C serial

engine training
Course

2009-10-4
General Engine Specifications

Bore......................114 mm [4.49 in]

Stroke....................135 mm [5.32 in]
Displacement....................8.27 liters [504.7 C.I.D.]
Engine Weight (dry) with Standard Accessories....................603 to 612 kg
[1330 to 1350 lb]
Wet Weight....................635 to 658 kg [1400 to 1450 lb]
Firing Order....................1-5-3-6-2-4
Valve Clearances:
Intake....................0.30 mm [0.012 in]
Exhaust....................0.61 mm [0.024 in]
Rotation, Viewed from the Front of the Engine....................Clockwise
Compression Ratio:
6C8.3....................16.4:1
6CT8.3....................17.3:1
6CTA8.3....................16.5:1
C8.3....................17.3:1 (low torque) or 18:1 (high torque)
Engine ratings-automotive
application
Engine Model Rating power Fuel pump Peak torque
(Kw@rpm) (N.m@rpm)

C220 20 162@2200 Bosch P7100/RQV-K 800@1400

C230 20 169@2200 WEIFU 830@1400

PW2000/RQV-K

C245 20 180@2200 Bosch P7100/RQV-K 1025@1400

C260 20 191@2200 Bosch P7100/RQV-K 1025@1400

C280 20 206@2200 WEIFU 1125@1400

PW2000/RQV-K

C300 20 221@2200 WEIFU 1125@1400

PW2000/RQV-K
C325 20) 231@2200 Bosch P7100/RQV-K 1200@1400
Engine Nomenclature

6CTAA8.3
Industrial Applications

8.3 = displacement in liters

AA = charge air aftercooled
T = turbocharged
C = engine series
6 = number of cylinders

C245 20

Automobile Applications
Engine Data plate

The engine data plate show specific information about your engine. The
engine serial number and control parts list (CPL) provide information for
ordering parts and service manuals.

The data plate is located on the top side of the gear housing. Have the
following engine data available when communicating with a Cummins
Authorized Repair Location. The information on the data plate is
mandatory when sourcing service parts.

1. Control parts list

(CPL)
2. Model
3. Engine serial
number
4. Emissions
certification
5. Horsepower and
rpm rating.
Fuel Injection Pump Data plate

The Bosch® fuel injection pump data plate is

located on the side of the injection pump. It
provides information for fuel pump calibration.

The Cummins part number for the fuel pump-

governor combination is located on the governor
data plate.
 C engine views

FRONT VIEW –C8.3

1. Engine air inlet 7. Vibration damper

2. Fan pulley 8. Fan belt tensioner
3. Fuel pump 9. Water pump
drive cover
10. Alternator
4. Front gear
11. Turbocharger air outlet
cover
12. Turbocharger air inlet
5. Drive belt
13. Engine oil fill.
6. Lubricating oil
pan drain plug
 C engine views

1. Engine air inlet 10. Lubricating oil LEFT VIEW C-8.3

dipstick
2. Shutoff solenoid
11. Front engine
3. M22 x 1.5 inlet
mounting bracket
(air)
12. Engine dataplate
4. Rear lifting
bracket 13. Fuel injection
pump
5. Fuel filter
14. Delivery valve
6. Fuel/water
separator 15. Fuel drain line
7. Fuel transfer 16. High-pressure fuel
pump lines
8. 3/4 x 16-inch 17. 1/2-inch NPTF
UNF tap for inlet (air)
magnetic pickup
18. Intake air heater.
9. Lubricating oil
pan drain plug
C engine views

Rear View - C8.3

1. Turbocharger exhaust
outlet
2. Flexplate mounting holes
3. Flywheel housing
4. Flywheel
5. Crankcase breather tube
6. Rear engine lifting
bracket.
 C engine views

1. Front engine 9. Lubricating oil

lifting bracket pan drain plug
Right View - C8.3
2. Water/coolant 10. Turbocharger
outlet oil drain
connection
11. Coolant filter
3. Lubricating oil
12. Starting motor
pressure (after
filter) 13. Rear engine
lifting bracket
4. Lubricating oil
pressure (before 14. Turbocharger
filter) exhaust outlet
5. Coolant heater 15. Turbocharger
port wastegate
actuator
6. Lubricating oil
cooler 16. Turbocharger
air inlet
7. Water/coolant
inlet 17. Engine oil fill.
8. Lubricating oil
filter
C engine views

Top View - C8.3

1. Turbocharger
2. 3/4 x 16-inch UNF
tap for magnetic
pickup
3. Crankcase breather
4. Engine air inlet
5. Thermostat
6. Exhaust manifold.
Cylinder Block Group
 Bearings, Main

The C Series engine has seven main bearings.

The lower bearing shells are all the same.

All of the upper bearing shells are the same except for the
Number 4 journal.

The Number 4 journal uses a flanged upper bearing shell.

The flanges on the bearing control the end thrust of the

crankshaft.

The upper bearings contain two oil holes. The lower bearings do
not.

Oversize service main bearings are available for reground

crankshafts.
 Bearings, Connecting Rod

The connecting rod bearings are a trimetal design with a steel

backing.

Oversize service rod bearings are available for use with

crankshafts that have been machined undersize.

The connecting rod bearing shells are identified by steel-stamped

characters on the back of the bearings.

The characters indicate either standard (STD) or the amount

oversize (OS).

If bearings are damaged, they must be replaced as a set.

Used bearings must be installed in the same location from which

they were removed.

Upper and low bearings are the same

 Crankshaft

The crankshaft is a forged steel, full -fillet-hardened, integrally

balanced unit.

The crankshaft thrust is controlled by a flanged, upper bearing

shell, which is located in the number four main bearing.

Oversized main service bearings are available for use with

reground crankshafts.

An oversized, flanged upper shell is available to permit clean-

up of the thrust
Gear Housing, Front

The gear train consists of:

Crankshaft Gear
Lubricating Oil Pump Gear
Idler Gear
Camshaft Gear
Fuel Injection Pump Gear
Accessory Drive Gear; if used

The gear housing provides a support for the fuel

injection pump.

the timing pin housing.

the engine data plate is on the gear housing.
 Crankshaft Seal

Crankshaft Seal, Front :

The front crankshaft seal is mounted in the front gear cover.

A double-lipped Teflon™ seal is used.

The sealing surface on the crankshaft must be clean and free

of lubricating oil during assembly.

Crankshaft Seal, Rear :

a double dust lip-style rear crankshaft seal in which the

rotating portion of the sealing occurs at the contact surface
between the lip of the seal and the crankshaft.

The rear crankshaft seal is installed in the flywheel housing

bore.
 Connecting Rod

C engine connecting rods are angle split units with machined

mating faces. The rod caps on these rods are secured with
capscrews.

