Nta855 Bom

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TM 5-2815-233-14
V
UNlVERSlTY OF VlRGlNIA
TECHNICAL MANUAL ALDERMAN LlBRARY
SEP 13 1991
OPERATOR' S, UNIT, INTERMEDIATE government documents
(DS) AND INTERMEDIATE (GS)
MAINTENANCE MANUAL
FOR
L ENGINE, DIESEL,
I* CUMMINS MODEL NTA - 855 -L4
NSN 2815-01-216-0939
UNIVERSITY OF VIRGINIA LIBRARY
X004815206
(Circle C) Copyright 1983

Cummins Engine Company, Inc.
Used by Permission
.1
HEADQUARTERS. DEPARTMENT OF THE ARMY
25 JULY 1986
i
TM 5-2815-233-14
TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
NO. 5-2815-233-14 WASHINGTON, D.C. , 25 July 1986
OPERATOR'S UNIT, INTERMEDIATE

(DS) AND INTERMEDIATE (GS)
MAINTENANCE MANUAL
ENGINE, DIESEl,
CUMMINS MODEL NTA-855-L4
NSN 2815-01-216-0939
NOTE:
This manual is printed in two parts as follows:
Part 1 consisting of Table of Contents, Operation and Maintenance instructions.
Part 2 consisting of a separate Table of Contents and Repair instructions.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistake or if you know of a way to improve the pro
cedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and
Blank Forms), or DA Form 2028-2 located in the back of this manual direct to: Commander, U.S. Army
Troop Support Command, ATTN: AMSTR-MCTS, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.
A reply will be furnished directly to you.
Table of Contents
Operating Instructions Specifications and Torque

Prestarting lnstructions 1-1 Lubricating Oil 3-1
Starting the Engine 1-3 Grease 3-5
Engine Warm-Up 1-6 Fuel Oil 3-6
Engine Speeds 1-6 Coolant 3-7
Engine Exhaust 1-7 Torque Specifications 3-8
High Altitude Operation 1-7
Engine Shutdown 1-7 Trouble-Shooting
Cold Weather Protection 1-8
Description 4-1
lndustrial Fire Pump Engines 1-11
Chart 4-2
Maintenance Operations
Schedule 2-2
Check Sheet 2-3
A Checks — Daily 2-7
A Checks — Weekly 2-11
B Checks 2-15
C Checks 2-34
D Checks 2-50
Index
Seasonal Maintenance Checks 2-54
Intro pg
Part 1
OPERATION AND MAINTENANCE
a
Operation and Cummins Diesel
Maintenance Engines
Agricultural
Industrial
Industiral Fire Pump
Railway
Copyright © 1980
Cummins Engine Company, lnc. Bulletin 3379052-09 Printed 10/80
b
Foreword
This is an engine operation and maintenance manual,

not a repair manual. The design of Cummins Engines
makes it possible to replace worn or damaged parts
with new or rebuilt parts with a minimum of down
time. Contact the nearest Cummins Distributor for
parts replacement as they are equipped and have well
informed, trained personnel to perform this service.
lf your shop is properly equipped to perform either
maintenance, unit replacement and/or complete
engine rebuild, contact the nearest Cummins Distribu
tors to obtain available repair manuals and arrange
for training of personnel.
For model identification of an engine, check the data-
plate. The letter and number code indicates breathing
(naturally aspirated except when letter "T" for turbo-
charged is present), cubic inch displacement, appli
cation and maximum rated horsepower.
Examples:
NTA-855-370 V-903-320
N=4 valve head V=Type engine
T=Turbocharger 903=Cubic lnch
A=Aftercooled Displacement
370= Maximum rated 320= Maximum Rated
horsepower horsepower
Cummins Engine Company, lnc.

