CUMMINS N14 ENGINE SERVICE REPAIR MANUAL
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CUMMINS N14 ENGINE SERVICE REPAIR MANUAL
- This manual contains complete rebuild specifications and information for the N14 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.
- 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 Literature Order 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.
- 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 ReConT exchange parts. These parts can be identified by the following trademarks.
TABLE OF CONTENTS:
CUMMINS N14 ENGINE SERVICE REPAIR MANUAL
MAIN MENU............................................................................. 0 COVER PAGE............................................................................ 1 FOREWORD.............................................................................. 2 TABLE OF CONTENTS..................................................................... 3 INTRODUCTION.......................................................................... 5 MANUAL ORGANIZATION............................................................... 6 TABLE OF CONTENTS............................................................. 6 GROUP CONTENTS................................................................ 6 INDEX......................................................................... 6 METRIC INFORMATION............................................................ 6 GENERAL REPAIR INSTRUCTIONS....................................................... 7 GENERAL SAFETY INSTRUCTIONS....................................................... 8 SYMBOLS USED IN THIS MANUAL....................................................... 9 SIMBOLOS USADOS EN ESTE MANUAL.................................................... 10 SYMBOLES UTILISES DANS CE MANUEL.................................................. 11 SYMBOLE........................................................................... 12 ILLUSTRATIONS..................................................................... 13 GLOSSARY OF TERMS................................................................. 14 ENGINE IDENTIFICATION............................................................. 16 ENGINE DIAGRAMS................................................................... 17 GENERAL CLEANING INSTRUCTIONS..................................................... 20 SOLVENT AND ACID CLEANING..................................................... 20 STEAM CLEANING................................................................ 20 GLASS OR PLASTIC BEAD CLEANING................................................ 20 GROUP 0 - ENGINE DISASSEMBLY AND ASSEMBLY............................................. 21 COOLANT - DRAINAGE................................................................ 31 ENGINE DISASSEMBLY AND ASSEMBLY - SERVICE TOOLS................................... 25 ENGINE DISASSEMBLY AND ASSEMBLY - GENERAL INFORMATION............................. 29 DISASSEMBLY................................................................... 29 ASSEMBLY...................................................................... 29 ENGINE - PREPARATION FOR CLEANING................................................. 30 COOLANT FILTER - REMOVAL.......................................................... 31 LUBRICATING OIL FILTER - REMOVAL.................................................. 31 CRANKCASE BREATHER - REMOVAL...................................................... 32 TURBOCHARGER - REMOVAL............................................................ 32 EXHAUST MANIFOLD - REMOVAL........................................................ 33 STARTING MOTOR - REMOVAL.......................................................... 33 FAN AND FAN SPACER - REMOVAL...................................................... 33 ALTERNATOR BELTS - REMOVAL........................................................ 33 ALTERNATOR - REMOVAL.............................................................. 34 ALTERNATOR MOUNTING BRACKET - REMOVAL............................................. 34 LUBRICATING OIL COOLER ASSEMBLY - REMOVAL......................................... 34 COOLANT INLET TRANSFER CONNECTION - REMOVAL....................................... 35 DIPSTICK TUBE AND HOUSING - REMOVAL............................................... 35 PISTON COOLING NOZZLES - REMOVAL.................................................. 35 WATER HEADER COVERS - REMOVAL..................................................... 36 ENGINE - INSTALLATION ON THE REBUILD STAND........................................ 36 FLYWHEEL - REMOVAL................................................................ 38 FLYWHEEL HOUSING - REMOVAL........................................................ 39 REAR COVER - REMOVAL.............................................................. 40 CRANKSHAFT SEAL, REAR - REMOVAL................................................... 40 FAN BELTS - REMOVAL............................................................... 40 FAN HUB AND FAN HUB SUPPORT BRACKET - REMOVAL..................................... 41 WATER PUMP BELT - REMOVAL......................................................... 41 CELECT™ COOLANT TEMPERATURE SENSOR - REMOVAL...................................... 41 THERMOSTAT HOUSING - REMOVAL...................................................... 42 AIR COMPRESSOR COOLANT INLET AND OUTLET TUBES - REMOVAL........................... 42 WATER PUMP - REMOVAL.............................................................. 43 ACCESSORY DRIVE PULLEY - REMOVAL.................................................. 43 VIBRATION DAMPER - REMOVAL........................................................ 43 ENGINE SUPPORT BRACKET, FRONT - REMOVAL........................................... 43 STC EXTERNAL OIL PLUMBING - REMOVAL............................................... 44 STC OIL CONTROL VALVE - REMOVAL................................................... 45 CELECT™ ACTUATOR HARNESS - REMOVAL................................................ 45 CELECT™ SENSOR HARNESS - REMOVAL.................................................. 47 CELECT™ ELECTRONIC CONTROL MODULE (ECM) - REMOVAL................................. 48 CELECT™ AMBIENT AIR PRESSURE SENSOR -REMOVAL...................................... 48 CELECT™ LUBRICATING OIL PRESSURE SENSOR - REMOVAL................................. 49 CELECT™ ECM COOLING PLATE - REMOVAL............................................... 49 FUEL PUMP - REMOVAL............................................................... 49 CELECT™ ENGINES............................................................... 49 STC ENGINES................................................................... 50 AIR COMPRESSOR - REMOVAL.......................................................... 50 ACCESSORY DRIVE - REMOVAL......................................................... 51 FUEL TUBING - REMOVAL............................................................. 51 CELECT™ ENGINE POSITION SENSOR (EPS) - REMOVAL.................................... 