Cummins C8.3 Engine Troubleshooting & Repair Manual

Covers: Cummins C Series Diesel Engines – 6C8.3, 6CT8.3, 6CTA8.3, C8.3
Pages: 868
Format: PDF
File size: 54mb
Works with: Windows/Mac/Tablet
Notes: Searchable, printable, instant download

This manual provides instructions for mechanical troubleshooting and repairs on the C8.3 series diesel engine in the chassis. Does NOT cover ISC engines. Fuel system troubleshooting/wiring diagrams sold separately.

11/2013 edition.

Topics:

General Information

• Introduction
• Engine Identification
• Engine Views
• Familiarization
• Complete Engine Overview

Troubleshooting Symptoms

• Troubleshooting Procedures and Techniques
• Troubleshooting Symptom Charts
• Air Compressor Air Pressure Rises Slowly
• Air Compressor Cycles Frequently
• Air Compressor Noise is Excessive
• Air Compressor Pumping Excess Lubricating Oil into the Air System
• Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
• Air Compressor Will Not Pump Air
• Air Compressor Will Not Stop Pumping
• Alternator Not Charging or Insufficient Charging
• Alternator Overcharging
• Coolant Contamination
• Coolant Loss
• Coolant Temperature Above Normal – Gradual Overheat
• Coolant Temperature is Above Normal – Sudden Overheat
• Coolant Temperature is Below Normal
• Coolant in the Lubricating Oil
• Coolant Temperature Above Normal – Sea Water Coolant System
• Crankcase Gases (Blowby
• Engine Acceleration or Response Poor
• Engine Difficult to Start or Will Not Start (Exhaust Smoke
• Engine Difficult to Start or Will Not Start (No Exhaust Smoke
• Engine Noise Excessive
• Engine Noise Excessive – Combustion Knocks
• Engine Noise Excessive – Connecting Rod
• Engine Noise Excessive – Main Bearing
• Engine Noise Excessive – Piston
• Engine Noise Excessive – Turbocharger
• Engine Power Output Low
• Engine Runs Rough at Idle
• Engine Runs Rough or Misfires
• Engine Speed Surges at Low or High Idle
• Engine Starts But Will Not Keep Running
• Engine Vibration Excessive
• Engine Will Not Crank or Cranks Slowly
• Engine Will Not Reach Rated Speed (RPM
• Engine Will Not Shut Off
• Excessive Noise
• Fuel Consumption Excessive
• Fuel Knock
• Fuel in Lubricating Oil
• Fuel or Lubricating Oil Leaking From Exhaust Manifold
• Intake Manifold Air Temperature Above Specification
• Intake Manifold Air Heater System Malfunctioning
• Lubricating Oil Consumption Excessive
• Lubricating Oil Pressure High
• Lubricating Oil Pressure Low
• Lubricating Oil Sludge in the Crankcase Excessive
• Lubricating Oil Temperature Above Specification
• Lubricating or Transmission Oil in the Coolant
• Smoke, Black-Excessive
• Smoke, White-Excessive
• Troubleshooting Overview

Complete Engine

• Engine Removal
• Engine Installation

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
• Cylinder Block
• Cylinder Liner
• Gear Cover, Front
• Gear Housing, Front
• Piston
• Piston Rings
• Timing Pin Housing
• Vibration Damper, Viscous
• Piston and Connecting Rod Assembly
• Engine Dataplate
• Crankshaft Wear Sleeve, Rear
• Block Stiffener Plate

Cylinder Head

• Valve Guide Seal, Cylinder Head
• Valve Guide, Cylinder Head
• Valve Seat Insert, Cylinder Head
• Valve, Cylinder Head
• Cylinder Head Gasket
• Injector Protrusion

Rocker Levers

• Overhead Set
• Rocker Lever
• Rocker Lever Cover
• Crankcase Breather Tube

Cam Followers/Tappets

• Push Rods or Tubes
• Tappet

Fuel System

• AFC Assembly
• Engine Fuel Heater, Electric
• Fuel Injection Pumps, In-Line
• Fuel Injection Pump, In-Line, Spill Port Timing
• Fuel Pump Control Lever and Spring
• Fuel Pump Idle Speed
• Fuel Shutoff Valve
• Fuel Lift Pump

Injectors and Fuel Lines

• 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 Supply Lines
• Injector
• Fuel Return Overflow Valve
• Injector Supply Lines (High Pressure)

Lubricating Oil System

• Engine Oil Heater
• Oil Cooler
• Dipstick
• Filter (Spin-On)
• Leaks
• Oil Pan
• Oil Pressure Regulator
• Oil Pump
• Suction Tube
• Thermostat
• Oil Analysis

Cooling System

• Drive Belt, Cooling Fan
• Coolant Filter
• Coolant Filter Head
• Coolant Filter Valve
• Coolant Thermostat
• Coolant Thermostat Housing
• Coolant Vent Lines
• Cooling System
• Cooling System – Air or Combustion Gas Test
• Engine Coolant Heater
• Fan Drive Idler Pulley Assembly
• Fan Hub, Belt Driven
• Fan Shroud Assembly
• Fan Spacer and Pulley
• Fan, Cooling
• Radiator
• Radiator Hoses
• Radiator Pressure Cap
• Sea Water Pump
• Supplemental Coolant Additive (SCA)
• Water Pump
• Sea Water Strainer
• Belt Tensioner, Automatic (Water Pump
• Sea Water System Diagnostics
• Sea Water Hoses

Air Intake System

• Aftercooler Assembly
• Air Crossover
• Air Intake Manifold
• Air Leaks, Air Intake and Exhaust Systems
• Charge-Air Cooler
• Air Intake Restriction
• Turbocharger
• Turbocharger Axial Clearance
• Turbocharger Oil Drain Line
• Turbocharger Oil Supply Line
• Turbocharger Radial Bearing Clearance
• Turbocharger Wastegate Actuator
• Intake Manifold Pressure
• Intake Manifold Air Heater Wiring Harness
• Intake Manifold Air Heater Temperature Sensor
• Intake Manifold Air Heater Element
• Intake Manifold Air Heater Control Module
• Intake Manifold Air Heater Solenoid Switch
• Intake Manifold Air Heater Speed Sensor

Exhaust System

• Exhaust Manifold, Dry
• Exhaust Restriction

Compressed Air System

• Air Compressor Carbon Buildup
• Air Compressor
• Air Governor – Air Compressor Will Not Pump
• Air Governor – Air Compressor Pumps Continuously
• Air Leaks, Compressed Air System

Electrical Equipment

• Alternator
• Alternator Bracket
• Alternator Pulley
• Batteries
• Battery Cables and Connections
• Starter Magnetic Switch
• Starter Switch
• Starter Solenoid
• Starting Motor
• Charging System Indicator

Engine Testing

• Engine Run-in
• Crankcase Blowby, Measure
• Engine Compression

Mounting Adaptations

• Flywheel
• Flywheel Housing
• Flywheel Housing, REPTO
• Flywheel Ring Gear
• Engine Mounts
• Propeller Shaft
• Marine Vibration Isolator

Generator, Main

Plugs