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Cummins M11 Series Engine (STC, CELECT™, CELECT™ Plus Models) Troubleshooting & Repair Manual – PDF DOWNLOAD
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Cummins M11 Series Engine (STC, CELECT™, CELECT™ Plus Models) Troubleshooting & Repair Manual – PDF DOWNLOAD
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Description
Cummins M11 Series Engine (STC, CELECT™, CELECT™ Plus Models) Troubleshooting & Repair Manual – PDF DOWNLOAD
FILE DETAILS:
Cummins M11 Series Engine (STC, CELECT™, CELECT™ Plus Models) Troubleshooting & Repair Manual – PDF DOWNLOAD
Language : English
Pages : 926
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Cummins M11 Series Engine (STC, CELECT™, CELECT™ Plus Models) Troubleshooting & Repair Manual – PDF DOWNLOAD
Foreword:
- This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and
assembly rebuild procedures are provided in the engine shop manual. Refer to Section i – Introduction for instructions
on how to use this manual. - Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
– Introduction. - The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures. - A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can
be ordered by filling out and mailing the Literature Order Form located in Section L – Service Literature. - The repair procedures used in this manual are recommended by Cummins Engine Co., Inc. Some service procedures
require the use of special service tools. Use the correct tools as described. - Cummins Engine Company, Inc. encourages the user of this manual to report errors, omissions, and recommendations
for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for
communicating your comments.
About this Manual:
- This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine related problems and
to provide recommended repair procedures. - The material in this manual covers all M11 Series engines. The manual is divided into sections. Each section is
equivalent to a group used in Cummins’ filmcard system. Some sections contain reference numbers and procedure
numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. - Procedure numbers are used to identify and reference specific repair procedures for correcting the problem.
- This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The
troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are
in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be
performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the
back of the manual to locate specific topics when not using the troubleshooting trees. - This manual covers all base engine repair procedures and some fuel system repair procedures for the STC fuel system.
Repair procedures and fault code diagnosis for the electronic fuel systems (CELECT™ and CELECT™ Plus) is covered
in Troubleshooting and Repair Manual, Bulletin No. 3666130.
How to Use the Manual:
This manual is organized to provide an easy flow from problem identification to problem correction. A list of troubleshooting
symptoms containing the most common engine problems is in the Troubleshooting Symptoms, Section (TS).
The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the
end user to the correct procedure for making the repair. Complete the following steps to locate and correct the problem.
(Step 1) Locate the symptom on the Section Contents pages of Section TS.
Reference to the page number where the Troubleshooting Symptom Tree is found is made
to the right of the symptom tree title.
(Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a probable
cause of the problem, starting at the top with the simplest and easiest to repair, and continuing
downward to the most difficult.
The right column of boxes provides a brief description of the corrective action with a reference
number to the correct procedure used to make the repair.
(Step 3) Locate the probable cause in the left column then turn to the procedure referenced in the right column.
(Step 4) The Troubleshooting Symptom Charts are based on the following assumptions:
1. The engine has been installed according to the manufacturer’s specifications.
2. The easiest repairs are done first.
TABLE OF CONTENTS:
Cummins M11 Series Engine (STC, CELECT™, CELECT™ Plus Models) Troubleshooting & Repair Manual – PDF DOWNLOAD
MAIN MENU....................................................................................................... 0 COVER PAGE...................................................................................................... 1 TABLE OF CONTENTS............................................................................................... 3 INTRODUCTION.................................................................................................... 5 ABOUT THIS MANUAL........................................................................................... 6 ACRONYMS AND ABBREVIATIONS.................................................................................. 15 GENERAL CLEANING INSTRUCTIONS............................................................................... 14 GLASS OR PLASTIC BEAD CLEANING.......................................................................... 14 SOLVENT AND ACID CLEANING............................................................................... 14 STEAM CLEANING.......................................................................................... 14 GENERAL REPAIR INSTRUCTIONS................................................................................. 13 WELDING ON A VEHICLE WITH AND ELECTRONIC CONTROLLED FUEL SYSTEM......................................... 13 GENERAL SAFETY INSTRUCTIONS................................................................................. 12 IMPORTANT SAFETY NOTICE................................................................................. 12 HOW TO USE THE MANUAL....................................................................................... 6 ILLUSTRATIONS............................................................................................... 11 SYMBOLS..................................................................................................... 7 ENGINE IDENTIFICATION........................................................................................... 16 ENGINE DIAGRAMS............................................................................................. 22 ENGINE IDENTIFICATION....................................................................................... 17 CUMMINS ENGINE NOMENCLATURE............................................................................. 18 ECM DATAPLATE........................................................................................... 17 ENGINE DATAPLATE........................................................................................ 17 FUEL PUMP DATAPLATE..................................................................................... 17 SPECIFICATIONS.............................................................................................. 19 AIR INTAKE SYSTEM....................................................................................... 21 BATTERIES (SPECIFIC GRAVITY)............................................................................ 21 COOLING SYSTEM.......................................................................................... 20 ELECTRICAL SYSTEM....................................................................................... 21 EXHAUST SYSTEM.......................................................................................... 21 FUEL SYSTEM............................................................................................. 20 GENERAL SPECIFICATIONS.................................................................................. 19 LUBRICATING OIL SYSTEM.................................................................................. 20 TROUBLESHOOTING SYMPTOMS........................................................................................ 25 PROCEDURES AND TECHNIQUES................................................................................... 27 TROUBLESHOOTING SYMPTOMS CHARTS............................................................................. 27 AIR COMPRESSOR AIR PRESSURE RISES SLOWLY................................................................ 28 AIR COMPRESSOR CYCLES FREQUENTLY........................................................................ 29 AIR COMPRESSOR NOISE IS EXCESSIVE....................................................................... 30 AIR COMPRESSOR PUMPING EXCESS LUBRICATING OIL INTO THE AIR SYSTEM....................................... 31 AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)....................... 33 AIR COMPRESSOR WILL NOT PUMP AIR........................................................................ 34 AIR COMPRESSOR WILL NOT STOP PUMPING.................................................................... 35 ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING........................................................ 36 ALTERNATOR OVERCHARGING................................................................................. 38 COMMUNICATION ERROR - ELECTRONIC SERVICE TOOL OR CONTROL DEVICE......................................... 39 CONNECTING ROD BEARING NOISE............................................................................162 COOLANT IN THE LUBRICATING OIL......................................................................... 42 COOLANT LOSS (EXTERNAL)................................................................................. 43 COOLANT LOSS - INTERNAL................................................................................. 45 COOLANT TEMPERATURE ABOVE NORMAL - GRADUAL OVERHEAT..................................................... 46 COOLANT TEMPERATURE IS ABOVE NORMAL - SUDDEN OVERHEAT................................................... 49 COOLANT TEMPERATURE IS BELOW NORMAL..................................................................... 51 CRANKCASE GASES (BLOWBY) EXCESSIVE...................................................................... 53 CRANKING FUEL PRESSURE IS LOW........................................................................... 54 DRIVEABLITY - GENERAL INFORMATION.......................................................................163 DRIVEABLITY /LOW POWER - CUSTOMER COMPLAINT FORM........................................................165 DRIVEABILITY/LOW POWER/EXCESSIVE FUEL CONSUMPTION - CHECKLIST...........................................166 ENGINE ACCELERATION OR RESPONSE POOR.................................................................... 56 ENGINE BRAKE DOES NOT OPERATE (CELECT OR CELECT PLUS)................................................... 61 ENGINE BRAKE - LOW RETARDING POWER OR SLOW TO ACTIVATE (CELECT OR CELECT PLUS).......................... 63 ENGINE BRAKE - ONE OR MORE CYLINDERS BRAKING WITH POWER SWITCH OFF (CELECT OR CELECT PLUS).............. 65 ENGINE DECELERATES SLOWLY (CELECT AND CELECT PLUS)...................................................... 67 ENGINE DECELERATES SLOWLY (PT).......................................................................... 68 ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE)............................................. 69 ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE).......................................... 72 ENGINE NOISE DIAGNOSTIC PROCEDURES - GENERAL INFORMATION................................................162 ENGINE NOISE EXCESSIVE.................................................................................. 75 ENGINE NOISE EXCESSIVE - COMBUSTION KNOCKS.............................................................. 78 ENGINE NOISE EXCESSIVE - CONNECTING ROD................................................................. 79 ENGINE NOISE EXCESSIVE - MAIN BEARING................................................................... 80 ENGINE NOISE EXCESSIVE - PISTON......................................................................... 82 ENGINE NOISE EXCESSIVE - TURBOCHARGER................................................................... 83 ENGINE POWER OUTPUT LOW (CELECT OR CELECT PLUS)......................................................... 84 ENGINE POWER OUTPUT LOW (PT)............................................................................ 90 ENGINE RUNS ROUGH AT IDLE............................................................................... 94 ENGINE RUNS ROUGH OR MISFIRES........................................................................... 97 ENGINE SHUTS OFF UNEXPECTEDLY OR DIES DURING DECELERATION............................................... 99 ENGINE SPEED SURGES AT LOW OR HIGH IDLE.................................................................102 ENGINE SPEED SURGES UNDER LOAD OR IN OPERATING RANGE....................................................105 ENGINE STARTS BUT WILL NOT KEEP RUNNING.................................................................108 ENGINE VIBRATION EXCESSIVE..............................................................................110 ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)....................................................112 ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)...............................................114 ENGINE WILL NOT SHUT OFF................................................................................116 FUEL CONSUMPTION EXCESSIVE (CELECT AND CELECT PLUS).....................................................118 FUEL CONSUMPTION EXCESSIVE (PT).........................................................................122 FUEL CONSUMPTION - CUSTOMER COMPLAINT FORM.............................................................168 FUEL CONSUMPTION - GENERAL INFORMATION..................................................................167 FUEL IN THE COOLANT.....................................................................................126 FUEL IN THE LUBRICATING OIL.............................................................................127 INTAKE MANIFOLD AIR TEMPERATURE ABOVE SPECIFICATION.....................................................129 INTAKE MANIFOLD PRESSURE (BOOST) IS BELOW NORMAL........................................................131 LOW IDLE ADJUST SWITCH DOES NOT WORK....................................................................133 LUBRICATING OIL CONSUMPTION EXCESSIVE...................................................................135 LUBRICATING OIL CONTAMINATED............................................................................134 LUBRICATING OIL IN THE FUEL.............................................................................137 LUBRICATING OIL PRESSURE HIGH...........................................................................138 LUBRICATING OIL PRESSURE LOW............................................................................139 LUBRICATING OIL SLUDGE IN THE CRANKCASE EXCESSIVE.......................................................142 LUBRICATING OIL TEMPERATURE ABOVE SPECIFICATION.........................................................144 LUBRICATING OR TRANSMISSION OIL IN THE COOLANT..........................................................145 MAIN BEARING NOISE......................................................................................162 OIL CONSUMPTION.........................................................................................169 