y —— Operation and Maintenance Manual a Marine and Industrial QSM11 Engine . Copyright® 2000 Bulletin 3666404-01 summin 1s Engine Company, Inc. Printed 07/00 c All rights reservedForeword This manual contains information for the correct operation and maintenance of your Cummins engine. it aiso includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins ‘Authorized Repair Locations and component manufacturers. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions i + Introduction. es Section i Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. ‘The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts, These paris can be identified by the following trademarks: Gee fz with the warranty or warranties. Note: Warranty information is located in Section W. Make sure you are fami applicable to your engine.ae Table of Contents Seation Introduction i Engine identification e Operating Instructions new 1 Maintenance Guid ao 2 Maintenance Procedures at Daily Interval ...... sessnna 3 Maintenance Procedures at 250 Hours or 6 Months .. 4 Maintenance Procedures at 600 Hours or 1 Year ..., 5 Maintenance Procedures at 1500 Hours or 1 Year 6 Maintenance Procedures at 6000 Hours or 2 Years aajanses 7 Adjustment, Repair, and Replacement A System Diagrams .... . D Service Literature L Component Manufacturers M Service Assistance seanses s ‘Troubleshooting Symptoms .... seesenese Ts Maintenance Specitications v Warranty wImportant Reference Numbers Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service ‘or maintenance is required. Part Name: Part Number Part Number Engine Model Engine Serial Number (ESN) Control Parts List (CPL) Fuel Pump Part Number Electronic Control Module (ECM) Eleotronic Control Module Serial Numbers (ECM) Filter Part Numbers: © Air Cleaner Element ‘© Lubricating Oil Filter Fuel ‘¢ Fuel-Water Separator © Coolant ‘¢ Remote Gas Governor Control Module (GCM) (it applicable) Belt Part Numbers: ° ° Clutch or Marine Gear (if applicable): ¢ Model ¢ Serial Number ‘¢ Part Number © Oil ype. ¢ Sea Water Pump = ~ Model = Pari Number mo)‘QSM11 Marine and Industrial _ a Section i - Introduction pate Section i - Introduction Section Contents About the Manual ... General Information ‘Acronyms and Abbreviations... ‘General Information .. General Cleaning Instructions. Glass or Plastic Bead Cleaniny Solvent and Acid Cleaning. Steam Cleaning General Repair instructions.. General Information .... i Welding on a Vehicle with an Electronic Controliad Fuel System General Safety Instructions Important Safety Notice How to Use the Manual... General Information Mustrations . General information Symbols so... General Iniormation To the Owner and Operator... General InformationQSM11 Marine and Industrial Page i-b eee Section i - Introduction THIS PAGE LEFT INTENTIONALLY BLANKQSM11 Marine and Industri Tp this Owner and Operator Section i - Introduction age [1 To the Owner and Operator General Information Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines, Section 2. Keep records of regularly scheduled maintenance, Use the correct fuel, cil, and coolant in your engine as specified in the Maintenance Specifications, Section V. Cummins Engine Company, Inc, uses the latest technology and the highest quality components to produce its engines. Cummins recommends using only genuine Cummins and FeCon® parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts suppor. | you have a probiem that can not be resolved by a Cummins Authorized Repair Location, follow the steps outlined in Service Assistance, Section S. 5 About the Manual General Information This manual contains information needed to operate and maintain your engine correctly, as recommended by Cummins Engine Company, Inc. Additional service literature can be ordered trom you local Cummins Distributor or with the order form found in Service Literature, Section L. For problems with literature orders, call 1-800-DIESELS (1-800-343-7357) for U.S.A. and Canada. This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle or original equipment manufacturer (OEM) for specific maintenance recommendations. Both metric and U.S. customary values are used. The metric value is listed first, followed by the U.S. customary in brackets, Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to Symbols in ‘Section i for a complete list of symbols and their definitions. Each section is preceded by a Section Contents to aid in locating information quickly. How to Use the Manual General Information This manualis organized according to intervals at which maintenance on your engine isto be performed. A maintenance chart (table) that gives required intervals and checks to be made is located in Saction 2. Locate the interval at which you are performing maintenance; then follow the steps given in that section for all the procedures to be performed. In addition, the procedures completed under the previous maintenance intervals must also be performed. Keep a record of all the checks and inspections made. A record form for recording the date or hours at which maintenance checks and inspections were performed is located in Section 2. Refer to Section TS for @ guide to troubleshooting your engine. Follow the directions given in Section TS to locate arid corract engine problems. Refer to Section V for specifications recommended by Cummins Engine Company, Inc., for your engine. Specifications and torque values for each engine system are given in Section V.‘Symbols = QSM11 Marine and Industrial Page F2 Section i - Introduction Symbols. General Information ‘The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: A A a & Ba el gw ® & = ® WARNING - Sorious personal injury or extensive property damage can result the waming instructions are not followed, CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if ‘the caution instructions are not followed. Indicates a REMOVAL. or DISASSEMBLY stop. Indicates an INSTALLATION or ASSEMBLY stop. INSPECTION is quired. CLEAN the part or assembly. PERFORM a mecharsal or ime MEASUREMENT. LUBRICATE tho part or assombly Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to & specific torque. PERFORM an lectrical MEASUREMENT. Refer to another location in this manual or another publication for additional information. ‘The component weighs 23 kg [50 Ib] or more. Yo avoid personal injury, use @ hoist or get assistance to lit the component.