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Cummins Engine V28 G28 Service Workshop Repair Shop Manual

Cummins Engine V28 G28 Service Workshop Repair Shop Manual

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Section i - Introduction
(99-204-002-shopds) About the Manual
(99-204-003-shopds) How to Use the Manual
(99-204-004) Symbols
(99-204-005) Illustrations
(99-204-006-tr) General Safety Instructions
(99-204-007-tr) General Repair Instructions
(99-204-008) General Cleaning Instructions
(99-204-009) Acronyms and Abbreviations

Section E - Engine and System Identification
(15-100-001-tr) Engine Identification
(15-100-002-tr) Engine Diagrams
(99-100-003) Cummins® Service Engine Model Product Identification

Section F - Familiarization
(15-000-999) Complete Engine - Overview
(15-001-999) Cylinder Block - Overview
(15-002-999) Cylinder Head - Overview
(15-003-999) Rocker Levers - Overview
(15-004-999) Cam Followers/Tappets - Overview
(15-005-999) Fuel System - Overview
(15-006-999) Injectors and Fuel Lines - Overview
(15-007-999) Lubricating Oil System - Overview
(15-008-999) Cooling System - Overview
(15-009-999) Drive Units - Overview
(15-010-999) Air Intake System - Overview
(15-011-999) Exhaust System - Overview
(15-012-999) Compressed Air System - Overview
(15-013-999) Electrical Equipment - Overview
(15-014-999) Engine Testing - Overview
(15-016-999) Mounting Adaptations - Overview

Section TS - Troubleshooting Symptoms
(99-t00-001-tr) Troubleshooting Procedures and Techniques
(99-t00-002) Troubleshooting Symptoms Charts
(3666014-t004-tr) Air Compressor Air Pressure Rises Slowly
(3666014-t005-tr) Air Compressor Cycles Frequently
(3666014-t006-tr) Air Compressor Noise is Excessive
(3666014-t007-tr) Air Compressor Pumping Excess Lubricating Oil into the Air System
(3666014-t008-tr) Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
(3666014-t009-tr) Air Compressor Will Not Pump Air
(3666014-t010-tr) Air Compressor Will Not Stop Pumping
(3666014-t013-tr) Alternator Not Charging or Insufficient Charging
(3666014-t014-tr) Alternator Overcharging
(3666014-t020-tr) Coolant Loss - External
(3666014-t021-tr) Coolant Loss - Internal
(3666014-t022-tr) Coolant Temperature Above Normal - Gradual Overheat
(3666014-t023-tr) Coolant Temperature Above Normal - Sudden Overheat
(3666014-t024-tr) Coolant Temperature Below Normal
(3666014-t025-tr) Coolant in the Lubricating Oil
(3666014-t027-tr) Crankcase Gases (Blowby) Excessive
(3666014-t029-tr) Cranking Fuel Pressure is Low
(3666014-t033-tr) Engine Acceleration or Response Poor
(3666014-t041-011-tr) Engine Decelerates Slowly (PT)
(3666014-t043-tr) Engine Difficult to Start or Will Not Start (Exhaust Smoke)
(3666014-t044-tr) Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
(3666014-t047-tr) Engine Noise Excessive
(3666014-t048-tr) Engine Noise Excessive - Combustion Knocks
(3666014-t049-tr) Engine Noise Excessive - Connecting Rod
(3666014-t050-tr) Engine Noise Excessive - Main Bearing
(3666014-t051-tr) Engine Noise Excessive - Piston
(3666014-t052-tr) Engine Noise Excessive - Turbocharger
(3666014-t057-011-tr) Engine Power Output Low (PT)
(3666014-t061-tr) Engine Runs Rough at Idle
(3666014-t062-tr) Engine Runs Rough or Misfires
(3666014-t064-tr) Engine Shuts Off Unexpectedly or Dies During Deceleration
(3666014-t066-tr) Engine Speed Surges at Low or High Idle
(3666014-t067-tr) Engine Speed Surges Under Load or in Operating Range
(3666014-t072-tr) Engine Starts But Will Not Keep Running
(3666014-t075-tr) Engine Vibration Excessive
(3666014-t077-tr) Engine Will Not Crank or Cranks Slowly (Air Starter)
(3666014-t078-tr) Engine Will Not Crank or Cranks Slowly (Electric Starter)
(3666014-t081-tr) Engine Will Not Shut Off
(3666014-t087-011-tr) Fuel Consumption Excessive (PT)
(3666014-t091-tr) Fuel in Coolant
(3666014-t092-tr) Fuel in the Lubricating Oil
(3666014-t096-tr) Intake Manifold Air Temperature Above Specification
(3666014-t097-tr) Intake Manifold Pressure (Boost) is Below Normal
(3666014-t102-tr) Lubricating Oil Consumption Excessive
(3666014-t103-tr) Lubricating Oil Contaminated
(3666014-t104-tr) Lubricating Oil Pressure High
(3666014-t105-tr) Lubricating Oil Pressure Low
(3666014-t106-tr) Lubricating Oil Sludge in the Crankcase Excessive
(3666014-t107-tr) Lubricating Oil Temperature Above Specification
(3666014-t108-tr) Lubricating or Transmission Oil in the Coolant
(3666014-t109-tr) Operating Fuel Pressure is Low
(3666014-t122-tr) Turbocharger Leaks Engine Oil or Fuel
(3666014-t126-tr) Variable Speed (VS) Governor - Speed is Not Set Correctly

