Cummins M11 Series Engine Service Repair Manual
Description:
Cummins M11 Series Engine Service Repair Manual
- This manual contains complete rebuild specifications and information for the M11 model engines, and all associated components manufactured by Cummins Engine Company, Inc. A listing of accessory and component suppliers’ addresses and telephone numbers is located in Section C. Suppliers can be contacted directly for any information not covered in this manual.
- Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in this section. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.
- When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (Troubleshooting and Repair, Specifications, Alternative Repair, and so on.) are available and can be ordered by filling out and mailing the LiteratureOrder Form located in the Service Literature Section L.
- Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged. Please use the postage paid, self-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual is 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, a Cummins Division Office, or the factory.
Table Of Contents:
Cummins M11 Series Engine Service Repair Manual
MAIN MENU...................................................................................... 0 COVER PAGE..................................................................................... 1 TABLE OF CONTENTS.............................................................................. 3 INTRODUCTION................................................................................... 5 ABOUT THE MANUAL........................................................................... 6 DEFINITION OF TERMS........................................................................ 15 GENERAL CLEANING INSTRUCTIONS.............................................................. 14 GLASS OR PLASTIC BEAD CLEANING......................................................... 14 SOLVENT OR ACID CLEANING............................................................... 14 STEAM CLEANING......................................................................... 14 GENERAL REPAIR INSTRUCTIONS................................................................ 13 WELDING ON A CELECT CONTROLLED VEHICLE................................................. 13 GENERAL SAFETY INSTRUCTIONS................................................................ 12 IMPORTANT SAFETY NOTICE................................................................ 12 HOW TO USE THE MANUAL...................................................................... 6 ILLUSTRATIONS.............................................................................. 11 SIMBOLOS................................................................................... 8 SYMBOLE.................................................................................... 9 SYMBOLES................................................................................... 10 SYMBOLS.................................................................................... 7 ENGINE IDENTIFICATION.......................................................................... 19 ENGINE DIAGRAMS............................................................................ 24 ENGINE INDENTIFICATION..................................................................... 20 ELECTRONIC CONTROL MODULE (ECM) DATAPLATE.............................................. 20 ENGINE DATAPLATE....................................................................... 20 ENGINE SPECIFICATIONS...................................................................... 21 AIR INTAKE SYSTEM...................................................................... 22 BATTERIES (SPECIFIC GRAVITY)........................................................... 23 COOLING SYSTEM......................................................................... 22 ELECTRICAL SYSTEM...................................................................... 23 EXHAUST SYSTEM......................................................................... 22 FUEL SYSTEM............................................................................ 23 GENERAL ENGINE DATA.................................................................... 21 LUBRICATING OIL SYSTEM................................................................. 22 ENGINE DISASSEMBLY AND ASSEMBLY - GROUP 00..................................................... 25 ENGINE ASSEMBLY............................................................................ 74 ACCESSORY DRIVE ASSEMBLY - INSTALLATION................................................110 ACCESSORY DRIVE OIL SEAL - INSTALLATION................................................134 ACCESSORY DRIVE PULLEY - INSTALLATION..................................................135 ACTUATOR HARNESS - INSTALLATION........................................................145 AIR COMPRESSOR - INSTALLATION..........................................................150 AIR COMPRESSOR AIR SUPPLY TUBE - INSTALLATION..........................................151 AIR COMPRESSOR COOLANT INLET TUBE FITTING - INSTALLATION...............................149 AIR COMPRESSOR COOLANT OUTLET TUBE - INSTALLATION......................................155 AIR INTAKE MANIFOLD - INSTALLATION.....................................................163 ALTERNATOR - INSTALLATION..............................................................166 ALTERNATOR AND BRACKET (BUS APPLICATIONS) - INSTALLATION...............................167 ALTERNATOR BELT (NON BUS APPLICATIONS) - INSTALLATION..................................167 ALTERNATOR DRIVE BELT (BUS APPLICATIONS) - INSTALLATION................................169 ALTERNATOR DRIVE PULLEY - INSTALLATION.................................................160 ALTERNATOR DRIVE SEAL - INSTALLATION...................................................160 AUTOMATIC BELT TENSIONER - INSTALLATION................................................132 CAM FOLLOWER ASSEMBLIES - INSTALLATION.................................................114 CAMSHAFT AND GEAR ASSEMBLY - INSTALLATION..............................................106 CONNECTING ROD SIDE CLEARANCE MEASUREMENT..............................................103 COOLANT FILTER - INTSTALLATION.........................................................171 CRANKSHAFT - INSTALLATION.............................................................. 81 CROSSHEADS - INSTALLATION..............................................................137 CYLINDER BLOCK - INSTALLATION ON REBUILD STAND......................................... 74 CYLINDER HEAD - INSTALLATION...........................................................116 CYLINDER LINERS - INSTALLATION......................................................... 74 DIPSTICK TUBE BRACKET - INSTALLATION...................................................162 DRAIN PLUGS - INSPECTION...............................................................171 ELECTRIC FAN CLUTCH (CUMMINS) - INSTALLATION...........................................156 ELECTRONIC CONTROL COOLING PLATE - INSTALLATION........................................153 ELECTRONIC CONTROL MODULE - INSTALLATION...............................................153 ENGINE - REMOVAL FROM THE REBUILD STAND................................................157 EXHAUST MANIFOLD - INSTALLATION........................................................162 FAN BELT - INSTALLATION................................................................169 FAN HUB (BELT DRIVEN) - INSTALLATION...................................................156 FAN HUB SUPPORT - INSTALLATION.........................................................155 FAN IDLER PULLEY - INSTALLATION........................................................156 FAN PULLEY AND FAN - INSTALLATION......................................................169 FLYWHEEL - INSTALLATION................................................................ 96 FLYWHEEL BORE RUNOUT - MEASUREMENT..................................................... 96 FLYWHEEL FACE RUNOUT - MEASUREMENT..................................................... 98 FLYWHEEL HOUSING - INSTALLATION........................................................ 87 FLYWHEEL HOUSING BORE ALIGNMENT - MEASUREMENT.......................................... 90 FLYWHEEL HOUSING FACE ALIGNMENT - MEASUREMENT.......................................... 91 FLYWHEEL HOUSING, REPTO - INSTALLATION................................................. 