter element.
• Screw on the new elements until the seal ring touches the filter housing, and then turn it by hand ½ - ¾
turns (do not use any tools to tighten the filters).
• Turn the valve 1 on the filter head to the ON position.
For detailed information, refer to Cummins Operation and Maintenance Manual.

Radiator cap
The radiator has an integrated expansion tank; the volume of air is such that there is enough volume for coolant
expansion when it is warming up to running temperature.
The radiator cap has a pressure limiting valve (1 bar) and a suction valve, to prevent any vacuum in the radiator.

Note!
If any of these two valves are not funtioning properly, coolant can leak during operation. So replace
the radiator cap on the machine.

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6.0.3 Fuel system

6.0.3.1 Fuel schematic

1 Fuel tank 5 Fuel radiator

2 Shut off valve 6 Inlet port on filters housing

3 Fuel filters

6.0.3.2 Fuel capacity

The maximum capacity of the fuel tank is 5220 liters (1380 US gallon).

6.0.3.3 To drain condensation

The condensation in the fuel system and fuel tank must be drained regularly. For interval, see maintenance
schedule and Cummins Operation and Maintenance Manual.

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To drain and clean the fuel tank

• A drain valve is installed on the bottom of the tank.

• To drain condensation, turn the drain plug 1 on the valve two turns counterclockwise until clean fuel ap-
pears, tighten the drain plug.
• To empty the tank, remove the tank cover, on the rear of the cab door and remove the drain valve 2 on
the bottom of the tank and drain the fuel into a suitable container.
• The tank and the strainer in the tank filler neck should be checked regularly for contamination.
• Change the strainer, and / or flush the tank if necessary.

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Draining and changing fuel filter cartridges

Unscrew and remove the 3 filter elements (pos. 3).

Each filter element is a combination fuel filter comprising a full flow element and a by-pass element.
Clean the sealing surfaces on the filter mounts.
Lightly lubricate the rubber seal on the new filters with oil.
Install and tighten the filters with both hands (see also enclosed CUMMINS engine operation and mainte-
nance manual).

6.0.3.4 Fuel filter change

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The fuel filters must be changed at regular intervals (see Cummins Operation and Maintenance Manual).
• Close the fuel shut off valve 2 near the fuel tank 1.
• Clean the area around the fuel filter head.
• Use a filter wrench to remove the fuel filter (see chapter 5 : tooling).
• Use a clean, lint-free towell and clean the filter head gasket surface.
• Use the correct filters.
• Apply a light film of clean engine oil to the filter gasket surface.
• Fill the filter with clean fuel.
• Install the filter on the filter head. Tighten the filter until the gasket contacts the filter head surface.
• Tighten the filter per the filter manufacturer’s instructions.
• Open the fuel shut off valve 2 near the fuel tank 1.

6.0.3.5 Bleeding procedure

• Fill the fuel tank with appropriate fuel (see Cummins Operation and Maintenance Manual) at is maximum
level.
• On the fuel pump, drain at the bottom point until clear fuel drains off.
• Try to start the engine.
• If the engine does not start, drain at the top point during cranking.
• Stop to drain when clear fuel drains off.

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