SPT03T0-15+INTRODUCCION MOTORES QSB3.9,QSB4.5,QSB5.9 INDUSTRIAL

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Publications Affected by This Service Parts Topic

Engine Operation andMaintenance

Base Engine Trouble-shooting and Repair

Fuel Troubleshoot-ing and Repair Shop

QSB3.9-30 3666194QSB4.5-30 3666194

QSB5.9-30 3666194

NOTE: Publications identified as Other include the following: 1 Master Repair Manual, 2 Parts Catalog, 3 Specifi-cations Manual, 4 Alternative Repair Manual, 5 Wiring Diagram, and 6 Features Manual.

Warranty Impact

None The information in this document has no effect on current warranty coverages or repair practices,nor does it authorize TRP or Campaign actions.

This service/parts topic introduces the latest versions of theQSB industrial engines. Thenew QSBX.X-30 engines willmeet the next level of both Envirnomental Protection Agency (EPA) and European emissions requirements whileproviding increased performance and reliability.

TheQSB.X-30 engines bring theadvantages of current full authority electronic controls to the industrialmarket as wellas the base engine reliability of the 2-valve current product engines. The electronic controls include: higher powerratings, electronic remote throttles, electronic fault codes, and built-in engine protection for oil pressure, coolanttemperature, intake manifold temperature, coolant level, and OEM-supplied pressures.

The QSBX.X-30 engine’s fuel system is the Bosch VP30 electronic rotary fuel injection pump. The VP30 is basedon the full authority electronic Bosch VP44 rotary fuel injection pump and the mechanical Bosch VE rotary fueinjection pump. The VP30 uses the mechanical body and pumping controls of the VE with the same electronic PDMas the VP44. By using the PDM fromthe VP44, the VP30 is able to use many of the same fault codes and all of theCummins electronic service tools.

The following table explains the differences between the new names of the QSB industrial engines.Engine Family Liter Displacement Fuel Injection Pump

TypeAspiration Type

QSB5.9-44-TAA 5.9 Bosch VP 44 Charge air cooledQSB5.9-30-TAA 5.9 Bosch VP 30 Charge air cooled

QSB5.9-30-T 5.9 Bosch VP 30 Turbocharged onlyQSB4.5-30-T 4.5 Bosch VP 30 Turbocharged only

QSB3.9-30-TAA 3.9 Bosch VP 30 Charge air cooled

Service/PartsTopics

T14Date J uly, 2003

Application:Industrial

No.03T0-15

Fuel Type:Diesel Only

File Group:00

SubjectIndustrial QSB3.9-30, QSB4.5-30, and QSB5.9-30

Cummins Inc., Columbus, Indiana 47202-3005Cummins Engine Company Ltd., Daventry, Northants, England NN11 5NURegistered Office: 46-50 Coombe Road, New Malden, Surrey KT3 4QLRegistered No. 573951 EnglandCopyright 2003

Cummins Inc.All rights reservedPage 1 of 48

http://summary.pdf/



Table of Contents

Engine Ratings .......................................................................................................................................... Page 3

New Engine Information ............................................................................................................................ Page 3

Electronic Features .................................................................................................................................... Page 4

Additional Service Literature ...................................................................................................................... Page 8

03T0-15Page 2



Engine Identification .................................................................................................................................. Page 9

Engine Diagrams ..................................................................................................................................... Page 13

Maintenance Schedule ............................................................................................................................ Page 28

Tool Requirements ................................................................................................................................... Page 29

Fuel Injection Pump, Rotary ..................................................................................................................... Page 30

Overhead Set .......................................................................................................................................... Page 36General Engine ........................................................................................................................................ Page 39

Fuel System ............................................................................................................................................. Page 39

Lubricating Oil System ............................................................................................................................. Page 39

Cooling System ....................................................................................................................................... Page 40

Air Intake System ..................................................................................................................................... Page 40

Exhaust System ....................................................................................................................................... Page 40

Electrical System ..................................................................................................................................... Page 40

Cummins/Fleetguard / Filter Specifications .............................................................................................. Page 41

Fuel Recommendations and Specifications .............................................................................................. Page 41Lubricating Oil Recommendations and Specifications .............................................................................. Page 42

Coolant Recommendations and Specifications ......................................................................................... Page 45

Engine Ratings

All QSB3.9-30, QSB4.5-30, and QSB5.9-30 engines use the Bosch VP30 electronically controlled fuel system. Inaddition, each engine is equipped with a Cummins designed electronic control module (ECM). Using these compo-nents, the available ratings are as follows:

EngineModel

AspirationType

RatedPower kW

(hp)

RatedSpeed(rpm)

Peak TorqueN-m (ft-

lb)

Peak TorqueSpeed(rpm)

GovernorBreak (rpm)

HighIdle

(rpm)

LowIdle

(rpm)

CPL

QSB5.9-30 Charge aircooled 138 (185) 2500 780 (575) 1500 2530 2707 750 8186QSB5.9-30 Charge air

cooled138 (185) 2200 780 (575) 1500 2230 2386 750 8296

QSB5.9-30 Charge aircooled

129 (173) 2500 719 (530) 1500 2530 2707 750 8186


129 (173) 2200 800 (590) 1500 2230 2386 750 8296


123 (165) 2000 733 (541) 1500 2030 2172 750 8400

QSB5.9-30 TurbochargedOnly

116 (155) 2500 597 (440) 1500 2530 2707 750 8187


116 (155) 2300 597 (440) 1500 2330 2493 750 8428


116 (155) 2200 597 (440) 1500 2230 2386 750 8300


104 (140) 2200 588 (434) 1500 2230 2386 750 8339


97 (130) 2500 506 (373) 1500 2530 2707 750 8340


97 (130) 2200 542 (400) 1400 2230 2386 750 8341


82 (110) 2500 414 (305) 1500 2530 2707 750 8263


82 (110) 2200 414 (305) 1500 2230 2386 750 8343


82 (110) 2500 414 (305) 1500 2530 2707 750 8401

03T0-15Page 3

(Continued)



EngineModel

AspirationType

RatedPower kW

(hp)

RatedSpeed(rpm)

Peak TorqueN-m (ft-

lb)

Peak TorqueSpeed(rpm)

GovernorBreak (rpm)

HighIdle

(rpm)

LowIdle

(rpm)

