Cummins C Series Engine Workshop Repair manual

Troubleshooting and Repair Manual C Series Engines

Foreword This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and assembly rebuild procedures are provided in the engine shop manual. Refer to Section i - Introduction for instructions on how to use this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction. The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures. A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in Service Literature (Section L). The repair procedures used in this manual are recommended by Cummins Inc. Some service procedures require the use of special service tools. Use the correct tools as described. Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual are based on the information in effect at the time of printing. Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.

Table of Contents Section Introduction ........................................................................................................................................................ i Engine and System Identification .................................................................................................................... E Familiarization .................................................................................................................................................... F Troubleshooting Symptoms ............................................................................................................................. TS Complete Engine - Group 00 ............................................................................................................................ 0 Cylinder Block - Group 01 ................................................................................................................................. 1 Cylinder Head - Group 02 .................................................................................................................................. 2 Rocker Levers - Group 03 ................................................................................................................................. 3 Cam Followers/Tappets - Group 04 ................................................................................................................. 4 Fuel System - Group 05 ..................................................................................................................................... 5 Injectors and Fuel Lines - Group 06 ................................................................................................................. 6 Lubricating Oil System - Group 07 ................................................................................................................... 7 Cooling System - Group 08 ............................................................................................................................... 8 Air Intake System - Group 10 ............................................................................................................................ 10 Exhaust System - Group 11 .............................................................................................................................. 11 Compressed Air System - Group 12 ................................................................................................................ 12 Electrical Equipment - Group 13 ...................................................................................................................... 13 Engine Testing - Group 14 ................................................................................................................................ 14 Mounting Adaptations - Group 16 .................................................................................................................... 16 Miscellaneous - Group 17 ................................................................................................................................. 17 Main Power Generator - Group 21 .................................................................................................................... 21 Service Literature .............................................................................................................................................. L Specifications .................................................................................................................................................... V Back .................................................................................................................................................................... back

C Series Section i - Introduction Page i-a Section i - Introduction Section Contents Page About the Manual .........................................................................................................................................................i-1 General Information.....................................................................................................................................................i-1 Acronyms and Abbreviations ...................................................................................................................................i-14 General Information...................................................................................................................................................i-14 General Cleaning Instructions ....................................................................................................................................i-9 Abrasive Pads and Abrasive Paper.............................................................................................................................i-9 Definition of Clean........................................................................................................................................................i-9 Fuel System...............................................................................................................................................................i-12 Gasket Surfaces........................................................................................................................................................ i-10 Plastic Bead Cleaning................................................................................................................................................i-11 Solvent and Acid Cleaning.........................................................................................................................................i-10 Steam Cleaning......................................................................................................................................................... i-11 General Repair Instructions ........................................................................................................................................i-7 General Information.....................................................................................................................................................i-7 Welding on a Vehicle with an Electronic Controlled Fuel System................................................................................i-8 General Safety Instructions ........................................................................................................................................i-5 Important Safety Notice...............................................................................................................................................i-5 How to Use the Manual ................................................................................................................................................i-2 General Information.....................................................................................................................................................i-2 Illustrations ...................................................................................................................................................................i-4 General Information.....................................................................................................................................................i-4 Symbols ........................................................................................................................................................................ i-3 General Information.....................................................................................................................................................i-3

C Series Page i-b Section i - Introduction This Page Left Intentionally Blank

C Series About the Manual Section i - Introduction Page i-1 About the Manual General Information 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' filmcard 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. This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual, if there are no electronic fault codes. This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the back of the manual to locate specific topics when not using the troubleshooting trees.

How to Use the Manual C Series Page i-2 Section i - Introduction How to Use the Manual General Information This manual is organized to provide an easy flow from problem identification to problem correction. A list of troubleshooting symptoms containing the most common problems is in the Troubleshooting Symptoms, Section (TS). The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair. Complete the following steps to locate and correct the problem. 1 Locate the symptom on the Section Contents pages of Section TS. • Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title. 2 The left column of boxes in the Troubleshooting Symptom Charts indicates a probable cause of the problem, starting at the top with the simplest and easiest to repair, and continuing downward to the most difficult. • The right column of boxes provides a brief description of the corrective action with a reference number to the correct procedure used to make the repair. 3 Locate the probable cause in the left column then turn to the procedure referenced in the right column. 4 The Troubleshooting Symptom Charts are based on the following assumptions: • The components have been installed according to the manufacturer's specifications. • The easiest repairs are done first. • All generic solutions are designed for the most common applications and Original Equipment Manufacturer (OEM). Refer to the Original Equipment Manufacturer's service manual for their specifications.

C Series Symbols Section i - Introduction Page i-3 Symbols General Information The following symbols have 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:

Cummins C Series Engine Workshop Repair manual

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