Columbus, lndiana, U.S.A.
Operating Instructions
A|l^l^|j nt% The en9'ne operator must assume the responsibility

0j engjne care while the engine is being operated.
InStrilCtlOnS There are comparatively few rules which the operator
must observe to get the best service from a Cummins
Diesel.
General— All Applications
New and Rebuilt Engines Break-In 4. lf the injector and valve or other adjustments have
been disturbed by any maintenance work, check
Cummins engines are run-in on dynamometers before to be sure they have been properly adjusted before
being shipped from the factory and are ready to be starting the engine.
put to work in applications such as emergency fire
trucks, rail car applications and generator sets. Priming the Lubricating System
ln other applications, the engine can be put to work, Note: On turbocharged engines, remove the oil inlet
but the operator has an opportunity to establish line from the turbocharger and prelubricate the
conditions for optimum service life during initial 100 bearing by adding 2 to 3 oz. [50 to 60 cc] of clean
hours of service by: lubricating oil. Reconnect the oil supply line.
1. Operating as much as possible at three-quarter 1. Fill the crankcase to the "L" (low) mark on the
throttle of load range. dipstick. See Lubricating Oil Specifications,
Section 3.
2. Avoiding operation for long periods at engine idle
speeds, or at the maximum horsepower levels in 2. Remove the plug from the lubricating oil crossover
excess of five minutes. passage on NH/NT-855 Engines, Fig. 1-1. Remove
the plug from the head of the lubricating oil filter
3. Developing the habit of watching the engine housing on V Engines, Fig's. 1-2, 1-3, 1-4, 1-5 and
instruments closely during operation and letting 1-6. On KT/KTA-1150 Engines, remove the plug
up on the throttle if the oil temperature reaches from the front of the oil cooler housing, Fig. 1-7.
200° F [121°C] or the coolant temperature exceeds
200° F [93° F].
4. Operating with a power requirement that allows
acceleration to governed speed when conditions
require more power.
5. Checking the oil level every 8 to 10 hours during
the break-in period.
New or Rebuilt Engines

Pre-Starting Instructions — First Time
Priming The Fuel System
1. Fill the fuel filter with clean No. 2 diesel fuel oil
meeting the specifications outlined in Section 3.
2. Remove the fuel pump suction line and wet the
gear pump gears with clean lubricating oil.
Fig. 1-1, (OM1001L). Lubricating system priming point—NT-855
3. Check and fill the fuel tanks. C.I.D. Engine
1-1
Fig. 1-2, (OM1002L). Lubricating system (Miming point—VT-903 Fig. 1-4, (K21902). Lubricating system priming point — KT(A)-2300
C.I.D. Engine Engine
Fig. 1-3, (OM1003L). Lubricating system priming point—V/VT-555 Fig. 1-5, (OM202). Lubricating system priming point — KTA-3067
C.I.D. Engine Engine
Caution: Do not prime the engine lubricating system Warning: Clean the area of any lubricating oil spilled
from the by-pass filter. while priming or filling the crankcase.
3. Connect a hand- or motor-driven priming pump 7. Fill the crankcase to the "H" (high) mark on the
line from a source of clean lubricating oil to the dipstick with oil meeting specifications, listed in
plug boss in the housing. Section 3. No change in oil viscosity or type is
needed for new or newly rebuilt engines.
4. Prime until a 30 psi [207 kPa] minimum pressure
is obtained. A dipstick oil gauge is located on the side of the
engine, Fig. 1-8. The dipstick has an "H" (high) (1) and
5. Crank the engine at least 15 seconds (with fuel
"L" (low) (2) level mark to indicate lubricating oil
shut-off valve closed or disconnected to prevent
supply. The dipstick must be kept with the oil pan, or
starting), while maintaining the external oil pres
engine, with which it was originally supplied.
sure at a minimum of 15 psi [103 kPa],
Cummins oil pans differ in capacity with different type
6. Remove the external oil supply and replace the installations and oil pan part numbers. Check the dip
plug. stick calibration. lf in doubt, your Cummins Distributor
1-2
Operating Instructions
can verify that you have the proper oil pan and dip
stick calibration.
Check Hydraulic Governor

Many engines used in stationary power applications
are equipped with hydraulic-governed fuel pumps
which use lubricating oil as an energy medium, same
weight as used in the engine. Oil level in the governor
sump must be at the full mark on the dipstick.
Engine applications in a cold environment
should use a lighter weight oil in the governor sump.
Check Air Connections
Check the air connections to the compressor and the
air equipment, as used, and to the air cleaners and air
Fig. 1-6, (V41816). Lubricating system priming point — V-1710 crossovers to assure that they all are secure and have
Engine
no damage.
Check Engine Coolant Supply
1. Remove the radiator or heat exchanger cap and
check the engine coolant supply. Add coolant
as needed.
2. Make a visual check for leaks and open the water
filter shut-off valves.
Starting the Engine