CPL


82 (110) 2200 414 (305) 1500 2230 2386 750 8402


97 (130) 2500 481 (355) 1500 2530 2707 750 8240

QSB3.9-30 Charge aircooled 93 (125) 2200 481 (355) 1500 2230 2386 750 8335


89 (120) 2500 475 (350) 1500 2530 2707 750 8334

Electronic Features

The customer can view, adjust, and enable/disable electronic features on the engines using the INSITE ™computer-based service tool. These programmable features include the following:

1. Accelerator Options

2. Alternator Droop

3. Automatic Boost Power

4. Fan Control

5. Fuel Consumption Rate Logger

6. Hot Shutdown Monitor

7. Idle Shutdown

8. Intermediate Speed Control

9. Multi-unit Synchronization

10. Remote Throttle

11. Switchable (alternate) Torque

12. Throttle Diagnostic Switch

13. Water-in-Fuel Sensor.

Refer to the QSB3.9-30, QSB4.5-30, QSB5.9-30 Operation and Maintenance Manual, Bulletin 4021388 for furtherexplanations of electronic features.

New Engine InformationGeneral InformationBase Engine (QSB4.5-30)

Thefollowingtableshows thenewcamshaft, connectingrods andbearings, crankshaft, cylinderhead, andengineblockfortheQSB4.5-30engine. TheQSB3.9-30andQSB5.9-30willusethe2-valvecurrentproductbaseenginecomponents.All of thenew QSB engines usefracture-splitconnecting rods. Refer to theTroubleshooting and Repair Manual for theupdated removal and installation procedures for the fracture-split connecting rods and rod caps.

Part Description Part Number Service Kit Part NumberBlock, engine 3938366 4089546

Camshaft 3968381 NAConnecting rod 3939407 NA

Connecting rod bearing(upper)

3939380 NA

Connecting rod bearing(upper)

3939390 NA

Crankshaft 3939367 NACylinder head 3968196 NA

03T0-15Page 4



Fuel Filter Heads

TheQSB3.9-30, QSB4.5-30, and QSB5.9-30engines will incorporate new3micronfuel filters.Because ofthe3 micronfuel filters, the new fuel filterhead adapter will not be compatiblewith older fuel filters. The following table shows partnumbers for the new fuel filter heads and adapters.

Fuel Filter Head PartNumber

Adapter Part Number

3942627 3942453

Fuel Injection Pumps

All QSB3.9-30, QSB4.5-30, and QSB5.9-30 engines are equipped with the Bosch VP30 fuel pump. This is anelectronically-controlled rotary distributor fuel pump. The fuel pump is controlled bythe Cummins ECM. The injectiontiming is electronically-controlled.

Fuel Injection Pumps QSB3.9-30, QSB4.5-30, and QSB5.9-30Engine Type Voltage Fuel Injection Pump Part

NumberQSB3.9-30 and

QSB4.5-3012VDC 3965404

QSB3.9-30 andQSB4.5-30

24VDC 3965405

QSB5.9-30 12VDC 3965402QSB5.9-30 24VDC 3965403

Fuel Transfer Pumps

Mechanical diaphragm-style fuel transfer pumps are used for the QSB3.9-30, QSB4.5-30, and QSB5.9-30 engines.

Fuel Transfer PumpsEngine Type Inlet Size Fuel Transfer Pump Part

NumberQSB4.5-30 1/4 inch 3966156

QSB4.5-30 andQSB5.9-30

1/4 inch 3966154

Injectors

All QSB3.9-30, QSB4.5-30, and QSB5.9-30 engines are equipped with fuel injectors with edge filters. The edge filtershelp protect the injectors fromforeign material thatmayhave entered the fuel system by using fuel pressure to breakup the material.

InjectorsEngine type Injector Nozzle Part

NumberInjector Kit Part Number

QSB3.9-30-TAA 3939696 4089270QSB4.5-30-T 3964919 4089468QSB5.9-30-T 3929490 3802677

QSB5.9-30-TAA 3939696 4089270

Injector Supply Lines

Thefollowing tableshows theinjectorsupplylinepartnumbers fortheQSB3.9-30, QSB4.5-30, andQSB5.9-30engines.

QSB3.9-30 Injector Supply LinesCylinder/Line Number Part Number

Number 1 3964494Number 2 3964496Number 3 3964499Number 4 3964501


Number 1 3964867Number 2 3964869Number 3 3964872

03T0-15Page 5

(Continued)




Number 4 3964874

QSB5.9-30-T Injector Supply LinesCylinder/Line Number Part Number

Number 1 3964731

Number 2 3964732Number 3 3964733Number 4 3964734Number 5 3964735Number 6 3964736

QSB5.9-30-TAA Injector Supply LinesCylinder/Line Number Part Number

Number 1 3964703Number 2 3964704Number 3 3964705Number 4 3964706Number 5 3964723Number 6 3964724

Pistons

The following table shows the piston part numbers for the QSB3.9-30, QSB4.5-30, and QSB5.9-30 engines.

PistonsEngine Type Piston Number Piston Kit NumberQSB4.5-30 3939398 4089462

QSB3.9-30, QSB5.9-30 3957416 4089461

Turbochargers

Holset HX30W and HX35W turbochargers have been optimized for the QSB3.9-30, QSB4.5-30, and QSB5.9-30engines.

Turbochargers QSB3.9-30-TAATurbocharger Part Num-

berOrientation Wastegate Pressure

(Bar)Turbocharger Kit Part

Number3598544 High-mount rear-out 1.48 40893193598545 High-mount rear-out 1.43 40893203598546 High-mount front-out 1.48 40893193598547 High-mount front-out 1.43 40893203598548 Low-mount rear-out 1.48 40893193599994 High-mount rear-out 1.43 4089320

Turbochargers QSB4.5-30-TTurbocharger Part Num-



Number4035053 High-mount front-out 0.85 4089467

4035054 High-mount front-out 0.85 40894674035055 Low-mount rear-out 0.85 4089467

Turbochargers QSB5.9-30-TTurbocharger Part Num-



Number3599726 High-mount rear-out 1.32 40894663599728 High-mount front-out 1.32 40894663599730 Low-mount front-out 1.32 4089466

03T0-15Page 6



Turbochargers QSB5.9-30-TAATurbocharger Part Num-



Number3596990 High-mount front-out 1.65 40253273596991 High-mount rear-out 1.65 40253283596992 Low-mount rear-out 1.65 40253283599480 Low-mount front-out 1.65 4089465

4035036 High-mount rear-out 1.65 40253284035037 High-mount rear-out 1.65 40253274035296 High-mount front-out 1.65 4025328

Water Pumps

Waterpumpswithstandardandhardenedpulleyswith revised weepchambers areusedfortheQSB3.9-30, QSB4.5-30,and QSB5.9-30 engines.