Section TT - Troubleshooting Symptoms (New Format)
(105-t02-1005a) Vibration Excessive

Section DS - Engine Disassembly - Group 00
(15-022-001_00-shopds) Service Tools
(15-007-037-shopds) Lubricating Oil System
(15-008-018-shopds) Cooling System
(15-007-013-shopds) Lubricating Oil Filter (Spin-On)
(15-008-006-shopds) Coolant Filter
(15-006-015-shopds) Fuel Filter (Spin-On Type)
(15-016-001-shopds) Engine Lifting Brackets
(15-007-025-shopds) Lubricating Oil Pan
(15-008-057-shopds) Sea Water Pump
(15-008-053-shopds) Heat Exchanger
(15-008-052-shopds) Expansion Tank
(15-013-005-shopds) Drive Belt, Alternator
(15-013-001-shopds) Alternator
(15-013-003-shopds) Alternator Bracket
(15-008-003-shopds) Drive Belt, Water Pump
(15-008-064-shopds) Water Pump Idler Assembly
(15-008-002-shopds) Drive Belt, Cooling Fan
(15-008-029-shopds) Fan Drive Idler Arm Assembly
(15-008-036-shopds) Fan Hub, Belt Driven
(15-008-035-shopds) Fan Hub Bracket
(15-008-005-shopds) Coolant Bypass Tube
(15-012-004-shopds) Air Compressor Coolant Lines
(15-008-007-shopds) Coolant Filter Head
(15-008-062-shopds) Water Pump
(15-001-052-shopds) Vibration Damper, Viscous
(15-001-051-shopds) Vibration Damper, Rubber
(15-001-022-shopds) Crankshaft Pulley
(15-016-002-shopds) Engine Support Bracket, Front
(15-009-020-shopds) PTO Housing, Front
(15-009-004-shopds) Accessory Drive Pulley
(15-013-020-shopds) Starting Motor
(15-016-004-shopds) Flexplate
(15-016-005-shopds) Flywheel
(15-016-006-shopds) Flywheel Housing
(15-007-003-shopds) Lubricating Oil Cooler
(15-007-040-shopds) Lubricating Oil Transfer Tube
(15-005-016-shopds) Fuel Pump
(15-012-014-shopds) Air Compressor
(15-009-001-shopds) Accessory Drive
(15-007-015-shopds) Lubricating Oil Filter Head
(15-001-024-shopds) Crankshaft Seal, Rear
(15-010-002-shopds) Aftercooler Assembly
(15-006-013-shopds) Fuel Drain Lines
(15-003-011-shopds) Rocker Lever Cover
(15-010-033-shopds) Turbocharger
(15-011-007-shopds) Exhaust Manifold, Dry
(15-011-008-shopds) Exhaust Manifold, Wet
(15-008-061-shopds) Water Manifold
(15-003-013-shopds) Rocker Lever Housing
(15-002-004-shopds) Cylinder Head
(15-001-053-shopds) Water Header Plate, Cylinder Block
(15-006-017-shopds) Fuel Filter Head
(15-004-015-shopds) Tappet
(15-009-011-shopds) Fuel Pump Drive
(15-001-035-shopds) Hand Hole Cover
(15-001-046-shopds) Piston Cooling Nozzle
(15-001-009-shopds) Camshaft Bearing Support
(15-001-031-shopds) Gear Cover, Front
(15-001-036-shopds) Idler Gear, Camshaft
(15-001-008-shopds) Camshaft
(15-001-033-shopds) Gear Housing, Front
(15-001-100-shopds) Piston Cooling Nozzle Oil Regulator
(15-007-035-shopds) Lubricating Oil Suction Tube (Block-Mounted)
(15-007-031-shopds) Lubricating Oil Pump
(15-001-054-shopds) Piston and Connecting Rod Assembly
(15-001-016-shopds) Crankshaft
(15-001-006-shopds) Bearings, Main
(15-001-007-shopds) Bearings, Thrust
(15-001-028-shopds) Cylinder Liner
(15-001-061-shopds) Idler Shaft, Camshaft Idler Gear

