This manual provides instructions for troubleshooting and repairing this engine in the chassis.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine.
This troubleshooting and repair manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures.
The manual is divided into sections. Each section is equivalent to a group used in Cummins' system. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting the problem.
The guide comes in PDF format. We recommend using Adobe PDF Reader, to be sure all images/graphics will display correctly.
Contents:
- Introduction
- About the Manual
- Acronyms and Abbreviations
- General Cleaning Instructions
- General Repair Instructions
- General Safety Instructions
- How to Use the Manual
- Illustrations
- Symbols
- Section E - Engine and System Identification
- Cummins® Service Engine Model Product Identification
- Engine Diagrams
- Engine Identification
- Section F - Familiarization
- Air Intake System - Overview
- Cam Followers/Tappets - Overview
- Complete Engine - Overview
- Compressed Air System - Overview
- Cooling System - Overview
- Cylinder Block - Overview
- Cylinder Head - Overview
- Electrical Equipment - Overview
- Engine Testing - Overview
- Exhaust System - Overview
- Flow Diagram, Air Intake System
- Flow Diagram, Compressed Air System
- Flow Diagram, Cooling System
- Flow Diagram, Exhaust System
- Flow Diagram, Fuel System
- Flow Diagram, Lubricating Oil System
- Fuel System - Overview
- Lubricating Oil System - Overview
- Section TS - Troubleshooting Symptoms
- Troubleshooting Procedures and Techniques
- Troubleshooting Symptoms Charts
- Troubleshooting Overview
- Section 0 - Complete Engine - Group 00
- Engine Installation
- Engine Removal
- Engine Storage - Long Term
- Service Tools
- Section 1 - Cylinder Block - Group 01
- Bearings, Connecting Rod
- Bearings, Main
- Block Stiffener Plate
- 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 Liner
- Engine Data plate
- Gear Cover, Front
- Gear Housing, Front
- Piston
- Piston and Connecting Rod Assembly
- Piston Rings
- Service Tools
- Timing Pin Housing
- Vibration Damper, Rubber
- Vibration Damper, Viscous
- Section 2 - Cylinder Head - Group 02
- Cylinder Head
- Cylinder Head Gasket
- Injector Protrusion
- Service Tools
- Valve Guide Seal, Cylinder Head
- Valve Guide, Cylinder Head
- Valve Seat Insert, Cylinder Head
- Valve, Cylinder Head
- Section 3 - Rocker Levers - Group 03
- Crankcase Breather Tube
- Overhead Set
- Rocker Lever
- Rocker Lever Cover
- Service Tools
- Section 4 - Cam Followers/Tappets - Group 04
- Push Rods or Tubes
- Service Tools
- Tappet
- Section 5 - Fuel System - Group 05
- AFC Assembly
- Engine Fuel Heater, Electric
- Fuel Injection Pump, In-Line, Spill Port Timing
- Fuel Injection Pumps, In-Line
- Fuel Lift Pump
- Fuel Pump Control Lever and Spring Fuel Pump Idle Speed
- Fuel Shutoff Valve
- Service Tools
- Section 6 - Injectors and Fuel Lines - Group 06
- AFC Air Tube
- Air in Fuel
- Fuel Drain Line Restriction
- Fuel Drain Lines
- Fuel Filter (Spin-On Type)
- Fuel Inlet Restriction
- Fuel Manifold (Drain)
- Fuel Return Overflow Valve
- Fuel Supply Lines
- Injector
- Injector Supply Lines (High Pressure)
- Section 7 - Lubricating Oil System - Group 07
- Engine Oil Heater
- Lubricating Oil Analysis
- Lubricating Oil Cooler
- Lubricating Oil Dipstick
- Lubricating Oil Dipstick Tube
- Lubricating Oil Filter (Spin-On)
- Lubricating Oil Leaks
- Lubricating Oil Pan
- Lubricating Oil Pressure Regulator (Main Rifle)
- Lubricating Oil Pump
- Lubricating Oil Suction Tube (Block-Mounted)
- Lubricating Oil System
- Lubricating Oil Thermostat
- Service Tools
- Section 8 - Cooling System - Group 08
- Belt Tensioner, Automatic (Water Pump)
- Coolant Filter
- Coolant Filter Head
- Coolant Filter Valve
- Coolant Thermostat
- Coolant Thermostat Housing
- Coolant Vent Lines
- Cooling System
- Coolant Replacer
- Cooling System - Air or Combustion Gas Test
- Drive Belt, Cooling Fan
- Engine Coolant Heater