Starting requires that clean air and fuel be supplied
to the combustion chambers in the proper quantities
at the correct time.
Normal Starting Procedure
Fig. 1-7, (OM1004L). Lubricating system priming point—KT/KTA Warning: Before starting be sure that everyone is clear
C.I.D. Engine of the engine and equipment.
lf the fuel system is equipped with an overspeed stop,
push the "Reset" button before attempting to start
the engine.
1. On units equipped with an air activated prelube
device, open the air valve to activate the piston in
the prelube device which will lubricate all moving
parts in the engine.
Note: On engines equipped with an oil pressure safety
switch, hold the fuel by-pass switch in the "start" posi
tion until the engine oil pressure reaches 7 to 10 psi
[48 to 69 kPa]; then, move it to the "run" position.
2. Set the throttle for idle speed and disengage the
driven unit.
Caution: Protect the turbocharger during start-up by
Fig. 1-6. (OM1005L). Checking engine oil level not opening the throttle or accelerating above 1000
1-3
Operation and Maintenance
Construction and Industrial
rpm until the idle speed oil pressure registers on Cold-Weather Starting
the gauge.
Note: A water jacket heater is recommended for
3. Open the manual fuel shut-down valve, if so stand-by generator set applications installed in a
equipped. Fig. 1-9. Electric shut-down valves cold climate.
operate as the switch is turned on. A manual over
ride knob provided on the forward end of the
electric shut-down valve allows the valve to be The glow plug system supplies heat to the cylinders
opened in case of an electric power failure. To so that compression temperatures are sufficient to
use, turn fully clockwise; return it to the run posi ignite the fuel.
tion after an electric repair.
To aid in starting the engine when the temperature
is 50° F [10.0° C] or below, an intake air preheater
is available.
Preheater equipment consists of a hand-priming
pump to pump fuel into the intake manifold, and a
switch to turn on the glow plug which is electrically
heated by the battery. Fuel burns in the intake mani
fold and heats the intake air.
Warning: Do not use vapor in conjunction with the
preheater. To do so could result in a fire.
To use the preheater for cold starting:
1 . Set the throttle in idle position. Turn the glow plug
toggle switch to the "ON" position. The red indi
cator light must be on.
2. After the red light has been on for 20 seconds,
Fig. 1-9, (V21970). Using manual override knob start cranking the engine. As soon as the engine
begins rotating, operate the preheater priming
pump to maintain 80 to 100 psi [552 to 689 kPa]
4. Pull the compression release (if so equipped) and fuel pressure. Use of the primer before the 20-
press the starter button or turn the switch-key to second interval will wet the glow plug and prevent
the "start" position. After three or four seconds of heating.
cranking, close the compression release (if so 3. lf the engine does not start within 30 seconds,
equipped) and continue to crank until the engine stop cranking. Wait one or two minutes and repeat
fires. the cranking operation.
Caution: To prevent permanent cranking motor 4. After the engine starts, pump the primer slowly to
damage, do not crank the engine for more than 30 keep the engine idling smoothly. ln cold weather
seconds continuously. If the engine does not fire this may require 4 to 5 minutes or longer. Do not
within the first 30 seconds, wait one to two minutes accelerate the engine.
before recranking. 5. When the engine has warmed up so it does not
falter between primer strokes, stop pumping.
5. At the initial start or after oil or filter changes and Close and lock the primer. Turn off the glow plug
after the engine has run for a few minutes, shut it toggle switch. (The red indicator light will go out.)
down and wait 15 minutes for the oil to drain back
into the pan. Check the engine oil level again; add 6. lf the engine gives no indication of starting during
oil as necessary to bring the oil level to the "H" the first three full strokes of the preheater pump,
mark on the dipstick. The drop in oil level is due to touch-check the intake manifold for heat. lf there
absorption by the oil filters. Never operate the is no heat, check the electrical wiring. lf the wiring
engine with the oil level below the low level mark is all right, remove the 1/8 inch pipe plug (1, Fig.
or above the high level mark. 1-10) from the manifold near the glow plug and
4
Manually Operated Valve
The manually operated valve, illustrated in Fig. 1-11
includes the valve body assembly (6), clamp (2) and
nylon tube (3). The fuel cylinder (1), atomizer fitting
(5) and pull control (7) must be ordered separately.
Standard pull or throttle control cables may be used,
to actuate the manual valve, if desired.
Electrically Operated Valve
The electrically operated valve, Fig. 1-12, includes the
valve body (7), 90 degree elbow (5), clamp (2), push
button switch (6), and nylon tube (3). The thermostat
is mounted on the engine exhaust manifold and cuts
out the valve by sensing manifold heat when the
engine is running. See parts catalog for fuel cylinder
Fig. 1-10.(OM1006L). Glow plug inspection hole
NT-855 C.I.D. Engine (1) and fuel atomizer fittings (4). These fittings must
close the glow plug manual switch for 15 seconds be ordered separately, as required.
and observe the glow plug through the 1/8 inch
plug hole. The glow plug should be white hot; if
not, connect the wiring to a 6- to 12-volt (as used)
source and check the amperage; it should be 30 to
32 (minimum). lf the glow plug is all right, check
the manual switch and resistor (if used) and
replace if necessary.
Note: The preheater priming pump, switches and
resistor are located at the instrument panel and are to
be checked during engine starting.
The cold starting aid, approved for use in Cummins
Engines, has been based upon starting aid capabili
ties to —25° F [—32° C].
Caution: Do not attempt to use vapor compound type
starting aids near heat, open flame or on engines
Fig. 1-12,(OM1008L). Electrically operated valve
equipped with a glow plug system.
lnstallation Recommendations
The atomizer fittings must be mounted in the engine
air intake manifold or inlet connection to provide an
equal distribution of starting fuel to each cylinder.
The atomizer holes are 180 degrees apart and must
be mounted so the spray is injected the "long way"
of the manifold. lf incorrectly installed, the spray goes
crosswise of the manifold.
Recommended Starting Technique Using
Fleetguard Starting Aid
1. Set the throttle for idle.
2. Disengage the driven unit or make sure gears are
in neutral.
Fig. 1-11,(OM1007L). Manually operated valve 3. Open the manual fuel shut-down valve, or electric
1-5
shut-down valve, whichever is used. Note: Engines in many applications are applied at a
lower than maximum rated speed; check the serial
4. Engage the starter and while cranking, apply
dataplate.
metered amounts of starting fluid until the engine
idles smoothly. Power generator units are pre-set to operate at a
specific governed rpm.
Use of Starting Fluid Without Metering Equipment
1. Spray starting fluid into the air cleaner intake,
while a second man cranks the engine. Table 1-1: Engine Speeds (RPM)
Warning: Never handle starting fluid near an open Engine Maximum