Section AS - Engine Assembly - Group 00
(15-022-001_00-shopas) Service Tools
(15-001-061-shopas) Idler Shaft, Camshaft Idler Gear
(15-001-028-shopas) Cylinder Liner
(15-001-007-shopas) Bearings, Thrust
(15-001-006-shopas) Bearings, Main
(15-001-016-shopas) Crankshaft
(15-001-054-shopas) Piston and Connecting Rod Assembly
(15-007-031-shopas) Lubricating Oil Pump
(15-007-035-shopas) Lubricating Oil Suction Tube (Block-Mounted)
(15-001-100-shopas) Piston Cooling Nozzle Oil Regulator
(15-001-033-shopas) Gear Housing, Front
(15-001-008-shopas) Camshaft
(15-001-036-shopas) Idler Gear, Camshaft
(15-001-031-shopas) Gear Cover, Front
(15-001-009-shopas) Camshaft Bearing Support
(15-001-046-shopas) Piston Cooling Nozzle
(15-001-035-shopas) Hand Hole Cover
(15-009-011-shopas) Fuel Pump Drive
(15-004-015-shopas) Tappet
(15-006-017-shopas) Fuel Filter Head
(15-001-053-shopas) Water Header Plate, Cylinder Block
(15-002-004-shopas) Cylinder Head
(15-003-013-shopas) Rocker Lever Housing
(15-008-061-shopas) Water Manifold
(15-011-008-shopas) Exhaust Manifold, Wet
(15-011-007-shopas) Exhaust Manifold, Dry
(15-010-033-shopas) Turbocharger
(15-003-011-shopas) Rocker Lever Cover
(15-006-013-shopas) Fuel Drain Lines
(15-010-002-shopas) Aftercooler Assembly
(15-001-024-shopas) Crankshaft Seal, Rear
(15-007-015-shopas) Lubricating Oil Filter Head
(15-009-001-shopas) Accessory Drive
(15-012-014-shopas) Air Compressor
(15-005-016-shopas) Fuel Pump
(15-007-040-shopas) Lubricating Oil Transfer Tube
(15-007-003-shopas) Lubricating Oil Cooler
(15-016-006-shopas) Flywheel Housing
(15-016-005-shopas) Flywheel
(15-016-004-shopas) Flexplate
(15-013-020-shopas) Starting Motor
(15-009-004-shopas) Accessory Drive Pulley
(15-009-020-shopas) PTO Housing, Front
(15-016-002-shopas) Engine Support Bracket, Front
(15-001-022-shopas) Crankshaft Pulley
(15-001-051-shopas) Vibration Damper, Rubber
(15-001-052-shopas) Vibration Damper, Viscous
(15-008-062-shopas) Water Pump
(15-008-007-shopas) Coolant Filter Head
(15-012-004-shopas) Air Compressor Coolant Lines
(15-008-005-shopas) Coolant Bypass Tube
(15-008-035-shopas) Fan Hub Bracket
(15-008-036-shopas) Fan Hub, Belt Driven
(15-008-029-shopas) Fan Drive Idler Arm Assembly
(15-008-002-shopas) Drive Belt, Cooling Fan
(15-008-064-shopas) Water Pump Idler Assembly
(15-008-003-shopas) Drive Belt, Water Pump
(15-013-003-shopas) Alternator Bracket
(15-013-001-shopas) Alternator
(15-013-005-shopas) Drive Belt, Alternator
(15-008-052-shopas) Expansion Tank
(15-008-053-shopas) Heat Exchanger
(15-008-057-shopas) Sea Water Pump
(15-007-025-shopas) Lubricating Oil Pan
(15-016-001-shopas) Engine Lifting Brackets
(15-006-015-shopas) Fuel Filter (Spin-On Type)
(15-008-006-shopas) Coolant Filter
(15-007-013-shopas) Lubricating Oil Filter (Spin-On)
(15-008-018-shopas) Cooling System
(15-007-037-shopas) Lubricating Oil System