51 LUBRICATING OIL TRANFER TUBE - REMOVAL............................................ 51 LUBRICATING OIL PUMP SIGNAL LINE - REMOVAL........................................ 52 LUBRICATING OIL PUMP - REMOVAL.................................................... 52 VISCOSITY SENSOR - REMOVAL........................................................ 52 CELECT™ BOOST PRESSURE SENSOR - REMOVAL........................................... 53 CELECT™ INTAKE AIR TEMPERATURE SENSOR - REMOVAL................................... 53 INTAKE MANIFOLD - REMOVAL......................................................... 53 ROCKER HOUSING COVERS - REMOVAL................................................... 54 ENGINE BRAKES - REMOVAL........................................................... 54 ROCKER LEVER SHAFT ASSEMBLIES - REMOVAL........................................... 54 VALVE CROSSHEADS - REMOVAL........................................................ 55 PUSH TUBES - REMOVAL.............................................................. 55 INJECTORS - REMOVAL............................................................... 55 CELECT ENGINES................................................................ 55 STC ENGINES................................................................... 56 ROCKER LEVER HOUSING - REMOVAL.................................................... 56 FUEL CROSSOVERS - REMOVAL......................................................... 57 CYLINDER HEADS - REMOVAL.......................................................... 57 CAM FOLLOWER ASSEMBLIES - REMOVAL................................................. 58 CAMSHAFT BEARING SUPPORT - REMOVAL................................................ 58 LUBRICATING OIL PAN - REMOVAL..................................................... 59 GEAR COVER - REMOVAL.............................................................. 59 CRANKSHAFT SEAL, FRONT - REMOVAL.................................................. 59 ACCESSORY DRIVE SEAL - REMOVAL.................................................... 59 CAMSHAFT - REMOVAL................................................................ 59 PISTON AND CONNECTING ROD ASSEMBLIES - REMOVAL.................................... 60 CYLINDER LINERS - REMOVAL......................................................... 62 CRANKSHAFT - REMOVAL.............................................................. 64 CYLINDER BLOCK - REMOVAL FROM THE REBUILD STAND................................... 66 CYLINDER BLOCK - INSTALLATION ON THE REBUILD STAND................................ 66 CRANKSHAFT - INSTALLATION......................................................... 68 CYLINDERS LINERS - INSTALLATION................................................... 77 PISTON AND CONNECTING ROD ASSEMBLIES - ASSEMBLY AND INSTALLATION.................. 81 REAR COVER - INSTALLATION......................................................... 85 CRANKSHAFT SEAL, REAR - INSTALLATION.............................................. 86 FLYWHEEL HOUSING - INSTALLATION................................................... 87 BORE ALIGNMENT - MEASUREMENT.................................................. 88 FACE ALIGNMENT - MEASUREMENT.................................................. 90 FLYWHEEL - INSTALLATION........................................................... 92 BORE ALIGNMENT - MEASUREMENT.................................................. 93 FACE ALIGNMENT - MEASUREMENT.................................................. 95 CYLINDER HEADS - INSTALLATION..................................................... 96 CAMSHAFT INSTALLATION............................................................. 98 CAM FOLLOWER ASSEMBLIES - INSTALLATION............................................100 INJECTION TIMING - GENERAL INFORMATION............................................100 TIMING TOOL INSTALLATION......................................................102 ACCESSORY DRIVE - INSTALLATION....................................................109 CELECT™ ENGINE POSITION SENSOR (EPS) - INSTALLATION...............................111 LUBRICATING OIL PUMP - INSTALLATION...............................................111 GEAR COVER - INSTALLATION.........................................................112 CRANKSHAFT SEAL, FRONT - INSTALLATION.............................................114 CAMSHAFT BEARING SUPPORT - INSTALLATION...........................................114 ACCESSORY DRIVE SEAL - INSTALLATION...............................................116 ACCESSORY DRIVE PULLEY - INSTALLATION.............................................117 LUBRICATING OIL PAN - INSTALLATION................................................118 FUEL CROSSOVERS - INSTALLATION....................................................118 ROCKER LEVER HOUSING - INSTALLATION...............................................118 INJECTORS - INSTALLATION..........................................................120 CELECT ENGINES................................................................120 STC ENGINES...................................................................121 PUSH TUBES - INSTALLATION.........................................................122 VALVE CROSSHEADS - INSTALLATION...................................................123 ROCKER LEVER SHAFT ASSEMBLIES - INSTALLATION......................................124 INJECTOR AND VALVE ADJUSTMENT.....................................................125 CELECT ENGINES................................................................125 STC ENGINES...................................................................129 ENGINE BRAKE - INSTALLATION.......................................................135 ENGINE BRAKE ADJUSTMENT...........................................................135 C-BRAKE.......................................................................135 C-BRAKE - ALTERNATE METHOD....................................................138 JACOBS BRAKE..................................................................139 ROCKER HOUSING COVERS - INSTALLATION..............................................139 INTAKE MANIFOLD - INSTALLATION....................................................140 CELECT™ INTAKE AIR TEMPERATURE SENSOR - INSTALLATION..............................141 CELECT™ BOOST PRESSURE SENSOR - INSTALLATION......................................141 VISCOSITY SENSOR - INSTALLATION...................................................141 LUBRICATING OIL PUMP SIGNAL - INSTALLATION........................................142 LUBRICATING OIL TRANSFER TUBE - INSTALLATION......................................142 FUEL TUBING - INSTALLATION........................................................143 AIR COMPRESSOR - INSTALLATION.....................................................144 FUEL PUMP - INSTALLATION..........................................................144 CELECT ENGINES................................................................144 STC ENGINES...................................................................145 CELECT™ ECM COOLING PLATE - INSTALLATION .........................................145 