Water Pump Part Num-ber

Pulley Material Water Pump Kit PartNumber

3285410 Standard 32862753285411 Hardened 3286227

Additional Service Literature

The QSB3.9-30, QSB4.5-30, and QSB5.9-30 engines will have a new Operation and Maintenance manual. Service-related information for the engine will beadded to the currenttroubleshootingandrepair manuals attheirnextrevisionand through Quikserv Online.

03T0-15Page 7



Additional Service LiteratureGeneral Information The following publications can be purchased:

Bulletin Title of Publication

3379001 Fuel for Cummins Engines Bulletin

3810340 Cummins Engine Oil Recommendations Bulletin

3666132 Coolant Requirements and Maintenance Bulletin

3379009 Operation - Cold Weather Bulletin

3379000 Air for Your Engine

3666017 B Series Shop Manual

3666028 6B, B5.9, ISB (6cylinder), ISB 3 (6 cylinder), QSB5.9-44, and QSB5.9-30 Series Stan-dard Repair Times

3666029 4B, B3.9, ISB (4 cylinder), ISB 3 (4 cylinder), QSB3.9-30 Series Standard Repair Times

3666109 Alternative Repair Manual, B and C Series Engines

3666193 Troubleshooting and Repair Manual, ISB and QSB5.9 Engines

3666194 Troubleshooting and Repair Manual, Electronic Control System, ISB and QSB5.9 En-gines, Volumes I and II

4021388 Operation and Maintenance Manual, QSB3.9-30, QSB4.5-30, and QSB5.9-30 SeriesEngines

4021399 QSB3.9-30, QSB4.5-30, and QSB5.9-30 Wiring Diagram

03T0-15Page 8



Engine IdentificationEngine Dataplate The engine dataplate shows specific facts about the en-gine.

The engine serial number and control parts list (CPL) pro-

vide data for ordering parts and service. The engine dataplate must not be changed unless ap-proved by Cummins Inc.

03T0-15Page 9



Have the following engine data available when communicating with a Cummins Authorized Repair Location. Theinformation on the dataplate is mandatory when sourcing service parts.

1. Control parts list (CPL)

2. Model

3. Engine serial number

4. Emissions certification

5. Horsepower and rpm rating.

03T0-15Page 10



NOTE: If the engine dataplate (1) is not readable, theengine serial number (2) can be identified on the engineblock, on top of the lubricating oil cooler housing. Addi-tional engine information is available by reading the ECMdataplate.

Cummins Engine Nomenclature The model number on the dataplate will be as shown.

NOTE: A QSB enginewith VP44fuelsystemwll bevisuallydistinguishable from a VP30 engine by the valve cover. A

VP44enginewill have a one-piece valve coverand a VP30engine will have individual valve covers.

The model name for the QSB engines provides the datashown below. For example:

QSB (1) 3.9 (2) - 30 (3) -TAA (4)1. Engine series2. Displacement in liters3. Fuel system identifier4. Aspiration Code

T: Turbocharged only TAA: Charge Air Cooled.

Fuel Injection Pump Dataplate

The VP30 fuel injection pump dataplate is located on thesideof the fuel pump. The dataplatecontains the followinginformation:

A. Pump serial numberB. Cummins part numberC. Key identifierD. Factory codeE. Bosch part numberF. Date code.

03T0-15Page 11



ECM Dataplate The electronic control module (ECM) dataplate shows in-formation about the ECM and how the ECM was pro-grammed. Thedataplate is locatedon theECM, above theECM connectors.

ThefollowinginformationisavailableontheECM dataplate:• ECM part number (PN)• ECM serial number (SN)• ECM date code (DC)• Engine serial number (ESN)• ECM code: Identifies the software number in the

ECM.

NOTE: Have theECM code for your engineavailable whencommunicating with a Cummins Authorized RepairLocation.

03T0-15Page 12



Engine DiagramsEngine Views The following illustrations show the locations of the major external engine components, filters, and other service andmaintenance 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.