88 FRONT CRANKSHAFT OIL SEAL - INSTALLATION...............................................132 FUEL FILTER - INSTALLATION.............................................................170 FUEL FILTER HEAD AND BRACKET - INSTALLATION............................................154 FUEL PUMP PLUMBING - INSTALLATION......................................................154 FUEL PUMP SUPPORT BRACKET - INSTALLATION...............................................150 FUEL PUMP (WITH AIR COMPRESSOR) - INSTALLATION.........................................152 FUEL PUMP (WITHOUT AIR COMPRESSOR) - INSTALLATION......................................152 GEAR COVER - INSTALLATION..............................................................130 GEAR HOUSING - INSTALLATION............................................................104 HAND HOLE COVER (EXHAUST SIDE OF ENGINE ) - INSTALLATION...............................162 HAND HOLE COVER (FUEL PUMP SIDE OF ENGINE ) - INSTALLATION.............................149 HIGH OIL PRESSURE REGULATOR - INSTALLATION............................................. 85 HYDRAULIC PUMP DRIVE - INSTALLATION....................................................109 IDLER GEAR ASSEMBLIES - INSTALLATION...................................................111 IDLER GEAR (REPTO) - INSTALLATION...................................................... 92 INJECTORS - INSTALLATION...............................................................136 JACOBS BRAKE HOUSING SPACER - INSTALLATION.............................................148 JACOBS BRAKE OIL SUPPLY HOSE - INSTALLATION............................................162 JACOBS ENGINE BRAKE - INSTALLATION.....................................................140 LUBRICATING OIL COOLER - INSTALLATION..................................................161 LUBRICATING OIL FILTER - INSTALLATION..................................................170 LUBRICATING OIL FILTER HEAD - INSTALLATION.............................................160 LUBRICATING OIL PAN - INSTALLATION.....................................................105 LUBRICATING OIL PUMP - INSTALLATION....................................................108 MAIN OIL PRESSURE REGULATOR - INSTALLATION............................................. 86 OVERHEAD - ADJUSTMENT..................................................................141 PISTON AND CONNECTING ROD - ASSEMBLY................................................... 99 PISTON AND CONNECTING ROD - INSTALLATION...............................................100 PISTON COOLING NOOZLE - INSTALLATION...................................................103 PUSH RODS AND TUBES - INSTALLATION.....................................................140 REAR CRANKSHAFT OIL SEAL - INSTALLATION................................................ 95 ROCKER LEVER ASSEMBLIES - INSTALLATION.................................................137 ROCKER LEVER COVER - INSTALLATION......................................................149 ROCKER LEVER HOUSING - INSTALLATION....................................................135 ROCKER LEVER SIDE CLEARANCE - ADJUSTMENT...............................................138 SENSOR HARNESS - INSTALLATION..........................................................147 STARTING MOTOR - INSTALLATION..........................................................155 STATIC INJECTION TIMING - CHECKING.....................................................121 STATIC INJECTION TIMING - GENERAL INFORMATION..........................................120 THERMOSTAT HOUSING - INSTALLATION......................................................166 THERMOSTAT HOUSING SUPPORT - INSTALLATION..............................................159 THRUST BEARING, LOWER BEARING SHELLS AND MAIN BEARING CAPS - INSTALLATION.............. 81 TORQUE CONVERTER COOLER DISC - INSTALLATION............................................165 TURBOCHARGER - INSTALLATION............................................................164 TURBOCHARGER DRAIN FITTING - INSTALLATION..............................................164 UPPER MAIN BEARING SHELLS - INFORMATION................................................ 80 VIBRATION DAMPER AND CRANKSHAFT PULLEY - INSTALLATION..................................133 VIBRATION DAMPER ECCENTRICITY - MEASUREMENT............................................134 VIBRATION DAMPER FACE - RUNOUT MEASUREMENT.............................................134 VISCOSITY SENSOR - INSTALLATION........................................................ 86 WATER FILTER HEAD - INSTALLATION.......................................................158 WATER HEADER PLATE - INSTALLATION......................................................158 WATER HEATER HOUSING - INSTALLATION....................................................158 WATER PUMP - INSTALLATION..............................................................159 ENGINE DISASSEMBLY......................................................................... 36 ACCESSORY DRIVE ASSEMBLY - REMOVAL..................................................... 62 ACCESSORY DRIVE OIL SEAL - REMOVAL..................................................... 62 ACCESSORY DRIVE PULLEY - REMOVAL....................................................... 61 AIR COMPRESSOR - REMOVAL............................................................... 49 AIR COMPRESSOR AIR SUPPLY TUBE - REMOVAL............................................... 48 AIR COMPRESSOR COOLANT TUBES - REMOVAL................................................. 50 AIR INTAKE MANIFOLD - REMOVAL.......................................................... 41 ALTERNATOR ADJUSTING LINK (NON BUS APPLICATIONS) - REMOVAL............................. 39 ALTERNATOR AND BRACKET (NON BUS APPLICATIONS) - REMOVAL................................ 39 ALTERNATOR AND BRACKETS (BUS APPLICATIONS)............................................. 40 ALTERNATOR BELT (BUS APPLICATIONS) - REMOVAL........................................... 39 ALTERNATOR BELT (NON BUS APPLICATIONS) - REMOVAL....................................... 38 ALTERNATOR DRIVE OIL SEAL - REMOVAL.................................................... 43 ALTERNATOR DRIVE PULLEY - REMOVAL...................................................... 43 BLOCK MOUNTED FRONT SUMP SUCTION TUBE - REMOVAL........................................ 57 CAM FOLLOWER ASSEMBLIES - REMOVAL...................................................... 56 CAMSHAFT - REMOVAL..................................................................... 64 COOLANT - DRAINING..................................................................... 36 COOLANT FILTER - REMOVAL............................................................... 37 CRANKSHAFT AND UPPER MAIN BEARING SHELLS - REMOVAL..................................... 70 CRANKSHAFT FRONT OIL SEAL - REMOVAL.................................................... 63 CRANKSHAFT PULLEY AND VIBRATION DAMPER - REMOVAL....................................... 62 CRANKSHAFT REAR OIL SEAL - REMOVAL..................................................... 59 CROSSHEADS - REMOVAL................................................................... 55 CYLINDER HEAD - REMOVAL................................................................ 55 CYLINDER LINERS - REMOVAL.............................................................. 71 ELECTRONIC CONTROL COOLING PLATE - REMOVAL............................................. 48 ELECTRONIC CONTROL MODULE - REMOVAL.................................................... 47 ENGINE - CLEANING...................................................................... 36 ENGINE - INSTALLATION ON REBUILD STAND................................................. 46 ENGINE - PREPARATION FOR CLEANING...................................................... 36 ENGINE BARRING TOOL - INSTALLATION..................................................... 66 EXHAUST MANIFOLD - REMOVAL............................................................. 41 FAN AND FAN HUB - REMOVAL.............................................................. 38 FAN DRIVE BELT - REMOVAL............................................................... 37 FAN HUB SUPPORT - REMOVAL.............................................................. 47 FLYWHEEL - REMOVAL..................................................................... 58 FLYWHEEL HOUSING - REMOVAL............................................................. 59 FLYWHEEL HOUSING, REPTO - REMOVAL...................................................... 