CELECT™ LUBRICATING OIL PRESSURE SENSOR - INSTALLATION............................146 CELECT™ AMBIENT AIR PRESSURE SENSOR - INSTALLATION................................146 CELECT™ ELECTRONIC CONTROL MODULE (ecm) - INSTALLATION............................146 CELECT™ SENSOR HARNESS - INSTALLATION.............................................147 CELECT™ ACTUATOR HARNESS - INSTALLATION...........................................148 STC OIL CONTROL VALVE - INSTALLATION..............................................149 STC EXTERNAL OIL PLUMBING - INSTALLATIONing - Installa-tion.......................150 ENGINE SUPPORT BRACKET, FRONT - INSTALLATION......................................151 VIBRATION DAMPER - INSTALLATION...................................................151 WATER PUMP - INSTALLATION.........................................................153 WATER PUMP BELT - INSTALLATION AND ADJUSTMENT.....................................154 THERMOSTAT HOUSING - INSTALLATION.................................................155 CELECT™ COOLANT TEMPERATURE SENSOR - INSTALLATION.................................155 AIR COMPRESSOR COOLANT INLET AND OUTLET TUBES - INSTALLATION......................155 FAN HUB AND FAN HUB SUPPORT - INSTALLATION........................................156 FAN BELTS - INSTALLATION AND ADJUSTMENT...........................................157 ENGINE - REMOVAL FROM THE REBUILD STAND...........................................158 PISTON COOLING NOZZLES - INSTALLATION.............................................159 DIPSTICK TUBE AND HOUSING - INSTALLATION..........................................160 WATER HEADER COVERS - INSTALLATION................................................160 COOLANT INLET TRANSFER CONNECTION - INSTALLATION..................................160 LUBRICATING OIL COOLER ASSEMBLY - INSTALLATION....................................161 ALTERNATOR MOUNTING BRACKET - INSTALLATION........................................162 ALTERNATOR - INSTALLATION.........................................................162 ALTERNATOR BELTS - INSTALLATION AND ADJUSTMENT....................................162 FAN AND FAN SPACER - INSTALLATION.................................................163 STARTING MOTOR - INSTALLATION.....................................................164 EXHAUST MANIFOLD - INSTALLATION...................................................164 TURBOCHARGER - INSTALLATION.......................................................165 CRANKCASE BREATHER TUBE - INSTALLATION............................................167 LUBRICATING OIL FILTER - INSTALLATION.............................................167 COOLANT FILTER - INSTALLATION.....................................................167 ENGINE - COVERING ALL OPENINGS....................................................168 GROUP 1 - CYLINDER BLOCK .............................................................169 CYLINDER BLOCK - SERVICE TOOLS....................................................171 CYLINDER BLOCK - EXPLODED VIEW....................................................174 CYLINDER BLOCK - GENERAL INFORMATION..............................................176 CYLINDER BLOCK - DISASSEMBLY......................................................177 CAM BORE REAR CUP PLUG - REMOVAL..............................................177 STRAIGHT THREAD PLUG AND PIPE PLUG - REMOVAL..................................177 DOWEL PIN - REMOVAL...........................................................178 CAMSHAFT BUSHINGS - REMOVAL...................................................179 CYLINDER BLOCK - CEANING AND INPECTION............................................179 CYLINDER BLOCK - CLEANING.....................................................179 CAMSHAFT BORE - CLEANING......................................................183 CAMSHAFT BORE - INSPECTION....................................................183 MAIN BEARING BORE ALIGNMENT - MEASUREMENT.....................................183 CYLINDER BLOCK - INSPECTION...................................................188 COOLANT PASSAGE - INSPECTION..................................................189 CYLINDER HEAD CAPSCREW HOLES - INSPECTION.....................................189 CYLINDER BLOCK - MACHINING........................................................190 CYLINDER BLOCK - DECK RESURFACING.............................................190 COOLANT PASSAGE - REPAIRING...................................................191 CYLINDER HEAD CAPSCREW HOLES - REPAIRING......................................194 CYLINDER BLOCK COUNTERBORE - INSPECTION AND MACHINING.............................198 CYLINDER BLOCK - ASSEMBLY ........................................................198 CAMSHAFT BUSHINGS - INSTALLATION..............................................198 DOWEL PIN - INSTALLATION......................................................202 STRAIGHT THREAD PLUG AND PIPE PLUG - INSTALLATION.............................202 CAM BORE REAR CUP PLUG - INSTALLATION.........................................204 CYLINDER LINERS - CLEANING AND INSPECTION.........................................204 CLEANING......................................................................204 INSPECTION....................................................................206 PISTONS - CLEANING AND INSPECTION.................................................209 CLEANING......................................................................209 INSPECTION....................................................................210 CONNECTING ROD ASSEMBLIES - CLEANING AND INSPECTION...............................211 CLEANING......................................................................211 INSPECTION....................................................................212 CONNECTING ROD RING DOWELS - REMOVAL..........................................215 CONNECTING ROD RING DOWELS - INSTALLATION.....................................215 CONNECTING RODS - BEND AND TWIST INSPECTION.......................................215 FIXTURE - CALIBRATION.........................................................215 ALIGNMENT - INSPECTION........................................................216 TWIST - INSPECTION............................................................217 CONNECTING ROD BEARINGS - CLEANING AND INSPECTION.................................217 CLEANING......................................................................217 INSPECTION....................................................................217 CRANKSHAFT ADAPTER - CLEANING AND INSPECTION......................................219 CLEANING......................................................................219 INSPECTION....................................................................219 CRANKSHAFT PULLEY - CLEANING AND INSPECTION.......................................220 CLEANING......................................................................220 INSPECTION....................................................................220 VIBRATION DAMPER - CLEANING AND