OPERATING FUEL PRESSURE IS LOW..........................................................................146 PISTON NOISE............................................................................................162 RESPONSE TEST - CELECT AND CELECT PLUS.................................................................164 SMOKE, BLACK - EXCESSIVE (CELECT AND CELECT PLUS).......................................................147 SMOKE, BLACK - EXCESSIVE (PT)...........................................................................150 SMOKE, WHITE - EXCESSIVE (CELECT AND CELECT PLUS).......................................................152 SMOKE, WHITE - EXCESSIVE (PT)...........................................................................155 STEP TIMING CONTROL (STC) VALVE IS NOT SHIFTING CORRECTLY...............................................157 TURBOCHARGER LEAKS ENGINE OIL OR FUELBVARIABLE SPEED (VS) GOVERNOR - FUEL LEAK AT THE THROTTLE SHAFT....158 VARIABLE SPEED (VS) GOVERNOR - FUEL LEAK AT THE THROTTLE SHAFT..........................................159 VARIABLE SPEED (VS) GOVERNOR - SPEED IS NOT SET CORRECTLY...............................................160 VARIABLE SPEED (VS) GOVERNOR - SURGE WITH ENGINE UNDER LOAD.............................................161 COMPLETE ENGINE - GROUP 00......................................................................................173 COMPLETE ENGINE - GENERAL INFORMATION.......................................................................174 ENGINE INSTALLATION.........................................................................................179 INSTALL.................................................................................................179 ENGINE REMOVAL..............................................................................................176 REMOVE..................................................................................................176 SERVICE TOOLS...............................................................................................175 ENGINE REMOVAL AND INSTALLATION.........................................................................175 CYLINDER BLOCK - GROUP 01.......................................................................................184 ACCESSORY DRIVE SEAL........................................................................................191 CLEAN...................................................................................................192 INSTALL.................................................................................................192 REMOVE..................................................................................................191 ALTERNATOR DRIVE SEAL.......................................................................................190 CLEAN...................................................................................................190 INSTALL.................................................................................................190 REMOVE..................................................................................................190 BEARINGS, CONNECTING ROD....................................................................................192 CLEAN...................................................................................................194 INSPECT FOR REUSE.......................................................................................194 INSTALL.................................................................................................195 REMOVE..................................................................................................192 BEARINGS, MAIN..............................................................................................197 CLEAN...................................................................................................198 INSPECT FOR REUSE.......................................................................................198 INSTALL.................................................................................................199 REMOVE..................................................................................................197 BEARINGS, THRUST............................................................................................202 INSTALL.................................................................................................203 REMOVE..................................................................................................202 CAMSHAFT....................................................................................................205 CLEAN...................................................................................................208 INSPECT FOR REUSE.......................................................................................209 INSTALL.................................................................................................210 REMOVE..................................................................................................205 CAMSHAFT BUSHINGS...........................................................................................214 CLEAN...................................................................................................214 INSPECT FOR REUSE.......................................................................................215 INSTALL.................................................................................................215 NUMBER ONE BUSHING - INSTALLATION...................................................................216 NUMBER SEVEN BUSHING - INSTALLATION.................................................................215 NUMBER SIX THROUGH NUMBER TWO BUSHING - INSTALLATION................................................216 REMOVE..................................................................................................214 CAMSHAFT END CLEARNACE......................................................................................303 MEASURE.................................................................................................303 CAMSHAFT GEAR (CAMSHAFT INSTALLED)..........................................................................218 INSPECT FOR REUSE.......................................................................................219 INSTALL.................................................................................................221 REMOVE..................................................................................................218 CAMSHAFT GEAR (CAMSHAFT REMOVED)............................................................................224 INSTALL.................................................................................................224 REMOVE..................................................................................................224 CONNECTING ROD..............................................................................................227 CLEAN...................................................................................................227 INSPECT FOR REUSE.......................................................................................227 INSTALL.................................................................................................229 REMOVE..................................................................................................227 CRANKSHAFT..................................................................................................229 ROTATION CHECK..........................................................................................229 CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)...............................................................229 CLEAN...................................................................................................230 INSPECT FOR REUSE.......................................................................................230 INSTALL.................................................................................................231 REMOVE..................................................................................................229 CRANKSHAFT PULLEY...........................................................................................233 INSPECT FOR REUSE.......................................................................................233 INSTALL.................................................................................................233 REMOVE..................................................................................................233 CRANKSHAFT SEAL, FRONT......................................................................................234 CLEAN...................................................................................................235 INSTALL.................................................................................................235 REMOVE..................................................................................................234 CRANKSHAFT SEAL, REAR.......................................................................................236 CLEAN...................................................................................................237 INSTALL.................................................................................................237 REMOVE..................................................................................................236 CYLINDER BLOCK AND LINER SEATS..............................................................................238 LEAK TEST...............................................................................................238 CYLINDER LINER..............................................................................................240 CLEAN...................................................................................................242 INSPECT FOR REUSE.......................................................................................242 INSTALL.................................................................................................244 REMOVE..................................................................................................240 CYLINDER LINER PROTRUSION...................................................................................297 MEASURE.................................................................................................298 PREPARATORY.............................................................................................297 GEAR COVER, FRONT...........................................................................................246 CLEAN...................................................................................................248 INSPECT FOR REUSE.......................................................................................249 INSTALL.................................................................................................250 REMOVE..................................................................................................246 GEAR HOUSING, FRONT.........................................................................................253 CLEAN...................................................................................................256 INSPECT FOR REUSE.......................................................................................256 INSTALL.................................................................................................257 REMOVE..................................................................................................253 IDLER GEAR, CAMSHAFT........................................................................................261 CLEAN...................................................................................................262 INSPECT FOR REUSE.......................................................................................262 INSTALL.................................................................................................264 REMOVE..................................................................................................261 IDLER GEAR, HYDRAULIC PUMP..................................................................................266 CLEAN...................................................................................................267 INSPECT.................................................................................................267 INSTALL.................................................................................................269 REMOVE..................................................................................................266 IDLER GEAR, WATER PUMP......................................................................................270 CLEAN...................................................................................................271 INSPECT FOR REUSE.......................................................................................272 INSTALL.................................................................................................274 REMOVE..................................................................................................270 PISTON......................................................................................................276 ASSEMBLE................................................................................................279 CLEAN...................................................................................................276 DISASSEMBLE.............................................................................................276 GENERAL INFORMATION.....................................................................................276 INSPECT FOR REUSE.......................................................................................277 ARTICULATED PISTON..................................................................................277 INSTALL.................................................................................................279 REMOVE..................................................................................................276 PISTON AND CONNECTING ROD ASSEMBLY..........................................................................287 ASSEMBLE................................................................................................292 CLEAN...................................................................................................290 DISASSEMBLE.............................................................................................289 INSPECT FOR REUSE.......................................................................................291 INSTALL.................................................................................................293 REMOVE..................................................................................................287 PISTON COOLING NOZZLE.......................................................................................279 INSPECT FOR REUSE.......................................................................................280 INSTALL.................................................................................................280 REMOVE..................................................................................................279 