59 FRONT ENGINE SUPPORT BRACKET - REMOVAL................................................. 63 FUEL FILTER - REMOVAL.................................................................. 37 FUEL LINES - REMOVAL................................................................... 49 FUEL PUMP - REMOVAL.................................................................... 49 FUEL SUPPLY HOSE AND FILTER HEAD - REMOVAL............................................. 47 GEAR COVER - REMOVAL................................................................... 63 GEAR HOUSING - REMOVAL................................................................. 65 HAND HOLE COVER AND DIPSTICK TUBE BRACKET - REMOVAL.................................... 45 HAND HOLE COVER (FUEL PUMP SIDE) - REMOVAL............................................. 50 HIGH OIL PRESSURE REGULATOR - REMOVAL.................................................. 71 HYDRAULIC PUMP DRIVE - REMOVAL......................................................... 50 HYDRAULIC PUMP OR COVER - REMOVAL...................................................... 50 IDLER GEAR ASSEMBLIES - REMOVAL........................................................ 63 INJECTORS - REMOVAL.................................................................... 55 INTERNAL ACTUATOR HARNESS - REMOVAL.................................................... 53 JACOBS ENGINE BRAKE - REMOVAL.......................................................... 52 LIFTING BRACKETS - REMOVAL............................................................. 46 LUBRICATING OIL - DRAINING............................................................. 36 LUBRICATING OIL COOLER - REMOVAL....................................................... 42 LUBRICATING OIL FILTER HEAD - REMOVAL.................................................. 42 LUBRICATING OIL FILTERS - REMOVAL...................................................... 37 LUBRICATING OIL PAN - REMOVAL.......................................................... 57 LUBRICATING OIL PUMP - REMOVAL......................................................... 64 LUBRICATING OIL TRANSFER TUBE - REMOVAL................................................ 57 MAIN BEARING CAPS, LOWER BEARING SHELLS AND THRUST BEARINGS - REMOVAL.................. 68 MAIN OIL PRESSURE REGULATOR - REMOVAL.................................................. 70 PISTON COOLING NOZZLES - REMOVAL....................................................... 66 PISTONS AND CONNECTING ROD - DISASSEMBLY............................................... 72 PISTONS AND CONNECTING RODS - REMOVAL.................................................. 66 PUSH RODS - REMOVAL.................................................................... 54 ROCKER LEVER ASSEMBLIES - REMOVAL ..................................................... 54 ROCKER LEVER COVER - REMOVAL........................................................... 51 ROCKER LEVER HOUSING - REMOVAL......................................................... 55 ROCKER LEVER HOUSING SPACER - REMOVAL.................................................. 52 SENSOR HARNESS AND SENSORS REMOVAL..................................................... 51 STARTING MOTOR - REMOVAL............................................................... 48 THERMOSTAT HOUSING - REMOVAL........................................................... 42 THERMOSTAT HOUSING SUPPORT - REMOVAL................................................... 44 TORQUE CONVERTER COOLER DISC - REMOVAL................................................. 42 TURBOCHARGER - REMOVAL................................................................. 40 TURBOCHARGER OIL DRAIN CONNECTION - REMOVAL............................................ 45 VISCOSITY SENSOR - REMOVAL............................................................. 70 WATER FILTER HEAD - REMOVAL............................................................ 45 WATER HEADER PLATE - REMOVAL........................................................... 45 WATER HEATER HOUSING - REMOVAL......................................................... 44 WATER PUMP - REMOVAL................................................................... 44 ENGINE DISASSEMBLY AND ASSEMBLY - GENERAL INFORMATION...................................... 34 ASSEMBLY............................................................................... 34 DISASSEMBLY............................................................................ 34 ENGINE LIFTING BRACKETS................................................................ 35 SERVICE TOOLS - DISASSEMBLY AND ASSEMBLY................................................... 28 CYLINDER BLOCK - GROUP 01......................................................................173 CAMSHAFT - CLEANING AND INSPECTION FOR REUSE...............................................220 CLEANING...............................................................................220 INSPECTION.............................................................................221 CAMSHAFT - MAGNETIC CRACK INSPECTION.......................................................226 BEARING JOURNAL - LIMITS OF ACCEPTANCE.................................................228 DEFINITIONS OF INDICATIONS.............................................................227 VALVE AND INJECTOR LOBE - LIMITS OF ACCEPTANCE.........................................228 CAMSHAFT BUSHING - REPLACEMENT.............................................................192 CLEANING...............................................................................192 INSPECTION.............................................................................193 INSTALLATION...........................................................................193 REMOVAL................................................................................192 CAMSHAFT GEAR - REPLACEMENT................................................................222 CLEANING...............................................................................223 INSPECTION.............................................................................223 INSTALLATION...........................................................................225 REMOVAL................................................................................222 CAMSHAFT OR IDLER GEAR - MAGNETIC CRACK INSPECTION.........................................229 CAMSHAFT OR IDLER GEAR - LIMITS OF ACCEPTANCE..........................................230 DEFINITIONS OF INDICATION..............................................................230 CONNECTING ROD - BEND AND TWIST INSPECTION.................................................218 ALIGNMENT INSPECTION...................................................................220 FIXTURE CALIBRATION....................................................................218 TWIST INSPECTION.......................................................................220 CONNECTING ROD - CLEANING AND INSPECTION FOR REUSE.........................................214 CLEANING...............................................................................214 INSPECTION.............................................................................215 CONNECTING ROD - MAGNETIC CRACK INSPECTION ................................................217 CONNECTING ROD - LIMITS OF ACCEPTANCE..................................................218 CONNECTING ROD BEARINGS - CLEANING AND INSPECTION FOR REUSE................................208 CLEANING...............................................................................208 INSPECTION.............................................................................208 CRANKSHAFT - CLEANING AND INSPECTIONS FOR REUSE............................................200 CLEANING...............................................................................200 INSPECTION.............................................................................200 CRANKSHAFT GEAR - REPLACEMENT..............................................................211 INSPECTION.............................................................................211 INSTALLATION...........................................................................212 REMOVAL................................................................................211 CRANKSHAFT MAGNETIC CRACK INSPECTION.......................................................202 COIL SHOT (CIRCUMFERENTAL MAGNETIZATION)...............................................203 HEAD SHOT (LONGITUDINAL