Section 0 - Complete Engine - Group 00
(15-022-001_00) Service Tools
(15-000-001) Engine Removal
(15-000-002) Engine Installation
(15-000-005) Engine Storage - Long Term
(15-000-006) Engine Storage - Short Term
(15-000-009) Engine Steam Cleaning

Section 1 - Cylinder Block - Group 01
(15-022-001_01) Service Tools
(15-001-005-tr) Bearings, Connecting Rod
(15-001-006-tr) Bearings, Main
(15-001-007-tr) Bearings, Thrust
(15-001-008-tr) Camshaft
(15-001-009-tr) Camshaft Bearing Support
(15-001-014) Connecting Rod
(15-001-016-tr) Crankshaft
(15-001-022-tr) Crankshaft Pulley
(15-001-024-tr) Crankshaft Seal, Rear
(15-001-026) Cylinder Block
(15-001-028-tr) Cylinder Liner
(15-001-030) Gear Cover Trunion Sleeve
(15-001-031-tr) Gear Cover, Front
(15-001-033-tr) Gear Housing, Front
(15-001-035-tr) Hand Hole Cover
(15-001-036-tr) Idler Gear, Camshaft
(15-001-043) Piston
(15-001-046-tr) Piston Cooling Nozzle
(15-001-047) Piston Rings
(15-001-051-tr) Vibration Damper, Rubber
(15-001-052-tr) Vibration Damper, Viscous
(15-001-053-tr) Water Header Plate, Cylinder Block
(15-001-054-tr) Piston and Connecting Rod Assembly
(15-001-061-tr) Idler Shaft, Camshaft Idler Gear
(15-001-066) Gear Cover Accessory Drive Bushing
(15-001-070) Cylinder Block Liner Bore Concentricity
(15-001-100-tr) Piston Cooling Nozzle Oil Regulator

Section 2 - Cylinder Head - Group 02
(15-022-001_02) Service Tools
(15-002-001-tr) Crosshead
(15-002-004-tr) Cylinder Head
(15-002-014) Injector Sleeve, Cylinder Head
(15-002-015) Spark Plug Adapter, NG
(15-002-032) Cylinder Head Capscrews

Section 3 - Rocker Levers - Group 03
(15-022-001_03) Service Tools
(15-003-001) Crankcase Breather (External)
(15-003-004) Overhead Set
(15-003-010) Rocker Lever Bushings
(15-003-011-tr) Rocker Lever Cover
(15-003-013-tr) Rocker Lever Housing

Section 4 - Cam Followers/Tappets - Group 04
(15-022-001_04) Service Tools
(15-004-004) Cam Follower Lever Socket
(15-004-014) Push Rods or Tubes
(15-004-015-tr) Tappet

Section 5 - Fuel System - Group 05
(15-005-016-tr) Fuel Pump
(15-005-043) Fuel Shutoff Valve
(102-005-232) Fuel Pump Pressurizing Assembly

Section 6 - Injectors and Fuel Lines - Group 06
(15-006-003) Air in Fuel
(15-006-013-tr) Fuel Drain Lines
(15-006-015-tr) Fuel Filter (Spin-On Type)
(15-006-017-tr) Fuel Filter Head
(15-006-020) Fuel Inlet Restriction
(15-006-025) Static Injection Timing
(15-006-026-tr) Injector