‘QSM11 Marine and Industrial Section i - Introduction Illustrations General Information ‘Some of the illustrations throughout this manual are ge- eric and will not look exactly like the 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 ean differ. Mlustrations Page -3 A sateGenoral Sat ions ‘QSM11 Marine and Industrial Senora Safety Instructions Section i - Introduction Generat Safety Instructions Important Safety Notice ~~ am WARNING A “improper practices, carelessness, or ignoring the warnings can cause burns, cuts, muti ‘other bodily injury or death. Read and understand allof the safety precautions and warnings before performing any repair. This fist contains the General safety precautions that must De followed to provide personal safety, Spacial safety precautions are included inthe procedures when they apply. on, asphyxiation or «Work in an area surrounding the product thatis dry, well it, 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 wear loose-fiting or to clothing. Remove all jewelry when working. > Disconnest the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator's compartment or on the controls, + Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the 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, «+ itan engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filer cap to reliove the pressure from the cooling system. + Always use blocks or proper stands to support the product before performing any service work. Do not work (on anything that is supported ONLY by lifting jacks or a hoist, «* Relieve all pressure in the air, oil, fuel and the cooling systems before any lines, fittings, or related items are removed of disconnected. Be alert for possible pressure when disconnecting any device from a system that titlizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. + To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel ang liquid refrigerant (Freon) lines in a well ventiiated area. To protect the environment, liquid refrigerant systems must be properly ‘emptied and filled using equipment that prevents the release of refrigerant gas ("iuorocarbons) into the etmo- sphere. Federal law requires captuting and recycling refrigerant. «= To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg {50 Io] or more. Make sute all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make Sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded, 's Corrosion Inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes. ‘Avoid prolonged of repeated contact with skin, Do not swallow internally, In case of contact, immodiately wash ‘skin with soap and water. In case of contact, immodiately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. + Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safely when using these materials. KEEP OUT OF REACH OF CHILDREN. 1 To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments. ‘+ Always use tools that are in good condition, Make sure you understand how to use the tools before performing lany service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts. « Always use the same fastener patt number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quailty i replacements are necessary. + Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. 2 Some state and federal agencies in the United States of Amarica have determined that used engine oil can be ‘eareinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. + Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.—-—QSM11-Marine and Industrial General Repair Instructions - Section i - Introduction Page 5 General Repair Instructions General Information This engine incorporates the latest technology at the time it was manufactured; yet, itis designed to be repaired using normal repeir practices performed to quality standards. ‘+ Cummins Engine Company, Inc. does not recommend or authorize any modifications or repairs to engines ‘or components except for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related components can cause personal injury or death. Below is a partial listing of components classified as safety-related: ir Compressor Flywheel Mounting Capscrews Air Controls Fuel Shutoff Assemblies ‘Air Shutoff Assemblies Fuel Supply Tubes Balance Weights Lifting Brackets Cooling Fan Throttle Controls Fan Hub Assembly Turbocharger Compressor Casing Fan Mounting Bracket(s) ‘Turbocharger Oil Drain Line(s) Fan Mounting Capserews Turbocharger Oil Supply Line(s) Fan Hub Spindle Turbocharger Turbine Casing Flywheel Vibration Damper Mounting Capscrews Flywheel Crankshaft Adapter * Follow all safety instructions noted in the procedures — Follow the manufacturer's recommendations for cleaning selvents and other substances used during the repair of the engine. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances, Always use good safety practices with tools and equipment ‘+ Provide a clean environment and follow the cleaning instructions specified in the procedures, — The engine and its components must be kept clean during any repait. Contamination of the engine or components will cause premature wear. ‘+ Perform the inspections specified in the procedures. ‘+ Replace all components or assemblies which are damaged or worn beyond the specifications + Use genuine Cummins new or ReCon® service parts and assemblies — The assembiy instructions have been written to use again as many components and assemblies as possible, When it is necsssary to replace @ component or assembly, the procedure is based on the use of now Curnmins or Curmmins ReCon® components. ll ofthe repair services described in this manual are available from alt Cummins Distributors and most Dealer locations. ‘+ Follow the specified disassembly and assembly procedures to avoid damage to the components Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location, Refer to Section L — Service Literature for ordering instructions. Welding on a Vehicle with an Electronic Controlled Fuel System A cauTiON A Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine mounted components is not recommended.General Cleaning Instructions QSM11 Marine and Industrial Page i-6 Section i - Introduction General Cleaning Instructions Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degreas Celsius (180 to 200 degrees Fahrenheit. ‘A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Cummins Engine Company, Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's, instructions, 7 Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank. A WARNING A Acid is extremely dangerous and can cause personal injury and damage the machinery. Always provide a tank of strong soda water as a neutralizing agent. Wear goggles and protective clothing to avoid serious personal injury. Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all of the capscrew holes and the oil drillings. If the parts are not to be used immediately after cleaning, dip them in a suitable rustprooting compound. The rustproofing compound must be removed from the parts before installation on the engine. Steam Cleaning ‘Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. Itis a good way to clean the oi drilings. A WARNING A When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. Do not steam clean the following parts: 4. Electrical Components 4, Fusl Pump 2. Wiring 5, Belts and Hoses 8, Injectors. 6. Bearings Glass or Plastic Bead Cleaning Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time. A cauTioN A Do not use glass or plastic bead cleaning on aluminum piston si aluminum ring grooves. Small particles of glass or plastic will embe ‘wear, Valves, turbocharger shafts, etc., can also be damaged. Follow the clea procedures. NOTE: Plastic bead biasting media, Part No, 3822735, can be used to clean aluminum ring grooves. Do not use any bead blasting media on pin bores or alurninum skirts. Follow the equipment manufacturer's cleaning instructions. The following guidelines can be used to adapt to manu: facturer’s instructions: 1, Bead size a. Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No. 3822735. b. Use U.S. siza No. 70 for piston domes with glass media. @. Use USS. siza No. 80 for general purpose cleaning with glass media. 2. Operating Pressure: a, Glass: Use 620 kPa {90 psi] for general purpose cleaning. b. Plastic: Use 270 kPa [40 psi] for piston cleaning, 3. Steam clean or wash the parts with solvent to remove all ofthe foreign material and glase or plastic beads atter cleaning. Fnse with hot water. Dry with compressed ai, * 8. Do not use glass bead cleaning on in the aluminum and result in premature 19 directions listed in theQSM11 Marine and Industrial General Cleaning Instructions Section i - Introduction Page i-7 4, Do not contaminate the wash tanks with glass or plastic beads.‘Acronyms and Abbreviations QSM1i Marine and industrial Page -8 Section i - Introduction Acronyms and Abbreviations General Information ‘The fellowing list contains some of the acronyms and abbreviations used In this manual AFC Air Fuol Control APL ‘American Petroleum Institute ASA ‘Air Signal Attenuator ASTM ‘American Socioty of Testing and Materials °C Coisius CARB California Air Resources Board GD. Cubic inch Displacement cNG Compressed Natural Gas CPL Control Parts List est Gentisiokes ECM Elactroni¢ Control Module — ECs Emission Control System EPA Environmental Protection Agency EPS Engine Position Sensor oF Fahrenheit cw Grose Vehicle Weight Ho. Mercury hp Horsepower HO Water iom Ignition Control Module vt Kilometers per Liter kPa. Kilopaseal ina Liquid Natural Gas ry Low Temperature Aftercooting MP Mixer Inlat Pressure MPa Megapascal mph Milos Per Hour mpq Miles Per Quart Nem Newton-meter NG Natural Gas OEM Original Equipment Manufacturer ppm Parts Per Millon psi Pounds Per Square inch PTO. Power Takeott cpm Rovolutions Per Minute SAE Society of Automotive Engineers sca ‘Supplemental Coolant Additive ste ‘Stop Timing Control : vs Variable Speed vss Vehicle Speed SensorQSM11 Marine and industrial Section E - Engine Identification Page E-a Section E - Engine Identification Section Contents Engine Diagrams... gine Views fatine Applications .. Engine Identification ... ‘Cummins Engine Nomenclature .... ECM Datapiate Engine Dataplate Fuel Injection Punip Batapiaie Specifications. ‘Air Intake Syster Marine and industrial Applications Battorios (Specific Gravity .. Compressed Air Systom ‘Cummins 18.7 CEM Modal Cummins 87:4 CFM Model Cooling System Marine and Industial Applications Electrical System .... Exhaust System .. Marine and Industrial Applications Fuel System .. oe Marine and industrial Applications General Specifications... erste Marine and Industrial Applications Lubricating Oi! System Marine and Industrial ApplicationsQSM11 Marine and Industrial Page E-b Section E - Engine Identification THIS PAGE LEFT INTENTIONALLY BLANKQSM11 Marine and Indus Section E - Engine Identit Engine Identificat Cummins Engine Nomenclature The Cummins engine nomenclature provides the data as, iustrated in the graphic. NOTE: The following letters designate some of the different market applications for a Cummins engine. + A= agriculture + © = construction + M-= marine. Engine Dataplate The engine dataplate shows important facts about your ‘engine, The engine serial number and CPL provide data for ‘ordering parts and service. The engine dataplate must not be changed unless approved by Cummins Engine Com- pany, nc ‘The dataplate is located on the fuel pump side of the engine, on the rocker housing. Have the following engine data available when communicating with a Cummins Au- thorized Repair Location. The following information on the Beeansary Exo] Enoine | __/Scondary Engng]Electronic Controlled Fuel System Page 1-26 Hard-Coupled ae imary Ena [Secondary Engine |-——{Secondary Enaine| Soft-Coupled Marine Throttle Datalink eae ‘Secondary Secondary Soft-Coupled ‘OEM interface 21-Pin ‘OEM Interface Ramese Gonnecter —_-Haenoaa ECM ECM ¥ 24 x bes Primary be ‘Engine Engine 48 VDC Su Output Gent Provider) Hard-Coupled QSM11 Marine and Industrial Section 1 - Operating Instructions. ‘The hard-coupled configuration has all secondary engines in series. The soft-coupled marine configuration has all engines con- nacted to a 11939 dataiink. In the soft-coupied contiguration, the primary engine out pus a throttle signal on ECM pin 24. This signal is received by the secondary engine(s) on ECM pin 17. The secondary engine also receives a +5-VDC suppiy (OEM provided) to ECM pin 16 to complete the circuit. This setup allows all engines to remain running if a secondary engine stops running, In the hard-coupled configuration, the primary engine out pute athrotie signal on ECM pin 24. This signalis receives by the secondary engines) on ECM pin 17. The secondary ‘engine also receives a +5-VDC supply (OEM provided) t0 ECM pin 18, The secondary engine then outputs the throtle signal on ECM pin 24 to the next secondary engine in the Series. This process is repeated by all secondary engines nti the throttle signal and + 5-VDC supply are received by the primary engine.QSM1t Marine and Industrial Section 1 - Operating Instructions In the soft-coupled marine configuration, the primary en- gine outputs a throttle signal to the J1939 datalink pins 31, 82, and 83, Secondary engines that are connected to the datalink then read the throttle value. The sott-coupied ma- rine application also allows for primary/secondary configu- ration via wiring harness jumpers (pins 29, 39, and 36) instead of specific caliorations. The soft-coupled marine configuration uses a multiple unit synchronization on/ott switch (pins 1 and 34) to control the enabling or disabling of the engine synchronization ‘The INSITE™ service tool can be used to monitor the fol lowing parameters: ‘* Multiple unit synchronization couple type (soft- coupled, hard-coupled, or soft-coupled marine) ‘+ Multiple unit synchronization engine type (primary or secondary) ‘+ Multiple unit synchronization on/off switch “+ Paroont pulses modulate oitput (ote sor ral). The multiple unit synchronization couple type is not ad- justable by the INSITE™ service too), but the type can be changed by downloading a calibration to the ECM. ‘This feature can only be enabled or disabled by calibration. An electronic service tool (1) will be required to download ‘a calibration from the ESDN (2) to the electronic control ‘module (3) if this feature needs to be enabled or disabled. Electronic Controlled Fuel System Page 1-27 fe a a se auus ques | Jwusipewa, | | Mus onOFF CoN $ [Secondary MUSID Engine UNE: En WiringElectronic Controlled Fuel System Page 1-28 QSM11 Marine and Industrial Section 1 - Operating Instructions Intermediate Speed Control ‘The intermediate-speed control feature can control the en- gine to three programmable engine set speeds (1, 2, 9) i three different modes of operation. The three set speeds are determined by a three-position switch and atwo-position switch, The three modes of operation are a manual normal