(lame. Never use it with a preheater or flame thrower Model Rated
equipment. Do not breathe the fumes. Use of too
much will cause excessively high pressures and deto All NH, NT. 855-R. 855-L 2100
nation, or over speed the engine. All NH. NT 2300
V-903 2600
2. Starting aid fumes will be drawn into the air intake VT-903 2400
manifold and the cold engine should start without V-378, V-504. V-555 3000
difficulty. V-378, V-504, V-555 3300
V-1710, V-1710-L 2100
Warning: Fuel oil or volatile fuel cold starting aids are KT-1150 2100
not to be used in underground mine or tunnel opera KTA-1150 2100
tions, if the engine is so equipped check with the local KT-2300 2100
U.S. Bureau of Mines Inspector for use of the starting KTA-2300 2100
aid. KTA-3067 2100
Engine Warm-Up
Oil Temperature
When the engine is started, it takes a while to get the
The oil temperature gauge normally should read
lubricating oil film re-established between shafts and
between 180° F [82° C] and 225° F [107° C]. Under full
bearings and between pistons and liners. The most
load conditions, an oil temperature of 240° F [1 16° C]
favorable clearances between moving parts are ob
for a short period is not cause for alarm.
tained only after all engine parts reach normal operat
ing temperature. Avoid seizing pistons in liners and Caution: Any sudden increase In oil temperature
running dry shafts in dry bearings by bringing the which is not caused by a load increase is a warning
engine up to operating speed gradually as it warms up. of possible mechanical failure and should be investi
gated at once.
On some emergency equipment (such as fire pump
engines) warm-up may not be necessary due to the During the warm-up period, apply the load gradually
equipment being housed inside a heated building. until the oil temperature reaches 140° F [60° C]. While
For an engine starting with a parasitic load, such as the oil is cold it does not do a good job of lubricating.
a fire pump, the coolant temperatures must be a mini Continuous operation or long periods of idle with oil
mum of 120° F (49° C]. temperatures below 140° F [60° C] may cause crank-
case dilution and acids in the lubricating oil which
Engine Speeds
quickly accelerate engine wear.
All Cummins engines are equipped with governors to
prevent speeds in excess of the minimum or pre Water Temperature
determined lower speed rating.
A water temperature of 160° to 200° F [71° to 93° C] is
The governor has two functions: First, it provides the the best assurance that the working parts of the
fuel needed for idling when the throttle is in the idle engine have expanded evenly to the most favorable oil
position. Second, it overrides the throttle and shuts off clearances. Maximum engine coolant temperatures
the fuel if the engine rpm exceeds the maximum rated should not exceed 200° F [93° C].
speed.
Keep the thermostats in the engine during summer
Speeds listed in Table 1-1 are for engines rated at and winter, avoid long periods of idling, and take the
maximum rpm and fuel rate. necessary steps to keep the water temperature up to a
1-6
Table 1-2: Oil Pressure PSI [kPa] @ 225° F [107°C]
Engine Series Minimum @ Idle Speed Rated Speed
NH/NT 8 [55] 40/70 [276/483]