PISTON RINGS................................................................................................281 INSPECT FOR REUSE.......................................................................................281 SERVICE TOOLS...............................................................................................187 CYLINDER BLOCK..........................................................................................187 VIBRATION DAMPER............................................................................................281 CLEAN...................................................................................................282 ECCENTRICITY CHECK......................................................................................284 INSPECT FOR REUSE.......................................................................................282 INSTALL.................................................................................................283 REMOVE..................................................................................................281 WOBBLE CHECK............................................................................................284 WATER HEADER PLATE, CYLINDER BLOCK..........................................................................284 CLEAN...................................................................................................285 INSPECT FOR REUSE.......................................................................................285 INSTALL.................................................................................................285 REMOVE..................................................................................................284 CYLINDER HEAD - GROUP 02........................................................................................305 CYLINDER HEAD...............................................................................................307 CLEAN...................................................................................................311 INSPECT FOR REUSE.......................................................................................312 INSTALL.................................................................................................318 LEAK TEST...............................................................................................317 PRESSURE TEST...........................................................................................315 REMOVE..................................................................................................307 SERVICE TOOLS...............................................................................................306 CYLINDER HEAD...........................................................................................306 ROCKER LEVERS - GROUP 03........................................................................................326 CRANKCASE BREATHER (INTERNAL)...............................................................................328 CLEAN...................................................................................................328 INSPECT FOR REUSE.......................................................................................328 INSTALL.................................................................................................329 REMOVE..................................................................................................328 OVERHEAD SET................................................................................................329 ADJUST..................................................................................................334 ENGINE BRAKE - ADJUST...............................................................................344 GENERAL INFORMATION.................................................................................334 INJECTOR ADJUSTMENT - CELECT AND CELECT PLUS ENGINES................................................336 INJECTOR ADJUSTMENT -STC ENGINES....................................................................340 VALVE ADJUSTMENT - CELECT AND CELECT PLUS ENGINES...................................................337 VALVE ADJUSTMENT - STC ENGINES......................................................................341 MEASURE.................................................................................................329 GENERAL INFORMATION.................................................................................329 VALVE AND INJECTOR LASH - CELECT AND CELECT PLUS ENGINES............................................331 VALVE LASH - STC ENGINES............................................................................332 ROCKER LEVER ASSEMBLY.......................................................................................345 ASSEMBLE................................................................................................350 ALUMINUM SUPPORTS...................................................................................351 CAST IRON SUPPORTS..................................................................................350 CLEAN...................................................................................................347 DISASSEMBLE.............................................................................................346 GENERAL INFORMATION.....................................................................................345 INSPECT FOR REUSE.......................................................................................348 INSTALL.................................................................................................352 REMOVE..................................................................................................345 ROCKER LEVER COVER..........................................................................................355 CLEAN...................................................................................................355 INSPECT FOR REUSE.......................................................................................355 INSTALL.................................................................................................356 REMOVE..................................................................................................355 ROCKER LEVER HOUSING........................................................................................357 CLEAN...................................................................................................359 INSPECT FOR REUSE.......................................................................................360 INSTALL.................................................................................................360 REMOVE..................................................................................................357 SERVICE TOOLS...............................................................................................327 ROCKER LEVERS...........................................................................................327 CAM FOLLOWERS/TAPPETS - GROUP 04................................................................................365 CAM FOLLOWER ASSEMBLY.......................................................................................367 ASSEMBLE................................................................................................370 CLEAN...................................................................................................368 DISASSEMBLE.............................................................................................368 INSPECT FOR REUSE.......................................................................................368 INSTALL.................................................................................................371 REMOVE..................................................................................................367 PUSH RODS OR TUBES..........................................................................................373 INSPECT FOR REUSE.......................................................................................374 INSTALL.................................................................................................375 REMOVE..................................................................................................373 SERVICE TOOLS...............................................................................................366 CAM/FOLLOWER/TAPPETS....................................................................................366 FUEL SYSTEM - GROUP 05..........................................................................................378 FLOW DIAGRAM, FUEL SYSTEM...................................................................................384 FUEL CONSUMPTION............................................................................................393 MEASURE.................................................................................................393 FUEL FLOW...................................................................................................396 INITIAL CHECK...........................................................................................396 LEAK TEST...............................................................................................398 PRESSURE TEST...........................................................................................397 MINIMUM CRANKING PRESSURE...........................................................................397 MINIMUM OPERATING PRESSURE..........................................................................397 FUEL PUMP...................................................................................................399 CLEAN...................................................................................................400 INSPECT FOR REUSE.......................................................................................401 INSTALL.................................................................................................401 CELECT OR CELECT PLUS...............................................................................401 STC.................................................................................................402 PRIME...................................................................................................403 CELECT OR CELECT PLUS...............................................................................403 GENERAL INFORMATION.................................................................................403 STC.................................................................................................404 REMOVE..................................................................................................399 CELECT OR CELECT PLUS...............................................................................399 STC.................................................................................................399 ROTATION CHECK..........................................................................................405 FUEL PUMP GEAR PUMP CHECK VALVE.............................................................................406 INSTALL.................................................................................................407 REMOVE..................................................................................................406 FUEL PUMP HIGH IDLE SPEED (VS GOVERNOR).....................................................................407 ADJUST..................................................................................................407 HIGH SPEED..........................................................................................408 IDLE SPEED..........................................................................................407 FUEL PUMP IDLE SPEED........................................................................................408 ADJUSTMENT..............................................................................................408 FUEL PUMP PRESSURE REGULATOR................................................................................423 INITIAL CHECK...........................................................................................423 FUEL PUMP PULSATION DAMPER..................................................................................410 INSPECTION FOR REUSE....................................................................................410 FUEL PUMP THROTTLE LEVER....................................................................................411 ADJUST..................................................................................................411 FUEL PUMP THROTTLE LINKAGE..................................................................................412 ADJUST..................................................................................................412 FUEL PUMP VS THROTTLE SHAFT HOUSING.........................................................................413 INSTALL.................................................................................................414 REMOVE..................................................................................................413 FUEL SHUTOFF VALVE (FSOV)...................................................................................416 INSPECT FOR REUSE.......................................................................................416 FUEL SYSTEM - GENERAL INFORMATION...........................................................................380 INSTALLATION RECOMMENDATIONS............................................................................381 INSTALLATION PUBLICATIONS...........................................................................381 OVERHEAD FUEL TANK REQUIREMENTS.....................................................................381 PROPER USE OF FUEL SYSTEM GAUGES....................................................................381 SERVICE TOOLS...............................................................................................391 FUEL SYSTEM.............................................................................................391 SPECIFICATIONS..............................................................................................388 FUEL RECOMMENDATIONS....................................................................................389 FUEL OIL RECOMMENDED PROPERTIES.....................................................................390 FUEL SYSTEM.............................................................................................388 STALL SPEED CHECK LIST......................................................................................424 IF THE STALL SPEED IS TOO HIGH, CHECK THE FOLLOWING:....................................................425 IF THE STALL SPEED IS TOO LOW, CHECK THE FOLLOWING:.....................................................424 STALL SPEED TEST............................................................................................418 STALL SPEED CHECK.......................................................................................418 CONVERTER TRANSMISSIONS STALL SPEED.................................................................418 TIME SPEED CHECK........................................................................................421 