This workshop manual provides instructions for troubleshooting and repairing this Cummins engine. This manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine.
Workshop manual is organized to provide an easy flow from problem identification to problem correction. This manual provides general information, specifications, diagrams, and service tools, troubleshooting information.
This workshop manual is a file PDF, which contains 732 pages, any one of which we can be printed easily. We recommend using Adobe PDF Reader, to be sure all images/graphics will display correctly.
Workshop manual integration of the following models:
EX255 - EX285 - FH270
G170 - G200 - FG75A - FG85A + FG105A
W170 - W190 - W230
Contents:
- Introduction
- About the Manual
- Acronyms and Abbreviations
- General Cleaning Instructions
- General Repair Instructions
- General Safety Instructions
- How to Use the Manual
- Illustrations
- Symbols
- Engine Identification
- Engine Diagrams
- Engine Identification
- Specifications
- Troubleshooting Symptoms
- Troubleshooting General Information
- Troubleshooting Procedures and Techniques
- Troubleshooting Symptoms Charts
- Group 00 - Complete Engine
- Complete Engine - General Information
- Engine Installation
- Engine Removal
- Service Tools
- Group 01 - Cylinder Block
- Bearings, Connecting Rod
- Bearings, Main
- Camshaft
- Camshaft Bushings
- Camshaft Gear (Camshaft Removed)
- Connecting Rod
- Crankshaft
- Crankshaft Gear, Front (Crankshaft Installed)
- Crankshaft Seal, Front
- Crankshaft Seal, Rear
- Crankshaft Wear Sleeve, Front
- Crankshaft Wear Sleeve, Rear
- Cylinder Block
- Cylinder Block - General Information
- Cylinder Liner
- Engine Data plate
- Gear Cover, Front
- Gear Housing, Front
- Piston
- Piston and Connecting Rod Assembly
- Piston Rings
- Service Tools
- Specifications
- Timing Pin Housing
- Vibration Damper
- Group 02 - Cylinder Head
- Cylinder Head
- Cylinder Head - General Information
- Cylinder Head Gasket
- Injector Protrusion
- Service Tools
- Valve, Cylinder Head
- Valve Guide, Cylinder Head
- Valve Guide Seal, Cylinder Head
- Valve Seat Insert, Cylinder Head
- Group 03 - Rocker Levers
- Crankcase Breather Tube
- Overhead Set
- Rocker Lever
- Rocker Lever Cover
- Service Tools
- Group 04 - Cam Followers/Tappets
- Cam Followers/Tappets - General Information
- Push Rods or Tubes
- Service Tools
- Tappet
- Group 05 - Fuel System
- AFC Assembly
- Engine Fuel Heater, Electric
- Flow Diagram, Fuel System
- Fuel Injection Pump, In-Line, Split Port Timing
- Fuel Injection Pumps, In-Line
- Fuel Lift Pump
- Fuel Pump Control Lever and Spring
- Fuel Pump Idle Speed
- Fuel Shutoff Valve
- Fuel System - General Information
- Service Tools
- Specifications
- Group 06 - Injectors and Fuel Lines
- AFC Air Tube
- Air in Fuel
- Fuel Filter (Spin-On Type)
- Fuel Inlet Restriction
- Fuel Manifold (Drain)
- Fuel Return Overflow Valve
- Fuel Supply Lines
- Injector
- Injector Supply Lines (High Pressure)
- Service Tools
- Group 07 - Lubricating Oil System
- Engine Oil Heater
- Flow Diagram, Lubricating Oil System
- Lubricating Oil Analysis
- Lubricating Oil Cooler Element
- Lubricating Oil Dipstick
- Lubricating Oil Dipstick Tube
- Lubricating Oil Filter (Spin-On)
- Lubricating Oil Leaks
- Lubricating Oil Pan
- Lubricating Oil Pressure Regulator (Main Riffle)
- Lubricating Oil Pump
- Lubricating Oil Suction Tube (Block-Mounted)
- Lubricating Oil System - General Information
- Lubricating Oil Thermostat