INSPECTION........................................221 CLEANING......................................................................221 INSPECTION....................................................................222 CRANKSHAFT - CLEANING AND INSPECTION..............................................222 CLEANING......................................................................222 INSPECTION....................................................................223 CRANKSHAFT GEAR - REPLACEMENT.....................................................227 REMOVAL.......................................................................227 INSPECTION....................................................................228 INSTALLATION..................................................................229 CRANKSHAFT BEARINGS - CLEANING AND INSPECTION.....................................230 MAIN BEARING - CLEANING.......................................................230 MAIN BEARING - INSPECTION.....................................................230 THRUST BEARING - INSPECTION...................................................231 CAMSHAFT - CLEANING AND INSPECTION................................................231 CLEANING......................................................................231 INSPECTION....................................................................232 CAMSHAFT GEAR - REPLACEMENT.......................................................233 REMOVAL.......................................................................233 CLEANING......................................................................234 INSPECTION....................................................................234 INSTALLATION..................................................................236 GEAR COVER - CLEANING AND INSPECTION..............................................237 CLEANING......................................................................237 INSPECTION....................................................................238 ACCESSORY DRIVE BUSHING - REPLACEMENT.........................................239 REAR COVER - CLEANING AND INSPECTION..............................................240 CLEANING......................................................................241 INSPECTION....................................................................241 MAGNETIC CRACK INSPECTION ........................................................242 GROUP 2 - CYLINDER HEAD ..............................................................243 CYLINDER HEAD - SERVICE TOOLS.....................................................244 CYLINDER HEA D - EXPLODED VIEW....................................................248 CYLINDER HEAD - GENERAL INFORMATION...............................................249 CYLINDER HEAD - CLEANING AND INSPECTION FOR REUSE.................................250 CLEANING......................................................................250 INSPECTION....................................................................251 CYLINDER HEAD - REBUILD...........................................................252 DISASSEMBLY...................................................................252 CLEANING......................................................................254 INSPECTION....................................................................256 GRINDING THE VALVE SEATS......................................................259 ASSEMBLY......................................................................263 CYLINDER HEAD - REPLACING THE VALVE GUIDES........................................267 DISASSEMBLY...................................................................267 CLEANING......................................................................267 INSPECTION....................................................................267 ASSEMBLY......................................................................268 CYLINDER HEAD - RING DOWEL REPLACEMENT............................................269 REMOVAL.......................................................................269 INSTALLATION..................................................................269 CYLINDER HEAD - REPLACING THE VALVE SEAT INSERTS..................................269 DISASSEMBLY...................................................................269 CLEANING......................................................................269 INSPECTION....................................................................270 ASSEMBLY......................................................................270 CYLINDER HEAD - GRINDING THE VALVES...............................................271 CLEANING......................................................................271 INSPECTION....................................................................272 CYLINDER HEAD - REPLACING THE INJECTOR SLEEVES....................................273 DISASSEMBLY...................................................................273 CLEANING AND INSPECTION.......................................................273 ASSEMBLY......................................................................274 CYLINDER HEAD - PRESSURE TESTING..................................................277 CYLINDER HEAD - MAGNETIC PARTICLE CHECKING........................................279 CYLINDER HEAD - VACUUM TESTING VALVE SEATING FOR REUSE............................280 CYLINDER HEAD - VALVES - MAGNETIC CRACK INSPECTION................................282 VALVE CROSSHEAD - CLEANING AND CHECKING FOR REUSE.................................283 CLEANING......................................................................283 INSPECTION....................................................................283 VALVE CROSSHEAD - MAGNETIC CRACK INSPECTION.......................................284 GROUP 3 - ROCKER LEVER HOUSING ASSEMBLY ..............................................285 ROCKER LEVER HOUSING ASSEMBLY - SERVICE TOOLS.....................................286 ROCKER LEVER HOUSING COVER - EXPLODED VIEW........................................287 ROCKER LEVER HOUSING ASSEMBLY - EXPLODED VIEW.....................................288 WATER MANIFOLD PLUMBING - EXPLODED VIEW...........................................290 ROCKER LEVER HOUSING ASSEMBLY - GENERAL INFORMATION...............................291 ROCKER LEVER - CLEANING AND INSPECTION FOR REUSE..................................292 DISASSEMBLY...................................................................292 CLEANING AND INSPECTION.......................................................292 ASSEMBLY......................................................................295 ROCKER LEVER BUSHING - REPLACEMENT................................................296 DISASSEMBLY...................................................................296 INSPECTION....................................................................297 ASSEMBLY......................................................................297 ROCKER LEVER - MAGNETIC CRACK