MAGNETIZATION).................................................202 MAGNETIC INSPECTION - LIMITS OF ACCEPTANCE.............................................204 CRANKSHAFT PULLEY - CLEANING AND INSPECTION FOR REUSE......................................213 CLEANING...............................................................................213 INSPECTION.............................................................................214 CYLINDER BLOCK - EXPLODED VIEW.............................................................178 CYLINDER BLOCK - GENERAL INFORMATION.......................................................179 CYLINDER BLOCK - INSPECTION FOR REUSE......................................................185 CAMSHAFT BUSHING INSIDE DIAMETER.......................................................192 CYLINDER LINER BORES - INSPECTION......................................................185 HIGH OIL PRESSURE REGULATOR SEAT DEPTH - MEASUREMENT...................................191 IDLER GEAR RING DOWEL BORE - MEASUREMENT...............................................191 MAIN BEARING BORE ALIGNMENT - INSPECTION...............................................186 MAIN BEARING BORE INSIDE DIAMETER - MEASUREMENT........................................190 MAIN OIL PRESSURE REGULATOR VALVE BORE - MEASUREMENT...................................191 THRUST BEARING SURFACE WIDTH - MEASUREMENT.............................................190 CYLINDER BLOCK.............................................................................179 ASSEMBLY...............................................................................183 CAM FOLLOWER STUDS - INSTALLATION..................................................184 DOWEL PINS - INSTALLATION..........................................................184 PIPE PLUGS - INSTALLATION..........................................................183 CLEANING...............................................................................181 DISASSEMBLY............................................................................179 CAM FOLLOWER STUDS - REMOVAL.......................................................181 DOWEL PINS - REMOVAL...............................................................180 IDLER SHAFT RING DOWELS - REMOVAL..................................................181 PIPE PLUGS - REMOVAL...............................................................180 CYLINDER LINER - CLEANING AND INSPECTION FOR REUSE.........................................194 CLEANING...............................................................................194 INSPECTION.............................................................................195 DIPSTICK TUBE BRACKET - CLEANING AND INSPECTION FOR REUSE..................................237 CLEANING...............................................................................237 INSPECTION.............................................................................238 GEAR COVER - CLEANING AND INSPECTION FOR REUSE.............................................236 CLEANING...............................................................................236 INSPECTION.............................................................................236 GEAR HOUSING - CLEANING AND INSPECTION FOR REUSE...........................................234 CLEANING...............................................................................234 INSPECTION.............................................................................235 NEEDLE BEARING INSTALLATION............................................................235 HAND HOLE COVER - CLEANING AND INSPECTION FOR REUSE........................................237 CLEANING...............................................................................237 INSPECTION.............................................................................237 IDLER GEAR ASSEMBLY - CLEANING AND INSPECTION FOR REUSE....................................197 CLEANING ..............................................................................197 INSPECTION.............................................................................198 MAIN BEARINGS - CLEANING AND INSPECTION FOR REUSE..........................................207 CLEANING...............................................................................207 INSPECTION.............................................................................207 PISTON - CLEANING AND INSPECTION FOR REUSE.................................................231 CLEANING...............................................................................231 INSPECTION.............................................................................232 PISTION RINGS - REMOVAL................................................................231 SERVICE TOOLS - CYLINDER BLOCK.............................................................175 VIBRATION DAMPER (VISCOUS) - CLEANING AND INSPECTION FOR REUSE.............................209 CLEANING...............................................................................209 INSPECTION.............................................................................209 CYLINDER HEAD - GROUP 02.......................................................................239 CYLINDER HEAD - CLEANING AND INSPECTION FOR REUSE..........................................245 CLEANING...............................................................................245 INSPECTION.............................................................................246 CYLINDER HEAD - EXPLODED VIEW..............................................................244 CYLINDER HEAD - GENERAL INFORMATION........................................................245 CYLINDER HEAD - PRESSURE TEST FOR REUSE....................................................267 CYLINDER HEAD - REBUILD....................................................................246 ASSEMBLY...............................................................................256 DISASSEMBLY............................................................................246 INSPECTION.............................................................................248 VALVE SEATS - GRINDING.................................................................255 CYLINDER HEAD - VACUUM TEST VALVE SEATING..................................................269 CYLINDER HEAD - VALVE GRINDING.............................................................263 INSPECTION.............................................................................263 CYLINDER HEAD INJECTOR SLEEVE - REPLACEMENT................................................264 ASSEMBLY...............................................................................265 DISASSEMBLY............................................................................264 INSPECTION.............................................................................264 CYLINDER HEAD OVERSIZE VALVE SEAT INSERT - INSTALLATION....................................262 CYLINDER HEAD VALVE GUIDE - REPLACEMENT....................................................258 ASSEMBLY...............................................................................259 DISASSEMBLY............................................................................258 ASSEMBLY...............................................................................259 CYLINDER HEAD VALVE SEAT INSERT - REPLACEMENT..............................................260 ASSEMBLY...............................................................................261 DISASSEMBLY............................................................................260 INSPECTION.............................................................................260 CYLINDER HEAD VALVES - MAGNETIC CRACK INSPECTION...........................................271 SERVICE TOOLS - CYLINDER HEAD..............................................................240 VALVE CROSSHEAD - CLEANING AND INSPECTION FOR REUSE........................................272 CLEANING...............................................................................272 INSPECTION.............................................................................272 VALVE CROSSHEAD - MAGNETIC CRACK INSPECTION................................................272 ROCKER LEVERS - GROUP 03.......................................................................275 CRANKCASE BREATHER (INTERNAL) - CLEANING AND INSPECTION....................................290 ROCKER