The letter or number on the connecting rod cap must be the

same as the letter or number on the connecting rod.

Do not assemble a new cap to a used connecting rod, or a used

cap to a new connecting rod.

The rod and cap must be replaced as an assembly if any

fretting damage is visible on either piece.

Service replacement rod bushings are available.

Piston & piston rings

The C engines use an aluminum one

piece piston with a cut out for the piston
cooling nozzle on one side

The top ring of the piston is a positive

twist keystone design. This ring allows
less carbon buildup and reduces the oil
consumption.

The middle compression ring is a

negative twist keystone design. The
keystone shape of the ductile iron second
ring allows for less carbon buildup and
reduces ring groove wear.
.
The third, or oil control ring, utilizes a coil
expander inside the ring. The ring itself
contains two chrome face rails.
 Camshaft

These engines use camshaft bushings with two oil drillings.

The bushings are installed in the block with the lower hole
in the bushing aligned with the drilling in the block
connecting the camshaft and crankshaft bores with the
main oil rifle.

These engines have camshafts with wider lobes and all

utilize large diameter tappets.

These engines also have a tapped hole in the nose of the

camshaft to facilitate removal and installation of the
camshaft gear, without removing the camshaft from the
engine.
 Tappet & Push rod

The valve tappets are mushroom shaped.

The offset position of the tappet against the camshaft lobe

causes the tappet to rotate as it lifts the push rod.

The ball end of the push rod fits into the ball socket in the tappet.

The other end of the push rod has a ball socket in which the ball
end of the rocker lever adjusting screw operates.

The tappets/the push rod must be installed in the same position

as removed.
Cylinder Liner

replaceable wet cylinder liners.

The mid-stop design is used to “locate” the liner in the block.

The cylinder liners have a bore of 114.05 mm regardless of displacement.

A press fit between the liner and the block aligns the top of the liner in the
block bore.

The mid-stop seat seals the lower end of the coolant cavity.

A-D Ring liner seal is used to separate the oil cavity from the coolant seat.
 Cylinder Liner

Check

cracking, scuffing, or scoring polishing not straight or not round

 Cylinder Liner

Remove

Insert the cylinder liner Turn the puller jackscrew Mark the cylinder number
puller, Part Number clockwise to loosen the liner on each liner.
3376015, into the top of from the cylinder block .Use
the cylinder block. both hands to remove the liner.
 Cylinder Liner

Clean

Use a soft wire brush or a fine Use solvent or steam (kerosene) Continue to lubricate the inside
fibrous abrasive pad clean the to clean the cylinder liners. of the liners and wipe clean
flange seating area until the paper towel shows no
Dry the cylinder liners with
gray or black residue.
compressed air
 Cylinder Liner

Inspect for Reuse

cracks on the inside and cracks under the flange. excessive corrosion or pitting.
outside.

vertical scratches Polishing A heavy polish

Cylinder Liner

Measure

Measure the liner inside diameter with dial bore gauge,

Part Number 3375072, in four places 90 degrees
apart at the top and bottom of the piston travel area.

Cylinder Liner Inside Diameter

114-114.04mm[4.488-4.49in]

Measure the outside diameter of the liner top press fit

area.
Cylinder Liner Outside Diameter (Top Press Fit)
130.938-130.958mm[5.155-5.1558in]

Measure the cylinder liner bore in the block .

Cylinder Liner Bore in Block (Press-Fit Bore)
130.90-130.95mm[5.154-5.156in]
 Cylinder Liner
install

Clean the combustion deck with Thoroughly flush the Lubricate surfaces (A) and (B)
a gasket scraper or Scotch. block .

coat the liner o-ring seals. When reusing rotate them Install the cylinder liners into the
45 degrees bore of the cylinder block
Cylinder Liner

measure

Measure the liner protrusion

0.03-0.12mm
Cylinder Block

C and L series engines share the same basic

block design.

cylinder block has an integral

Oil cooler housing
Water pump housing
Oil pump housing
Coolant intake port
Thermostat housing
Internal water bypass
two saddle jet piston cooling nozzles for per
cylinder
Cylinder Head Group
 Cylinder Head

The cylinder head is a one-piece, cross-

flow design with two valves per cylinder.

The valve guides and seats are replaceable.

The cylinder head has a cast intake

manifold and fuel filter head. The injectors
are mounted in the head for direct injection
into the cylinders.

The cylinder head gasket is a specialized

metal design with a fire ring to seal the
cylinder bores. The gasket also provides
orifices to control coolant flow.
 Valve Guide Seal

Worn valve stem seals are typically

detected by excessive smoke at idle,
or when the engine is unloaded and
the vehicle is going downhill.

Hardening of the material and wear or

damage to the sealing surfaces will
cause the valve seals to leak.
Rocker Lever

rocker lever rocker levers pedestal

assembly assembly

shaft a common rocker levers oil manifold.

Valve
remove
a dimple to identify the exhaust valves from the
intake valves.

Mark the valves to identify their location.

NOTE: If the valve springs, collets, retainers, and

valve guide seals are to be used again, they must
be installed in their original location.

Compress the valve springs with valve spring

compressor, Part Number 3375962.

Release the valve spring and remove the valve

spring retainer and valve spring.

Remove the valve.

 Valve

Inspect

abnormal wear 9.48-9.50mm the valve stem tip for flatness

bent valves. Max 2.21mm 65.66mm

Valve

Install

NOTE: All cylinder head components must be clean before installing

them.

1. Install new valve stem seals.

2. Lubricate the valve stems with clean SAE 90W oil.
3. Install the valves in their original locations.
4. Assemble the valve spring and retainer.
5. Install and compress the valve spring retainer assembly, using valve
spring compressor, Part No. 3375962.
6. Install new valve collets and release the valve spring compressor
tension.
7. After assembly, hit the valve stems with a plastic hammer to make sure
that the collets are installed properly.
 Valve

Install

Install new valve stem

seals Lubricate the
valve stems

Install new valve collets hit the valve stems

compress the valve spring
retainer assembly
 Valve Guide

Measure the inside diameter of the valve guide bore

in the cylinder head.

Valve Guide Bore without Pin Inside Diameter

15.931-15.971mm(0.6272-0.6288in)

If the valve guide bore is worn larger than the

maximum specified, the cylinder head must be
replaced.

Inspect the valve guides for scuffing, scoring, chips,

or cracks.

Measure the valve guide inside diameter.

Valve Guide Bore with Pin, Inside Diameter.
9.539-9.559mm(0.3755-0.3763in)
Overhead Set

Remove valve cover.

Locate top dead center for cylinder Number 1 by

rotating the crankshaft slowly while pressing on the
engine timing pin.

When the engine timing pin engages the hole in the

camshaft gear, cylinder Number 1 is at top dead
center on the compression stroke.

disengage the engine timing pin.

