CUMMINS A Series A2000 A2300 Engine Workshop Service Manual

A Series Troubleshooting and Repair Manual Definition of Terms 5 About the Manual The procedures in this manual were developed for an in-chassis environment. The information has been grouped by the main engine systems. The Table of Contents defines the systems. The index at the beginning of each section subdivides the instructions for the various components of the system. Wrench sizes and special tools are identified in the procedures as needed. How to Use the Manual The organization of this manual is based on the troubleshooting logic presented in Section 2. To fix a problem, find the logic chart for the particular symptom. Follow the steps specified until the problem is corrected. The left column of the charts indicates a probable cause. The right column provides a brief description of the corrective action with a reference to the repair procedure or diagnostic discussion when appropriate. The logic charts reflect three basic considerations: 1. Assumes the engine has provided satisfactory service prior to the problem. 2. Performing the easiest things first. 3. Most logical cause in descending order. If the problem occurs with a new engine or after repair of the engine, the diagnostics discussion for each major system will provide guidance for sorting out the cause of the problem.

A Series Troubleshooting and Repair Manual Definition of Terms 6 Generic Symbols The following group of symbols has 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. WARNING – Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUSION – Minor personal injury can result or a part, an assembly or the engine can be damaged if the Caution instructions are not followed. The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Indicates a REMOVAL or DISASSEMBLY step. Indicates an INSTALLATION or ASSEMBLY step. INSPECTION is required. CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque PERFORM an electrical MEASUREMENT. Refer to another location in this manual or another publication for additional information.

A Series Troubleshooting and Repair Manual Definition of Terms 7 Definition of Terms The following is a list of guidelines for each procedure in the “repair Sections” of the Troubleshooting and Repair Manual. The procedure will be given first; followed by a definition o the step or steps involved. Check Inspect Test Adjust Visually Inspect Remove Clean Disassemble Repair Note Replace Install Star Pattern Torque Sequence Examine a component or system for damage, excessive wear, accuracy, safety, or performance. Examine a component or dimension to make sure it meets the required specifications. Check or compare the performance of a component or system to established specifications. Complete the necessary steps to set or adjust the component, assemblies, or system in the required setting or position. Look for any obvious damage or problem. Take off a component or assembly Remove dirt, grease or other contamination. Take the component or assembly apart. Restore a component or assembly to a serviceable condition within the established specifications. Only the easiest and simplest repairs will be made to a component or assembly. If a component or assembly must be rebuilt; it must be replaced with a new or Cummins Diesel Recon, Inc. replacement or be rebuilt at a Cummins authorized repair location. Install a new, properly rebuilt, or Cummins Diesel Recon, Inc. component or assembly in place of one which is removed. Place a component or assembly in the correct position.

A Series Troubleshooting and Repair Manual Definition of Terms 8 Illustrations The illustrations used in the Diagnosis Sections of this manual are intended to give an example of a problem, show what to look for and where to look for the problem. Most of the illustrations are generic and might not look exactly like the engine or parts used in your application. Some illustrations contain symbols to indicate an action required and an acceptable or unacceptable condition. Unacceptable Acceptable Direction of Movement (Action) The illustrations used in the Replacement Sections are intended to show replacement procedures when the engine is installed in a chassis. The illustration may differ from your application, but the procedure given will be the same.

A Series Troubleshooting and Repair Manual Definition of Terms 9 External Engine Components The pictures which follow show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models. Note: The pictures are only a reference to show a typical engine. Exhaust Side [Naturally Aspirated] Intake Side [Naturally Aspirated] 1. Exhaust Manifold 2. Oil Fill Cap 3. Fan 4. Fuel Injection Pump 5. Crankshaft Pulley 6. Dip Stick 7. Oil Filter 1. Intake Manifold 2. Alternator 3. Thermostat housing 4. Starting Motor

A Series Troubleshooting and Repair Manual Definition of Terms 10 Exhaust Side [Turbocharged] Intake Side [Turbocharged] 1. Fuel Filter 2. Crankshaft Pulley 3. Cooling Fan 4. Exhaust Manifold 5. Dipstick 6. Oil Cooler 7. Fuel Injection Pump 8. Turbocharger Oil Drain Tube 1. Turbocharger 2. Alternator 3. Thermostat Housing 4. Intake Manifold 5. Starting Motor 6. Turbocharger Oil Tube 7. Oil Fill Cup 8. Air Crossover Tube