HOUSING AND COVER (AUTOMOTIVE) - EXPLODED VIEW......................................278 ROCKER LEVER - MAGNETIC CRACK INSPECTION...................................................289 ROCKER LEVER ASSEMBLY - CLEANING AND INSPECTION FOR REUSE..................................279 ASSEMBLY...............................................................................281 DISASSEMBLY............................................................................279 INSPECTION.............................................................................280 ROCKER LEVER ASSEMBLY - REBUILD............................................................283 ASSEMBLY...............................................................................286 DISASSEMBLY............................................................................283 INSPECTION.............................................................................284 ROCKER LEVER BUSHING - REPLACEMENT.........................................................287 ASSEMBLY...............................................................................288 DISASSEMBLY............................................................................287 INSPECTION.............................................................................288 ROCKER LEVER COVER - CLEANING AND INSPECTION FOR REUSE.....................................290 CLEANING...............................................................................290 INSPECTION.............................................................................290 ROCKER LEVER HOUSING - CLEANING AND INSPECTION FOR REUSE...................................289 CLEANING...............................................................................289 INSPECTION.............................................................................289 ROCKER LEVERS - EXPLODED VIEW..............................................................277 ROCKER LEVERS - GENERAL INFORMATION........................................................279 SERVICE TOOLS - ROCKER LEVERS..............................................................276 CAM FOLLOWERS - GROUP 04.......................................................................291 CAM FOLLOWER ASSEMBLY - CLEANING AND INSPECTION FOR REUSE..................................294 ASSEMBLY...............................................................................297 DISASSEMBLY............................................................................294 INSPECTION.............................................................................295 CAM FOLLOWER ASSEMBLY - EXPLODED VIEW .....................................................293 CAM FOLLOWER ASSEMBLY - GENERAL INFORMATION................................................294 CAM FOLLOWER ASSEMBLY - REBUILD............................................................298 ASSEMBLY...............................................................................302 DISASSEMBLY............................................................................298 INSPECTION.............................................................................299 CAM FOLLOWER LEVER - MAGNETIC CRACK INSPECTION (ROLLER REMOVED)............................307 CAM FOLLOWER LEVER - ROLLER REPLACEMENT....................................................303 ASSEMBLY...............................................................................305 DISASSEMBLY............................................................................303 INSPECTION.............................................................................304 CAM FOLLOWER LEVER SOCKET - REPLACEMENT (ROLLER REMOVED)...................................308 ASSEMBLY...............................................................................309 DISASSEMBLY............................................................................308 INSPECTION.............................................................................308 PUSH RODS AND TUBES - CLEANING AND INSPECTION FOR REUSE....................................309 INSPECTION.............................................................................309 SERVICE TOOLS - CAM FOLLOWER ASSEMBLY......................................................292 FUEL SYSTEM - GROUP 05.........................................................................311 FUEL PUMP - CLEANING AND INSPECTION FOR REUSE..............................................312 CLEANING...............................................................................312 INSPECTION.............................................................................313 FUEL PUMP - GENERAL INFORMATION............................................................312 FUEL PUMP - REBUILD........................................................................314 ASSEMBLY...............................................................................318 DISASSEMBLY............................................................................314 FUEL DAMPER - ASSEMBLY.................................................................321 FUEL DAMPER - DISASSEMBLY AND INSPECTION...............................................321 FUEL SHUTOFF VALVE - ASSEMBLY..........................................................322 FUEL SHUTOFF VALVE - CLEANING AND INSPECTION...........................................322 FUEL SHUTOFF VALVE - DISASSEMBLY.......................................................321 FUEL SUPPLY PUMP - TEST................................................................323 INSPECTION.............................................................................316 INJECTORS AND FUEL LINES - GROUP 06............................................................325 FUEL TUBES, FITTINGS AND MOUNTING PARTS - CLEANING AND INSPECTION FOR REUSE................330 INSPECTION.............................................................................330 INJECTOR - CELECT - EXPLODED VIEW..........................................................326 INJECTORS - CALIBRATION....................................................................329 INJECTORS - CLEANING AND INSPECTION FOR REUSE..............................................328 INSPECTION.............................................................................328 INJECTORS - GENERAL INFORMATION............................................................327 INJECTORS - REBUILD........................................................................329 LUBRICATING OIL SYSTEM - GROUP 07..............................................................331 LUBRICATING OIL COOLER - CLEANING AND INSPECTION FOR REUSE.................................342 CLEANING...............................................................................342 INSPECTION.............................................................................342 PRESSURE TEST THE OIL COOLER ELEMENT...................................................343 LUBRICATING OIL DIPSTICK - CALIBRATION.....................................................337 LUBRICATING OIL DIPSTICK AND DIPSTICK TUBE - CLEANING AND INSPECTION FOR REUSE.............337 CLEANING ..............................................................................337 INSPECTION.............................................................................337 LUBRICATING OIL FILTER HEAD - CLEANING AND INSPECTION FOR REUSE............................338 CLEANING...............................................................................338 INSPECTION.............................................................................339 LUBRICATING OIL FILTER HEAD - REBUILD......................................................339 ASSEMBLY...............................................................................341 DISASSEMBLY............................................................................339 LUBRICATING OIL PAN - CLEANING AND INSPECTION FOR REUSE....................................335 CLEANING...............................................................................335 INSPECTION.............................................................................335 LUBRICATING OIL PAN TRANSFER TUBE - CLEANING AND INSPECTION FOR REUSE......................336 CLEANING...............................................................................336 INSPECTION.............................................................................336 LUBRICATING OIL PUMP - CLEANING AND INSPECTION FOR REUSE...................................344 