Overhead Set

Intake clearance: 0.30 mm [0.012 in].

Exhaust clearance: 0.61 mm [0.024 in].

Check/set valves with engine cold - below 60°C

[140°F].

NOTE: The clearance is correct when some

resistance is “felt” when the feeler gauge is slipped
between the valve stem and the rocker lever.

Check/adjust the valves indicated for STEP A (I =

intake; E = exhaust).

After tightening the rocker lever locknut, check the

valve clearance to make sure the valve clearance
has not changed.
Torque Value: 24nm
Overhead Set

Mark vibration damper and rotate the crankshaft

360 degrees.

Set the valves indicated for STEP B.

After tightening the rocker lever locknut, check the

valve clearance to make sure the valve clearance
has not changed.
Torque Value: 24 nm

Install new sealing o-rings on the capscrews.

Install the valve cover and wastegate sensing tube.

Torque Value: 24 nm
Fuel system
The fuel transfer pump

mechanically driven by a plunger

running against a special lobe on the
camshaft.

contains a pumping piston (A) and

check valves (B) (C) to control the
flow of fuel.
fuel injection pump

PW2000 PW PUMP
The pressure relief valve

Function
arrangement in the supply side of the fuel
circuit creates a self-bleeding system on the
A-type fuel injection pump.

Air introduced during replacement of any

supply-side components will automatically
bleed out of the fuel system.

Small amounts of air can be bled from the fuel

injection pump by operating the hand primer
on the fuel transfer pump or by cranking the
engine.

The relief valve is a ball and spring type and is

set to open at 690 kPa [100 psi] +/- 70 kPa [10
psi] and is not adjustable.
Fuel Filter (Spin-On Type)

Filtration and separation of water from the

fuel is important for trouble-free operation
and long life of the fuel system.

Make sure to use the correct fuel filter

element for your engine.

The fuel filter element has a valve that must

be opened daily to drain any collected water.

A dual water separator/filter adapter

provides additional filtering capacity. The
fuel flows through the adapter to a larger
combination fuel/water separator filter, and
back to the fuel filter for final filtering.
Injector Supply Lines (High
Pressure)
deliver fuel at injection pressure to the injectors.

they are clamped securely and routed so they do not contact each other or
any other components.

The high-pressure pulses will cause the lines to expand and contract
during the injection cycle.

The length, internal size, and rigidity of the high-pressure fuel lines is
critical to smooth engine operation.

Do not weld or substitute line. Use only the specified part number for the
engine.
Injector

All engines use 7-mm closed nozzles, hole-type

injectors.

the injectors can have different part numbers for

different engine ratings.

The last four digits of the Cummins part number is

used to identify the injectors.

Use only the specified injector for the engine.

High-Pressure Fuel Line.

Fuel Drain Manifold.

Fuel Manifold (Drain)

The fuel system is designed to use fuel to cool

and lubricate the fuel injection pump plungers
and injectors.

Fuel is continually vented from the fuel injection

pump and a small amount of fuel leaks by the
injector needle valve during injection.

This fuel is returned to the fuel filter head (1) by

the fuel drain manifold (2).
AFC Air Tube

The AFC (air-fuel control) tube allows intake

manifold pressure to adjust the fuel metering.

if the engine is equipped with a turbocharger, the

fuel pump meters more fuel for additional
horsepower.
Fuel Inlet Restriction

Test

Install a fitting at the inlet of the transfer pump.

Install a vacuum gauge, Part No. 3375274.
Vacuum Gauge Range :
0-508mmhg[0-20inhg]
Start the engine.
Run at low or high idle.
Inlet Restriction at Low/High Idle
Max 101.6mmhg[4.7inhg]
If the fuel inlet restriction is above specification,
check the OEM fuel lines from the fuel tank for
proper size, kinks and bends, and clogged fuel lines.
Make sure there are no clogged fuel strainers or
malfunctioning check valves.
Fuel Drain Line Restriction

Test

Remove the fuel drain hose.

Install the adapter, Part Number ST-434-2, and
pressure gauge, Part Number ST-1273, between the
fuel drain hose and the engine fuel drain fitting.
Start and operate the engine at high idle, no load.
Fuel Drain Restriction
Max 508mmhg[20inhg]

If the fuel drain line restriction is above specifications,

inspect the fuel drain line.
Air in Fuel

Air from uncorrected leaks in the supply circuit will

make the engine:
Difficult to start
Run rough
Misfire
Produce low power
Emit excessive smoke
Produce fuel knock.

Open the banjo bleed screw to bleed the low pressure

fuel line.
Air in Fuel

A source often overlooked for air to enter the fuel system is

between the inlet of the prefilter and the suction tube in the
fuel tank. Fuel tanks that have the outlet fitting at the top will
have a suction tube that extends to the bottom of the fuel tank.

Cracksor pin holes in the weld that join the suction tube to the
fitting can let air enter the fuel system.

Check all the fittings from the fuel supply on the fuel tank to
the fuel inlet of the fuel transfer pump; make sure they are all
tight. Use a sight glass at the fuel transfer pump inlet to check
for air in the supply line.

Since the fuel transfer pump provides a positive pressure

through the fuel filter and supply line to the fuel injection
pump, loose connections or defective seals will show as a fuel
leak and not as an air leak.
Fuel Injection Pumps, In-Line

Install

Make certain that the cylinder Number 1 is at top dead

center.

The fuel injection pump also has a timing pin (1), located
in the governor housing, to position the fuel injection
pump shaft to correspond with top dead center for
cylinder Number 1. The timing pin must be reversed and
stored in the housing (2) after the fuel injection pump is
installed.

Remove the fuel injection pump timing pin access plug.

Fuel Injection Pumps, In-Line

Remove the timing pin.

If the timing tooth is not aligned with the timing pin hole,
rotate the fuel injection pump shaft until the timing tooth
aligns.

Reverse the position of the timing pin so that the slot of

the timing pin will fit over the timing tooth in the fuel
injection pump.
Fuel Injection Pumps, In-Line

Install and secure the timing pin with the access plug.

Make certain that the o-ring seals for the fill orificeand
pilot are correctly installed and are not damaged.

Lubricate the mounting flange with clean lubricating

engine oil.

Before installing the fuel pump drive gear, clean the

injection pump shaft and gear tapers with QD Contact
Cleaner, Part Number 3824510, by spraying into the
gap between the shaft and the gear.

Dry the surface with compressed air.

Fuel Injection Pumps, In-Line

Slide the fuel injection pump shaft through the drive

gear, and position the fuel injection pump flange onto
the mounting studs.

Install the fuel injection pump mounting nuts.

Install the support bracket, if equipped.