set speed operation, a low speed limit operation, and ahigh speed limit operation. NOTE: These three modes of operation are set by the ‘calibration and are not customer-adjustable. ‘An intermediate-speed droop is also programmable. NOTE: Depending on the electronic calibration, the third intermediate speed switch can act as a validation switch, ‘The purpose of the validation switch is to eliminate acci- dentally switching to intermediate speed 1 or 2. To switch tointermediate speed 1 oF 2, the validation switch must be ‘engaged first; then move the intermediate-speed switch to Yor. This feature also uses a momentary increment and dec Tement switch to raise the engine set speed while in operation.QSM11 Marine and Industrial Section 1 - Operating instructions Switched Outputs This feature provides up to two fully independent switched outputs for OEM use. The state of each switched output is determined by up to 12 different inputs to the ECM. The ECM can provide different outputs if any of the inputs are above or below calibratad thresholds. Each switched out- put is independent of the other in contiolling parameter input and threshold settings. This feature can be enabled or disabled with INSITE. The thresholds can not be ad- justed with INSITE, ‘The EOM can determine the state of the switched outputs based on the following possible inputs (either or both switched outputs can use the same inputs): * Engine speed * Fueling command (cubic mm per second) * Boost pressure (in Hg) * Auniliary speed input (rpm) + Oil pressure (psi) Coolant temperature (degrees Fahrenheit) Commanded throttle (percent) ISC 2 status (off or active) OEM temperature (degrees Fahrenheit) + OEM pressure (psi) ‘+ OEM supplied sensor (valts) ‘+ OEM supplied ewiteh (open or ground) Each of these inputs can have a specified threshold and threshold type (over or under). Each of the switched out- puts can be calibrated toelther “on” or “off” after athresh- old is crossed. Also, each output can be calibrated to change statesf either any threshold is crossedor all thresh- olds are crossed. Throttle Activated Diagnostic Switch ‘Throttle-activated diagnostic switch is intended to etimi- rate the need for a dash-mounted diagnostic switch, which is used to activate the diagnostic mode to display active fault codes in a sequence of flashing lamps. The throttle- activated diagnostic switch feature eliminates the need for a dash-mounted diagnostic switch by providing a simple ‘sequence of throttle movements that activate the diagnos- mode, NOTE: This feature will work with all throttle types. Electronic Controlled Fue! System Page 1-29Electronic Controlled Fuel System QSM11 Marine and Industrial Page 1-30 Section 1 - Operating Instructions When the engines notrunning, the keyswitch is turned on, — Essase and the feature flagis enabled, a sequence of three throttle — cycles from 30 to 70 percent within a specific time will activate the diagnostic mode. The incrementdecrement ‘switch can be used to navigate to the next or previous fault 0-30%, 70-100% Code. In case these switches are not avaliable, a throttle — yele from 30 te 70 percent will also increment to the next fault. 0-30%, 70-100%%, W&eE A sensitive mode is enabled when this feature is enabled. ‘The sensitive mode ig an algorithm that will automatically activate the diagnostic mode when the engine is not run- ning, the keyswitch is tumed on, and any throttle-related errors are detected, This allows the user to activate the diagnostic mode when throttle errors prevent them from doing so with throttle movements. Duty Cycle Monitor ‘The duty cycle monitor tracks the time the engine spends in 50 different operating regions. These operating regions Torque Duty Cycle Map ‘ - are bsoee on engine speed and engin ove. 2S slelsiat sc Lome 9 _ Noto = Sed ve “This feature provides two short-term 500-hour resettable data blocks and one long-term 100,000-hour nonrasettable data block. fea eaQSM11 Marine and Industrial Section 1 - Operating Instructions Fuel Consumption Rate Logger ‘The fuel consumption rate feature allows an electronic service tool to access fuel consumption data (1 =time, 2 gallonsihour).. ‘This feature provides two resettable 40-hour fuel consump- tion periods (1 and 2). Each period records fuel consump- tion data in forty 1-hour segments. These 40 data segments ‘can be graphed to show fuel consumption over both 40- hour periods (A=hours, B = gallons/nour). ‘An instantaneous fuel consumption rate and 2 nonreset- table lifetime or running average fuel consumption rate are available on the monitor screen of an electronic service tool. In addition, the two 40-hour fuel consumption periods are individually resattable using an electronic service tool. Electronic Controlled Fuel System Page 1-31Electronic Controlled Fuel System QSM1 Marine and Industrial Page 1-32 Section 1 - Operating Instructions. Maintenance Monitor NOTE: The maintenance monitor is designed to alert the ‘operator ofthe need fora routine maintenance stop. Main- q tenance records must still be maintained for historical pur- fae) nm poses. L NOTE: The maintenance monitor uses data received from uo [= the ECM to determine the amount of fuel burned. When- Ky ever a VSS, injector circuit, or battery voltage fault has . ‘occurred, the maintenance monitor data canbe inaccurate. The maintenance monitor is an optional feature that will alert the operator when itis time to change oll and perform any other simultaneous maintenance tasks, The mainte- hance monitor continuously monitors the time the engine has been operating and the amount of fuel burned to de- termine when it is time to change oll. ‘The operator must stil be alert for ary indications that the engine needs other service. ‘The maintenance monitor has three modes of operation: Cie TB ~ + Automatic mode ‘+ Time mode. The automatic mode alerts the operator when its time to change cil based on Cummins recommended interval. It determines the maintenance interval based on engine op- erating time and tuel burned. ‘When the automatic mode Is selected, the severe oil drain interval duty cycle is the default. ‘The original factory programmed value is AUTOMATIC.QSM11 Marine and Industrial _ Section 1 - Operating Instructions A caution A Reter to Oil Drain Intervals in Section V of this manual when selecting the correct oll change interval for your application. Cummins Engine Company, Inc. does not recommend exceeding these published intervals and is not responsible for damage sustained due to overex- tended drain intervals, ‘The maintenance monitor automatic mode is easily ad- justed to accommodate severe-, normal. or light-duty ap- plications and Valvoline® Premium Blue 2000™ engine oil, Thisis done by using a Compulink™ or Echek™ service tool to enter an interval factor that corresponds to the appro- priate duty cycle and type of product used. When selecting the correct interval factor for your app! cation, refer to Section V, Oil Drain Interval, to determine which oil drain interval duty cycle fits your application: Severe duty, normal duty, or light duty. Once the duty cycle