VS GOVERNER ADJUSTING SCREW SEALING WASHERS.................................................................422 INSTALL.................................................................................................422 REMOVE..................................................................................................422 VS GOVERNER IDLE SPRING.....................................................................................422 INSTALL.................................................................................................423 REMOVE..................................................................................................422 INJECTORS AND FUEL LINES - GROUP 06.............................................................................426 AFC NO AIR CHECK............................................................................................487 MEASURE.................................................................................................487 AIR IN FUEL.................................................................................................445 TEST....................................................................................................445 GEAR PUMP DRAIN METHOD..............................................................................446 SIGHTGLASS METHOD...................................................................................445 CYLINDER MISFIRES OR SMOKES.................................................................................450 AUTOMATED CYLINDER PERFORMANCE TEST.....................................................................451 CELECT OR CELECT PLUS...............................................................................451 CYLINDER CUTOUT TEST....................................................................................451 CELECT OR CELECT PLUS...............................................................................451 STC.................................................................................................452 EXHAUST MANIFOLD TEMPERATURE TEST.......................................................................453 EXHAUST MANIFOLD TILT-BACK METHOD.......................................................................453 GENERAL INFORMATION.....................................................................................450 ECM COOLING PLATE...........................................................................................454 INSTALL.................................................................................................455 REMOVE..................................................................................................454 FUEL DRAIN LINE RESTRICTION.................................................................................456 MEASURE.................................................................................................456 FUEL FILTER (SPIN-ON TYPE)..................................................................................457 INSTALL.................................................................................................458 REMOVE..................................................................................................457 FUEL INLET RESTRICTION......................................................................................459 MEASURE.................................................................................................459 FUEL SUPPLY LINES...........................................................................................461 INSPECT FOR REUSE.......................................................................................461 REMOVE..................................................................................................461 INJECTOR ...................................................................................................468 INSTALL.................................................................................................471 CELECT OR CELECT PLUS...............................................................................471 STC.................................................................................................475 REMOVE..................................................................................................468 CELECT OR CELECT PLUS...............................................................................468 STC.................................................................................................470 INJECTORS AND FUEL LINES - GENERAL INFORMATION..............................................................427 THEORY OF OPERATION - CELECT AND CELECT PLUS FUEL SYSTEM................................................434 HYDROMECHANICAL SUBSYSTEM...........................................................................436 INJECTION CYCLE.....................................................................................437 THEORY OF OPERATION - PT FUEL SYSTEM....................................................................427 THEORY OF OPERATION - STC FUEL SYSTEM...................................................................430 SERVICE TOOLS...............................................................................................443 INJECTORS AND FUEL LINES................................................................................443 STATIC INJECTION TIMING.....................................................................................463 MEASURE.................................................................................................464 SETUP...................................................................................................463 STC OIL CONTROL VALVE (MECHANICAL)..........................................................................477 INITIAL CHECK...........................................................................................477 INSTALL.................................................................................................482 REMOVE..................................................................................................481 STC OIL DELIVERY SYSTEM BLOCKAGE............................................................................485 INITIAL CHECK...........................................................................................485 LEAK TEST...............................................................................................485 STC OIL DELIVERY SYSTEM DIAGNOSTICS.........................................................................482 TEST....................................................................................................482 LUBRICATING OIL SYSTEM - GROUP 07...............................................................................491 FLOW DIAGRAM, LUBRICATING OIL SYSTEM........................................................................494 LUBRICATING OIL AND FILTERS.................................................................................498 INSPECT.................................................................................................498 LUBRICATING OIL CONTAMINATION...............................................................................535 FLUORESCENT DYE TRACER..................................................................................535 FUEL PRESSURE TEST......................................................................................536 LUBRICATING OIL COOLER......................................................................................498 CLEAN...................................................................................................499 INSTALL.................................................................................................501 PRESSURE TEST...........................................................................................500 REMOVE..................................................................................................498 LUBRICATING OIL DIPSTICK....................................................................................502 CALIBRATE...............................................................................................502 LUBRICATING OIL DIPSTICK HOUSING............................................................................503 CLEAN...................................................................................................504 INSPECT FOR REUSE.......................................................................................504 INSTALL.................................................................................................504 REMOVE..................................................................................................503 LUBRICATING OIL FILTER (CANISTER-TYPE)......................................................................504 LEAK TEST...............................................................................................504 LUBRICATING OIL FILTER HEAD.................................................................................507 ASSEMBLE................................................................................................509 CLEAN...................................................................................................508 DISASSEMBLE.............................................................................................507 INSPECT FOR REUSE.......................................................................................508 INSTALL.................................................................................................510 REMOVE..................................................................................................507 LUBRICATING OIL FILTER (SPIN ON)............................................................................505 GENERAL INFORMATION.....................................................................................505 INSTALL.................................................................................................506 REMOVE..................................................................................................506 LUBRICATING OIL HIGH PRESSURE RELIEF VALVE..................................................................511 INTIAL CHECK............................................................................................511 INSPECT FOR REUSE.......................................................................................512 INSTALL.................................................................................................513 REMOVE..................................................................................................512 LUBRICATING OIL LEAKS.......................................................................................513 MAINTENANCE CHECK.......................................................................................513 EXTERNAL............................................................................................513 LUBRICATING OIL PAN.........................................................................................514 CLEAN...................................................................................................516 DRAIN...................................................................................................514 FILL....................................................................................................519 INSPECT FOR REUSE.......................................................................................516 INSTALL.................................................................................................517 FRONT SUMP PAN......................................................................................517 REAR SUMP PAN.......................................................................................518 REMOVE..................................................................................................515 FRONT SUMP PAN......................................................................................515 REAR SUMP PAN.......................................................................................516 LUBRICATING OIL PRESSURE GAUGE..............................................................................520 TEST....................................................................................................520 LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE).............................................................521 INSPECT FOR REUSE.......................................................................................521 INSTALL.................................................................................................523 REMOVE..................................................................................................521 LUBRICATING OIL PUMP........................................................................................523 INSPECT FOR REUSE.......................................................................................524 INSTALL.................................................................................................525 REMOVE..................................................................................................523 LUBRICATING OIL SYSTEM......................................................................................527 PRIME...................................................................................................527 LUBRICATING OIL SYSTEM - GENERAL INFORMATION................................................................493 LUBRICATING OIL TEMPERATURE GAUGE...........................................................................528 TEST....................................................................................................528 LUBRICATING OIL THERMOSTAT..................................................................................528 INSPECT FOR REUSE.......................................................................................529 INSTALL.................................................................................................529 REMOVE..................................................................................................528 LUBRICATING OIL TRANSFER TUBE...............................................................................530 CLEAN...................................................................................................530 INSPECT FOR REUSE.......................................................................................531 INSTALL.................................................................................................531 REMOVE..................................................................................................530 LUBRICATING OIL VISCOSITY SENSOR............................................................................533 INSPECT FOR REUSE.......................................................................................533 INSTALL.................................................................................................534 REMOVE..................................................................................................533 SERVICE TOOLS ..............................................................................................496 LUBRICATING OIL SYSTEM..................................................................................496 