ASSEMBLY...............................................................................347 CLEANING...............................................................................344 DISASSEMBLY............................................................................345 INSPECTION.............................................................................346 LUBRICATING OIL PUMP - REBUILD.............................................................349 LUBRICATING OIL SYSTEM - EXPLODED VIEW.....................................................333 LUBRICATING OIL SYSTEM - GENERAL INFORMATION...............................................335 SERVICE TOOLS - LUBRICATING OIL SYSTEM.....................................................332 COOLING SYSTEM - GROUP 08......................................................................351 FAN HUB - CLEANING AND INSPECTION FOR REUSE................................................373 CLEANING...............................................................................373 INSPECTION.............................................................................373 FAN HUB - EXPLODED VIEW....................................................................355 FAN HUB AND FAN IDLER PULLEY - GENERAL INFORMATION.........................................357 FAN HUB (BELT DRIVEN) - REBUILD............................................................373 ASSEMBLY...............................................................................378 CLEANING...............................................................................375 DISASSEMBLY............................................................................373 INSPECTION.............................................................................376 FAN IDLER PULLEY - CLEANING AND INSPECTION FOR REUSE.......................................383 CLEANING...............................................................................383 INSPECTION.............................................................................383 FAN IDLER PULLEY - REBUILD.................................................................383 ASSEMBLY...............................................................................387 CLEANING...............................................................................386 DISASSEMBLY............................................................................383 INSPECTION.............................................................................386 FAN IDLER PULLEY AND BRACKET - EXPLODED VIEW...............................................356 HEATER HOUSING, THERMOSTAT SUPPORT AND WATER HEADER COVER - CLEANING AND INSPECTION........390 CLEANING...............................................................................390 INSPECTION.............................................................................392 SERVICE TOOLS - COOLING SYSTEM.............................................................352 THERMOSTAT - OPERATING TEMPERATURE INSPECTION..............................................394 TEST...................................................................................394 THERMOSTAT HOUSING ASSEMBLY - REBUILD......................................................392 ASSEMBLY...............................................................................393 CLEANING...............................................................................392 DISASSEMBLY............................................................................392 INSPECTION.............................................................................393 WATER FILTER HEAD ASSEMBLY - CLEANING AND INSPECTION FOR REUSE.............................395 CLEANING...............................................................................395 INSPECTION.............................................................................395 WATER FILTER HEAD ASSEMBLY - REBUILD.......................................................395 ASSEMBLY...............................................................................397 CLEANING...............................................................................396 DISASSEMBLY............................................................................395 INSPECTION.............................................................................396 WATER PUMP - CLEANING AND INSPECTION FOR REUSE.............................................358 CLEANING...............................................................................358 INSPECTION.............................................................................358 WATER PUMP - REBUILD.......................................................................359 ASSEMBLY...............................................................................367 CLEANING...............................................................................363 DISASSEMBLY............................................................................359 INSPECTION.............................................................................364 WATER PUMP ASSEMBLY - EXPLODED VIEW........................................................354 WATER PUMP ASSEMBLY - GENERAL INFORMATION..................................................357 DRIVE UNITS - GROUP 09.........................................................................399 ACCESSORY DRIVE PULLEY - CLEANING AND INSPECTION FOR REUSE.................................415 CLEANING...............................................................................415 INSPECTION.............................................................................415 DRIVE UNITS - GENERAL INFORMATION..........................................................403 FUEL PUMP AND COMPRESSOR DRIVE.........................................................403 HYDRAULIC PUMP DRIVE...................................................................403 FUEL PUMP AND COMPRESSOR DRIVE - CLEANING INSPECTION FOR REUSE.............................404 CLEANING...............................................................................404 INSPECTION............................................................................404 FUEL PUMP AND COMPRESSOR DRIVE - EXPLODED VIEW.............................................401 FUEL PUMP AND COMPRESSOR DRIVE - REBUILD...................................................405 ASSEMBLY...............................................................................409 CLEANING...............................................................................406 DISASSEMBLY............................................................................405 INSPECTION.............................................................................406 HYDRAULIC PUMP DRIVE - CLEANING AND INSPECTION FOR REUSE...................................411 CLEANING...............................................................................411 INSPECTION.............................................................................411 HYDRAULIC PUMP DRIVE - EXPLODED VIEW.......................................................402 HYDRAULIC PUMP DRIVE - REBUILD.............................................................412 ASSEMBLY...............................................................................414 CLEANING...............................................................................412 DISASSEMBLY............................................................................412 INSPECTION.............................................................................413 SERVICE TOOLS - DRIVE UNITS................................................................400 AIR INTAKE SYSTEM - GROUP 10...................................................................417 AIR INTAKE SYSTEM - GENERAL INFORMATION....................................................420 CAC AIR INTAKE SYSTEM EXPODED VIEW........................................................419 INTAKE MANIFOLD - CLEANING AND INSPECTION FOR REUSE........................................422 CLEANING...............................................................................422 INSPECTION.............................................................................422 SERVICE TOOLS - AIR INTAKE SYSTEM..........................................................418 TURBOCHARGER - CLEANING AND INSPECTION FOR REUSE..........................................421 CLEANING ..............................................................................421 