ischosen, use an interval factor of 1.00 for severe duty, 1.50 for normal duty, and 2.00 for light duty. NOTE: These interval factors must be adjusted accord- ingly if Vaivolive® Premium Slue 2000 oil is used to extend the oil drain interval. Refer to the Vaivolive® Premium Blue 2000 product literature to determine how much your drain interval can be extended, ‘Tho time mode allows the customer to enter a desired time interval. The maintenance monitor will then monitor the time the engine has been operating and alert the operator when the interval has been consumed. Alerting the operator: The maintenance monitor will alert the operator of the need to change oll by flashing the engine protection lamp (fluids lamp) for approximately 12 seconds after key-on. The flashing sequence will be three ‘quick ashes, followed by a pause. This flash sequence will go through five cycles in the 12-second period. This 36° ‘quence will occur at every Key-on until the maintenance monitor has been reset. NOTE: The diagnostic switch must be in the OFF position for the flashing sequence to occur Electronic Controlled Fuel System Page 1-33 Pom 7 faa ao uno | 412SecondsElectronic Controlled Fuel System Page 1-34 QSM11 Marine and Industrial Section 1 - Operating Instructions Resetting the Maintenance Monitor. The maintenance monitor can be reset using an INSITE™ service tool or by following steps 1 through 10 below. Steps 3 through 8 must be done within 12 seconds in order for the maintenance monitor tobe reset. The diagnostic switch must be in the OFF position and the vehicle air system must be fully charged. 4. Tumon the keyswitch (engine must not be operating) 2, Mako sure brakes are released (service and trailer brakes) 3. Hold throttle pedal at 100-percent throttle 4, Press and release service brake three times 5. Release throttle pedal 6. Depress and hold throttle pedal at 100-percent throttle again Press and release service brake three more times . Release throttle pedal . The light will flash three times Tum off the keyswitch. Ve Release Brakes| Throttle 100% | Brake 3 Times ‘Throttle 0% ON, f if fi SL & Z x) ® ® © alo Throttle 190% | Brake 3 Times | Throttle 0% 3 Flashes x HNL asf be BY) hy ge |” ® } Yolo Ns SIeR@ all |WARNING) x ae / R i 3 -| Fun |— | Flashes ye ry ‘As soon as the throttle pedalis released (stop 8), the engine protection lamp will flash three quick flashes. This means that the reset command has been received and the main tenance monitor will resetits distance (miles or kilometers), time (hours), and fuel (gallons or liters) to zero the nexttime the Keyswitch is turned off (step 10). NOTE: If the engine protection lamp does not flash after the throttle pedal is released on step 8 above, the reset sequence must be performed again.QSM11 Marine and Industrial Section 1 - Operating Instructions When viewing maintenance monitor data with an INSITE™ service tool, the following maintenance data can be viewed (or printed from the ECM: ‘+ Percent of present interval consumed (by either dis- tance, time, or fuel burned) ‘+ Distance since fast reset * Time since last reset Resot og (distance and time at the last three resets). ‘The interval factor is only used in the maintenance moni- tor Auto mode to adjust the following applications: ‘= Severe duly = Normal duty ‘© Light duty ‘+ Extended interval when using Valvoline® Premium Blue® 2000 ‘+ Other products that extond maintenance intervals, The interval factor can be adjusted between 0 and 5.0. ‘The original factory programmed value is 1- ‘The maintenance monitor interval alert percentage al- lows the user to enter the percentage of the present interval at which the light should come on indicating the need for an oll change. The parameter allows the user to obtain an ‘early warning of the need for a maintenance stop. For example, if the distance mode is set to 24,194 km [18,000 mij and the interval alert percentage is set to $0 percent, the lamp will illuminate at 21,774 km [13,500 mi, ich is 90 percent of 24,174 km [15,000 miles]. ‘The interval alert percentage can be set between Oand 100 percent. ‘The original factory programmed value is 100 percent. Electronic Controlled Fuel System Page 1-35Electronic Controlled Fuel System Page 1-36 Section 1 - Operating Instructions Fault Lamp Sequencing ‘The fault lamp sequencing feature is used to determine ‘whether the diagnostic dashboard lamps have been in- stalled and wired correctly. After key-on, all dashboard Giagnostic lamps will turn on at once and then turn off in sequence. Diagnostic Fault Codes Marine Applications Engine Fault and Maintenance Lamps ‘The ENGINE FAULT and MAINTENANCE lamps are ilu: minated for 2 seconds when the keyswitch is turned to the ‘ON position. Alter 2 seconds, the red STOP ENGINE lamp will turn off. STOP CHECK ‘After an additional */2 second, the amber CHECK ENGINE ENGINE ENGINE) famp will turn off, After an additional '/2 second, the amber ENGINE MAINT lamp will turn of. The lamps will remain off until a fault is detected. NOTE: This is a self-test feature of the lamp wiring and lamps. NOTE: The names and colors of the lamps can vary with vessel manufacturer if non-Cummins panels are used. ‘The following chart summarizes the different lamps and their operation. Lamp Operation Feature Operator Message _[~Cheak Engine Stop Engine Engine Maint Tamp Display Power-up lamp test [On then off ‘On then off On then off Diagnostics Fault code flashout | ~Flasn once/code | Flash code Nurr= Engine Protection | __ System probi Siow flash Tntorval expired iS fast fash Intent rest ‘3x5 fast flash Diagnostics | Nonfatal system error_| On stead Diagnostics Fatal system error On steady Diagnostics | Maintenance required On steady if the STOP or CHECK ENG lamp comes on when the engine is running, it means a fault code has been. recorded. ‘The lamp will remain on as long as the fault exists. The severity of the fault will determine the lamp that will come on.QSM11 Marine and Industrial Section 1 - Operating Instructions STOP ENGINE Lamp ‘The STOP ENGINE lampis aed lamp. This lamp indicates that the engine needs to be shut down before permanent damage ocours to the engine. NOTE: The engine should be shut off as soon as it can be shut off safaly. The engine should not be run until the fault is corrected. This lamp is also used to flash out the fault code number in the diagnostic mode. CHECK ENGINE Lamp ‘The CHECK ENGINE lamp comes on during a nontatal eystem error. The engine can still be run, but the fault should be corrected as soon as possible. NOTE: In the diagnostic mode, the check engine lamp will flash after the stop engine lamp completes the three-digit fault code. ENGINE MAINT Lamp ‘The ENGINE MAINT lamp comes on when engine mair tenance is required. Engine Diagnostics When a fault or maintenance lamp is It, the engina diag- nostics switch allows the operator to view the fault codes. ‘The receptacle to the right of the switch is for the tect cian's computer connection using INSITE" or Echek™ ser- vice tool. Active fault codes can be viewed using the stop engine warning lamp as described