Mounting nuts 44 n.m 32 ft-lb

Support bracket nuts 32 n.m 24 ft-lb

Fuel Injection Pumps, In-Line

Install and tighten the fuel injection pump retaining nut

and washer.
Torque Value: 12n.m

Disengage the engine timing pin.

Remove the access plug.

Add the following quantity of clean engine oil:

RSV 450 ml [0.48 qt]
RQV 750 ml [0.79 qt]
RQVK 750 ml [0.79 qt]
Fuel Injection Pumps, In-Line

Install the access plug. Torque Value: 28n.m

Remove the fuel injection pump timing pin plug.

Reverse the position of the timing pin.
Install the timing pin, plug, and sealing washer.
Tighten the timing pin plug. Torque Value: 15 nm
Tighten the fuel injection pump drive gear nut.
9Nippondenso 123 nm
9Bosch® A pump 85 nm
9Bosch® MW pump 105 nm
9Bosch® P3000/P7100 195 nm

Install the gear cover access cap hand-tight.

Fuel Pump Idle Speed-RSV

Adjust

RSV Governor Solenoid

Idle speed adjustment for engines with RSV governors

requires the setting of both the low-idle speed screw (1)
and the bumper spring screw (2).

Loosen the locknut and back out the bumper spring

screw until there is no change in engine speed.
Fuel Pump Idle Speed-RSV

Loosen the locknut and adjust the idle speed screw to

40 to 50 rpm less than the desired speed.

Turn the idle speed screw:

Counterclockwise to decrease rpm
Clockwise to increase rpm.

Tighten the locknut.

Torque Value: 8 nm

Turn the bumper spring screw clockwise until the

desired idle speed is obtained.

Tighten the locknut.

Torque Value: 8 nm
Fuel Pump Idle Speed-RQVK

Idle speed adjustment on fuel injection pumps with

RQV or RQVK governors requires setting only the stop
screw.

Turn the idle stop screw:

Counterclockwise to raise the rpm
Clockwise to decrease the idle speed.

Loosen the locknut and turn the idle speed screw to the
desired idle speed.

Tighten the locknut.

Torque Value: 8 nm
Flow Diagram, Fuel System
Flow Diagram, Fuel System

1. Fuel from supply tank

2. Prefilter or screen
3. Fuel transfer pump
4. Fuel/water separator
5. Fuel filter
6. Low-pressure supply line
7. Turbocharger boost control line
8. Bosch® PES.MW injection pump
9. Bosch® PES.A injection pump
10. Bosch® PES.P injection pump
11. Fuel drain manifold
12. High-pressure fuel lines
13. Hole-type injectors
14. Fuel return to supply tank.
Fuel System Specifications

Maximum Fuel Filter Pressure Drop across Filters:34 kPa [5 psi]

Maximum Inlet Restriction to Fuel Transfer Pump:100 mm Hg [4 in Hg]

Maximum Allowable Return Line Restriction:518 mm Hg [20.4 in Hg]

Lubrication system
Lubricating Oil Pump

The pump mounts to a bore machined into the

cylinder block.

Gear type pump.

Driven by the crankshaft gear.

Lubricating Oil Pan

recommends the use of a high-quality CF class 15W-40

A front sump (1), rear sump (2), or center sump (3)

lubricating oil pan option can be used depending on the
application

Assemble the washers and capscrews to secure the

lubricating oil pan, as illustrated.

Tighten all capscrews in the sequence shown in the

accompanying chart. Torque Value: 28 nm
Lubricating Oil Suction Tube

the lubricating oil suction tube is a formed steel

tube with a castor iron mount at the cylinder
block

The mounting of the lubricating oil suction tube

will vary with the type lubricating oil pan used
Lubricating Oil Filter (Spin-On)

Venturi tube Full-flow lubricating oil filter

Bypass lubricating oil filter

the lubricating oil thermostat.

Remove the lubricating oil thermostat.

Clean and inspect the lubricating oil thermostat

bore before assembly.

Install and tighten the oil cooler bypass valve.

Torque Value: 50 nm
Lubricating Oil Pressure
Regulator

Install a new sealing o-ring on the

threaded plug and lubricate with clean
engine oil. Install the pressure regulator
assembly.
Torque Value: 80 nm
Lubricating Oil Cooler

oil cooler oil cooler cover

cover housing

gaskets
Oil cooler
 Flow Diagram, Lubricating Oil
System

1. Gerotor lubricating oil pump 6. To lubricating oil pump 11. To lubricating oil filter
oil pan
2. Pressure regulating valve 12. Full-flow lubricating oil
closed 7. Lubricating oil cooler filter
3. Pressure regulating valve 8. Filter bypass valve 13. From lubricating oil filter
open
9. Filter bypass valve closed 14. Main lubricating oil rifle.
4. From lubricating oil pump
10. Filter bypass valve open
5. To lubricating oil cooler
Flow Diagram, Lubricating Oil
System

1. Lubrication oil filter

2. Turbocharger lubricating oil supply
3. Turbocharger lubricating oil drain
4. To main lubricating oil rifle.
Flow Diagram, Lubricating Oil
System

1. From lubricating oil cooler

2. Main lubricating oil rifle
3. To camshaft
4. To piston cooling nozzle
5. From main lubricating oil rifle
6. To connecting rod bearing.
Flow Diagram, Lubricating Oil
System

1. From cam bushings

2. Transfer slot
3. Rocker lever support
4. Rocker lever shaft
5. Rocker lever bore
6. Rocker lever.
Specifications

Oil Pressure
At Idle Speed - Minimum....................69 kPa [10 psi]
Normal Operating Speed....................205 kPa to 517 kPa [30 psi to 75 psi]
Regulated Pressure....................517 kPa [75 psi]
Maximum Allowable Temperature....................120°C [250°F]
Maximum Operational Angularity of Oil Pan (see engine mounting)
Front Down....................45 degrees
Front Up....................35 degrees
Side to Side....................45 degrees
Oil Capacity of Standard Engine:
Standard Oil Pan (Pan Only)....................18.9 liters [20 qt]
Standard Oil Pan with Cylinder Block Stiffener Plate (Pan
Only)....................19.9 liters [21 qt]
Oil Pan Low to High:
Standard Oil Pan....................15.1 to 18.9 liters [16 to 20 qt]
Standard Oil Pan with Cylinder Block Stiffener Plate....................16.1 to 19.9
liters [17 to 21 qt]
Total System Capacity....................19.9 liters [21 qt]
Total System Capacity (excluding bypass Filter)....................21.9 liters [23.2 qt]
Cooling System
Water Pump

The water pump pulls coolant from the bottom of the

radiator and pumps it through the engine back to the
top of the radiator for cooling.

A worn or malfunctioning water pump will not

produce the flow required to prevent the engine from
running hot.