SPECIFICATIONS..............................................................................................495 CUMMINS/FLEETGUARD FILTER SPECIFICATIONS................................................................495 LUBRICATING OIL FILTERS.............................................................................495 LUBRICATING OIL SYSTEM..................................................................................495 COOLING SYSTEM - GROUP 08.......................................................................................539 COOLANT FILTER..............................................................................................558 INSTALL.................................................................................................559 REMOVE..................................................................................................558 COOLANT FILTER HEAD.........................................................................................560 CLEAN...................................................................................................560 INSPECT FOR REUSE.......................................................................................561 INSTALL.................................................................................................561 REMOVE..................................................................................................560 COOLANT HEATER HOUSING......................................................................................562 CLEAN...................................................................................................563 INSPECT FOR REUSE.......................................................................................563 INSTALL.................................................................................................564 REMOVE..................................................................................................562 COOLANT TEMPERATURE GAUGE...................................................................................558 INITIAL CHECK...........................................................................................558 COOLANT THERMOSTAT..........................................................................................564 INSPECT FOR REUSE.......................................................................................567 INSTALL.................................................................................................568 LEAK TEST...............................................................................................564 REMOVE..................................................................................................566 COOLANT THERMOSTAT HOUSING SUPPORT..........................................................................569 CLEAN...................................................................................................571 INSPECT FOR REUSE.......................................................................................571 INSTALL.................................................................................................572 REMOVE..................................................................................................569 COOLANT THERMOSTAT SEAL.....................................................................................574 CLEAN...................................................................................................574 INSPECT FOR REUSE.......................................................................................575 INSTALL.................................................................................................575 REMOVE..................................................................................................574 COOLANT VENT LINES..........................................................................................576 INITIAL CHECK...........................................................................................576 COOLING SYSTEM..............................................................................................577 CLEAN...................................................................................................578 DRAIN...................................................................................................577 FILL....................................................................................................580 PRESSURE TEST...........................................................................................582 COOLING SYSTEM - AIR OR COMBUSTION GAS TEST.................................................................583 INITIAL TEST............................................................................................583 AIR COOLING SYSTEM..................................................................................583 LEAK TEST...............................................................................................584 AIR COMPRESSOR......................................................................................585 COMBUSTION GAS LEAK.................................................................................586 FAN, SHUTTER, OR HEATER AIR CONTROL VALVE...........................................................584 COOLING SYSTEM - GENERAL INFORMATION........................................................................542 COOLING SYSTEM DIAGNOSTICS..................................................................................589 ANALYZING THE DATA......................................................................................593 GENERAL INFORMATION.....................................................................................589 SETUP...................................................................................................590 TEST....................................................................................................591 OPERATIONAL WORKSHEET...............................................................................592 COOLING SYSTEM PRECHARGE....................................................................................594 CUSTOMER PRECHARGE METHOD...............................................................................595 FACTORY PRECHARGE METHOD................................................................................594 GENERAL INFORMATION.....................................................................................594 DRIVE BELT, COOLING FAN.....................................................................................556 INSPECT FOR REUSE.......................................................................................556 INSTALL.................................................................................................557 REMOVE..................................................................................................556 FAN CLUTCH, AIR-DISENGAGED..................................................................................595 GENERAL INFORMATION.....................................................................................595 MAINTENANCE CHECK.......................................................................................595 FAN CLUTCH, AIR-ENGAGED.....................................................................................596 GENERAL INFORMATION.....................................................................................596 MAINTENANCE CHECK.......................................................................................596 FAN CLUTCH, ELECTRIC........................................................................................596 INSPECT FOR REUSE.......................................................................................598 INSTALL.................................................................................................599 REMOVE..................................................................................................596 FAN CLUTCH, ON-OFF..........................................................................................600 GENERAL INFORMATION.....................................................................................600 INITIAL CHECK...........................................................................................600 FAN CLUTCH, VISCOUS.........................................................................................602 GENERAL INFORMATION.....................................................................................602 INITIAL CHECK...........................................................................................602 INSTALL.................................................................................................605 REMOVE..................................................................................................605 FAN, COOLING................................................................................................610 INSPECT FOR REUSE.......................................................................................610 INSTALL.................................................................................................611 REMOVE..................................................................................................610 FAN DRIVE IDLER PULLEY ASSEMBLY.............................................................................605 INITIAL CHECK...........................................................................................605 INSTALL.................................................................................................606 REMOVE..................................................................................................606 FAN HUB, BELT DRIVEN.......................................................................................607 INITIAL CHECK...........................................................................................607 INSTALL.................................................................................................608 REMOVE..................................................................................................607 FAN SHROUD ASSEMBLY.........................................................................................609 INITIAL CHECK...........................................................................................609 FAN SPACER AND PULLEY.......................................................................................609 INSPECT FOR REUSE.......................................................................................609 INSTALL.................................................................................................610 REMOVE..................................................................................................609 FLOW DIAGRAM, COOLING SYSTEM................................................................................543 RADIATOR....................................................................................................611 INITIAL CHECK...........................................................................................611 RADIATOR HOSES..............................................................................................612 INSPECT FOR REUSE.......................................................................................612 RADIATOR PRESSURE CAP.......................................................................................612 INSPECT FOR REUSE.......................................................................................612 RADIATOR SHUTTER ASSEMBLY...................................................................................613 INITIAL CHECK...........................................................................................613 SERVICE TOOLS ..............................................................................................554 COOLING SYSTEM..........................................................................................554 SPECIFICATIONS..............................................................................................545 COOLANT REPLACEMENT REQUIREMENTS........................................................................553 COOLING SYSTEM..........................................................................................545 COOLING SYSTEM SEALING ADDITIVES........................................................................548 COOLING SYSTEM SOLUBLE OILS.............................................................................548 FLEETGUARD DCA4 SERVICE FILTERS AND LIQUID PRECHARGE....................................................550 FULLY FORMULATED COOLANT/ANTIFREEZE.....................................................................547 GENERAL INFORMATION.....................................................................................546 SUPPLEMENTAL COOLANT ADDITIVE (SCA).....................................................................549 TEST INTERVALS..........................................................................................552 TESTING SCA CONCENTRATION LEVEL CC-2602 TEST KIT........................................................551 PRECAUTIONS AND INSTRUCTIONS FOR PROPER KIT USE.....................................................551 THERMO CONTROL SETTINGS.................................................................................546 TORQUE CONVERTER COOLER.....................................................................................620 GENERAL INFORMATION.....................................................................................620 WATER PUMP..................................................................................................614 CLEAN...................................................................................................616 INSPECT FOR REUSE.......................................................................................617 INSTALL.................................................................................................617 REMOVE..................................................................................................614 WIRING HARNESS, CUMMINS ELECTRIC FAN CLUTCH.................................................................621 GENERAL INFORMATION.....................................................................................621 INITIAL CONNECTIONS.....................................................................................621 INSTALL.................................................................................................627 REMOVE..................................................................................................625 DRIVE UNITS - GROUP 09..........................................................................................630 ACCESSORY DRIVE.............................................................................................632 CLEAN...................................................................................................633 INSPECT FOR REUSE.......................................................................................633 INSTALL.................................................................................................634 REMOVE..................................................................................................632 ACCESSORY DRIVE PULLEY......................................................................................636 