Cummins N14 Series Engines Shop Manual – PDF DOWNLOAD

Cummins N14 Series Engines Shop Manual – PDF DOWNLOAD

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Cummins N14 Series Engines Shop Manual – PDF DOWNLOAD

Language : English
Pages : 587
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Cummins N14 Series Engines Shop Manual – PDF DOWNLOAD

The Cummins N14 Series Engines Shop Manual is a comprehensive technical reference guide that provides detailed information on the maintenance, repair, and overhaul of the Cummins N14 Series Engines. This engine series is a popular choice for heavy-duty applications such as on-highway trucks, mining, construction equipment, and marine vessels. The shop manual is an essential resource for mechanics, technicians, and service personnel who are responsible for servicing and maintaining these engines.

The Cummins N14 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 N14 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 N14 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 N14 Series Engines continue to operate at peak performance, with maximum efficiency and reliability over their long service life.

TABLE OF CONTENTS:

Cummins N14 Series Engines Shop Manual – PDF DOWNLOAD

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