B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 014-005   Engine Testing (Engine Dynamometer)

Engine Lifting Fixture, Part Number 3822512

Use engine lifting fixture, Part Number 3822512, to remove the engine from the chassis.
Refer to Procedure 000-001 (Engine Removal) in Section 1.

Install the engine to the test stand.

Align and connect the dynamometer. Refer to the manufacturer’s instructions for aligning and testing the engine.

NOTE: Make sure the dynamometer capacity is sufficient to permit testing at 100 percent of the engine-rated horsepower. If the capacity is
not enough, the testing procedure
must be modified to the restrictions of the dynamometer.

Coolant Plumbing

Install the coolant temperature sensor.

Connect the coolant supply to the water inlet connection (1).

Connect the coolant return to the water outlet connection (2).

Install the drain plugs, close all the water draincocks, and make sure all the clamps and fittings are tight.

Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill (or expansion) tank.
Refer to Procedure 008-018 (Cooling System) in Section 8.

Inspect the engine for coolant leaks at connections, fittings, plates, and plugs. Repair as necessary.

Water Manometer, Part Number ST-1111-3

Air Inlet Restriction

Connect a water manometer, Part Number ST-1111-3, to the turbocharger air inlet pipe to test air restriction.

NOTE: The manometer connection
must be installed at a 90-degree angle to the airflow in a straight section of pipe, one pipe diameter before the turbocharger.

NOTE: A vacuum gauge, Part Number ST-434, can be used in place of the water manometer.

Pressure Gauge, Part Number ST-1273

Exhaust Restriction

WARNING  This component contains mercury, a chemical known to some state and federal agencies to cause birth defects or other reproductive harm. Do not dispose. Recycle in accordance with state regulations.

Connect a mercury manometer to a straight section of the exhaust piping near the turbocharger outlet to check exhaust restriction.

NOTE: A pressure gauge, Part Number ST-1273, can be used in place of the mercury manometer.

NOTE: For automotive applications, a tapped hole is provided on the inlet side of the catalyst for checking exhaust restrictions.

Attach the lubricating oil temperature sensor in the location shown.

Attach the lubricating oil pressure sensor to the main oil rifle drilling in the cylinder block.

CAUTION  The lubricating oil system must be primed before operating the engine after it has been rebuilt to avoid internal damage.

Prime the lubricating oil system.
Refer to Procedure 007-037 (Lubricating Oil System) in Section 7.

Attach the throttle control lever onto the throttle body.

CAUTION  Do not attempt to install pipe thread fittings in plastic or rubber intake piping. Failure to do so will result in damage to threads.

Use INSITE™ electronic service tool, if available, to monitor intake manifold pressure during the test. This eliminates the need to install a gauge as shown below.

If the charge air cooler tube does
not have a pipe plug and tapped hole, perform the following procedure:

• Remove the charge air cooler tube from the engine.
• Drill and tap a 1/8-inch pipe thread hole in the charge air cooler tube in the location shown.
• Clean all metal shavings from the charge air cooler tube.
• Install the charge air cooler tube.

Pressure Gauge, Part Number ST-1273

To determine the amount of turbocharger boost, remove the pipe plug in the air crossover tube.

Install the intake manifold pressure sensor or pressure gauge, Part Number ST-1273.

Blowby Checking Tool, Part Number 3822476

Water Manometer, Part Number ST-1111-3

For accurate engine crankcase blowby measurement, insert a blowby checking tool in the crankcase breather vent.

Refer to Procedure 014-010 (Crankcase Blowby, Measure) in Section 14 for blowby specifications.

Connect a water manometer to the blowby tool. A pressure gauge can be used in place of the manometer.

To be able to unload the compressor, connect a source of compressed air to the unloader (1). This air line
must contain a valve between the source and the unloader.

NOTE: All air compressors manufactured by Cummins Inc.
must be
loaded during engine run-in. All air compressors
must be
unloaded during the engine performance check.

NOTE: The compressed air load in the accompanying illustration
must be attached to the air compressor outlet (2).

To provide a load on the air compressor, connect an air tank (2) to the compressor outlet; use steel tubing or a high-temperature hose (1).

Install an air regulator (3) that can maintain tank air pressure of 345 kPa to 517 kPa [50 psi to 75 psi] at both the minimum and the maximum engine rpm.

Inspect the voltage rating on the starter motor before installing the electrical wiring.

Attach electrical wires to the starter motor and the batteries if used, negative (-) cable last.

NOTE: If another method of starting the engine is used, follow the manufacturer’s instructions to make the necessary connections.