INSPECT FOR REUSE.......................................................................................636 INSTALL.................................................................................................637 REMOVE..................................................................................................636 ALTERNATOR DRIVE PULLEY.....................................................................................637 INSPECT FOR REUSE.......................................................................................638 INSTALL.................................................................................................638 REMOVE..................................................................................................637 HYDRAULIC PUMP DRIVE........................................................................................638 CLEAN...................................................................................................639 INSPECT FOR REUSE.......................................................................................640 INSTALL.................................................................................................641 REMOVE..................................................................................................638 SERVICE TOOLS ..............................................................................................631 DRIVE UNITS.............................................................................................631 AIR INTAKE SYSTEM - GROUP 10...................................................................................645 AFTERCOOLER.................................................................................................650 CLEAN...................................................................................................651 INSPECT FOR REUSE.......................................................................................651 INSTALL.................................................................................................652 PRESSURE TEST...........................................................................................651 REMOVE..................................................................................................650 AIR INTAKE MANIFOLD.........................................................................................653 CLEAN...................................................................................................654 INSPECT FOR REUSE.......................................................................................654 INSTALL.................................................................................................654 REMOVE..................................................................................................653 AIR INTAKE RESTRICTION......................................................................................663 MEASURE.................................................................................................663 AIR INTAKE SYSTEM - GENERAL INFORMATION.....................................................................646 GENERAL INFORMATION.....................................................................................646 AIR LEAKS, AIR INTAKE AND EXHAUST SYSTEMS..................................................................656 MAINTENANCE CHECK.......................................................................................656 CHARGE AIR COOLER (CAC) ....................................................................................658 CLEAN...................................................................................................658 INSPECT FOR REUSE.......................................................................................659 LEAK TEST...............................................................................................659 PRESSURE DIFFERENTIAL TEST..............................................................................661 TEMPERATURE DIFFERENTIAL TEST...........................................................................660 FLOW DIAGRAM, AIR INTAKE SYSTEM.............................................................................647 SERVICE TOOLS...............................................................................................649 AIR INTAKE SYSTEM.......................................................................................649 SPECIFICATIONS..............................................................................................648 AIR INTAKE SYSTEM.......................................................................................648 TURBOCHARGER................................................................................................664 CHECK FOR CORRECT COMPONENT.............................................................................669 CLEAN...................................................................................................665 INSPECT FOR REUSE.......................................................................................665 INSTALL.................................................................................................667 REMOVE..................................................................................................664 TURBOCHARGER AXIAL CLEARANCE................................................................................669 MEASURE.................................................................................................669 TURBOCHARGER BLADE DAMAGE...................................................................................670 INSPECT FOR REUSE.......................................................................................670 TURBOCHARGER COMPRESSOR SEAL LEAKS..........................................................................671 LEAK TEST...............................................................................................671 TURBOCHARGER RADIAL BEARING CLEARANCE.......................................................................672 MEASURE.................................................................................................672 TURBOCHARGER TURBINE SEAL LEAKS.............................................................................673 LEAK TEST...............................................................................................673 EXHAUST SYSTEM - GROUP 11.......................................................................................676 EXHAUST MANIFOLD, DRY.......................................................................................679 ASSEMBLE................................................................................................680 CLEAN...................................................................................................679 DISASSEMBLE ............................................................................................679 INSPECT FOR REUSE.......................................................................................680 INSTALL.................................................................................................680 REMOVE..................................................................................................679 EXHAUST RESTRICTION.........................................................................................681 MEASURE.................................................................................................681 FLOW DIAGRAM, EXHAUST SYSTEM................................................................................677 SPECIFICATIONS..............................................................................................678 EXHAUST SYSTEM..........................................................................................678 COMPRESSED AIR SYSTEM - GROUP 12................................................................................683 AIR COMPRESSOR..............................................................................................698 INSPECT FOR REUSE.......................................................................................699 INSTALL.................................................................................................699 REMOVE..................................................................................................698 AIR COMPRESSOR CARBON BUILDUP...............................................................................689 INITIAL CHECK...........................................................................................689 AIR COMPRESSOR CYLINDER HEAD (HOLSET QE MODELS).............................................................710 ASSEMBLE................................................................................................715 QE, EUROPEAN........................................................................................720 QE, NON-EUROPEAN....................................................................................715 CLEAN...................................................................................................713 DISASSEMBLE.............................................................................................710 INSPECT FOR REUSE.......................................................................................713 AIR COMPRESSOR CYLINDER HEAD (HOLSET SS AND E-TYPE MODELS)..................................................704 ASSEMBLE................................................................................................708 CLEAN...................................................................................................705 DISASSEMBLE.............................................................................................704 INSPECT FOR REUSE.......................................................................................706 AIR COMPRESSOR CYLINDER HEAD (HOLSET ST MODELS).............................................................726 ASSEMBLE................................................................................................736 CLEAN...................................................................................................734 DISASSEMBLE ............................................................................................726 INSPECT FOR REUSE.......................................................................................734 AIR COMPRESSOR PIN BORE WEAR ...............................................................................691 INITIAL CHECK...........................................................................................691 AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY..................................................................694 CLEAN...................................................................................................695 INITIAL CHECK...........................................................................................694 INSPECT FOR REUSE.......................................................................................696 INSTALL.................................................................................................696 HOLSET QE MODELS....................................................................................696 HOLSET SS, E-TYPE, AND ST MODELS....................................................................696 REMOVE..................................................................................................694 HOLSET QE MODELS....................................................................................695 HOLSET SS, E-TYPE, AND ST MODELS....................................................................694 AIR GOVERNER (AIR COMPRESSOR PUMPS CONTINUOUSLY)............................................................702 INITIAL CHECK...........................................................................................702 AIR GOVERNOR (AIR COMPRESSOR WILL NOT PUMP).................................................................701 INITIAL CHECK...........................................................................................701 AIR LEAKS, COMPRESSED AIR SYSTEM............................................................................704 INITIAL CHECK...........................................................................................704 COMPRESSED AIR SYSTEM - GENERAL INFORMATION.................................................................684 SERVICE TOOLS...............................................................................................688 COMPRESSED AIR SYSTEMS..................................................................................688 SPECIFICATIONS..............................................................................................686 COMPRESSED AIR SYSTEM...................................................................................686 HOLSET SS296/SS296E/QE296A/C MODELS.................................................................686 HOLSET SS338/QE338 A/C MODELS.......................................................................686 HOLSET ST676 A/C MODEL..............................................................................687 ELECTRICAL EQUIPMENT - GROUP 13 ................................................................................746 ALTERNATOR..................................................................................................750 INITIAL CHECK...........................................................................................750 INSTALL.................................................................................................751 REMOVE..................................................................................................751 BATTERIES...................................................................................................755 INITIAL CHECK...........................................................................................755 BATTERY CABLES AND CONNECTIONS..............................................................................756 INITIAL CHECK...........................................................................................756 DRIVE BELT, ALTERNATOR......................................................................................752 ADJUST..................................................................................................754 ADJUSTMENT LINK TYPE................................................................................754 AUTOMATIC BELT TENSIONER............................................................................754 INSTALL.................................................................................................752 ADJUSTMENT LINK TYPE................................................................................753 AUTOMATIC BELT TENSIONER............................................................................752 REMOVE..................................................................................................752 ADJUSTMENT LINK TYPE ...............................................................................752 AUTOMATIC BELT TENSIONER............................................................................752 ELECTRICAL EQUIPMENT - GENERAL INFORMATION.................................................................747 SERVICE TOOLS...............................................................................................749 