Cummins M11 Series Engines Shop Manual – PDF DOWNLOAD

Cummins M11 Series Engines Shop Manual – PDF DOWNLOAD

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Cummins M11 Series Engines Shop Manual – PDF DOWNLOAD

Language : English
Pages : 585
Downloadable : Yes
File Type : PDF
Size: 14.5 MB

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Cummins M11 Series Engines Shop Manual – PDF DOWNLOAD

The Cummins M11 Series Engines Shop Manual is a technical reference guide designed to provide comprehensive information on the maintenance, repair, and overhaul of the Cummins M11 Series Engines. This engine series is a popular choice for heavy-duty applications such as construction equipment, mining, marine vessels, and on-highway trucks. The shop manual is an essential resource for mechanics, technicians, and service personnel who are responsible for servicing and maintaining these engines.

The Cummins M11 Series Engines Shop Manual covers all aspects of the engine, including the construction, operation, troubleshooting, and maintenance. It provides detailed instructions and specifications for disassembly, inspection, repair, assembly, and testing of engine components. The manual is organized into several sections, each of which covers a specific aspect of the engine. These sections include:

1. Introduction: This section provides an overview of the M11 Series Engines, including specifications, application information, and general operating guidelines.
2. Engine Disassembly and Assembly: This section provides detailed instructions for disassembling and assembling the engine, including removal and installation of major components such as the cylinder head, camshaft, crankshaft, pistons, and connecting rods. The manual includes detailed illustrations and specifications to help technicians perform these tasks safely and efficiently.
3. Cylinder Block: This section provides information on the construction and maintenance of the engine block, including block disassembly and assembly, cylinder liner replacement, and bearing replacement.
4. Cylinder Head: This section covers the removal and installation of the cylinder head, as well as cylinder head disassembly, inspection, and repair.
5. Lubrication System: This section provides detailed information on the lubrication system, including oil pump removal and installation, oil filter replacement, and oil pressure testing.
6. Cooling System: This section provides information on the engine’s cooling system, including water pump removal and installation, radiator removal and installation, and thermostat replacement.
7. Fuel System: This section covers the engine’s fuel system, including fuel pump removal and installation, fuel injector replacement, and fuel system troubleshooting.
8. Air Intake and Exhaust System: This section provides information on the engine’s air intake and exhaust system, including air filter replacement, turbocharger removal and installation, and exhaust manifold removal and installation.
9. Electrical System: This section provides information on the engine’s electrical system, including alternator and starter motor removal and installation, as well as troubleshooting procedures for electrical faults.

The Cummins M11 Series Engines Shop Manual is an essential resource for maintaining and repairing these engines. It provides a comprehensive guide to servicing the engine and includes detailed instructions, specifications, and illustrations to help technicians perform tasks accurately and safely. The manual is a valuable tool for ensuring that Cummins M11 Series Engines continue to operate at peak performance, with maximum efficiency and reliability over their long service life.

TABLE OF CONTENTS:

Cummins M11 Series Engines Shop Manual – PDF DOWNLOAD

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