INSPECTION.............................................................................421 EXHAUST SYSTEM - GROUP 11......................................................................423 EXHAUST MANIFOLD - CLEANING INSPECTION FOR REUSE...........................................425 CLEANING...............................................................................425 DISASSEMBLY............................................................................425 INSPECTION.............................................................................426 EXHAUST SYSTEM - EXPLODED VIEW.............................................................424 EXHAUST SYSTEM - GENERAL INFORMATION.......................................................425 AIR EQUIPMENT - GROUP 12.......................................................................429 AIR COMPRESSOR - CLEANING AND INSPECTION FOR REUSE.........................................434 CLEANING...............................................................................434 INSPECTION.............................................................................434 AIR EQUIPMENT - GENERAL INFORMATION........................................................430 COMPRESSED AIR SYSTEMS FLOW DIAGRAMS.......................................................433 ELECTRICAL EQUIPMENT - GROUP 13................................................................437 ALTERNATOR ADJUSTING LINK - CLEANING AND INSPECTION FOR REUSE..............................439 INSPECTION.............................................................................439 ALTERNATOR BRACKET - CLEANING AND INSPECTION FOR REUSE.....................................439 INSPECTION.............................................................................439 ALTERNATOR BRACKET (BUS APPLICATIONS) - CLEANING AND INSPECTION FOR REUSE..................440 CLEANING...............................................................................440 INSPECTION.............................................................................440 AUTOMATIC BELT TENSIONER BRACKET (BUS APPLICATIONS) - CLEANING AND INSPECTION FOR REUSE....442 CLEANING...............................................................................442 AUTOMATIC BELT TENSIONER (BUS APPLICATIONS) - CLEANING AND INSPECTION FOR REUSE............441 CLEANING...............................................................................441 INSPECTION.............................................................................441 ELECTRICAL EQUIPMENT - GENERAL INFORMATION.................................................438 STARTING MOTOR - CLEANING AND INSPECTION FOR REUSE.........................................439 CLEANING...............................................................................439 INSPECTION.............................................................................440 WIRING DIAGRAMS............................................................................439 ENGINE TESTING - GROUP 14......................................................................443 CHASSIS DYNAMOMETER........................................................................479 GENERAL TEST PROCEDURE.................................................................481 CHARGE AIR COOLER RESTRICTION......................................................488 COOLANT PRESSURE...................................................................488 ENGINE BLOWBY......................................................................487 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER......................................482 EXHAUST AIR RESTRICTION............................................................487 FUEL DRAIN LINE RESTRICTION........................................................484 FUEL INLET RESTRICTION.............................................................483 FUEL RATE..........................................................................483 INTAKE AIR RESTRICTION.............................................................486 INTAKE AIR TEMPERATURE CONTROL - CHASSIS DYNAMOMETER TEST..........................485 INTAKE MANIFOLD PRESSURE...........................................................485 LUBRICATING OIL PRESSURE ..........................................................488 OPERATION..............................................................................479 DYNAMOMETER WORKSHEET......................................................................461 ENGINE DYNAMOMETER - INSTALL ENGINE........................................................464 AIR COMPRESSOR.........................................................................470 AIR INLET RESTRICTION..................................................................467 COOLANT PLUMBING.......................................................................464 ENGINE BLOWBY..........................................................................468 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER..........................................469 ENGINE THROTTLE CONTROL................................................................471 EXHAUST RESTRICTION....................................................................467 FUEL DRAIN LINE RESTRICTION ...........................................................470 FUEL INLET RESTRICTION.................................................................469 FUEL PRESSURE..........................................................................469 FUEL RATE..............................................................................468 INTAKE AIR TEMPERATURE CONTROL.........................................................465 INTAKE MANIFOLD PRESSURE...............................................................468 LUBRICATING OIL PRESSURE...............................................................467 LUBRICATING OIL TEMPERATURE............................................................467 STARTING MOTOR.........................................................................471 ENGINE PAINTING............................................................................492 ENGINE RUN-IN PROCEDURE -CHASSIS DYNAMOMETER...............................................488 ENGINE RUN-IN PROCEDURE - ENGINE DYNAMOMETER...............................................475 ENGINE RUN-IN PROCEDURE - WITHOUT DYNAMOMETER..............................................491 ON-HIGHWAY.............................................................................491 ENGINE STORAGE - LONG TERM.................................................................495 REMOVE THE ENGINE FROM LONG TERM STORAGE...............................................498 ENGINE STORAGE - SHORT TERM................................................................493 REMOVE THE ENGINE FROM SHORT TERM STORAGE..............................................495 ENGINE TESTING - GENERAL INFORMATION.......................................................444 CHASSIS DYNAMOMETER, PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN..........................444 DEFINITION OF TERMS ON ENGINE PERFORMANCE CURVE........................................445 ENGINE DYNAMOMETER RUN-IN..............................................................444 FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER.................................447 INSTALLATION.......................................................................447 OPERATION..........................................................................448 GENERAL RUN-IN PROCEDURES..............................................................446 IN-SERVICE RUN-IN......................................................................444 INTAKE MANIFOLD BOOST PRESSURE CORRECTION FACTORS......................................450 ENGINE TESTING - SPECIFICATIONS............................................................460 SERVICE TOOLS - ENGINE TESTING.............................................................462 INSTRUMENTS AND CONTROLS - GROUP 15............................................................501 INSTRUMENTS AND CONTROLS - GENERAL INFORMATION.............................................502 AIR HEATERS............................................................................502 COOLANT HEATERS........................................................................502 FUEL WARMERS...........................................................................502 GAUGES.................................................................................502 OIL