KOBELCO CUMMINS SERIE C ENGINES WORKSHOP MANUAL – PDF DOWNLOAD

Description

KOBELCO CUMMINS SERIE C ENGINES WORKSHOP MANUAL – PDF DOWNLOAD

DESCRIPTION:

KOBELCO CUMMINS SERIE C ENGINES WORKSHOP MANUAL – PDF DOWNLOAD

Workshop manual integration of the following models:
EX255 – EX285 – FH270
G170 – G200 – FG75A – FG85A + FG105A
W170 – W190 – W230

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 filling out and mailing the Literature Order Form located in Section L – Service Literature.
• The repair procedures used in this manual are recommended by Cummins Engine Co., 1,, :, Some service procedures require the use of special service tools. Use the correct tools as described.
• Cummins Engine Company, 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 Engine Company, 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. These parts can be identified by the following trademarks:

About the Manual

This C Series Engine 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 by system. Each section provides general information, specifications, diagrams, and service tools, where applicable.

The specific repair procedures are referenced in the Troubleshooting Symptoms Charts. How to Use the Manual This manual is organized to provide an easy flow from problem identification to problem correction. A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms, Section TS.

This manual is designed to use the Troubleshooting Symptoms as a guide in locating the problem and directing the end user to the correct procedure for making the necessary repairs to the engine. Complete the following steps to locate and correct any problems:

1. Locate the symptom on the Section Contents page of Section TS.

2. Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title.

3. 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.

4. 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.

5. Locate the probable cause in the left column then turn to the procedure referenced in the right column.

The Trouble shooting Symptom Charts are based on the following assumptions:

• The engine has been installed according to the OEM’s specifications.

• The easiest repairs are done first.

• “Generic” solutions to cover problems with the most common applications and OEM. Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications and torque values for each engine system are given in Section V.

General Safety Instructions

Important Safety Notice

WARNING 

Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or death.

Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply.

• Make sure the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.

• Always wear protective glasses and protective shoes when working.

• Rotating parts can cause cuts, mutilation or strangulation.

• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.

• Disconnect the battery (negative[-) cable first) and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s compartment or on the controls.

• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure.

• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system.

• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work.

• Relieve all pressure in the air, oil, fuel and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel and liquid refrigerant (freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant.

• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded.

• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. • Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.

• To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments.

• Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts.

• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary.

• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

• Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.

• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations
TABLE OF CONTENTS:

KOBELCO CUMMINS SERIE C ENGINES WORKSHOP MANUAL – PDF DOWNLOAD

SERIE C CUMMINS ENGINES……………… 1
Table of Contents……………….. 4
Introduction……………………. 5
Engine Identification……………. 15
Troubleshooting Symptoms…………. 33
Complete Engine-Group 00………….119
Cylinder Block-Group 01…………..129
Cylinder Head-Group 02……………275
Rocker Levers-Group 03……………311
Cam Followers/Tappets-Group 04…….329
Fuel System-Group 05……………..349
Injectors and Fuel Lines-Group 06….387
Lubricating Oil System-Group 07……417
Cooling System-Group 08…………..461
Air Intake System-Group 10………..509
Exhaust System-Group 11…………..549
Compressed Air System-Group 12…….557
Electrical Equipment-Group 13……..577
Engine Testing-Group 14…………..611
Mounting Adaptions-Group 16……….625
Miscellaneous-Group 17……………665
Service Literature……………….671
Component Manufacturers…………..675
Specifications…………………..681
Index…………………………..725
KOBELCO CUMMINS SERIE C ENGINES WORKSHOP MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M