Cummins M11 Series Engine Shop Manual – PDF DOWNLOAD 

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Cummins M11 Series Engine Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Cummins M11 Series Engine Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 585
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Cummins M11 Series Engine Shop Manual – PDF DOWNLOAD 

Foreword:

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 Shop Manual – PDF DOWNLOAD 

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

S.V 12/12/24