INSPECTION..........................................298 ROCKER HOUSING COVERS - CLEANING AND INSPECTION FOR REUSE.........................298 CLEANING......................................................................298 INSPECTION....................................................................299 ROCKER LEVER HOUSING ASSEMBLY - CLEANING AND INSPECTION FOR REUSE.................299 WATER MANIFOLD TUBE - REMOVAL.................................................299 CLEANING......................................................................301 INSPECTION....................................................................301 INSTALLATION..................................................................302 STC OIL PLUMBING - CLEANING AND INSPECTION FOR REUSE..............................303 RING AND PIN DOWEL - REPLACEMENT..................................................304 REMOVAL.......................................................................304 INSTALLATION..................................................................305 METRI-PACK PASS THROUGH CONNECTOR - REPLACEMENT...................................305 REMOVAL.......................................................................305 INSTALLATION..................................................................306 GROUP 4 - CAM FOLLOWER ASSEMBLY.......................................................307 CAM FOLLOWER ASSEMBLY - SERVICE TOOLS.............................................308 CAM FOLLOWER ASSEMBLY - EXPLODED VIEW.............................................309 CAM FOLLOWER ASSEMBLY - GENERAL INFORMATION.......................................310 CAM FOLLOWER ASSEMBLY - CLEANING AND INSPECTION FOR REUSE.........................311 CLEANING......................................................................311 INSPECTION....................................................................311 CAM FOLLOWER ASSEMBLY - REBUILD...................................................313 DISASSEMBLY...................................................................313 CLEANING......................................................................314 INSPECTION....................................................................314 ASSEMBLY......................................................................317 CAM FOLLOWER LEVER - ROLLER REPLACEMENT...........................................318 DISASSEMBLY...................................................................318 CLEANING......................................................................319 INSPECTION MAGNETIC CRACK.....................................................319 INSPECTION - DIMENSIONAL......................................................319 ASSEMBLY......................................................................321 CAM FOLLOWER SOCKET - REPLACEMENT.................................................323 PUSH ROD - CLEANING AND INSPECTION FOR REUSE......................................324 CLEANING......................................................................324 INSPECTION....................................................................324 GROUP 5 - FUEL SYSTEM ................................................................326 FUEL PUMP - GENERAL INFORMATION...................................................327 FUEL PUMP - CLEANING AND INSPECTION FOR REUSE.....................................328 CLEANING - PT FUEL PUMP.......................................................328 CLEANING - CELECT™ FUEL PUMP..................................................329 INSPECTION - PT FUEL PUMP.....................................................329 INSPECTION - CELECT™ FUEL PUMP...............................................331 FUEL PUMP - REBUILD...............................................................332 PT............................................................................332 CELECT™.......................................................................332 FUEL PUMP - CALIBRATION ..........................................................332 GROUP 6 - INJECTORS AND FUEL LINES ...................................................334 INJECTOR - PT (TYPE D) STEP TIMING CONTROL - EXPLODED VIEW........................335 INJECTOR - CELECT - EXPLODED VIEW.................................................337 INJECTORS - PT (TYPE D) STEP TIMING CONTROL (STC) GENERAL INFORMATION.............338 INJECTORS - CELECT - GENERAL INFORMATION..........................................338 STEP TIMING CONTROL (STC) OIL CONTROL VALVE - GENERAL INFORMATION.................338 INJECTORS - CLEANING THE EXTERIOR AND INSPECTION FOR REUSE........................339 CLEANING STC..................................................................339 CLEANING CELECT...............................................................339 INSPECTION STC................................................................339 INSPECTION - CELECT...........................................................340 INJECTORS - REBUILD...............................................................341 INJECTORS - CALIBRATION...........................................................341 STC OIL CONTROL VALVE - CLEANING..................................................341 FUEL TUBES, FITTINGS, AND MOUNTING PARTS - CLEANING AND INSPECTION FOR REUSE......342 CLEANING......................................................................342 INSPECTION....................................................................342 GROUP 7 - LUBRICATING OIL SYSTEM......................................................343 LUBRICATING OIL SYSTEM - SERVICE TOOLS............................................344 LUBRICATING OIL SYSTEM - EXPLODED VIEW............................................345 LUBRICATING OIL PUMP ASSEMBLY - EXPLODED VIEW.....................................346 LUBRICATING OIL COOLER - EXPLODED VIEW............................................347 LUBRICATING OIL SYSTEM - GENERAL INFORMATION......................................349 LUBRICATING OIL PAN - CLEANING AND INSPECTION FOR REUSE...........................350 CLEANING......................................................................350 INSPECTION....................................................................350 LUBRICATING OIL TRANSFER TUBE - CLEANING AND INSPECTION FOR REUSE.................351 CLEANING......................................................................351 INSPECTION....................................................................351 LUBRICATING OIL DIPSTICK AND DIPSTICK TUBE - CLEANING AND INSPECTION FOR REUSE....351 CLEANING......................................................................351 INSPECTION....................................................................351 LUBRICATING OIL DIPSTICK - CALIBRATION............................................351 LUBRICATING OIL PUMP - CLEANING AND INSPECTION FOR REUSE..........................352 CLEANING......................................................................352 INSPECTION....................................................................353 LUBRICATING OIL PUMP - REBUILD....................................................353 DISASSEMBLY...................................................................353 CLEANING......................................................................355 INSPECTION....................................................................355 ASSEMBLY......................................................................358 LUBRICATING OIL PUMP BODY AND COVER BUSHING - REPLACEMENT.........................361 DISASSEMBLY...................................................................361 INSPECTION....................................................................361 ASSEMBLY......................................................................362 LUBRICATING OIL PUMP DRIVEN GEAR BUSHING - REPLACEMENT............................367 DISASSEMBLY...................................................................367 INSPECTION....................................................................367 ASSEMBLY......................................................................367 LUBRICATING OIL PUMP DRIVE GEAR OR SHAFT - REPLACEMENT............................368 DISASSEMBLY...................................................................368 INSPECTION....................................................................368 ASSEMBLY......................................................................369 LUBRICATING OIL PUMP DRIVEN SHAFT - REPLACEMENT...................................369 DISASSEMBLY...................................................................369 INSPECTION....................................................................369 ASSEMBLY......................................................................370 LUBRICATING OIL COOLER ASSEMBLY REBUILD...........................................370 DISASSEMBLY...................................................................370 CLEANING......................................................................373 INSPECTION....................................................................373 TESTING - OIL COOLER CORE.....................................................375 TESTING - LUBRICATING OIL FILTER BYPASS VALVE POPPET VALVE SPRING.............377 ASSEMBLY......................................................................377 INSTALLATION - OIL COOLER CORE................................................378 INSTALLATION - LUBRICATING OIL FILTER BYPASS VALVE............................380 GROUP 8 - COOLING SYSTEM .............................................................381 COOLING SYSTEM - SERVICE TOOLS....................................................382 N14 WATER PUMP AND IDLER ASSEMBLY - EXPLODED VIEW.................................384 WATER PUMP AND IDLER ASSEMBLY - GENERAL INFORMATION...............................385 WATER PUMP ASSEMBLY...............................................................386 CLEANING......................................................................386 INSPECTION....................................................................386 WATER PUMP ASSEMBLY - REBUILD.....................................................387 DISASSEMBLY...................................................................387 CLEANING......................................................................388 INSPECTION....................................................................389 ASSEMBLY......................................................................391 WATER PUMP IDLER ASSEMBLY - CLEANING AND INSPECTION...............................394 CLEANING......................................................................394 INSPECTION....................................................................395 WATER PUMP IDLER ASSEMBLY - REBUILD...............................................395 DISASSEMBLY...................................................................395 CLEANING......................................................................396 INSPECTION....................................................................396 ASSEMBLY......................................................................397 THERMOSTAT HOUSING - CLEANING AND INSPECTION......................................399 DISASSEMBLY...................................................................399 CLEANING......................................................................400 INSPECTION....................................................................400 ASSEMBLY......................................................................402 COOLANT FILTER HEAD INSERT........................................................403 COOLANT FILTER SHUTOFF VALVE......................................................403 FAN - CLEANING AND INSPECTION.....................................................403 CLEANING......................................................................403 INSPECTION....................................................................403 WATER TRANSFER TUBES - CLEANING AND INSPECTION....................................404 CLEANING......................................................................404 INSPECTION....................................................................404 GROUP 9 - DRIVE UNITS ................................................................405 DRIVE UNITS - SERVICE TOOLS.......................................................406 ACCESSORY DRIVE - EXPLODED VIEW...................................................407 DRIVE UNITS - GENERAL INFORMATION.................................................408 ACCESSORY DRIVE...............................................................408 ACCESSORY DRIVE - CLEANING AND INSPECTION FOR REUSE...............................409 CLEANING......................................................................409 INSPECTION....................................................................409 ACCESSORY DRIVE - REBUILD ........................................................409 DISASSEMBLY...................................................................409 CLEANING......................................................................410 INSPECTION....................................................................410 ASSEMBLY......................................................................412 ACCESSORY DRIVE GEAR - REPLACEMENT ...............................................414 DISASSEMBLY...................................................................414 CLEANING......................................................................414 INSPECTION....................................................................414 ASSEMBLY......................................................................415 ACCESSORY DRIVE PULLEY - CLEANING AND INSPECTION FOR REUSE........................417 CLEANING......................................................................417 INSPECTION....................................................................417 ACCESSORY DRIVE PULLEY WEAR SLEEVE - REPLACEMENT..................................417 REMOVAL.......................................................................417 