Cummins C8.3 Engine Troubleshooting & Repair Manual

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Covers: Cummins C Series Diesel Engines – 6C8.3, 6CT8.3, 6CTA8.3, C8.3
Pages
: 868
Format: PDF
Compatibility: Windows/Mac/Tablet

This manual provides instructions for mechanical troubleshooting and repairs on the C8.3 (C Series) diesel engine in the chassis. The Cummins C8.3 Engine Troubleshooting & Repair Manual manual does not contain electronic control system troubleshooting.

Topics in the Cummins C8.3 Engine Troubleshooting & Repair Manual:

Introduction

Engine Identification
Engine Diagrams

Familiarization
Complete Engine – Overview
Cylinder Block – Overview
Cylinder Head – Overview
Cam Followers/Tappets – Overview
Fuel System – Overview
Flow Diagram, Fuel System
Lubricating Oil System – Overview
Flow Diagram, Lubricating Oil System
Cooling System – Overview
Flow Diagram, Cooling System
Air Intake System – Overview
Flow Diagram, Air Intake System
Exhaust System – Overview
Flow Diagram, Exhaust System
Compressed Air System – Overview
Flow Diagram, Compressed Air System
Electrical Equipment – Overview
Electronic Wiring Diagrams
Engine Testing – Overview

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

Service Tools
Engine Removal
Engine Installation

Service Tools
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

Service Tools
Cylinder Head
Valve Guide Seal, Cylinder Head
Valve Guide, Cylinder Head
Valve Seat Insert, Cylinder Head
Valve, Cylinder Head
Cylinder Head Gasket
Injector Protrusion

Service Tools
Overhead Set
Rocker Lever
Rocker Lever Cover
Crankcase Breather Tube

Service Tools
Push Rods or Tubes
Tappet

Service Tools
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

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

Service Tools
Engine Oil Heater
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
Lubricating Oil Analysis

Service Tools
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

Service Tools
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 Manifold, Dry
Exhaust Restriction

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

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

Service Tools
Engine Testing (Chassis Dynamometer
Engine Run-in (Chassis Dynamometer
Engine Run-in (Without Dynamometer
Engine Run-in (Engine Dynamometer
Crankcase Blowby, Measure
Engine Compression

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

Cup Plug
Pipe Plug
Straight Thread Plug

Generator, Main

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