A streak or chemical buildup at the weep hole is not

justification for water pump replacement.
Coolant & coolant filter

Use ethylene-glycol base antifreeze to protect the engine

to -37°C [-35°F] throughout the year.

Antifreeze is essential in all climates. It broadens the

operating temperature range by lowering the coolant
freezing point and by raising the coolant boiling point.

The cooling system must contain the proper coolant

additive units to provide the best chemical protection.

The correct coolant filter to be used is determined by the

total cooling system capacity and other operational factors.
Radiator Pressure Cap

The radiator cap actually increases the boiling point

of the coolant reach 107℃.

The radiator cap has a pressure relief valve. The valve

has a preset rating that allows it to take just up to a
certain amount of pressure.

Be sure the correct radiator cap is being used.

Inspect the rubber seal of the pressure cap for damage.

Inspect the radiator fill neck for cracks or other

damage.

Pressure-test the radiator cap.

thermostat

The thermostat‘s main job is to allow the engine to

heat up quickly, and then to keep the engine at a
constant temperature.

It does this by regulating the amount of water that

goes through the radiator.

Once the temperature of the coolant rises to

between 81- 83℃, the thermostat starts to open,
allowing coolant to flow through the radiator. when
the coolant reaches 95℃, the thermostat is open all
the way.

Minimum Recommended operating

Temperature:71℃
Flow Diagram, Cooling System
Cylinder head
1. Cylinder block 1. Flow from upper
2. Coolant inlet coolant manifold
3. Water pump impeller 2. Flow to liner cavity
4. Coolant flow to oil cooler Cylinder
5. Coolant flow past oil cooler 3. head gasket
6. Upper coolant manifold 4. Coolant flow orifice.
7. Coolant flow to cylinder head.
 Flow Diagram, Cooling System

1. Thermostats
2. Flow to water pump inlet
3. Bypass passage open
4. Flow from lower coolant manifold
1. Flow past cylinder liners 5. Partial coolant flow to radiator
2. Lower coolant manifold. 6. Restricted flow to bypass
7. Flow to radiator
8. Bypass closed.
Cooling System

Coolant Capacity (engine only) for 6C8.3, 6CT8.3, 6CTA8.3, C8.3....................9.9

liters [10.5 qt]

Standard Modulating Thermostat - Range for 6C8.3, 6CT8.3, 6CTA8.3,

C8.3....................81°C to 95°C [178°F to 203°F]

Maximum Allowable Operating Temperature for 6C8.3, 6CT8.3, 6CTA8.3,

C8.3....................100°C [212°F]

Minimum Recommended Operating Temperature for 6C8.3, 6CT8.3, 6CTA8.3,

C8.3....................70°C [158°F]

Minimum Recommended Pressure Cap for 6C8.3, 6CT8.3, 6CTA8.3,

C8.3....................50 kPa [7 psi]
Air Intake System
Air Intake System - Overview

Air is pulled into the engine through an air filter. Clean air is very important to the
life of the engine; dust and dirt can damage the cylinders very quickly.

Make sure that a high-quality air cleaner is used and that it is periodically replaced
according to the manufacturer‘s recommendations.

On turbocharged, aftercooled engines, intake air from the turbocharger flows through
the cooling fins of the aftercooler before entering the intake manifold. The cooled air
becomes more dense and contains more oxygen; which allows more fuel to be
injected, further increasing the power output from the engine.

On turbocharged engines, the energy from the exhaust is used to drive the turbine
wheel of the turbocharger. The turbine wheel and shaft drive the compressor wheel,
which forces more air into the cylinders for combustion. The additional air provided
by the turbocharger allows more fuel to be injected to increase the power output of
the engine.
Turbocharger
The purpose of a turbocharger is to compress the air
flowing into the diesel engine, this lets the engine
squeeze more air into a cylinder and more air means
that more fuel can be added. The engine burns air
and fuel to create mechanical power, the more air
and fuel it can burn the more powerful it is.

In simple terms, a turbocharger comprises of a

turbine and a compressor connected by a common
shaft supported on a bearing system.

The turbocharger converts waste energy from an

engine‘s exhaust gases into compressed air, which it
pushes into the engine.

This allows the engine to burn more fuel producing

more power and improve the overall efficiency of
the combustion process.
Turbocharger

Wastegate

Some turbocharged engines use a wastegate

turbocharger to limit the maximum boost
pressure that the turbocharger can develop.

Wastegate operation is controlled by an actuator

that senses intake manifold pressure and
balances it against a preset spring-load.

The wastegate valve is located in the turbine

inlet passage. When open, it diverts a portion of
the exhaust gas around the turbine wheel,
thereby controlling the shaft speed and boost.
Turbocharger

bearing housing

turbine wheel

compressor impeller
Turbocharger

Journal bearing arrangement

Journal bearings are manufactured from

specially developed bronze or brass
bearing alloys.

The manufacturing process is designed to

create geometric tolerances and surface
finishes to suit very high speed operation.
Turbocharger

Measure the radial clearance of the shaft.

Turbocharger Radial Clearance (B):0.30-
0.46mm[0.012-0.018in]

The turbocharger must be removed for replaced

if the clearances are out of specification

Measure the turbocharger shaft end play:0.069 -

0.131mm
charge air cooler

Be used to cool engine intake air after it has passed through

a turbocharger, but before it enters the engine. The idea is
to return the air to a lower temperature, for the optimum
power for the combustion process within the engine.

If the engine experiences a turbocharger failure or any

other occasion where oil or debris is put into the charge air
cooler, the charge air cooler must be cleaned.

Do not use caustic cleaners to clean the charge air cooler.

The maximum temperature differential between ambient

temperature and intake manifold temperature must not be
greater than 25°C [77°F] when the engine at rated rpm
and load.
Air Intake Leaks

Loose connections or cracks in the suction side of

the intake pipe on turbocharged engines allow debris
to be ingested into the turbocharger compressor and
then forced into the engine.

Debris drawn into the air suction side can damage

the compressor blades, causing an imbalance
resulting in bearing failure.
Air Intake Leaks

Excessive smoke and low power from a

turbocharged engine can be caused by pressurized
air leaking from loose connections, or cracks in the
crossover tube or intake manifold. This can cause a
noise problem.

In addition to the inspection for cracks and loose

fittings, liquid soap can be applied to the charge-air
cooler connections and the manifold cover sealing
surfaces to find the leaks. The leaks will create
bubbles that are easier to detect. Measurement of
manifold pressure is described in this section.
Air Intake Restriction

Maximum intake air restriction is 635 mm H2O [25.0

in H2O] for turbocharger engines.

The engine must be operated at rated rpm and full

load to check maximum intake air restriction. Replace
the air cleaner element when the restriction reaches
the maximum allowable limit, or clean according to
the manufacturer‘s recommendations.
Air Intake Restriction

Check the air cleaner service indicator, if equipped. Change

the filter element when the red indicator flag (2) is at the
raised position in the window (1).