HEATERS............................................................................502 SAFETY CONTROLS........................................................................503 MOUNTING ADAPTATIONS - GROUP 16................................................................505 FLYWHEEL - CLEANING AND INSPECTION FOR REUSE...............................................509 ASSEMBLY...............................................................................510 DISASSEMBLY............................................................................509 INSPECTION.............................................................................509 FLYWHEEL HOUSING - CLEANING AND INSPECTION FOR REUSE.......................................511 CLEANING...............................................................................511 INSPECTION.............................................................................512 FLYWHEEL RING GEAR - REPLACEMENT...........................................................510 ASSEMBLY...............................................................................511 DISASSEMBLY............................................................................510 INSPECTION.............................................................................510 FRONT ENGINE SUPPORT - CLEANING AND INSPECTIONS............................................512 MOUNTING ADAPTATIONS - EXPLODED VIEW.......................................................507 MOUNTING ADAPTATIONS - GENERAL INFORMATION.................................................509 REAR ENGINE POWER TAKEOFF - EXPLODED VIEW..................................................508 REAR ENGINE POWER TAKEOFF (REPTO) REBUILDING...............................................512 ASSEMBLY...............................................................................516 CLEANING...............................................................................514 DISASSEMBLY............................................................................512 INSPECTION.............................................................................514 SERVICE TOOLS - MOUNTING ADAPTATIONS.......................................................506 SPECIFICATIONS - GROUP 18......................................................................521 CAPSCREW MARKINGS AND TORQUE VALUES........................................................566 CAPSCREW MARKINGS AND TORQUE VALUES - METRIC...........................................566 CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY...................................567 COMPONENT SPECIFICATIONS AND TORQUE VALUES.................................................523 AIR EQUIPMENT - INSPECTION SPECIFICATIONS..............................................559 AIR INTAKE SYSTEM - INSPECTION SPECIFICATIONS..........................................559 CAM FOLLOWER ASSEMBLY - REBUILD SPECIFICATIONS.........................................550 COOLING SYSTEM - REBUILD SPECIFICATIONS................................................554 COOLING SYSTEMS - TORQUE VALUES........................................................556 CYLINDER BLOCK - REBUILD SPECIFICATIONS................................................538 CYLINDER BLOCK - TORQUE VALUES.........................................................546 CYLINDER HEAD - REBUILD SPECIFICATIONS.................................................546 CYLINDER HEAD - TORQUE VALUES..........................................................549 DRIVE UNITS - REBUILD SPECIFICATIONS...................................................557 ELECTRICAL EQUIPMENT - INSPECTION SPECIFICATIONS.......................................560 ENGINE ASSEMBLY - CAPSCREW TORQUE VALUES...............................................528 ENGINE ASSEMBLY - SPECIFICATIONS.......................................................523 ENGINE TESTING - TEST SPECIFICATIONS...................................................560 EXHAUST SYSTEM - TORQUE VALUES.........................................................559 FUEL PUMP - REBUILD SPECIFICATIONS.....................................................551 FUEL PUMP - TORQUE VALUES..............................................................552 INJECTORS - REBUILD SPECIFICATIONS.....................................................553 LUBRICATING OIL SYSTEMS - SPECIFICATIONS...............................................553 LUBRICATING OIL SYSTEMS - TORQUE VALUES................................................554 MOUNTING ADAPTATIONS - REBUILD SPECIFICATIONS..........................................560 ROCKER LEVER ASSEMBLY - REBUILD SPECIFICATIONS.........................................549 VEHICLE BRAKING - REBUILD SPECIFICATIONS...............................................560 DRIVE BELT TENSION.........................................................................562 INJECTIONS TIMING CODES....................................................................561 NEWTON-METER TO FOOT-POUND CONVERSTION CHART...............................................565 PIPE PLUG TORQUE VALUES....................................................................567 SPECIFICATIONS - GENERAL INFORMATION.......................................................522 TAP-DRILL CHART - U.S. CUSTOMARY & METRIC..................................................568 WEIGHT AND MEASURES - CONVERSION FACTORS...................................................564 VEHICLE BRAKING - GROUP 20.....................................................................569 VEHICLE BRAKING - GENERAL INFORMATION......................................................570 SERVICE LITERATURE.............................................................................571 ADDITIONAL SERVICE LITERATURE..............................................................572 SERVICE LITERATURE ORDERING LOCATION.......................................................573 COMPONENT MANUFACTURERS: NAMES AND ADDRESSES..................................................577 COMPONENT MANUFACTURERS' ADDRESSES.........................................................578 AIR COMPRESSORS............................................................................578 AIR CYLINDERS..............................................................................578 AIR HEATERS................................................................................578 AIR STARTING MOTORS........................................................................578 ALTERNATORS................................................................................578 AUXILIARY BRAKES...........................................................................578 BELTS......................................................................................578 CATALYTIC CONVERTERS.......................................................................578 CLUTCHES...................................................................................578 COOLANT HEATERS............................................................................578 DRIVE PLATES...............................................................................578 ELECTRIC STARTING MOTORS...................................................................579 ENGINE PROTECTION CONTROLS.................................................................579 FAN CLUTCHES...............................................................................579 FANS.......................................................................................579 FILTERS....................................................................................579 FLEXPLATES.................................................................................579 FUEL WARMERS...............................................................................579 GAUGES.....................................................................................579 GOVERNORS..................................................................................579 HEAT SLEEVES...............................................................................580 HYDRAULIC AND POWER STEERING PUMPS.........................................................580 OIL HEATERS................................................................................580 TORQUE CONVERTERS..........................................................................581 INDEX..........................................................................................581
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