Section 7 - Lubricating Oil System - Group 07
(15-022-001_07) Service Tools
(15-007-003-tr) Lubricating Oil Cooler
(15-007-009-tr) Lubricating Oil Dipstick
(15-007-011) Lubricating Oil Dipstick Tube
(15-007-013-tr) Lubricating Oil Filter (Spin-On)
(15-007-015-tr) Lubricating Oil Filter Head
(15-007-025-tr) Lubricating Oil Pan
(15-007-031-tr) Lubricating Oil Pump
(15-007-035-tr) Lubricating Oil Suction Tube (Block-Mounted)
(15-007-037-tr) Lubricating Oil System
(15-007-040-tr) Lubricating Oil Transfer Tube
(100-007-083) Lubricating Oil and Filter Analysis

Section 8 - Cooling System - Group 08
(15-022-001_08) Service Tools
(15-008-002-tr) Drive Belt, Cooling Fan
(15-008-003-tr) Drive Belt, Water Pump
(15-008-005-tr) Coolant Bypass Tube
(15-008-006-tr) Coolant Filter
(15-008-007-tr) Coolant Filter Head
(15-008-014) Coolant Thermostat Housing
(15-008-018-tr) Cooling System
(15-008-029-tr) Fan Drive Idler Arm Assembly
(15-008-036-tr) Fan Hub, Belt Driven
(15-008-040) Fan, Cooling
(15-008-047) Radiator Pressure Cap
(15-008-052-tr) Expansion Tank
(15-008-053-tr) Heat Exchanger
(15-008-057-tr) Sea Water Pump
(15-008-061-tr) Water Manifold
(15-008-062-tr) Water Pump
(15-008-064-tr) Water Pump Idler Assembly
(99-008-067) Sea Water Strainer

Section 9 - Drive Units - Group 09
(15-022-001_09) Service Tools
(15-009-001-tr) Accessory Drive
(15-009-002) Accessory Drive Bushing
(15-009-003) Accessory Drive Gear and Shaft
(15-009-004-tr) Accessory Drive Pulley
(15-009-005) Accessory Drive Pulley Wear Sleeve
(15-009-011-tr) Fuel Pump Drive
(15-009-020-tr) PTO Housing, Front
(15-009-032) Water Pump Drive Pulley
(15-009-034) Woodward Governor Drive

Section 10 - Air Intake System - Group 10
(15-022-001_10) Service Tools
(15-010-002-tr) Aftercooler Assembly
(15-010-006) Aftercooler Coolant Tube
(15-010-019) Air Crossover
(15-010-031) Air Intake Restriction
(15-010-033-tr) Turbocharger
(15-010-040) Turbocharger Compressor Seal Leaks

Section 11 - Exhaust System - Group 11
(15-011-007-tr) Exhaust Manifold, Dry
(15-011-008-tr) Exhaust Manifold, Wet
(15-011-009) Exhaust Restriction

Section 12 - Compressed Air System - Group 12
(15-012-014-tr) Air Compressor
(15-012-019) Air Leaks, Compressed Air System

Section 13 - Electrical Equipment - Group 13
(15-013-001-tr) Alternator
(15-013-003-tr) Alternator Bracket
(15-013-005-tr) Drive Belt, Alternator
(15-013-020-tr) Starting Motor
(15-013-022) Alternator Adjusting Link

Section 14 - Engine Testing - Group 14
(15-022-001_14) Service Tools
(15-014-001) Dynamometer Worksheet
(15-014-004) Engine Run-in (Without Dynamometer)
(15-014-006) Engine Run-in (Engine Dynamometer)
(00-014-012) Engine Compression

Section 16 - Mounting Adaptations - Group 16
(15-022-001_16) Service Tools
(15-016-001-tr) Engine Lifting Brackets
(15-016-002-tr) Engine Support Bracket, Front
(15-016-004-tr) Flexplate
(15-016-005-tr) Flywheel
(15-016-006-tr) Flywheel Housing
(15-016-008) Flywheel Ring Gear
(00-016-010) Engine Mounts

Section 17 - Miscellaneous - Group 17
(15-017-001) Capscrew
(15-017-002) Cup Plug
(15-017-005) Flexible Hose
(15-017-007) Pipe Plug
(15-017-011) Straight Thread Plug

Section L - Service Literature
(15-205-001) Additional Service Literature
(99-205-002) Service Literature Ordering Location
(99-205-004) Cummins Customized Parts Catalog

Section V - Specifications
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