Operation and DET Curler ave Tle] C Series Engines « UA UL CME g s rere CP Retard tsi ane ar Cor Foerhsine nen Orr ference ste R0 UI Gore kc) Ne akc Pr ore acces ‘Surrey KTS 4QL, ra m hae Cen Are tna Ud er aon a ahd eo es os Selbciens aminesOperation and Maintenance Manual C Series Engines U.S.A., Canada, Australia, New Zealand, and Puerto ico Copyright © 1993 Cummins Engine Company, Inc. All rights reserved Bulletin No. 3810248-08 Printed 6/93 Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins Authorized Repair Locations and component manufacturers, Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on infor- mation in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location. ‘The latest technology and the highest quality components were used to produce this engine. When replacement paris are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be Identified by the following trademarks: EE Fleelguand’ = szieses i aa ® P| Note: Warranty information is located in Section W. Make sure you are familiar with the warranty or warranties applicable to your engine.Table of Contents Page No. Introduction te ii i Engine Identification ‘ f E Operating Instructions... ‘ 2 cinerea 1 Maintenance Guidelines: 4 1 sta Daily Maintenance Procedures. 3 Maintenance Procedures at 10,000 Kilometers [6,000 Miles] 250 Hours or 3 Months....... a : 4 Maintenance Procedures at 19,000 Kilometers [12,000 Miles] ata r 5 Maintenance Procedures at 38,000 Kilometers [24,000 Miles] _ 1000 Hours or 12 Months nib 6 Maintenance Procedures at 77,000 Kilometers [48,000 Miles) 2000 Hours or 2 Years 2 7 System Diagrams Eloi is Abe Z D Troubleshooting Are : T Page No. ‘Adjustment, Repair and Replacement. A Specifications and Torque Values...... v Service Assistance s Component Manufacturers. c Warranty .... Ww Literature L Index xSection i - Introduction C Series Page I-t Section i - Introduction Section Contents ‘About the Manual Definition of Term: General Safety Instructions... Important Satety Notice How to Use the Manual... Ulustrations rs Symbols ..... is To The Owner and Operator. 2 Section i - Introduction ‘About the Manual C Series. Page I3 About the Manual This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Engine Company, Inc. Additional service literature (Shop Manual, Troubleshooting and Repair Manual, ‘etc) can be ordered by filing out and mailing the Literature Order Form located in Service Literature, Section L. This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to page iS for a complete listing of symbols and their definitions. Each section is preceded by a “Section Contents" to aid in locating information more quickly.Section i - Introduction Symbols C Series Page i-5 Symbols ‘The following symbols have been used in this manual to help communicate the intent of the instructions. Wher one of the symbols appears, it conveys the meaning defined below: PERFORM a mechanical or time MEA- WARNING - Serious personal injury or ex- A SUREMENT. tensive property damage can result if the ‘warning instructions are not followed. LUBRICATE the part or assembly. CAUTION - Minor personal injury can re- AX __sittrapart, an assemby,or the engine ‘can be damaged if the caution instructions are not followed. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. Indicates a REMOVAL or DISASSEMBLY stop. PERFORM an olectrical MEASUREMENT. Indicates an INSTALLATION or ASSEM- BLY step. 57, ae Refer to another location in this manual or another publication for additional informa- INSPECTION is required. tion, CLEAN the part or assembly. The component weighs 23 kg [50 Ib] or more. To avoid personal injury, use a hoist or get assistance to lift the component @® } "emne Section i - Introduction Mlustrations C Series Page i-8 Illustrations Use the illustrations in this manual as a guide to perform the action or the repair described. Many illustrations are generic and will not look exactly like the engine or the parts used in your application. In order to provide clarity to illustrations, some illustrations show parts removed that are not related to the specific parts given in the text. Most of the illustrations contain symbols to indicate an action required or to indicate an acceptable (OK) or un- acceptable (not OK) condition.Section E - Engine and Component Identification C Series Sec Engine Identific: Engine Diagram... General Specifications Injection Pump Dataplate. Definition of Terms Page i-12 Definition of Terms AFC API ASA ASTM c care cp. cm cPL ost Dca ecu E.c.s. EPA EPS F feb eww Hg HP. H.0 Air Fuel Control ‘American Petroleum Institute Air Signal Attenuator ‘American Society of Testing and Materials Celsius California Air Resources Board Cubic Inch Displacement Centimeter Control Parts List Centistokes Diesel Coolant Additive Electronic Control Module Emission Control System Environmental Protection Agency Engine Position Sensor Fahrenheit Foot Pound Gross Vehicle Weight Mercury Horsepower Water ind km kml kPa, mm MPa MPH wpa Nem, OEM ppm psi PTO RPM Page E-1 nn E - Engine and Component Identification Section Contents Section i - Introduction C Series Inch Pound Kilograms Kilometers Kilometers per Liter Kilopascal Liter Meter Millimeter Megapascal Miles Per Hour Miles Per Quart Newton-meter Original Equipment Manufacturer Parts Per Million Pounds Per Square Inch Power Takeotf Revolutions Per Minute Society of Automotive Engineers Step Timing Control Variable Speed Vehicle Speed Sensor Page £2 E9 ES £3Engine Identification Page E- Section E - Engi ‘and Component Identitiation e2 C Series Engine Identification Engine Dataplate The engine dataplates show specific information about the engine. The engine serial number (1) and Control Parts List (CPL) (2) provide information for ordering parts and service needs, NOTE: The engine dataplate must not be changed unless approved by Cummins Engine Company, Inc. Secor [ERT inn fem" ee rm [om [ome caret a cae ‘Magen USA. geesaze | coer | Catayseur No_ ni See SST Egaie = ei a De aeons eresomn ower sigeemesemmn [Se Sent oac ea EE] pane Seccecaeasenee Neca aaa = Saccao a8 mace Pave em tee ae aaa arias aoe femeate = ion aes aaee oP 5 ap9pigb Section E - Engine and Component Identification Engine Identification C'Series Page £3 Cummins Engine Nomenclature ‘The model name for engines in automotive applications provides the data shown in the example: Example © 83-275 LL pates Horsepower Displacement in Liters Engine Series for non-automotive applications: Example ecTAas [_E ossplacementin Lier Atercooled Turbocharged Engine Series ‘— Number of Cylinders ‘The following example shows a model name of an engineInjection Pump Dataplate Section E - Engine and Component Identification Page E-4 C Series Injection Pump Dataplate The injection pump dataplate is located on the side of the injection pump. It provides information for fuel injection pump calibration. ‘The Cummins part number for the fuel injection pump and governor combination is located on the governor dataplate. and Component Identification General Specifications GENERAL ENGINE DATA 6ca3 BCTE.S BOTAGS cas Bore - mm in] > Ta TB] Stroke - mm fin] 2495 [5.32] - Displacement «iter tin} 8.27 (504.5) - Engine Weight (Ory) With Standard ‘Accessories ‘Wet Weight Firing Order Valve Clearances = intake ~ mm [in] 0.30 [0.012] Exhaust = mm fin] 0.61 [0.024] Compression Ratio 164 1734 1651 17.3:0°H81"* Rotation, viewed from the front of the engine Aspiration Naturally Aspirated x ~ Turbocharged x = Aitercooied x = Charge Air Cooled (CAC) x * High Torque * Low Torque 603-612 Kg [1330-1350 Ib} : 635-658 Kg [1400-1450 Ib} = 1SG624 + Clockwise -