After the air cleaner has been serviced, reset the button (3)
in the end of the service indicator.

NOTE: Do not operate the engine without an air cleaner.

Intake air must be filtered to prevent dirt and debris from
entering the engine and causing premature wear.
Flow Diagram, Air Intake System

1. Intake air inlet to

turbocharger
2. Turbocharger air to charge air
cooler
3. Charge air cooler
4. Intake manifold - integral part
of cylinder head
5. Intake valve.
Specifications

Maximum Intake Restriction

Clean Air Filter Element.................254 mm H2O [10.0 in H2O]

Dirty Air Filter Element.................635 mm H2O [25.0 in H2O]

Exhaust System
exhaust leaks or restrictions

Inspect for exhaust leaks at the exhaust manifold,

turbocharger, exhaust pipe(s) , muffler restrictions.

Leaks or restrictions will cause the turbine and

impeller to operate at a lower speed and reduce the
amount of air being forced into the cylinders. The
symptoms of a restricted or leaking exhaust system
are:
Excessive smoke
Low intake manifold pressure
Low power.
Exhaust Manifold

Three-Piece Manifold.

When Install , Apply a thin coat of anti-seize, Part

No. 3824879, to the capscrew threads.

The exhaust manifold gaskets are nondirectional.

Install the exhaust manifold.

Follow the tightening sequence shown in the

illustration.
Torque Value: 43 nm
 Flow Diagram, Exhaust System

1. Exhaust valve
2. Exhaust manifold
3. Turbocharger

4. Turbocharger exhaust outlet

Specifications

Maximum Exhaust Back Pressure……….76 mm Hg [3 in Hg]

Operating
Instructions
Operating Instructions

Do not operate the engine at excessive full-throttle

operation below peak torque rpm for more than 30
seconds.

Do not operate the engine beyond high-idle speed

under any circumstances. Operating the engine
beyond high-idle speed can cause severe engine
damage.
Operating Instructions

Allow the engine to idle 3 to 5 minutes after a

full-load operation before shutting it off. This
allows the engine to cool gradually and
uniformly.

To prevent damage to the starter, do not engage

the starting motor more than 30 seconds. Wait 2
minutes between each attempt to start (electrical
starting motors only).
Operating Instructions

If the engine does not start after three attempts, check the fuel supply system. An
absence of blue or white exhaust smoke during cranking indicates that no fuel is
being delivered to the combustion chambers.
Operating Instructions

The engine must have adequate oil pressure within

15 seconds after starting. If the WARNING lamp
indicating low oil pressure has not gone out or
there is no oil pressure indicated on the gauge
within 15 seconds, shut off the engine
immediately to avoid engine damage. Confirm the
correct oil level in the oil pan.

Idle the engine 3 to 5 minutes before operating

with a load.
Operating Instructions

Increase the engine speed (rpm) slowly to

provide adequate lubrication to the bearings and
to allow the oil pressure to stabilize.
Operating Instructions

Do not operate the engine at low idle for long

periods. Long periods at low idle, more than 10
minutes, can damage an engine because
combustion chamber temperatures will decrease
and the fuel will not completely burn. This will
cause carbon to build up around the injector
spray holes and piston rings, which can cause
the valves to stick. To avoid damage, operate the
engine at higher idle.
Maintenance
Maintenance Procedures at Daily
Intervals

Before starting the engine, check the lubricating

oil and coolant levels; look for:

¾Leaks

¾Loose or damaged parts

¾Worn or damaged belts

¾Any change in engine appearance.

Maintenance Procedures at Daily
Intervals

Inspect the belt.

Check the belt for intersecting cracks.

Transverse (across the belt width) cracks are

acceptable.

Longitudinal (direction of belt length) cracks

that intersect with transverse cracks are not
acceptable.

Replace the belt if it is frayed or has pieces of

material missing.
Maintenance Procedures at Daily
Intervals
Inspect the fan for

Cracks

loose rivets

bent or loose blades

Check the fan to make sure it is securely

mounted.

Tighten the capscrews if necessary.

Replace any fan that is damaged.

Maintenance Procedures at Daily
Intervals

Drain the water and sediment from the fuel-water

separator daily.
Maintenance Procedures at 10,000 Kilometers
[6,000 Miles], 250 Hours or 3 Months

Change the lubricating oil and filters to remove

the contaminants suspended in the lubricating oil.

Check maximum intake air restriction at rated

rpm and full load.
Maximum intake air restriction is 635 mm H2O
[25.0 in H2O] for turbocharger engines.
Maintenance Procedures at 10,000 Kilometers
[6,000 Miles], 250 Hours or 3 Months

Check the air cleaner service indicator,

Inspect the intake piping for cracked hoses,

loose clamps, or punctures that can damage the
engine.
Maintenance Procedures at 19,000
Kilometers [12,000 Miles], 500 Hours or
6 Months

Check the antifreeze concentration.

Change the coolant filter

change the fuel filter

Maintenance Procedures at 38,000
Kilometers [24,000 Miles], 1,000 Hours
or 1 Year

valve lash adjustment are to be performed at the

initial 38,000 km [24, 000 mi] adjustment.
Subsequent adjustments are to be performed at
77,000 km [48,000 mi] intervals.

Measure the belt deflection

Maintenance Procedures at 38,000
Kilometers [24,000 Miles], 1,000 Hours
or 1 Year

Check the location of the drive belt on the belt

tensioner pulley.

measure the tension in the drive belt.

Maintenance Procedures at 38,000
Kilometers [24,000 Miles], 1,000 Hours
or 1 Year

Check the tensioner arm, pulley, and stops for

cracks. If any cracks are noticed, the tensioner
must be replaced.

With the belt on, verify that neither tensioner

arm stops are in contact with the spring casing
stop. If either stop is touching, the drive belt
must be replaced. After replacing the belt, if the
tensioner arm stops are still in contact with the
spring casing stop, replace the tensioner.
Maintenance Procedures at 38,000
Kilometers [24,000 Miles], 1,000 Hours
or 1 Year

check the torque of the tensioner capscrew.

With the belt removed, verify that the tensioner

arm stop is in contact with the spring case stop. If
these two are not touching, the tensioner must be
replaced.
Maintenance Procedures at 77,000
Kilometers [48,000 Miles], 2,000 Hours
or 2 Years

Air Compressor – Inspect

Change the coolant
Check the damper
Troubleshooting
Troubleshooting Procedures and
Techniques

A thorough analysis of the customer‘s complaint is the key to successful

troubleshooting. The more information known about a complaint, the faster and
easier the problem can be solved.