A Series Troubleshooting and Repair Manual Definition of Terms 11 Engine Specifications Engine Model A2000 A2300 General Engine Data Naturally Aspirated Engine Weight(Dry) Less Flywheel and Electronics 169 kg [373 lb] Compression Ratio 21:1 Bore [mm/inch] 84 [3.31] 88 [3.46] Stroke [mm/inch] 94 [3.7] Displacement [ℓ/in3] 2.08 [127] 2.29 [139] Firing Order 1-3-4-2 Intake 0.3 mm [0.012 in] Valve Clearance Exhaust 0.3 mm [0.012 in] Rotation Viewed from the Front of the Engine Clockwise Lubrication System Naturally Aspirated Regulating Valve Opening Pressure 290 – 390kPa [42-56 psi] Total System 7.0 [1.85] Lubricating Oil Capacity [ℓ/gal] Standard Oil Pan Only 6.5 [1.72] Lubricating Oil Pressure at Idle(Max. Allowable) 69 kPa [10 psi] Lubricating Oil Pressure at Rated(Min. Allowable) 245 kPa [35 psi] Oil Filter Differential Pressure to Open Bypass Valve 98 kPa [14 psi] Number of liters [qt] from Low to High 2.0 ℓ [0.53 gal] Lubrication System Forced Lubrication with Pump Cooling System Naturally Aspirated Coolant Capacity (Engine Only) [ℓ/gal] 3.0 [0.7] Start 71 [160] Standard Modulating Thermostat Range [℃/℉] Pulley Open 85 [185] Cooling System Forced Lubrication with Pump Air Induction System Naturally Aspirated Maximum Allowable Intake Restriction at Rated Speed and Load with Dirty Filter Element 6.23 kPa [635 mmAq] Exhaust System Naturally Aspirated Maximum Allowable Exhaust Restriction at Rated Speed and Load with Dirty Filter Element 5.88 kPa [600 mmAq] Fuel System Naturally Aspirated Injection Pressure 150 kPa [22 psi] Starting System Electric starting with Starter Motor (12 V –2.0 kW)

A Series Troubleshooting and Repair Manual Coolant System 12 Troubleshooting Logic Engine Diagrams A schematic of each of the major engine systems is provided at the beginning of the section of the manual devoted to troubleshooting and repairing that particular system. The diagrams depict flow through the various engine systems. The information and configuration of the components illustrated in the drawings are of a general nature. Some items for specific applications and installations may be different. Each Section also contains a discussion regarding diagnosing malfunctions for that specific system. Knowledge of the systems can help you troubleshoot and repair the engine. Problem Isolation and Correction The following Troubleshooting Logic is designed to help you organize your study of a problem and to plan a procedure to correct it. The series of fault/logic charts given do not provide all the answers, but they should stimulate a train of thought that will lead you to the source of the trouble. Be sure to consider any maintenance or repair action that could have caused the problem. If the engine surges or runs rough initially after not being used for 2 months or more, do not assume that the engine has a malfunction. Varnish can form on the internal parts of the injection pump and the oil film can drain from the piston rings. Operate the engine for at least 5 minutes before troubleshooting. The basic procedure is as follows: Study the problem thoroughly. Relate the symptoms to your knowledge of the engine components and systems. Double-check before beginning the disassembly. Solve the problem by deduction starting with the easiest things. Determine the cause of the problem and make a thorough repair. After making corrections, operate the engine in normal conditions to verify the cause of the problem was corrected.

A Series Troubleshooting and Repair Manual Coolant System 13 Troubleshooting Logic Troubleshooting Logic Page List of Symptoms Alternator Not Charging or Insufficient Charging Coolant Loss Coolant Temperature Above Normal Coolant Temperature Below Normal Compression Knocks Contaminated Coolant Contaminated Lube Oil Engine Cranks But Will Not Start – No Smoke From Exhaust Engine Hard to Start Or Will Not Start – Smoke From Exhaust Engine RPM Will Not Reach Rated Speed Engine Runs Rough or Misfiring Engine Starts But Will Not Keep Running Engine Will Not Crank Or Cranks Slowly Engine Will Not Shut Off Excessive Engine Noises Excessive Engine Smoke Excessive Fuel Consumption Excessive Vibration Fuel or Oil Leaking From Exhaust Manifold Low Power Lube Oil Loss Lubricating Oil Pressure Low Lubricating Oil Pressure Too High Rough Idle (Irregularly Firing Or Engine Shaking) Surging (Engine Speed Change)

A Series Troubleshooting and Repair Manual Coolant System 14 Engine Will Not Crank or Cranks Slowly Cause Correction Starting Motor Operating But Not Cranking the Engine Remove the Starting Motor and Check for Broken Teeth on the Flywheel or Broken Starting Motor Spring. Refer to Page 134 OK Crankshaft Rotation Restricted Bar the Engine to Check for Rotational Resistance. Refer to Page 134. OK Starting Circuit Connections Loose Or Corroded Clean and Tighten Connections. Refer to Page 133. OK Battery Charge Low Check Battery Voltage. Refer to Page 133. OK No Voltage to Starter Solenoid Check Voltage to Solenoid. Refer to Page 133. OK Solenoid or Starting Motor Malfunction Replace Starting Motor. Refer to Page 140.

CUMMINS A Series A2000 A2300 Engine Workshop Service Manual

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