- Service Tools
- Specifications
- Group 08 - Cooling System
- Belt Tensioner, Automatic (Water Pump)
- Coolant Filter Head
- Coolant Filter Valve
- Coolant Thermostat
- Coolant Thermostat Housing
- Coolant Vent Lines
- Cooling System
- Cooling System - Air or Combustion Gas Test
- Cooling System - General Information
- Drive Belt, Cooling Fan
- Engine Coolant Heater
- Fan, Cooling
- Fan Drive Idler Pulley Assembly
- Fan Hub, Belt Driven
- Fan Shroud Assembly
- Fan Spacer and Pulley
- Flow Diagram, Cooling System
- Radiator
- Radiator Pressure Cap
- Service Tools
- Specifications
- Supplement Coolant Additive (SCA)
- Water Pump
- Group 10 - Air Intake System
- Aftercooler Assembly
- Air Crossover
- Air Intake Manifold
- Air Intake Restriction
- Air Intake System - General Information
- Air Leaks, Air Intake and Exhaust Systems
- Charge-Air Cooler (CAC)
- Flow Diagram, Air Intake System
- Service Tools
- Specifications
- Turbocharger
- Turbocharger Axial Clearance
- Turbocharger Radial Bearing Clearance
- Turbocharger Wastegate Actuator
- Group 11 - Exhaust System
- Exhaust Manifold, Dry
- Exhaust Restriction
- Exhaust System - General Information
- Flow Diagram, Exhaust System
- Specifications
- Group 12 - Compressed Air System
- Air Compressor
- Air Compressor Carbon Buildup
- Air Governor (Air Compressor Pumps Continuously)
- Air Governor (Air Compressor Will Not Pump)
- Air Leaks, Compressed Air System
- Compressed Air System - General Information
- Flow Diagram, Compressed Air System
- Specifications
- Group 13 - Electrical Equipment
- Alternator
- Alternator Bracket
- Alternator Pulley
- Batteries
- Battery Cables and Connections
- Electrical Equipment - General Information
- Electronic Wiring Diagrams
- Service Tools
- Specifications
- Starter Magnetic Switch
- Starter Solenoid
- Starter Switch
- Starting Motor
- Group 14 - Engine Testing
- Engine Run_in (Chassis Dynamometer)
- Engine Run_in (Without Dynamometer)
- Engine Testing - General Information
- Engine Testing (Chassis Dynamometer)
- Service Tools
- Specifications
- Group 16 - Mounting Adaptations
- Engine Mounts
- Flywheel
- Flywheel Housing
- Flywheel Housing, REPTO
- Flywheel Ring, Gear
- Service Tools
- Group 17 - Miscellaneous
- Service Literature
- Additional Service Literature
- Service Literature Ordering Location
- Component Manufacturers
- Component Manufacturers Addresses
- Specifications
- Air Intake System - Specifications
- Air Intake System - Torque Values
- Cam Followers / Tappets - Specifications
- Capscrew Markings and Torque Values
- Compressed Air System - Specifications
- Compressed Air System - Torque Values
- Cooling System - Specifications
- Cooling System - Torque Values
- Cylinder Block - Specifications
- Cylinder Block - Torque Values
- Cylinder Head - Specifications
- Cylinder Head - Torque Values
- Drive Belt Tension
- Electrical Equipment - Torque Values
- Exhaust System - Specifications
- Fraction, Decimal, Millimeter Conversions
- Fuel System - Specifications
- Fuel System - Torque Values
- Injectors and Fuel Lines - Specifications
- Injectors and Fuel Lines - Torque Values
- Mounting Adaptations - Specifications
- Mounting Adaptations - Toque Values
- Newton-Meter to Foot-Pound Conversion Chart
- Pipe Plug Torque Values
- Rocker Levers - Specifications
- Rocker Levers - Torque Values
- Tap-Drill Chart - U.S. Customary and Metric
- Weights and Measures - Conversion Factors
- Index
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