The Troubleshooting Symptom Charts are organized so that a problem can be located
and corrected by doing the easiest and most logical things first. Complete all steps in
the sequence shown from top to bottom.

It is not possible to include all the solutions to problems that can occur; however,
these charts are designed to stimulate a thought process that will lead to the cause and
correction of the problem.
Troubleshooting Procedures and
Techniques

Follow these basic troubleshooting steps.

Get all the facts concerning the complaint.

Analyze the problem thoroughly.
Relate the symptoms to the basic engine systems and components.
Consider any recent maintenance or repair action that can relate to the complaint.
Double-check before beginning any disassembly.
Solve the problem by using the symptom charts and doing the easiest things first.
Determine the cause of the problem and make a thorough repair.
After repairs have been made, operate the engine to make sure the cause of the
complaint has been corrected.
Smoke, Black — Excessive

1. Engine is being lugged down (Use lower gear ).

2. Load is excessive (Reduce the load. Check and clean the vessel bottom, or
change the propeller. Refer to manufacturer‘s instructions).
3. Plugged air filter (Inspect the air cleaner element. Replace as needed ).
4. AFC plunger not fully open (Inspect AFC air tube and fuel drain lines for
restriction. Inspect the AFC operation ).
5. Intake air source is incorrect (If the vehicle is equipped with a valve to switch
the intake source from under the hood to outside, position and set valve for the
season )
6. Aftercooler restricted (if equipped) (Inspect for plugged passages in the
aftercooler ).
7. Exhaust system restriction (Check the exhaust system for any restrictions ).
8. Charge air cooler is restricted or leaking (Inspect the charge air cooler for air
restrictions or leaks ).
Smoke, Black — Excessive

9. Air leak between the turbocharger and the intake manifold （Check for leaks in
the air crossover tube, charge air cooler connections, hoses, or through holes in
the manifold cover and repair or replace if necessary ）
10. Exhaust leaks at the manifold or turbocharger （Check and correct any leaks in
the exhaust manifold or turbocharger gaskets. Check for a cracked exhaust
manifold ）
11. Turbocharger wastegate is malfunctioning （Check the wastegate for correct
operation ）
12. Turbocharger is worn or malfunctioning （Check for the specified boost
pressure. Inspect the turbocharger. Replace if necessary )
13. Fuel contaminated （Verify by operating the engine with clean fuel from a
temporary tank ).
14. Injectors worn or malfunctioning （Remove and test the injectors. Replace as
necessary .
Smoke, Black — Excessive

15. 15、Injector sealing washer not correct （Check to see if an extra sealing
washer is installed under injector. Remove any additional sealing washer ）
16. 16、Injector sealing washer not correct （Remove injector and install the
proper sealing washer ）
17. 17、Fuel injection pump timing is not correct （Put the engine at top dead
center. Check and adjust the fuel timing ）
18. 18、Fuel injection pump is malfunctioning （Remove the fuel injection pump.
Check the calibration of the fuel injection pump ）
19. 19、Piston rings not sealing (blue smoke) （Check for excessive blowby)
Smoke, White — Excessive

1. Starting procedure is not correct （Verify the correct starting procedure ）

2. Coolant temperature is below specification or the intake manifold air
temperature is below specification （Refer to the Coolant Temperature Below
Normal symptom tree ）
3. Intake manifold heater wiring harness malfunctioning （Check the wiring
harness ）
4. Poor fuel quality or wrong fuel grade （Verify by operating the engine from a
temporary supply of number 2 diesel fuel. Check fuel specifications for proper
fuel grade ）
5. Fuel injection pump timing is not correct （Put the engine at top dead center.
Check and adjust the fuel timing ）
6. Injector sealing washer not correct （Remove injector and install the proper
sealing washer ）
Smoke, White — Excessive

7. Injector sealing washer not correct （Remove injector and install the proper
sealing washer ）
8. Injectors worn or malfunctioning （Remove and test the injectors. Replace as
necessary ）
9. Coolant is leaking into the combustion chamber （Refer to the Coolant Loss -
Internal symptom tree ）
10. Fuel injection pump is malfunctioning （Remove the fuel injection pump.
Check the calibration of the fuel injection pump ）
Crankcase Gases (Blowby) Excessive

1. Air compressor is malfunctioning （Isolate the air compressor by disconnecting

the air inlet and outlet lines. Check blowby. If blowby is within specifications,
rebuild or replace the air compressor ）
2. Cylinder head valve guides are excessively worn（Check the valve guides for
wear. Replace the cylinder head if necessary. ）
3. Pistons or piston rings are worn, damaged, or not correct（Check the pistons
for correct part numbers Check the pistons and rings for wear and damage. ）
4. Turbocharger oil seal is leaking （Check the turbocharger compressor and
turbine seals. ）
Fuel Knock

1. Starting aid is necessary for cold weather or starting aid is malfunctioning

（Check for the correct operation of the starting aid. ）
2. Coolant temperature is above specification（Refer to the Coolant Temperature
Above Normal - Gradual Overheat symptom tree. ）
3. Air in the fuel system（Bleed the fuel system and check for suction leaks.）
4. Poor fuel quality or wrong fuel grade（Verify by operating the engine from a
temporary supply of number 2 diesel fuel. Check fuel specifications for proper
fuel grade.）
5. Engine under excessive load（Check for added loading from malfunctioning
accessories or other engine-driven units, brakes dragging, or other changes in
vehicle loading. Disengage engine-driven units.）
6. Injectors worn or malfunctioning（ Remove and test the injectors. Replace as
necessary.）
7. Fuel injection pump timing is not correct（Put the engine at top dead center.
Check and adjust the fuel timing. ）
Engine Speed Surges at Low or
High Idle
1. Fuel level is low in the tank（Fill the supply tank.）
2. Engine under excessive load（Check for added loading from malfunctioning
accessories or other engine-driven units, brakes dragging, or other changes in
vehicle loading. Disengage engine-driven units. ）
3. Throttle linkage misadjusted or damaged（Adjust or repair the linkage. Refer to
the OEM service manual. ）
4. Idle speed is set too low for accessories（Check and adjust the low-idle screw. ）
Fuel leak（Check the fuel lines, fuel connections, fuel delivery valve seals, and
fuel filters for leaks. Check the fuel lines from the supply tank(s).）
5. Fuel filter or fuel inlet restriction（Check the flow through the fuel filter.
Replace the fuel filter if necessary. Clean all prefilters and screens. Check the
fuel suction line for restriction. ）
6. Air in the fuel system（Bleed the fuel system and check for suction leaks.）
Injectors worn or malfunctioning （Check the injectors and replace any
malfunctioning injectors.）
7. Fuel injection pump is malfunctioning（Remove the fuel injection pump.
Check the calibration of the fuel injection pump.）
Engine Acceleration or Response Poor