below. Electronic Controlled Fuel System Page 1-37 ENGINE} MAINT. y/y STOF CHECK ENGINE ENGINE \/t NS ENGINE} MAINT. Wy STOP CHECK) ENGINE ENGINE! WN \MWUy ENGINE! MAINT, “IWS STOP CHECK) JENGINE ENGINE| °Electronic Controlled Fue! System Page 1-38 & of QSM11 Marine and industrial Section 1 - Operating Instructions To view the fault codes: 1, The engine must be shut off (not running) 2. The Keyswitch must be in the ON position 3, The ENG DIAG switch (1) must be in the ON position. ‘The check engine and stop engine lamps flash if there are any fault codes to display. It there are no fault codes to display, the check engine and stop engine lamps will remain lit. If there are fault codes to be displayed, the check engine lamp will lash momentarily. Then the stop engine iamp will flash the first, second, and third digits of the fault code. Example: Fault Code 432 4 flashes, pause 3 flashes, pause 2 flashes, NOTE: The check engine lamp will flash between each fault code. ‘The pattern repeats itself until the fault is cleared or the switch is turned off. To view the next fault code, press the rpm: switch (4) in the + direction, ‘To view the previous fault code, press the rpm & switch (4) in the - direction.QSM11 Marine and industrial Section 1 - Operating Instructions ‘The audible alarm (8) comes on anytime the warning or caution symbols are illuminated, ‘The alarm slience button (6) will temporarily silence the audible alarm, NOTE: The alarm will be silenced for up to 2 minutes. As Jong as the fault condition exists, the alarm will “chirp” ‘every 2 minutes to remind the operator that a fault exists, The alarm silence button (6) is also usedto test the warning ‘and caution symbo! lamps (1) and the gauges. NOTE: To test the gauges and symbol lamps, press the alarm silence button (6) while turning on the keyswitch, The alarm will come on for § seconds and for 25 seconds all symbols will illuminate and the gauge needies will move from the lowest position to the highest position and back to the lowest position, Industrial Applications ‘The system can show and record operation irregularities that present themselves as fault codes. These codes will ‘make troubleshooting easier. The fault codes are recorded in the ECM. They can be read using the two fault lamps in the cab panel or with INSITE™, NOTE: Not all engine irregularities are shown as fault codes. Electronic Controlled Fuel System Page 1-39Electronic Controlled Fuel System Page 1-40 “O|@ ‘There are two types of fault codes: ‘+ Engine electronic fuel system codes ‘+ Engine-protection system codes. ‘The engine electronic fuel system fault codes can be seen ‘on the WARNING and STOP lights in the cab panel. NOTE: Inactive fault codes can not be blinked out on the {wo lights in the cab panel. An INSITE™ service tool must bbe used to read inactive faults in the ECM, Refer to your Cummins Authorized Repair Location. The STOP fauitlight will be red. The WARNING light willbe yellow or red, depending on the OEM’s preference. When the vehicle keyswitch is turned on and the diagnostic switch isoff, al three lights wil illuminate to check their operation. ‘The lights will go off in sequence after about 2 seconds. ‘The lights will remain off until a fault code is recorded. If a light remains on, an active fault exists. {f the STOP light (red) is illuminated while operating, the fault can be engine disabling. The equipment must be shut off as soon as it can be done in a safe manner. The equip ‘ment must remain parked as long as this fault exists. Ifthe WARNING light (yellow or red) is illuminated, the equip- ment can be safely operated, but the fault must be cor- rected as soon as possible.QSM11 Marine and Industrial Section 1 - Operating instructions ‘The engine protection system logs separate fault codes for ‘ut-of-range conditions associated with any ofthe following sensors: * Coolant temperature * Coolant level + Oil temperature + Oil pressure ‘+ Intake manifold temperature, This system will activate an in-cab warning device when an ‘outiofrange condition occurs. The warning device is a light, a buzzer, or both. This system will also activate the yellow tiuid lamp, if equipped. If the engine protection system light or buzzer comes on ‘while driving, it means a fault code has been recorded. The tamp will remain on as long as the fault exists, and engine Power and speed will gradually be reduced. If the out-oF ange conditions continue, the light will start to flash or blink. I the engine protection shutdown feature is enabled, the engine will be shut down to help prevent engine dam: age. ‘The fault must be corrected as soon as possible, ‘Tum off the engine. To check for engine electronic fuel system and engine protection system fault codes, move the iagnostic switch to the ON position, or connect the short- ing plug into the diagnostic connector. Electronic Controlled Fuel System Page 1-41 Fautt Code oN off OFFElectronic Controlled Fuel System Page 1-42 ON Ht ON fears] perm Neat Bees Eee Recorded weneor Sel) Foor comet sor || const © Flashing = uo el ae || Be a | ee Example Fault Code Sequences Savery i —— = SSE Ey fe 1 1 Bir 1 Blink Bink a, Fault Code QSM11 Marine and industrial Section 1 - Operating Instructions ‘Tur the keyswitch to the ON position. If no active fault codes are recorded, both lights will come ‘on and stay on. f active fault codes are recorded, both lights will come on momentarily, then begin to flash the code of the recorded faults. ‘Tho fault code will flash in the following sequence: First, a WARNING (yellow) light will lash. Then there will be a short 1- or 2-second pause after wich the number of the recorded fault code will fash in STOP (red). There will bea 1- or 2-second pause between each number. When the number has finished flashing in red, @ yellow light will ‘appear again, The three-digit code will repeat in the same sequence. ‘The lights will continue to flash the same code until the system is told to do something else. To go to the next fault code, move the CRUISE CONTROLIPTO switch momen- tarily to the RESUME/ACCEL position. You can go back to the previous fault code by momentarily moving the CRUISE CONTROLIPTO switch to the SET/COAST position. It only one active fault is recorded, the system will continuously display the same fault code when elther RESUME/ACCEL or SETICOAST switch is depressed.QSM11 Marine and Industrial Section 1 - Operating Instructions Engine Protection System Marine and Industrial Applications ‘The engines are equipped with an engine protection eys- tem, The system monitors critical engine temperatures and, pressures, and will log diagnostic faults when an abnormal ‘operating condition occurs. If an out-of-range condition, exists and engine derate action is to be initiated, the op- erator will be alerted by an in-cab warning light. The warn= ing light witl blink or flash when out-o-range conditions continue to get worse. The driver must pull to the side of the road, when itis safe to do $0, to reduce the possibility of engine damage. NOTE: Engine power and speed will be gradually reduced, depending on the level of severity