CLEANING AND INSPECTION.......................................................418 INSTALLATION..................................................................419 GROUP 10 - INTAKE AIR SYSTEM .........................................................420 SERVICE TOOLS.....................................................................421 INTAKE AIR SYSTEM - EXPLODED VIEW.................................................422 INTAKE AIR SYSTEM - GENERAL INFORMATION...........................................423 TURBOCHARGER - CLEANING AND INSPECTION............................................424 CLEANING......................................................................424 INSPECTION....................................................................424 TURBOCHARGER SHAFT AXIAL CLEARANCE CHECKING ......................................426 TURBOCHARGER BEARING RADIAL CLEARANCE - CHECKING..................................426 INTAKE AIR PIPING - ELBOWS........................................................427 INSPECTION....................................................................427 INTAKE MANIFOLD - CLEANING AND INSPECTION.........................................427 CLEANING......................................................................427 INSPECTION....................................................................427 GROUP 11 - EXHAUST SYSTEM ............................................................428 EXHAUST SYSTEM - EXPLODED VIEW....................................................429 EXHAUST SYSTEM - GENERAL INFORMATION..............................................430 EXHAUST MANIFOLD - CLEANING AND INSPECTION FOR REUSE..............................431 DISASSEMBLY...................................................................431 CLEANING......................................................................431 INSPECTION....................................................................431 ASSEMBLY......................................................................431 EXHAUST MANIFOLD TURBOCHARGER MOUNTING STUD - REPLACEMENT (11-02).................432 MOUNTING HOLE THREADS - INSPECTION............................................432 GROUP 12 - AIR EQUIPMENT..............................................................433 AIR EQUIPMENT - GENERAL INFORMATION...............................................434 AIR COMPRESSOR................................................................434 AIR COMPRESSOR - CLEANING AND INSPECTION FOR REUSE................................435 CLEANING......................................................................435 INSPECTION....................................................................435 GROUP 13 - ELECTRICAL EQUIPMENT ......................................................437 ELECTRICAL EQUIPMENT - GENERAL INFORMATION........................................438 WIRING DIAGRAMS...............................................................439 ALTERNATOR BRACKET - CLEANING AND INSPECTION FOR REUSE ...........................439 CLEANING......................................................................439 INSPECTION....................................................................439 ALTERNATOR ADJUSTING LINK - CLEANING AND INSPECTION FOR REUSE.....................439 CLEANING......................................................................439 INSPECTION....................................................................439 STARTING MOTOR - CLEANING AND INSPECTION FOR REUSE ...............................439 CLEANING......................................................................439 INSPECTION....................................................................440 GROUP 14 - ENGINE TESTING ............................................................441 GENERAL INFORMATION...............................................................442 IN-CHASSIS RUN-IN.............................................................442 ENGINE DYNAMOMETER RUN-IN.....................................................442 CHASSIS DYNAMOMETER, PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN.................442 DEFINITION OF TERMS ON ENGINE PERFORMANCE CURVE...................................443 GENERAL RUN-IN PROCEDURES.........................................................444 GENERAL ENGINE TEST/RUN-IN SPECIFICATIONS.........................................446 ENGINE TESTING - SERVICE TOOLS....................................................447 ENGINE DYNAMOMETER - INSTALL ENGINE ..............................................449 FUEL RATE.....................................................................452 FUEL INLET RESTRICTION........................................................452 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER.................................452 FUEL PRESSURE.................................................................453 FUEL DRAIN LINE RESTRICTION...................................................453 ELECTRONIC HOOKUP - CELECT ENGINES ONLY.......................................454 PRIMING THE LUBRICATING OIL AND FUEL SYSTEMS......................................458 LUBRICATING OIL SYSTEM PRIMING................................................458 FUEL SYSTEM PRIMING - PT SYSTEM...............................................462 FUEL SYSTEM PRIMING - CELECT SYSTEM...........................................463 ENGINE RUN-IN PROCEDURE - ENGINE DYNAMOMETER......................................464 CHASSIS DYNAMOMETER OPERATION.....................................................469 GENERAL TEST PROCEDURE - CHASSIS DYNAMOMETER......................................471 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER.................................472 FUEL PRESSURE (STC ENGINES ONLY)..............................................472 FUEL RATE.....................................................................473 FUEL INLET RESTRICTION........................................................473 FUEL DRAIN LINE RESTRICTION...................................................474 INTAKE MANIFOLD PRESSURE......................................................474 CHARGE AIR COOLER RESTRICTION.................................................475 INTAKE AIR RESTRICTION........................................................475 EXHAUST AIR RESTRICTION.......................................................476 ENGINE BLOWBY.................................................................476 LUBRICATING OIL PRESSURE......................................................477 COOLANT PRESSURE..............................................................477 ENGINE RUN-IN PROCEDURE - CHASSIS DYNAMOMETER.....................................478 ENGINE RUN-IN PROCEDURE WITHOUT DYNAMOMETER.......................................481 ON-HIGHWAY....................................................................481 OFF-HIGHWAY...................................................................481 ENGINE PAINTING ..................................................................482 ENGINE STORAGE - SHORT TERM.......................................................483 REMOVE THE ENGINE FROM SHORT TERM STORAGE.....................................485 ENGINE STORAGE - LONG TERM .......................................................485 REMOVE THE ENGINE FROM LONG TERM STORAGE......................................487 GROUP 15 - INSTRUMENTS AND CONTROLS...................................................489 INSTRUMENTS AND CONTROLS - GENERAL INFORMATION....................................490 GROUP 16 - MOUNTING ADAPTATIONS.......................................................492 MOUNTING ADAPTATIONS .............................................................493 SERVICE TOOLS.................................................................493 EXPLODED VIEW.................................................................494 GENERAL INFORMATION...........................................................495 FLYWHEEL..........................................................................496 CLEANING AND INSPECTION FOR REUSE.............................................496 CLEANING......................................................................496 INSPECTION....................................................................496 FLYWHEEL RING GEAR................................................................497 REPLACEMENT...................................................................497 FLYWHEEL HOUSING - CLEANING AND INSPECTION FOR REUSE..............................497 CLEANING......................................................................497 INSPECTION....................................................................498 REDOWEL TO CYLINDER BLOCK.....................................................498 FRONT ENGINE SUPPORT BRACKET - CLEANING AND INSPECTION FOR REUSE..................504 CLEANING......................................................................504 INSPECTION....................................................................504 GROUP 18 - SPECIFICATIONS.............................................................505 GENERAL ENGINE SPECIFICATIONS.....................................................507 GENERAL ENGINE DATA...........................................................507 INTAKE SYSTEM.................................................................507 LUBRICATION SYSTEM............................................................507 COOLING SYSTEM................................................................508 EXHAUST SYSTEM................................................................508 FUEL SYSTEM...................................................................508 ELECTRICAL SYSTEM.............................................................508 CAPSCREW MARKINGS AND TORQUE VALUES...............................................509 CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY..........................509 PIPE PLUG TORQUE VALUES...........................................................510 DECIMAL AND METRIC EQUIVALENTS....................................................511 SPECIFICATIONS - GENERAL INFORMATION..............................................512 ENGINE ASSEMBLY...................................................................513 SPECIFICATIONS................................................................513 CAPSCREW TORQUE VALUES........................................................518 CYLINDER BLOCK....................................................................533 REBUILD SPECIFICATIONS........................................................533 TORQUE VALUES.................................................................541 CYLINDER HEAD.....................................................................542 REBUILD SPECIFICATIONS........................................................542 CYLINDER HEAD - TORQUE VALUES.................................................547 ROCKER LEVER HOUSING ASEMBLY .....................................................548 REBUILD SPECIFICATIONS........................................................548 TORQUE VALUES.................................................................549 CAM FOLLOWER ASSEMBLY.............................................................550 REBUILD SPECIFICATIONS........................................................550 FIXED INJECTION TIMING....................................................550 MVT INJECTION TIMING......................................................550 TORQUE VALUES.................................................................555 FUEL PUMP - REBUILD SPECIFICATIONS................................................556 INJECTORS - REBUILD SPECIFICATIONS................................................556 LUBRICATING OIL SYSTEM............................................................557 CAPACITIES....................................................................557 TORQUE VALUES.................................................................559 LUBRICATING OIL PUMP - INSPECTION SPECIFICATIONS..................................557 WATER PUMP ASSEMBLY - REBUILD SPECIFICATIONS......................................561 FAN HUB - INSPECTION SPECIFICATIONS...............................................562 THERMOSTAT HOUSING ASSEMBLY - REBUILD SPECIFICATIONS..............................563 THERMOSTAT (RESERVE FLOW COOLING) - OPERATING TEMPERATURE.........................564 COOLING SYSTEM - TORQUE VALUES....................................................566 FUEL PUMP AND COMPRESSOR DRIVE....................................................568 REBUILD SPECIFICATIONS........................................................568 TORQUE VALUES.................................................................569 TURBOCHARGER - INSPECTION SPECIFICATIONS..........................................570 AIR COMPRESSOR - INSPECTION SPECIFICATIONS........................................570 ENGINE TESTING - TEST SPECIFICATIONS..............................................571 VEHICLE BRAKING - REBUILD SPECIFICATIONS..........................................571 GROUP 20 - VEHICLE BRAKING ...........................................................572 VEHICLE BRAKING - GENERAL INFORMATION.............................................573 JACOBS ENGINE BRAKE...........................................................573 CUMMINS C BRAKE...............................................................573 COMPONENTS MANUFACTURERS: NAMES AND ADDRESSES.........................................574 SERVICE LITERATURE....................................................................577 ADDITIONAL SERVICE LITERATURE.....................................................578 SERVICE LITERATURE ORDERING LOCATION..............................................579 SERVICE PUBLICATIONS ORDER FORM...................................................580 INDEX.................................................................................582 LITERATURE SURVEY FORM................................................................587
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