1. Engine air inlet2. Intake manifold temperature sensor

3. Intake manifold pressure sensor

4. Fuel filter/water separator

5. Lubricating oil dipstick

6. Fuel inlet connection

7. Magnetic pickup location, 3/4 -16 UNF

8. Electronic control module (ECM)

9. Crankcase breather tube

10. Fuel lift pump

11. Lubricating oil pressure switch12. Fuel drain connection

13. Engine position sensor

14. Front engine mounting bracket

15. Engine dataplate

16. High pressure fuel lines

17. Fuel injection pump

18. Intake air preheater (optional).

QSB3.9-30 Air Intake Side View

03T0-15Page 13



1. Rear engine lifting bracket

2. Turbocharger exhaust outlet

3. Flexplate mounting holes

4. Flywheel housing

5. Flywheel/flexplate.

QSB3.9-30 Rear View

03T0-15Page 14



1. Fuel injection nozzles

2. Turbocharger wastegate activator

3. Lubricating oil fill

4. Front engine lifting bracket

5. Water outlet

6. Lubricating oil filter7. Water inlet

8. Lubricating oil cooler

9. Lubricating oil drain

10. Provision for lubricating oil immersion heater

11. Starter motor and solenoid

12. Provision for coolant heater.

QSB3.9-30 Exhaust Side View

03T0-15Page 15



1. Turbocharger air outlet


3. Engine air inlet

4. Fuel pump drive cover

5. Front gear cover

6. Accessory drive cover (optional)7. Fan drive belt

8. Front Pulley

9. Water pump

10. Automatic belt tensioner

11. Water inlet

12. Alternator

13. Fan pulley

14. Coolant temperature sensor15. Turbocharger air inlet.

QSB3.9-30 Front View

03T0-15Page 16



1. Water outlet

2. Turbocharger

3. Exhaust manifold

4. Magnetic pickup location, 3/4 - 16 UNF


6. Intake manifold temperature sensor

7. Engine air inlet

8. Coolant temperature sensor.

QSB3.9-30 Top View

03T0-15Page 17








6. Magnetic pickup location, 3/4 - UNF7. Electronic control module (ECM)


9. Fuel lift pump

10. Lubricating oil pressure switch

11. Fuel drain connection




15. High pressure fuel lines16. Fuel injection pump



03T0-15Page 18






4. Flywheel housing


QSB4.5-30 Rear View

03T0-15Page 19




2. Turbocharger wastegate activator



5. Water outlet





11. Starter motor and solenoid

12. Provision for coolant heater.


03T0-15Page 20



1. Turbocharger air crossover tube



4. Front gear cover

5. Accessory drive cover (optional)

6. Fan drive belt7. Front Pulley

8. Water pump


10. Water inlet

11. Alternator

12. Fan pulley

13. Coolant temperature sensor

14. Turbocharger air inlet.


03T0-15Page 21



1. Water outlet

2. Turbocharger

3. Exhaust manifold

4. Magnetic pickup location, 3/4-16 UNF



7. Turbocharger air crossover tube


QSB4.5-30 Top View

03T0-15Page 22



1. Engine air inlet





6. Fuel lift pump7. Magnetic pickup location, 3/4-16 UNF



10. Lubricating oil pressure switch

11. Electronic control module (ECM)

12. Fuel drain connection




16. High pressure fuel lines17. Fuel injection pump



03T0-15Page 23






4. Flywheel housing


QSB5.9-30 Rear View

03T0-15Page 24




2. Turbocharger wastegate actuator



5. Water outlet



9. Provision for coolant heater



12. Starter motor and solenoid.


03T0-15Page 25



1. Turbocharger air outlet


3. Engine air inlet


5. Front gear cover

6. Accessory drive cover (optional)7. Fan drive belt

8. Vibration damper

9. Water pump


11. Water inlet

12. Alternator

13. Fan pulley

14. Coolant temperature sensor15. Turbocharger air inlet.


03T0-15Page 26



1. Water outlet

2. Turbocharger

3. Exhaust manifold

4. Magnetic pickup location, 3/4-16 UNF



7. Engine air inlet


Maintenance Schedule (102-002)General InformationListed below are the section numbers that contain specific instructions for performing the maintenance checks.

Performmaintenance atwhichever interval occurs first. Ateach scheduled maintenance interval, performall previousmaintenance checks that are due for scheduled maintenance.

Daily or Refueling - Maintenance Check 4 ................................................................................. Section 3• Air Intake Piping - Inspect• Air Tank and Reservoirs - Drain• Cooling Fan - Check/Correct• Crankcase Breather Tube - Inspect• Drive Belt - Check/Correct• Engine Coolant Level - Check/Correct• Engine Lubricating Oil Level - Check/Correct• Fuel-Water Separator - Drain

Every 250 Hours or 3 Months - Maintenance Check 1, 4 ............................................................. Section 4• Air Cleaner Restriction - Check/Correct• Air Compressor Mounting Hardware - Check/Correct• Charge Air Cooler - Check/Correct• Charge Air Piping - Check/Correct• Fuel Injection Pump Mounting Hardware - Check/Correct• Lubricating Oil and Filters - Change• Radiator Hoses - Check

QSB5.9-30 Top View

03T0-15Page 27



Every 500 Hours or 6 Months - Maintenance Check 2, 3, 4 ......................................................... Section 5• Engine Coolant - Antifreeze Check• Fuel Filter, Canister-Type - Replace• Fuel Filter, Spin-on-Type - Replace• Lubricating Oil and Filters - Change

Every 1000 Hours or 1 Year - Maintenance Check 4 ................................................................... Section 6• Cooling Fan Belt Tensioner - Check/Correct• Drive Belts - Check/Correct• Fan Hub, Belt-Driven - Check/Correct• Overhead Set - Adjust

Every 2000 Hours, or 2 Years - Maintenance Check 3, 4 .............................................................. Section 7• Air Compressor Discharge Line - Check/Correct• Cooling System - Drain, Flush, and Fill• Vibration Damper, Rubber - Check• Vibration Damper, Viscous - Check

1. Thelubricatingoil andoil filterintervalcanbe adjustedbasedonapplication, fuel consumption, grossvehicleweight,and idle time. for engine whose aspiration is turbocharged only, refer to Table 1 in the Oil Drain Intervals section.

2. Thelubricatingoil andoil filterintervalcanbe adjustedbasedonapplication, fuel consumption, grossvehicleweight,and idle time. Forengines whose aspiration is charged air cooled, refer to Table 1 in theOil Drain Intervals section.

3. Antifreeze check interval is every oil change or 500 hours, or 6 months, whichever occurs first. The operator mustuse a heavy-duty year-round antifreeze thatmeets the chemical composition of GM6038M. The antifreeze changeinterval is 2 years, 2000hours, or320,000km[200,000 mi], whicheveroccurs first.Antifreeze is essential for freeze,overheat, and corrosion protection.

4. Follow the manufacturer ’s recommended maintenance procedures for the starter, alternator, generator batteries,electrical components, charge air cooler, radiator, air compressor, air cleaner, Freon ™compressor, and fan clutch.Refer to the component manufacturers in Section M.

Oil Drain IntervalsRefer to Table 1 to determine the maximumrecommended oil change and filter change intervals in hours or months,whichever comes first.

Table 1: Aspiration Turbocharged Only and Aspiration Charge Air CooledCummins Engine

Standard Classifica-tion (CES)

American Pe-troleum Insti-tute Classifi-cation (API)

InternationalClassifica-

tions

Engine Ratings WhoseAspirations are

Turbocharged Only

Engine Ratings WhoseAspiration are Charge

Air Cooled

CES-20078 CES-20077CES-20076 CES-20072

CES-20071

API CI-4/SK API CI-4 API

CH-4 API CH-4/SJ

ACEA E-5 Glo-bal DHD-1

250 hours or 6 months 500 hours or 6 months

CES-20075 API CF-4/SG ACEA E-3ACEA E-2

J AMA DH-1

125 hours or 3 months 250 hours or 3 months

API CG-4/SHAPI CD API

CE

ACEA E-1 Obsolete. Do not Use Obsolete. Do Not Use

Tool Requirements (102-004)General InformationMostof the maintenance operations described in this manual can be performed with common hand tools (metric andsociety of Automotive Engineers (SAE) wrenches, sockets, and screwdrivers).