- Fan Drive Idler Pulley Assembly
- Fan Hub, Belt Driven
- Fan Shroud Assembly
- Fan Spacer and Pulley
- Fan, Cooling
- Heat Exchanger
- Radiator
- Radiator Hoses
- Radiator Pressure Cap
- Sea Water Hoses
- Sea Water Pump
- Sea Water Strainer
- Sea Water System Diagnostics
- Service Tools
- Supplemental Coolant Additive (SCA)
- Water Pump
- Section 10 - Air Intake System - Group 10
- Aftercooler Assembly
- Air Crossover
- Air Intake Manifold
- Air Intake Restriction
- Air Leaks, Air Intake and Exhaust Systems
- Charge-Air Cooler
- Intake Manifold Air Heater Control Module
- Intake Manifold Air Heater Element
- Intake Manifold Air Heater Solenoid Switch
- Intake Manifold Air Heater Speed Sensor
- Intake Manifold Air Heater Temperature Sensor
- Intake Manifold Air Heater Wiring Harness
- Intake Manifold Pressure
- Service Tools
- Turbocharger
- Turbocharger Axial Clearance
- Turbocharger Oil Drain Line
- Turbocharger Oil Supply Line
- Turbocharger Radial Bearing Clearance
- Turbocharger Wastegate Actuator
- Section 11 - Exhaust System - Group 11
- Exhaust Manifold, Dry
- Exhaust Restriction
- Section 12 - Compressed Air System - Group 12
- Air Compressor
- Air Compressor Carbon Buildup
- Air Governor (Air Compressor Pumps Continuously)
- Air Governor (Air Compressor Will Not Pump)
- Air Leaks, Compressed Air System
- Section 13 - Electrical Equipment - Group 13
- Alternator
- Alternator Bracket
- Alternator Pulley
- Batteries
- Battery Cables and Connections
- Charging System Indicator
- Service Tools
- Starter Magnetic Switch
- Starter Solenoid
- Starter Switch
- Starting Motor
- Section 14 - Engine Testing - Group 14
- Crankcase Blowby, Measure
- Engine Compression
- Engine Run-in (Chassis Dynamometer)
- Engine Run-in (Engine Dynamometer)
- Engine Run-in (Without Dynamometer)
- Engine Testing (Chassis Dynamometer)
- Service Tools
- Section 16 - Mounting Adaptations - Group 16
- Engine Mounts
- Flywheel
- Flywheel Housing
- Flywheel Housing, REPTO
- Flywheel Ring Gear
- Marine Vibration Isolator
- Propeller Shaft
- Service Tools
- Section 17 - Miscellaneous - Group 17
- Cup Plug
- Pipe Plug
- Straight Thread Plug
- Section 21 - Main Power Generator - Group 21
- Section L - Service Literature
- Additional Service Literature
- Cummins Customized Parts Catalog
- Service Literature Ordering Location
- Section V - Specifications
- Air Intake System
- Air Intake System - Group 10 - Specifications
- Air Intake System - Group 10 - Torque Values
- Cam Followers/Tappets - Group 04 - Specifications
- Capscrew Markings and Torque Values
- Compressed Air System
- Compressed Air System - Group 12 - Specifications
- Compressed Air System - Group 12 - Torque Values
- Cooling System
- Cooling System - Group 08 - Specifications
- Cooling System - Group 08 - Torque Values
- Cylinder Block - Group 01 - Specifications
- Cylinder Block - Group 01 - Torque Values
- Cylinder Head - Group 02 - Specifications
- Cylinder Head - Group 02 - Torque Values
- Drive Belt Tension
- Electrical Equipment - Group 13 - Torque Values
- Electrical System
- Engine Testing
- Exhaust System
- Exhaust System - Group 11 - Specifications
- Exhaust System - Group 11 - Torque Values
- Fraction, Decimal, Millimeter Conversions
- Fuel System
- Fuel System - Group 05 - Specifications
- Fuel System - Group 05 - Torque Values
- General Engine
- Injectors and Fuel Lines - Group 06 - Specifications
- Injectors and Fuel Lines - Group 06 - Torque Values
- Lubricating Oil System
- Lubricating Oil System - Group 07 - Specifications
- Lubricating Oil System - Group 07 - Torque Values
- Mounting Adaptations - Group 16 - Specifications
- Mounting Adaptations - Group 16 - Torque Values
- Newton-Meter to Foot-Pound Conversions
- Pipe Plug Torque Values
- Rocker Levers - Group 03 - Specifications
- Rocker Levers - Group 03 - Torque Values
- Tap-Drill Chart - U.S. Customary and Metric
- Weights and Measures - Conversion Factors
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