of the observed con tion. The engine protection system wil not shut down the ‘engine unless the engine protection shutdown feature has been selected. If the feature has been selected and the engine does shut down, the engine can be restarted by turing off the keyswiteh, then turning it back on. ‘The indicator symbols (1) provide additional information on the type of fault that the ECM has detected. The individual symbols will flash during a fault condition, NOTE: Pressing the alarm cancel button (6) when the key: ‘switch is turned on will illuminate the symbols for aseli-tast. Low Engine Oil Pressure “The low engine oil pressure lamp (7) comes on when the engine cil pressure is below specification. Refer to Section \V for the ail pressure specifications. Electronic Controlled Fuel System Page 1-43Electronic Controlled Fuel System Page 1-44 QSM11 Marine and Industrial Section 1 - Operating Instructions High Intake Manifold Temperature ‘The high intake manifold temperature lamp (1) comes on when the intake manifold temperature is above specification, High Engine Oil Temperature ‘The high engine oll temperature lamp (2) comes on when the engine oll temperature is above specification. Water in Fuel ‘The water-in-fus! lamp (8) interfaces with the optional water- in-fuel sensor in the primary fuel filter, It comes on when there is water in the fuol filter. High Coolant Temperature The high coolant temperature lamp (4) comes on when the engine coolant temperature is above specification.QSM1i Marine and Industrial Section 1 - Operating Instructions Low Coolant Level The low coolant level lamp (6) comes on when the coolant level is below specitication. Refer to Section V for the coolant specifications. Low Battery Voltage NOTE: This voltage lamp only applies to marine applica- tions. ‘The low battery voltage lamp (6) comes on when the battery voltage is below specification, Circuit Breakers Marine Applications The QSM1t marine engine is equipped with two circuit breakers, located on the ECM side of the engine. A 5.amp circuit breaker (1) is used for keyswitched power and a 10-amp circuit breaker (2) is used for nonkeyswitched ower. The circuit breaker panel also houses a 40-pin OEM ‘connector (3) Electronic Controlled Fuel System Page 1-45Electromagnetic Interference (EMI) QSM11 Marine and Industrial Page 1-46 Section 1 - Operating Instructions Electromagnetic Interference (EMI) General Information Marine and Industrial Applications Some heavy-duty diese! engine applications ullize accessories (CB radios, mobile transmitters, and so forth) that generate and use radio frequency energy that, if not installed and used properly, can cause electromagnetic inter- {erence conditions to exist between the accessory and Cummins electronically controlled fuel system, Cummins is not liable for any performance problems with either the fuel system or the accessory due to electromagnetic interference. Electromagnetic interference Is not considered by Cummins to be an engine failure and, therefore, is not wartantable. System EMI Susceptibility Marine and Industrial Applications Your Cummins product has been designed and tested for minimum sensitivity to incoming electromagnotic energy. “Teating has shown that there is no engine performance degradation at relatively high energy levels; however if very high energy levels are encountered, then come noneritical diagnostic fault code logging can occur. The fusl system electromagnetic interference susceptibility evel will protect your engine from most, if not all, electromagnetic energy- emitting devices that meet the Federal Communications Commission legal requirements. ‘System EMI Radiation Levels Marine and Industrial Applications ‘Your Cummins product has also been desioned and tested to emit minimum electromagnetic energy. Testing has shown that the fual system, when properly installed on vehicles, meets or exceeds by a wide margin Part 15 of the Federal ‘Communications Commission Rules and SAE J1551 specifications. Other accessories should be designed with the proper filtering to reject electromagnetic noise emission from their system. Experience has shown that tne electronically ‘controlled fuel system on vehicles will not inter‘ere with onboard communication equipment for urban and suburban background electromagnetic noise levels; however, the system, if used with accessories that are not installed properly ‘or do not utilize adequate filtering designs, can interfere with onboard communications equipment in rural applications where background radio frequency noise levels are very low. If an interference condition is observed, follow the suggestions below to reduce the amount of interference: 4. Locate the receiving antenna as far away from the engine and as high as possible, 2. Locate the receiving antenna as far away as possible from all metal obstructions (exhaust stacks, and so forth). 3. Consult a representative of the accessory supplier in your area to: — Calibrate the device for proper frequency, power output, and sensitivity (both base- and remote-site devices must be properly calibrated accurately — Obtain antenna reflective energy data measurements to determine the optimum antenna location = Obtain optimum antenna type and mounting arrangement for your application = Make sure your accessory equipment model s built for maximum ftering o eject incoming electromagnetic noise.QSM11 Marine and Industrial Section 1 - Operating instructions Operating Techniques General Information The engines produce maximum power at an rpm fess than governed engine speed. ‘To obtain optimum engine performance on a grade, allow the engine speed to load down to near torque peak before shifting. This will result in an engine operating speed in the ‘maximum power zone after the shift is completed. Refer to the engine dataplate for torque peak rpm and ‘governed speed rpm. Operating Techniques Page 1-47 Power rpm Max. Power Governed Speed soonOperating Techniques QSM11 Marine and Industrial Page 1-48 Section 1 - Operating Instructions NOTES.QSMI11 Marine and industrial Section 2 - Maintenance Guidelines Page 2a Section 2 - Maintenance Guidelines Section Contents Page Maintenance Guidelines - Overview... : 2a General Information .. : 2A Maintenance Record Form 26 Maintenance Data 26 Maintenance Schedule 22 Genoral Information ... 22 Marine Applications... 22 il Drain Intervals 228 24 jeneral Information .. 