1. Interview the operator to verify the complaint.

2. Operator technique is not correct（Explain correct engine operation to the
operator.).
3. Fuel level is low in the tank（Fill the supply tank.）.
4. Fuel inlet restriction（Check for fuel inlet restriction. ）.
5. Fuel grade is not correct for the application or the fuel quality is poor（Operate
the engine from a tank of high-quality fuel.）.
6. Fuel inlet temperature to pump is above specification（Fill the fuel tank, turn
off or bypass the fuel heaters, and check the fuel cooler.）.
7. Air intake system restriction（Check the air intake system for restriction.） 进
气受阻.
8. Drivetrain is not correctly matched to the engine（Check for correct gearing
and drivetrain components.） .
Engine Acceleration or Response Poor

9. Vessel is malfunctioning or parasitics are excessive（Check the vessel bottom,

propeller, transmission, and driven accessories. Refer to the manufacturer‘s
instructions. ）
10. Clutch is malfunctioning or is not correct（Compare the drivetrain
specifications to Cummins recommendations. Check the clutch for correct
operation. Refer to the OEM service manual. ）
11. Vehicle parasitics are excessive（ Check the vehicle brakes for dragging,
transmission malfunction, cooling fan operation cycle time, and engine-driven
units. Refer to the OEM service manual. ）
12. Propeller damaged or not at the correct pitch（Inspect or replace propeller.
Refer to the manufacturer‘s instructions. ）
13. Fuel leak（Check the fuel lines, fuel connections, and fuel filters for leaks.
Check the fuel lines to the supply tanks. Refer to the OEM service manual.）
Engine Acceleration or Response Poor

14. Fuel transfer pump is malfunctioning（Check the fuel lift pump for correct
operation. Check the pump output pressure. Replace the fuel lift pump if
necessary.）
15. Fuel pump overflow valve is malfunctioning（Check the overflow valve.）
16. Air in the fuel system（Check for air in the fuel system. Vent air from the
system. ）
17. Charge air cooler is restricted or leaking（Inspect the charge air cooler for air
restrictions or leaks.）
18. Aftercooler is restricted （Check the aftercooler for restriction.）
19. Air intake or exhaust leaks（Inspect the air intake and exhaust systems for air
leaks.）
Engine Acceleration or Response Poor

20. Turbocharger is not correct（Check the turbocharger part number Replace the
turbocharger if necessary. ）
21. Turbocharger wastegate is malfunctioning （Check the wastegate for correct
operation.）
22. Exhaust brake adjustment is not correct（Check the exhaust brake adjustment.）
23. Exhaust system restriction is not within specification（Check the exhaust
system for restrictions. ）
24. Turbocharger wheel clearance is out of specification（Check the radial bearing
clearance and axial clearance. Inspect the turbocharger. Repair or replace the
turbocharger if necessary. ）
25. Overhead adjustments are not correct（Measure and adjust the overhead
settings.）
26. Injectors are not correct（ Replace the injectors if necessary.）
27. Injector is malfunctioning（Inspect the injectors. Replace the injectors as
necessary.）
Engine Acceleration or Response Poor

27. Fuel supply line restriction between the fuel pump and the injectors（Check the
fuel supply line from the fuel pump to the cylinder head for sharp bends that
can cause restrictions.）
28. Fuel injection pump timing is not correct（Put the engine at top dead center.
Check and adjust the fuel timing.）
29. Fuel injection pump is malfunctioning（Remove and test the fuel injection
pump. Replace the pump if necessary.）
30. Internal engine damage（Analyze the oil and inspect the filters to locate an area
of probable damage. ）
Engine Starts But Will Not Keep
Running
1. Fuel level is low in the tank（Fill the supply tank. Refer to the OEM service
manual. ）
2. Engine under excessive load（Check for added loading from malfunctioning
accessories or other engine-driven units, brakes dragging, or other changes in
vehicle loading. Disengage engine-driven units. ）
3. Fuel shutoff valve malfunctioning（Inspect the fuel shutoff valve (FSOV) hold
coil resistance and supply voltage.）
4. Idle speed is set too low for accessories（Check and adjust the low-idle screw.
Refer to the OEM service manual. ）
5. Air in the fuel system（Bleed the fuel system and check for suction leaks.）
6. Fuel filter or fuel inlet restriction（Check the flow through the fuel filter.
Replace the fuel filter if necessary. Clean all prefilters and screens. Check the
fuel suction line for restriction.）
Engine Starts But Will Not Keep
Running
7. Fuel is waxing due to cold weather（Check the fuel heater, if installed. Weather
conditions sometimes require a fuel heater. ）
8. Excessive water in the fuel filter（Drain the fuel water separator and replace
the fuel filter.）
9. Fuel contaminated（Verify by operating the engine with clean fuel from a
temporary tank.）
10. Fuel drain line is restricted（Check the fuel drain lines for restriction. Clear or
replace the fuel lines, check valves, or tank vents as necessary.）
11. Intake and exhaust system restricted（Check the intake and exhaust systems for
restrictions. Inspect the intake air filter and replace as necessary.）
Engine Difficult to Start or Will Not Start
(No Exhaust Smoke)

1. Starting procedure is not correct（Verify the correct starting procedure.）

2. No fuel in supply tank（Check and replenish fuel supply. Check fittings and
hose connections and hose conditions.）
3. Fuel shutoff valve is malfunctioning（Check for loose wires and verify that the
fuel shutoff valve is functioning. Check to be sure manual shutoff lever is in the
run position.）
4. Fuel transfer pump malfunctioning（Inspect the fuel transfer pump. Replace if
necessary. ）
5. Fuel filter or fuel inlet restriction（Check the flow through the fuel filter.
Replace the fuel filter if necessary. Clean all prefilters and screens. Check the
fuel suction line for restriction. ）
6. Excessive water in the fuel filter（Drain the fuel water separator and replace
the fuel filter. ）
7. Intake and exhaust system restricted（Check the intake and exhaust systems for
restrictions. Inspect the intake air filter and replace as necessary. ）
Engine Difficult to Start or Will Not Start
(No Exhaust Smoke)
8. Fuel injection pump not getting fuel or air in fuel（Check fuel flow or bleed
fuel system.）
9. Fuel return restriction excessive（Inspect the fuel return lines for
restrictions.）
10. Fuel pump return overflow valve is malfunctioning（Inspect the return
overflow valve. Replace if necessary.）
11. Fuel injection pump timing is not correct（Put the engine at top dead center.
Check and adjust the fuel timing. ）
12. Fuel injection pump is malfunctioning（Remove the fuel injection pump.
Check the calibration of the fuel injection pump.）
13. Camshaft timing is not correct after engine rebuild or repair（Check the gear
train timing alignment.）