The following is a list of special service tools required for some maintenance operations:

Tool Part Number DescriptionST-1273 Pressure gauge3375045 Torque wrench (0 to 175 ft-lb)3375049 Oil filter wrench3376807 Engine coolant and fuel filter wrench

03T0-15Page 28

(Continued)



Tool Part Number Description3824556 Charge air cooler (CAC) pressure kit3824591 Engine barring gear3824783 Torque wrench (0 to 300 in-lb)CC-2800 RefractometerCC-2802 Coolant test kit3824842 M10 Compuchek fitting

3377161 Digital multimeterContact a Cummins Authorized Repair Location for the required service tools.

03T0-15Page 29



Fuel Injection Pump, Rotary (005-014)General Information The fuel injection pump (VP30) is an electronic rotary dis-tributor pump. The pump performs four basic functions:

1. P roducingthe high fuel pressurerequired for injection2. Metering the exact amount of fuel for each injection

cycle3. Distributing the high-pressure, metered fuel to each

cylinder at the precise time4. Varying the timing relative to engine speed.

A cam plate with a single plunger, a rotor, and an elec-tronically controlled fueling solenoid valve is used to de-velop and distribute the high pressure required for injec-tion.

A worn or damaged internal transfer pump, plunger, orfueling valve can affect the pressure and amount of fuelinjected, thus reducing the power from the engine. Gen-erally, if the fuel injection pump is injecting fuel from oneoutlet, it will deliver from all outlets.

VP30 Timing Principles - Timing in the VP30 is controlledbyan internal timingpistoncoupled to acamringinsidethepump. The timing piston is moved by fuel pressure. Theamount of fuel pressure in the timing piston assemblyhousing is controlled by an internal transfer pump and apulsating timing solenoid valve.

As pump speed increases, the fuel pressure to the timingpiston assembly also increases. Based on the inputs fromthe fuel pump control module, the timing solenoid valvepulses tovarythepressuretomovethetimingpiston,whichresults in the cam ring moving to the desired position toachieve the commanded timing.

The more pressure created by the internal transfer pumpand timing solenoid valve, the more the timing will ad-vance; therefore, timing range capability is increased athigher rpms.

03T0-15Page 30



Preparatory StepsWARNING

Fuel is flammable. Keep all cigarettes, flames, pilotlights, arcingequipment, and switches out of the work area and areas sharing ventilation to reduce the pos-sibilityofseverepersonalinjuryordeathwhenworkingon the fuel system.

WARNINGDo not vent the fuel system on a hot engine; this cancause fuel to spill onto a hot exhaust manifold, whichcan cause a fire.

Disconnect and remove the following:

• Battery cables, negative (-) cable first.

• Fuel return line. Refer to Procedure 006-013.

• Fuel pump supplyline. Referto Procedure 006-024.

• High-pressure lines. Refer to Procedure 006-051.

• 9-pinelectricalconnectorfromthefuelpumpcontrol

module.

RemoveIt is recommended to bar the engine over so that the key-wayon thegearis atthe12-o ’clockpositionwhenremovingthe fuel pump. This position can be foundby taking theoilfill or fuel pump gear access cap off, whichever applies,and aligning the keyway in the fuel pump gear to the 12o’clock position off the front cover.

NOTE: Doingthe above will helpprevent the fuel pump keyfrom falling into the housing if it is loose.

The special washer on the Bosch VP30 injection pumpmust be removed so the lock screw can be tightenedagainst the driveshaft.

Torque Value: 30 N • m [22 ft-lb]

NOTE: Wire the washer to the pump.

03T0-15Page 31



Remove the fuel pump support bracket.

Remove thecrankcasebreatherandgear retainingnutandwasher. Refer to Procedure 003-018.

Pullthe fuel injectionpumpdrivegearloosefromthepumpdriveshaft.

NOTE: Do not drop the drive gear keywhen removing thepump.

Remove the two mounting nuts and one capscrew, andremove the fuel injection pump.

03T0-15Page 32



CleanUse a clean, dry cloth to wipe all of the oil off the back of the gear housing mounting surface and pump housing.

Inspect for ReuseInspect the mounting surfaces for damage.

Inspect the fuel pump mounting o-ring for cuts or damage.

InstallCAUTION

The driveshaft must be clean and free of all oil before

installation. Failure to doso canresultin thedrivegearslipping on the shaft.

Install the fuel pump key into the pump driveshaft. RefertoProcedure 005-032.

Use an evaporative cleanser (e.g., brakecleaner, isopropylalcohol) to clean the pump shaft and gear bore.

Thekeyedgearand shaft allow for thefuel injection pumpto be installed in any position, as long as the markings on

the front gear train align and a gear has not slipped.Carefully rotate the engine until the keyway on the gearlines up with the key on the pump.

NOTE: If installing a new or ReCon fuel pump, the shaftwill come locked at engine top dead center. Rotating theengine to top dead center on the number 1 cylinder com-pression stroke will align the keyway to thepump. Refer toProcedure 001-033.

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Install the pump. Make sure the key does not fall into thegearhousing. Takecare not to damagethepumpmountingo-ring.

NOTE: The engine must be rotated to align the keywayinthe gear with the keyed pump shaft.

Hand-tighten the mounting capscrews.

Install the pump driveshaft nut and spring washer. Thepump will rotate slightly because of gear helix and clear-ance. This is acceptable provided the pump is free to moveon the flange slots and the crankshaft does not move.


Tighten the fuel injection pump mounting nuts andcapscrew.

Torque Value:Nut 24 N • m [18 ft-lb]Capscrew 14 N • m [10 ft-lb]

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Install thespecial washeron theVP30fuelpump to unlockthe pump shaft.

Install the injection pump support bracket. Finger-tightenall capscrews before final tightening.

Tighten the brackets in the following sequence:1. Brace-to-block capscrews2. Bracket-to-fuel pump brace capscrews.

Tighten all capscrews on the support bracket.


Tighten the pump driveshaft retaining nut.


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Install the access cap.

Finishing StepsInstall and connect the following;

• Low-pressure fuel lines. Refer to Procedure 006-024.

• Fuel inlet. Refer to Procedure 006-024.• Fuel return lines. Refer to Procedure 006-013.• High-pressure lines. Refer to Procedure 006-051.• 9-pin connector to the VP30 fuel pump.• Battery cables, negative (-) cable last.• Bleed all air from the fuel system, if needed. Refer

to Procedure 006-003.