ELECTRICAL EQUIPMENT....................................................................................749 SPECIFICATIONS..............................................................................................748 ELECTRICAL SYSTEM.......................................................................................748 STARTER MAGNETIC SWITCH.....................................................................................756 CURRENT CHECK...........................................................................................756 STARTER SOLENOID............................................................................................759 VOLTAGE CHECK...........................................................................................759 STARTER SWITCH..............................................................................................758 VOLTAGE.................................................................................................758 STARTING MOTOR..............................................................................................761 INSTALL.................................................................................................762 REMOVE..................................................................................................761 ENGINE TESTING - GROUP 14.......................................................................................763 DYNAMOMETER WORKSHEET.......................................................................................774 ENGINE RUN-IN (CHASSIS DYNAMOMETER).........................................................................785 RUN-IN INSTRUCTIONS.....................................................................................785 ENGINE RUN-IN (ENGINE DYNAMOMETER)..........................................................................799 RUN-IN INSTRUCTIONS.....................................................................................799 ENGINE RUN-IN (WITHOUT DYNAMOMETER).........................................................................789 RUN-IN INSTRUCTIONS.....................................................................................789 OFF-HIGHWAY APPLICATIONS............................................................................789 ON-HIGHWAY APPLICATIONS.............................................................................789 ENGINE TESTING - GENERAL INFORMATION........................................................................764 FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER..................................................767 ENGINE TESTING (CHASSIS DYNAMOMETER).......................................................................775 SETUP...................................................................................................775 TEST....................................................................................................777 ENGINE TESTING (ENGINE DYNAMOMETER).........................................................................790 SETUP...................................................................................................790 ENGINE TESTING (PORTABLE DYNAMOMETER OR LOAD BANK)..........................................................802 GENERAL INFORMATION.....................................................................................802 SERVICE TOOLS ..............................................................................................771 ENGINE TESTING..........................................................................................771 SPECIFICATIONS..............................................................................................770 ENGINE TESTING..........................................................................................770 MOUNTING ADAPTATIONS - GROUP 16.................................................................................804 ENGINE LIFTING BRACKETS.....................................................................................806 CLEAN...................................................................................................806 INSPECT FOR REUSE.......................................................................................806 INSTALL.................................................................................................806 REMOVE..................................................................................................806 ENGINE SUPPORT BRACKET, FRONT...............................................................................807 CLEAN...................................................................................................807 INSPECT FOR REUSE.......................................................................................807 INSTALL.................................................................................................808 REMOVE..................................................................................................807 FLYWHEEL....................................................................................................808 CLEAN...................................................................................................809 INSPECT FOR REUSE.......................................................................................809 INSTALL.................................................................................................810 MEASURE.................................................................................................811 BORE RUN OUT........................................................................................811 FACE RUN OUT........................................................................................813 REMOVE..................................................................................................808 FLYWHEEL HOUSING ...........................................................................................814 CLEAN...................................................................................................815 INSPECT FOR REUSE.......................................................................................816 INSTALL.................................................................................................816 MEASURE.................................................................................................817 FACE ALIGNMENT......................................................................................817 BORE ALIGNMENT......................................................................................817 REMOVE..................................................................................................814 FLYWHEEL HOUSING, REPTO.....................................................................................819 CLEAN...................................................................................................822 INSPECT FOR REUSE.......................................................................................823 INSTALL.................................................................................................824 MEASURE.................................................................................................825 BORE ALIGNMENT......................................................................................825 FACE ALIGNMENT......................................................................................826 REMOVE..................................................................................................819 FLYWHEEL RING GEAR..........................................................................................830 INSTALL.................................................................................................830 REMOVE..................................................................................................830 SERVICE TOOLS...............................................................................................805 MOUNTING ADAPTATIONS....................................................................................805 MISCELLANEOUS HARDWARE - GROUP 17...............................................................................833 CUP PLUG....................................................................................................834 CLEAN...................................................................................................834 INSPECT FOR REUSE.......................................................................................834 INSTALL.................................................................................................835 REMOVE..................................................................................................834 PIPE PLUG...................................................................................................835 CLEAN...................................................................................................836 INSPECT FOR REUSE.......................................................................................836 INSTALL.................................................................................................836 REMOVE..................................................................................................835 STRAIGHT THREAD PLUG........................................................................................837 CLEAN...................................................................................................837 INSPECT FOR REUSE.......................................................................................837 INSTALL.................................................................................................837 REMOVE..................................................................................................837 VEHICLE BRAKING - GROUP 209.....................................................................................840 ENGINE BRAKE................................................................................................841 ADJUST..................................................................................................847 CLEAN...................................................................................................844 INITIAL CHECK...........................................................................................841 INSPECT FOR REUSE.......................................................................................845 INSTALL.................................................................................................845 REMOVE.................................................................................................843 SERVICE LITERATURE..............................................................................................849 ADDITIONAL SERVICE LITERATURE...............................................................................850 LITERATURE ORDER FORM.......................................................................................852 SERVICE LITERATURE ORDERING LOCATION........................................................................851 COMPONENT MANUFACTURERS.........................................................................................854 COMPONENT MANUFACTURERS' ADDRESSES..........................................................................855 AIR COMPRESSORS.........................................................................................855 AIR CYLINDERS...........................................................................................855 AIR HEATERS.............................................................................................855 AIR STARTING MOTORS.....................................................................................855 ALTERNATORS.............................................................................................855 AUXILIARY BRAKES........................................................................................855 BELTS...................................................................................................855 CATALYTIC CONVERTORS....................................................................................855 CLUTCHES................................................................................................855 COOLANT HEATERS.........................................................................................856 COOLANT LEVEL SWITCHES..................................................................................855 DRIVE PLATES............................................................................................856 ELECTRIC STARTING MOTORS................................................................................856 ELECTRONIC SWITCHES.....................................................................................856 ENGINE PROTECTION SWITCHES..............................................................................856 FAN CLUTCHES............................................................................................856 FANS....................................................................................................856 FAULT LAMPS.............................................................................................856 FILTERS.................................................................................................856 FLEXPLATES..............................................................................................856 FUEL COOLERS............................................................................................856 FUEL WARMERS............................................................................................856 GAUGES..................................................................................................856 GOVERNORS...............................................................................................857 HEAT SLEEVES............................................................................................857 HYDRAULIC AND POWER STEERING PUMPS......................................................................857 IN-LINE CONNECTORS......................................................................................857 OIL HEATERS.............................................................................................857 PRELUBRICATION SYSTEMS..................................................................................857 READIATORS..............................................................................................857 THROTTLE ASSEMBLIES.....................................................................................857 TORQUE CONVERTERS.......................................................................................857 SPECIFICATIONS..................................................................................................859 AIR INTAKE SYSTEM - SPECIFICATIONS..........................................................................895 AIR INTAKE RESTRICTION..................................................................................895 TURBOCHARGER AXIAL CLEARANCE............................................................................895 TURBOCHARGER RADIAL BEARING CLEARANCE...................................................................895 AIR INTAKE SYSTEM - TORQUE VALUES...........................................................................896 