CUMMINS M11 SERIES ENGINES SERVICE REPAIR MANUAL – PDF DOWNLOAD

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CUMMINS M11 SERIES ENGINES SERVICE REPAIR MANUAL

CUMMINS M11 SERIES ENGINES SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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CUMMINS M11 SERIES ENGINES SERVICE REPAIR MANUAL

• This manual contains complete rebuild specifications and information for the M11 model engines, and all associated components manufactured by Cummins Engine Company, Inc. A listing of accessory and component suppliers’ addresses and telephone numbers is located in Section C. Suppliers can be contacted directly for any information not covered in this manual.
• Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in this section. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.
• When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (Troubleshooting and Repair, Specifications, Alternative Repair, and so on.) are available and can be ordered by filling out and mailing the LiteratureOrder Form located in the Service Literature Section L.
• Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged. Please use the postage paid, self-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Engine Company, Inc.
• reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location, a Cummins Division Office, or the factory.
• The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts. These parts can be identified by the following trademarks:

TABLE OF CONTENTS:

CUMMINS M11 SERIES ENGINES SERVICE REPAIR MANUAL

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

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