Overhead Set (003-004)General InformationRefer to the Engine Identification in Section E.

Preparatory StepsRemove the rocker lever covers.

Locate top dead center (TDC) for cylinder Number 1.

Use a 1/2-inch drive, Engine Barring Tool, Part Number3824591 torotate the engine ( clockwise when facing thedamper)until Number 4 (for4 cylinder)orcylinderNumber6 (for 6 cylinder) intake rockerarmstarts to open the intakevalve.

Wiggle the rocker arm while barring the engine; when therocker arm gets tight, stop barring.

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Adjust Theclearanceiscorrectwhensomeresistanceis feltwhenthe feelergaugeis slippedbetween the valve stemand therocker lever.

Torque Value:Intake clear-ance 0.254 mm [0.010 in]Exhaust clear-ance 0.508 mm [0.020 in]

Four-Cylinder

Make sure the engine is at top dead center (TDC) forcylinder Number 1.

Set only valves indicatedbythe arrows (E = exhaust, I =intake). Do not set valves that are not indicated.

Holding the locknut steady with the wrench, adjust thevalve clearance with the screwdriver or Allen wrench.

Tighten the locknut, and measure the valve lash again.


Mark the vibration damper and rotate the crankshaft 360degrees.

Adjust the valves as indicated in the illustration.


Set only valves indicatedbythe arrows (E = exhaust, I =intake). Do not set valves that are not indicated.

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Six-Cylinder

Make sure the engine is at top dead center (TDC) forcylinder Number 1.

Set only the valves indicated by the arrows in the illustra-tion (E = exhaust, I = intake).

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.


Mark the pulley and rotate the crankshaft 360 degrees.

Adjust the valves as indicated in the illustration.

Set only the valves indicated by the arrows in the illustra-tion (E = exhaust, I = intake). Do not set valves that arenot indicated.


Finishing StepsCheck the rocker lever cover(s) for cracks.

Install the rocker lever cover.

Tightenthe capscrews.Referto Section V fortorque value.

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Clean and Inspect for ReuseCheck the rocker lever cover(s) for cracks.

If cracks are found, replace rocker lever cover.

InstallInstall the rocker cover(s).

Tighten the capscrews.


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General EngineSpecificationsHorsepower (refer to engine dataplate)

Bore and StrokeQSB3.9-30 and QSB5.9-30 ................................................................... 102 mm [4.02 in] x 120 mm [4.72 in]QSB4.5-30 ........................................................................................... 102 mm [4.02 in] x 138 mm [5.42 in]

DisplacementQSB3.9-30 ........................................................................................................................ 3.9 liters [238 C.I.D.]QSB4.5-30 ........................................................................................................................ 4.5 liters [275 C.I.D.]QSB5.9-30 ........................................................................................................................ 5.9 liters [359 C.I.D.]

Compression Ratio Turbocharged Only

QSB4.5-30 .......................................................................................................................................... 17.3:1QSB5.9-30 .......................................................................................................................................... 18.0:1

Charge Air CooledQSB3.9-30 .......................................................................................................................................... 18.0:1QSB5.9-30 .......................................................................................................................................... 18.0:1

Firing OrderQSB3.9-30 and QSB4.5-30 .................................................................................................................... 1-3-4-2QSB5.9-30 ....................................................................................................................................... 1-5-3-6-2-4

Engine Weight (with standard accessories):Dry Weight

QSB3.9-30 and QSB4.5-30 ................................................................................................... 338 kg [745 lb]QSB5.9-30 ............................................................................................................................ 432 kg [952 lb]

Crankshaft Rotation (viewed from the front of the engine) .................................................................... Clockwise

Valve Clearance:Intake .................................................................................................................................. 0.25 mm [0.010 in]Exhaust ............................................................................................................................... 0.51 mm [0.020 in]

Fuel SystemSpecificationsForperformance and fuel rate values, refer to the Engine Data Sheet or the fuel injectionpump for the particularmodelinvolved.

Engine Idle Speed ....................................................................................................................... 700 to 1000 rpm

Maximum Fuel Inlet Restriction to Lift Pump ............................................................................... 14 kPa [4 in Hg]

Fuel Pressure Range at Fuel Filter Outlet (engine cranking) ............................................ 21 to 28 kpa [3 to 4 psi]

Fuel Pressure Range at Fuel Filter Inlet (engine running at idle) ...................................... 34 to 48 kPa [5 to 7 psi]

Maximum Pressure Drop Across Fuel Filter ..................................................................................... 34 kPa [5 psi]

Fuel Drain Line Maximum Restriction ............................................................................................ 70 kPa [10 psi]

Fuel Inlet Maximum Temperature ..................................................................................................... 70 ° C [158 ° F]

Engine Minimum Cranking Speed ............................................................................................................ 110 rpm

Lubricating Oil SystemSpecificationsOil Pressure:

Low Idle (minimum allowed) ....................................................................................................... 69 kPa [10 psi]At Rated Speed (minimum allowed) ......................................................................................... 207 kPa [30 psi]

Regulated Pressure ..................................................................................................................... 449 kPa [65 psi]

Oil Capacity of Standard Engine:Standard:

Pan Only (QSB3.9-30 and QSB4.5-30) ................................................................................. 9.5 liters [10 qt]

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Pan Only (QSB5.9-30) ........................................................................................................ 14.2 liters [15 qt] Total System (QSB3.9-30 and QSB4.5-30) ........................................................................ 10.9 liters [11.5 qt] Total System (QSB5.9-30) ................................................................................................ 16.3 liters [17.2 qt]

Deep Sump:Pan Only (QSB3.9-30 and QSB4.5-30) ............................................................................ 14.5 liters [15.3 qt]Pan Only (QSB5.9-30) ..................................................................................................... 24.0 liters [25.4 qt] Total System (QSB3.9-30 and QSB4.5-30) ....................................................................... 15.9 liters [16.8 qt] Total System (QSB5.9-30) ................................................................................................ 26.1 liters [27.6 qt]

Oil Pan Low - High:Standard Pan (QSB3.9-30 and QSB4.5-30) ........................................................... 8.5 to 9.5 liters [9 to 10 qtStandard Pan (QSB5.9-30) ................................................................................ 12 to 14.2 liters [13 to 15 qt]Deep Sump (QSB3.9-30 and QSB4.5-30) ................................................. 11.5 to 14.5 liters [12.1 to 15.3 qt]Deep Sump (QSB5.9-30) ............................................................................. 16.5 to 24 liters [17.4 to 25.4 qt]

NOTE: Some applications use a slightly different lubricating oil pan capacity. Contact a local Cummins AuthorizedRepair Facility if you have questions.