24 Tool Requirements... a General Information ny BaQSM11 Marine and Industrial Page 2-b Section 2 - Maintenance Guidelines THIS PAGE LEFT INTENTIONALLY BLANKQSM11 Marine and Industrial 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 enging is operating in ambient temperatures consistently below -18°C [0°F] or above 38°C [10°F], perform ‘maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a dusty environment. Contact your Cummins Authorized Repair Location for recommended intervals. ‘Some maintenance procedures require special tools or must be performed by a qualified technician. These procedures are outlined in the specific manuals as follows: Procedure Bulletin Description. Repair and rebuild components ‘9668075 Shop Manual, M11 Series Engines Troubleshoot and repair components, 3666322 Troubleshooting and Repair Manual, ISM/ QSM11 Series Engines Troubleshoot and repair electronics 9666268 Troubleshooting and Repair Manual Elec: tronic Control System, ISM and QSW1t En- gines is equipped with a component or an accessory not manufactured by Cummins Engine Company, inc., mponent manufacturer's maintenance recommendations, Use the chart provided at the end of this section as a convenient way to keep a record of maintenance performed. Tool Requirements General Information Most of the maintenance operations described in this manual can be performed with common hand tools, metric and ‘SAE wrenches, sockets, and screwdrivers, ‘The following is a list of special service tools required for some of the maintenance operations: Tool Part Number: Description: 3397028 Oil filter wrench 3376592 Torque wrench (valve and injactor adjustment) 8163196 ‘Torque wrench adapter (used with 3976592 torque wrench) 3823024 Injector puller 3998145 Engine coolant and fue! filter wrench 3822524 Belt tension gauge, click type (v-belts and v-ribbed with 4 or 5 ribs) 3822525 Belt tension gauge, click type (v-ribbed with 6 to 12 ribs) ST-138 Belt tension gauge (v-belts) sT-s37 Dial depth gauge sT-1272-1 Chip removing toot sT-1293, Belt gension gauge (v-ribbed belts) cc-2800 Refractometer cc-2602 Coolant test kit Contact your nearest Cummins Authorized Repair Location for the required service tools,Maintenance Schedule QSM11 Marine and Industrial Page 2-2 Section 2 - Maintenance Guidelines Maintenance Schedule General Information Marine Applications ‘QSMi1 Marine and Industrial Applications Maintenance Schedul Daily of Refueling |] Every 250 Hours or 6 Every 600 Hours or 1] Every 1500 Hours or [Every 6000 Hours or Months" Year! + Year" 2 Years! ‘> Operators report |» Replace fuel fiter Marine ‘= Chock: "> Flush cooling sys Drain fuelswater | (spin-on type) © Adjust overhead | — Water pump tem Separator © Change: set = Turbocharger | # Check vibration © Check: = Lubricating oil = Engine mounting] damper = Drive belts and filters bolts Industrial = Lubricating oi! | ~ Coolant fiter ~ Air leaks, air in- | © Check: level © Check: take and exhaust] - Fan drive Idler = Coolant level | = Supplemental systems lley assembly = Air cleaner re- coolant additive = Aircleaner as- | — Fan hub, belt striction (SCA) sembly (engine- driven Marine = Engine wiring mounted) = Turbocharger © Disassemble, harness = Cooling system | — Air compressor clean, prime and Marine hoses assemble sea wa- |e Inspect sacrificial = Batteries ter strainer plug = Air cleaner ré * Check marine striction ar ‘* Clean engine Industrial Marine © Drain air tanks ‘Inspect sea water and reserveirs pump «Check: «Flush sea water = Crankcase system breather tube Industrial = Charge-air pip- ‘ Adjust overhead ing set © Inspect fan, cook ‘© Check radiator ing shutter assembl Note: Refer to the appropriate sections for complete inspection and maintenance procedures. 1. These maintenance intorvals must be performed at hours or months, whichever interval occurs first. At each scheduled maintenance interval, perform all previous maintenance procedures that are due for scheduled maintenance. 2, Follow the gear manufacturer's recommended maintenance procedures for checking, fling, and changing oil. Some gear manufacturers require an initial oil change at low hours, in addition to their regular mainte- nance. 2. Fuel bum is the most accurate method for determining oll change intervals. Oil change intervals can bo re- quired more frequently, depending on the quaiiy of ol available. Refer to the Oil Drain Intervals tablo inthis Section for additional oil change intervals. 4. Do not change the coolant fiter if the SCA concentration level is over three units. 8. Depending upon the quality of electrical bonding and water conditions, increased maintenance of the zinc anode plugs could be necessary.QSM1i Marine and industri Maintenance Schedule Section 2 - Maintenance Guidelines Page 2-3 Oil Drain Intervals ‘GSM Marine Engines - Oil Drain Intervals O11 Type Fuel Burned Hours Months | A@peplable Ora G65 thers [1750 gal] 15 a Tr9001" Cet 73,249 liters [9500 gal] 250 é TF900T CH-4 (OES 20077 78,142 liters (4000 gal) 300 1% Lra0oT CES 20076" 15.142 Iters (4000 gal) 300 2 LFBOOT™, Note: 1. CF-4 oil isnot recommended and should only be used if better quality oil isnot available, 2. Valvoline® Premium Biue® meets and exceeds API CH-4 and CES20071 specifications, 3. Valvaline® Premium Blue 2000 meats and exceeds CES 20076 specifications. 4, Oil filters must meet CES 10065 specifications. LF9001meets and exceads CES 10065 specifications. (QSMii industrial Engines - Oi Drain Intervals by Duly Gyele (hours) ‘Severe Heavy Medium Tight Fuel Consumption >13 gainer 10 to 13 galshr Paster < 88 gal/hr APIO 150 200 250 300 ‘APL GG 250. 300. 400 500. ‘API GH-4 or AGEA ES 3007 350 300. B00. (CES20076 or CES20077 350 400 350 700 Note 1, Valvoline Premium Blue and Premium Blue 2000 mest 20076 standards. 2, Limit oif change interval to 250-hour max for all oil grades if 40% of the operating time is in ambient tem- peratures above 98°C [100°F] to prevent engine damage due to oll degradation resulting from righ ot peratures. 3, Cummins does not recommend the use of CE or CD grade oils. If CO or CE cils must be used, make the Ol drain intervals half of tne API CF values, 4. Engine oil drain intervals need to be reduced by 50% when fuel sultur content exozeds 0.5%. 5. Oil fiers must meet CES 10065 specications. LFG001 meets and exceads CES 10066 specifications,Page References for Maintenance Instructions QSM11 Marine and industrial Page 2-4 Section 2 - Maintenance Guidelines Page References for Maintenance instructions General Information For your convenience, listed below are the page numbers that contain specific instructions for performing the main- tenance cheoks listed in the maintenance schedule. Daily or Retueling Air Cleaner Restriction - Maintenance Check 38 ‘Air Tanks and Reservoirs - Drain 9 Charge-Air Piping - Maintenance Check woe 38 Coolant Level - Maintenance Check 38 Crankcase Breather Tube - Maintenance Check... caer 2 Drive Bolts - Maintenance Check 38 Fan, Cooling - Inspect for Reuse sone Bo Fusl-Water Separator - Drain 2 Lubricating Oit Level - Maintenance Check 33 ‘Marine Gear - Maintenance Check 38 ‘Sea Water Strainer: General Information Prime. Every 250 Hours or 6 Months Coolant Filter: Install nese Remove Engine Wiring Harness Fuel iter (spn-ortype: Install. Remove enn Lubricating Oil and Filters: Drain’ Fill Sacrificial Plug Inspect for Reuse Install. Remove ‘Supplemental Coolant Additive (SCA) - Maintenance Check... Every 600 Hours or 1 Year Overhead Set - Adjust. Every 1500 Hours or 1 Year Air Cleaner Assembly (engine-mounted) - Maintenance Check Ais Cleaner Restriction - Maintenance Check .. Air Leaks, Air Intake and Exhaust Systems - Maintenance Check Batteries - Maintenanoa Cheok swine Cooling System Hoses - Maintenance Check Engine Mounting Bolts - Maintenance Check ..