AFTERCOOLER.............................................................................................896 AIR INTAKE MANIFOLD.....................................................................................896 AIR LEAKS, AIR INTAKE AND EXHAUST SYSTEMS...............................................................896 TURBOCHARGER............................................................................................897 CAM FOLLOWERS/TAPPETS - SPECIFICATIONS......................................................................879 CAM FOLLOWER ASSEMBLY...................................................................................879 CAM FOLLOWERS/TAPPETS - TORQUE VALUES.......................................................................880 CAM FOLLOWER ASSEMBLY...................................................................................880 CAPSCREW MARKINGS AND TORQUE VALUES.........................................................................912 CAPSCREW MARKINGS AND TORQUE VALUES - METRIC............................................................913 CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY....................................................914 COMPRESSED AIR SYSTEM - TORQUE VALUES.......................................................................900 AIR COMPRESSOR..........................................................................................900 AIR COMPRESSOR CYLINDER HEAD (HOLSET QE MODELS).........................................................900 AIR COMPRESSOR CYLINDER HEAD (HOLSET SS AND E-TYPE MODELS)..............................................900 AIR COMPRESSOR CYLINDER HEAD (HOLSET ST MODELS).........................................................900 AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY..............................................................900 COOLING SYSTEM - SPECIFICATIONS.............................................................................889 COOLANT THERMOSTAT......................................................................................889 FAN DRIVE IDLER PULLEY ASSEMBLY.........................................................................889 FAN HUB, BELT DRIVEN....................................................................................889 WATER PUMP..............................................................................................889 COOLING SYSTEM - TORQUE VALUES..............................................................................890 COOLANT FILTER HEAD.....................................................................................890 COOLANT HEATER HOUSING..................................................................................890 COOLANT THERMOSTAT......................................................................................890 COOLANT THERMOSTAT HOUSING SUPPORT......................................................................890 DRIVE BELT, COOLING FAN.................................................................................890 FAN CLUTCH, ELECTRIC....................................................................................891 FAN CLUTCH, VISCOUS.....................................................................................891 FAN, COOLING............................................................................................891 FAN HUB, BELT DRIVEN....................................................................................891 FAN SPACER AND PULLEY...................................................................................891 WATER PUMP..............................................................................................891 CYLINDER BLOCK - SPECIFICATIONS.............................................................................863 BEARINGS, CONNECTING ROD................................................................................863 BEARINGS, MAIN..........................................................................................863 BEARINGS, THRUST........................................................................................863 CAMSHAFT................................................................................................863 CAMSHAFT BUSHINGS.......................................................................................863 CAMSHAFT GEAR (CAMSHAFT INSTALLED)......................................................................864 CONNECTING ROD..........................................................................................864 CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)...........................................................865 CYLINDER LINER PROTRUSTION..............................................................................869 GEAR HOUSING, FRONT.....................................................................................866 IDLER GEAR, CAMSHAFT....................................................................................866 IDLER GEAR, HYDRAULIC PUMP..............................................................................867 IDLER GEAR, WATER PUMP..................................................................................868 PISTON COOLING NOZZLE...................................................................................869 PISTON RINGS............................................................................................869 CYLINDER BLOCK - TORQUE VALUES..............................................................................871 ACCESSORY DRIVE SEAL....................................................................................871 ALTERNATOR DRIVE SEAL...................................................................................871 BEARINGS, MAIN..........................................................................................871 CAMSHAFT................................................................................................871 CRANKSHAFT PULLEY.......................................................................................871 CRANKSHAFT SEAL, FRONT..................................................................................871 CRANKSHAFT SEAL, REAR...................................................................................872 CYLINDER LINER PROTRUSION...............................................................................873 GEAR COVER, FRONT.......................................................................................872 GEAR HOUSING, FRONT.....................................................................................872 IDLER GEAR, CAMSHAFT....................................................................................872 IDLER GEAR, HYDRAULIC PUMP..............................................................................872 IDLER GEAR, WATER PUMP..................................................................................873 PISTON AND CONNECTING ROD ASSEMBLY......................................................................873 PISTON COOLING NOZZLE...................................................................................873 WATER HEADER PLATE, CYLINDER BLOCK......................................................................873 CLYINDER HEAD - SPECIFICATIONS..............................................................................874 CYLINDER HEAD...........................................................................................874 CYLINDER HEAD - TORQUE VALUES...............................................................................875 CYLINDER HEAD...........................................................................................875 DRIVE BELT TENSION..........................................................................................908 DRIVE UNITS - SPECIFICATIONS................................................................................893 ACCESSORY DRIVE.........................................................................................893 HYDRAULIC PUMP DRIVE....................................................................................893 DRIVE UNITS - TORQUE VALUES.................................................................................894 ACCESSORY DRIVE.........................................................................................894 ACCESSORY DRIVE PULLEY..................................................................................894 ALTERNATOR DRIVE PULLEY.................................................................................894 HYDRUALIC PUMP DRIVE....................................................................................894 ELECTRICAL EQUIPMENT - TORQUE VALUES........................................................................902 ALTERNATOR..............................................................................................902 DRIVE BELT, ALTERNATOR..................................................................................902 STARTING MOTOR..........................................................................................902 EXHAUST SYSTEM - SPECIFICATIONS.............................................................................898 EXHAUST RESTRICTION.....................................................................................898 EXHAUST SYSTEM - TORQUE VALUES..............................................................................899 EXHAUST MANIFOLD, DRY...................................................................................899 FRACTION, DECIMAL, MILLIMETER CONVERSIONS...................................................................909 FUEL SYSTEM - SPECIFICATIONS................................................................................881 FUEL FLOW...............................................................................................881 FUEL SYSTEM - TORQUE VALUES.................................................................................882 FUEL PUMP...............................................................................................882 FUEL PUMP GEAR PUMP CHECK VALVE.........................................................................882 FUEL PUMP PULSATION DAMPER..............................................................................882 FUEL PUMP VS THROTTLE SHAFT HOUSING.....................................................................882 FUEL SHUTOFF VALVE......................................................................................882 INJECTION TIMING CODES......................................................................................907 INJECTORS AND FUEL LINES - SPECIFICATIONS...................................................................883 FUEL DRAIN LINE RESTRICTION.............................................................................883 FUEL INLET RESTRICTION..................................................................................883 INJECTORS AND FUEL LINES - TORQUE VALUES....................................................................884 ECM COOLING PLATES......................................................................................884 INJECTOR................................................................................................884 STC OIL CONTROL VALVE (MECHANICAL)......................................................................884 LUBRICATING OIL SYSTEM - SPECIFICATION......................................................................885 LUBRICATING OIL HIGH PRESSURE RELIEF VALVE..............................................................885 LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE).........................................................885 LUBRICATING OIL PUMP....................................................................................886 LUBRICATING OIL SYSTEM - TORQUE VALUES......................................................................887 LUBRICATING OIL COOLER..................................................................................887 LUBRICATING OIL DIPSTICK HOUSING........................................................................887 LUBRICATING OIL FILTER HEAD.............................................................................887 LUBRICATING OIL PAN.....................................................................................887 LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE).........................................................888 LUBRICATING OIL PUMP....................................................................................888 LUBRICATING TRANSFER TUBE...............................................................................888 LUBRICATING OIL VISCOSITY SENSOR........................................................................888 MISCELLANEOUS - SPECIFICATIONS..............................................................................905 MOUNTING ADAPTATIONS - SPECIFICATIONS.......................................................................903 FLYWHEEL HOUSING........................................................................................903 MOUNTING ADAPTATIONS - TORQUE VALUES........................................................................904 ENGINE LIFTING BRACKETS.................................................................................904 ENGINE SUPPORT BRACKET, FRONT...........................................................................904 FLYWHEEL................................................................................................904 FLYWHEEL HOUSING........................................................................................904 FLYWHEEL HOUSING, REPTO.................................................................................904 NEWTON-METER TO FOOT-POUND CONVERSION CHART.................................................................911 PIPE PLUG TORQUE VALUES.....................................................................................915 ROCKER LEVERS - SPECIFICATIONS..............................................................................876 OVERHEAD SET............................................................................................876 ROCKER LEVER ASSEMBLY...................................................................................876 ROCKER LEVERS - TORQUE VALUES...............................................................................877 CRANKCASE BREATHER (INTERNAL............................................................................877 ROCKER LEVER ASSEMBLY...................................................................................877 ROCKER LEVER COVER......................................................................................877 ROCKER LEVER HOUSING....................................................................................878 TAP-DRILL CHART - U.S. CUSTOMARY AND METRIC.................................................................916 VEHICLE BRAKING - TORQUE VALUES.............................................................................906 ENGINE BRAKE............................................................................................906 WEIGHT AND MEASURES - CONVERSION FACTORE....................................................................910 INDEX...........................................................................................................917
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