Cooling SystemSpecificationsCoolant Capacity (QSB3.9-30 and QSB4.5-30) (engine only ) ....................................................... 7.9 liters [8.3 qt]

Coolant Capacity (QSB5.9-30) (engine only ) .............................................................................. 9.8 liters [10.4 qt]

Standard Modulating Thermostat - Range ............................................................ 82 ° C to 93 ° C [180 ° F to 199 °

Maximum allowed Operating Temperature ...................................................................................... 102 ° C [215 °

Minimum Recommended Operating Temperature ............................................................................. 71 ° C [160 °

Minimum Recommend Pressure Cap .............................................................................................. 48 kPa [7 psi]

Maximum Recommended Pressure Cap ...................................................................................... 103 kPa [15 psi]

Air Intake SystemSpecificationsMaximum Intake Restriction (clean air filter element) ................................................... 381 mm H 2 O [15.0 in H 2

Maximum Intake Restriction (dirty air filter element) .................................................... 635 mm H 2 O [25.0 in H 2

Recommended Intake P iping Size (inner diameter for QSB3.9-30 and QSB4.5-30) ............................ 76 mm [3 in]

Recommended Intake Piping Size (inner diameter for QSB5.9-30) ................................................ 101.6 mm [4 in]

Exhaust SystemSpecificationsMaximum Back Pressure from Piping and Silencer (combined):

Hg ..................................................................................................................................... 76 mm Hg [3 in Hg]H2 O .......................................................................................................................... 1016 mm H 2 O [40 in H 2

Recommended Exhaust Piping Size (inner diameter for QSB3.9-30 and QSB4.5-30) ........................ 76 mm [3 in]

Recommended Exhaust Piping Size (inner diameter for QSB5.9-30) ............................................. 101.6 mm [4 in]

Electrical SystemSpecificationsMinimum Recommended Battery Capacity at-18 ° C [9 ° F]:

12-VDC Starter:QSB3.9-30 and QSB4.5-30 with Light Accessories ......................................................................... 625 CCAQSB5.9-30 with Light Accessories .................................................................................................. 800 CCAQSB3.9-30 and QSB4.5-30 with Heavy Accessories ....................................................................... 800 CCAQSB5.9-30 with Heavy Accessories ................................................................................................ 950 CCA

24-VDC Starter:QSB3.9-30 and QSB4.5-30 with Light Accessories ......................................................................... 400 CCAQSB5.9-30 with Light Accessories .................................................................................................. 400 CCAQSB3.9-30 and QSB4.5-30 with Heavy Accessories ....................................................................... 400 CCA

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QSB5.9-30 with Heavy Accessories ................................................................................................ 475 CCA

Maximum allowable Starting Circuit Resistance (12-VDC) ..................................................................... 0.001 ohm

Maximum allowable Starting Circuit Resistance (24-VDC ..................................................................... 0.002 ohm

NOTE: Typical light accessories include alternator, small steering pump, and disengaged clutch.

NOTE: Typical heavy accessories include hydraulic pump and torque converter.

Cummins/Fleetguard Filter SpecificationsGeneral InformationFleetguard /Nelson is a subsidiary of Cummins Inc. Fleetguard /Nelson filters are developed through joint testing atCummins and Fleetguard /Nelson. Fleetguard /Nelson filters are standard on new Cummins engines. Cummins Inc.recommends their use.

Fleetguard /Nelson products meet all Cummins Source Approval Test standards to provide the quality filtrationnecessary to achieve the engine ’s design life. If other brands are substituted, the purchaser must insist on productsthat the supplier has tested to meet Cummins high-quality standards.

Cummins can not be responsible forproblems caused bynongenuine filters thatdo not meetCummins performanceor durability requirements.

Filter Part NumbersLubricating Oil FilterQSB3.9-30 and QSB4.5-30Cummins part number 3934429Fleetguard /Nelson part number LF3805QSB5.9-30Cummins part number 3934430Fleetguard /Nelson part number LF3806Fuel FiltersQSB3.9-30, QSB4.5-30, and QSB5.9-30Spin-on Filter:Cummins part number 3991498Fleetguard /Nelson part number FS19616

Fuel Recommendations and SpecificationsFuel Recommendations

WARNINGDo not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.

CAUTIONDue to theprecise tolerances of diesel injectionsystems, it is extremely important that the fuel bekept cleanand free of dirt or water. Dirt or water in the systemcan cause severe damage to both the fuel pump and thefuel injectors.

Cummins Inc. recommends the use of ASTM number 2D fuel. The use of number 2 diesel fuel will result in optimumengine performance.

At operating temperatures below 0 ° C [32 ° F], acceptable performance can beobtained byusingblends ofnumber 2Dand number 1D.

Lighter fuels can reduce fuel economy.

The viscosity of the fuel must be kept above 1.3 cSt at 40 ° C [104 ° F] to provide adequate fuel system lubrication.

The following chart lists acceptable substitute fuels for this engine.

Acceptable Substitute Fuels

Number 1DDiesel (1) (2)

(3)

Number 2DDiesel (3)

Number 1K Kerosene

J et-A J et-A1 J P-5 J P-8 J et-B J P-4 CITE

A OK Not OK A A A A Not OK Not OK Not OK

03T0-15Page 42

(Continued)



Acceptable Substitute Fuels

Number 1DDiesel (1) (2)

(3)

Number 2DDiesel (3)

Number 1K Kerosene

J et-A J et-A1 J P-5 J P-8 J et-B J P-4 CITE

1. An ‘‘A’’ means OK only if fuel lubricity is adequate. This means the BOCLE number is 3100 or greater as measured with the U.S. Armyscuffing BOCLE test. The limits for acceptable lubricity are specified as a wear scar diameter ≤ 400 micrometers using the high-frequency reciprocating rig test method.

2. Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not warrantable.

3. Winter blend fuels, such as found at commercial fuel-dispensing outlets, are combinations of number 1D and 2D diesel fuels and areacceptable.

Additional informationforfuel recommendationsand specifications canbefoundinFuelforCumminsEngines, Bulletin3379001. See ordering information in the back of this manual.

Lubricating Oil Recommendations and SpecificationsGeneral Information

CAUTIONA sulfated ash limit of 1.85 percent has been placed on all engine lubricating oils recommended for use inCumminsengines.Higherashoils cancausevalveand/orpistondamageandleadtoexcessiveoil consumption.

The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a criticalfactor in maintaining engine performance and durability.

Cummins Inc. recommends the use of high-quality SAE 15W-40 heavy-duty engine oil, such as Valvoline PremiumBlue , which meets performance specifications as listed below.

NOTE: In areas where CH-4/SJ or CG-4/SH oils are not available, refer to Oil Drain Intervals in Section 2.

Cummins EngineeringStandard Classification

(CES)

American Petroleum In-stitute Classification

(API)

European AutomobileManufacturers Associa-

tion Classification(ACEA)

Comments

API CD API CEAPI CG-4/SH

ACEA E-1 OBSOLETE. DO NOTUSE.

CES-20075 API CF-4/SG ACEA E-2 ACE E-3 J AMA

DH-1

Minimum acceptable oil

classification for midrangeengines.CES-20071 CES-20076 API CH-4/SJ API CH-4 Global DHD-1 – Acceptable oil classifica-

tion for midrange en-gines.

CES-20072 CES-20077 API CH-4 ACEA E-3 Similar in performance toCES-20071 but validatedunder European test stan-dards. Excellent oil formidrange engines.

CES-20078 API CI-4/SK API CI-4 Excellent oil for midrangeengines.

A sulfatedashlimitof1.0masspercentis suggestedforoptimumvalve and pistondepositand oilconsumptioncontrol.

For further details and discussion of engine lubricating oils for Cummins engines, refer to Cummins Engine OilRecommendations, Bulletin 3810340.

03T0-15Page 43



The API service symbols are shown in the accompanyingillustration. The upper half of the symbols displays theappropriate oil categories.

The lower half can contain words to describe oil energy-conserving features.

The center section identifies the SAE oil viscosity grade.

As the engine oil becomes contaminated, essential oil ad-ditives are depleted. Lubricating oils protect the engine aslong as these additives are functioning properly. Progres-sive contamination of the oil between oil and filter changeintervals is normal. The amount of contamination will vary

depending on the operation of the engine, kilometers ormiles on the oil, fuel consumed, and new oil added.

Extending oil and filter change intervals beyond the rec-ommendationswill decreaseenginelifedueto factorssuchas corrosion, deposits, and wear.

Refer to the oil drain chart in this section to determinewhich oil drain interval to use for your application.

03T0-15Page 44



New Engine Break-in OilsSpecial “break-in ” engine lubricating oils are not recommended for new or rebuilt Cummins engines. Use the sametype of oil during the break-in as is used in normal operation.

Additional informationregardinglubricatingoilavailability throughouttheworld is available in the EMA LubricatingOilsData Book for Heavy-Duty Automotive and Industrial Engines. The data book can be ordered from the EngineManufacturers Association, Two North LaSalle Street - Suite 2200, Chicago, IL, U.S.A. 60602. The telephone numberis (312) 827-8733.

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Arctic OperationCAUTION

The use of a synthetic-base oil does not justify ex-tended oil change intervals. Extended oil change in-tervals can decrease enginelife due to factors such ascorrosion, deposits, and wear.

Theuse of low-viscosity oils, such as 10W or 10W-30, canbe used to aid in starting the engine and in providingsufficient oil flow at ambient temperatures below -5 ° C[23 ° F]. However, continuous use of low-viscosity oils candecrease engine life due to wear. Refer to the accompa-nying chart.

If an engine is operated in ambient temperatures consis-tently below -23 ° C [-9 ° F] and there are no provisions tokeep the engine warm when it is not in operation, use asynthetic CH/SF orhigherAPI classificationengine oilwithadequate low-temperature properties such as 5W-20 or5W-30.

Theoilsupplieris responsibleformeeting theperformanceservice specifications represented with its product.

Coolant Recommendations andSpecificationsFully Formulated Coolant/AntifreezeUse low-silicate antifreeze that meets ASTM4985(GM6038M specification) criteria.

Cummins Inc. recommends using either a 50/50mixture of good-quality water and fully formulated antifreeze, or fullyformulated coolant when filling the cooling system.

Good-quality water is important for cooling systemperfor-mance. Excessive levels of calcium and magnesium con-tribute to scaling problems, and excessive levels of chlo-rides and sulfates cause cooling system corrosion.

Water QualityCalcium Magnesium

(hardness)Maximum170 ppm as

(CaCO 3 + MgCO 3 )Chloride 40 ppm as (CI)

Sulfur 100 ppm as (SO 4 )

Cummins Inc. recommends using Fleetguard Compleat.It is available inboth glycol forms (ethyleneandpropylene).

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Fullyformulatedantifreeze must bemixedwithgood-qualitywater at a 50/50 ratio (40- to 60-percent working range). A50/50mixtureofantifreezeandwatergives a -36 ° C [-33 ° F]freezing point and a 108 ° C [226 ° F] boiling point, which isadequatefor locations inNorth America. Theactual lowestfreezingpointofethylene glycol antifreeze is at68percent.Using higher concentrations of antifreeze will raise thefreezingpointof the solutionand increase the possibilityof

a silica gel problem.

A refractometer must be used to measure the freezingpoint of the coolant accurately . Use Fleetguardrefractometer, Part Number C2800.

Do not use a floating ball hydrometer. Using floating ballhydrometers can give an incorrect reading.

Cooling System Sealing AdditivesDo not usesealingadditivesinthecoolingsystem. Theuseof sealing additives will:

• Buildup in coolant low-flow areas

• Plug the radiator and oil cooler

• Possibly damage the water pump seal.

03T0-15Page 47



Cooling System Soluble OilsDo not use soluble oils in the cooling system. The use of soluble oils will:

• Corrode brass and copper

• Damage heat transfer surfaces

• Damage seals and hoses.

03T0-15Page 48

Documents

SPT03T0-15+INTRODUCCION MOTORES QSB3.9,QSB4.5,QSB5.9 INDUSTRIAL