Big Cam ll 8 [55] 25/45 [172/310]
VT-350, V-903, VT-903 5 [34] 40/65 [276/448]
V/VT-378, V/VT-504, V/VT-555 10 [69] 50/90 [345/620]
V/VT/VTA-1710 15 [103] 50/90 [345/620]
KT/KTA-1150 15 [103] 45/70 [310/483]
KT/KTA-2300 @ 2100 RPM 15 [103] 45/70 [310/483]
KT/KTA-2300 @ 1500. 1800 or 1950 RPM 15 [103] 40/70 [276/483]
KT/KTA-3067 @ 2100 RPM 20 [138] 45/70 [310/483]
KT/KTA-3067 @ 1500 or 1800 RPM 15 [103] 40/70 [276/483]
minimum of 160° F [71° C]. lf necessary in cold 1. Place the VS speed control lever in the operating
weather, use radiator shutters or cover a part of the position.
radiator to prevent overcooling.
2. Lock the standard throttle in the full-open position.
Oil Pressure 3. Engage the power take-off.
Normal engine oil pressures at 225° F [107°C] oil To return to standard throttle:
temperature are listed in Table 1-2.
1. Disengage the power take-off.
Note: lndividual engines may vary from the above 2. Return the standard throttle to the idle position.
normal pressures. Observe and record the pressure
when the engine is new to serve as a guide for an 3. Lock the VS speed control lever in the maximum
speed position.
indication of progressive engine condition. (High oil
pressure during start-up is not cause for alarm.) For
Engine Shut-Down
record purposes these readings are more accurate
and reliable when taken immediately after an oil Idle Engine A Few Minutes Before Shut-Down
change.
lt is important to idle an engine 3 to 5 minutes before
shutting it down to allow the lubricating oil and water
High Altitude Operation
to carry heat away from the combustion chamber,
Some engines, particularly naturally aspirated, lose bearings, shafts, etc. This is especially important with
horsepower when they are operated at high altitude turbocharged engines.
because the air is too thin to burn as much fuel as at
The turbocharger contains bearings and seals that are
sea level. This loss is about 3 percent for each 1000 ft
subject to the high heat of combustion exhaust gases.
[304.8 m] of altitude above sea level for a naturally
While the engine is running, this heat is carried away
aspirated engine. Operate the engine using a lower
by oil circulation, but if the engine is stopped sudden
power requirement at high altitude to prevent smoke
ly, the turbocharger temperature may rise as much as
and over-fueling.
100° F [38° C]. The results of the extreme heat may be
seized bearings or loose oil seals.
Power Take-Off Application With PT (type G)
VS Fuel Pump Do Not ldle Engine for Excessively Long Periods
The VS fuel pump governor lever is used to change Long periods of idling are not good for an engine
the standard governed speed of the engine from rated because the combustion chamber temperatures drop
speed to an intermediate power take-off speed. so low the fuel may not burn completely. This will
cause carbon to clog the injector spray holes and
When changing from the standard speed range to the
piston rings and may result in stuck valves.
power take-off speed with the engine idling on stand
ard throttle, operate as follows. lf the engine coolant temperature becomes too low,
1-7
raw fuel will wash the lubricating oil off the cylinder
walls and dilute the crankcase oil so all moving parts
of the engine will suffer from poor lubrication.
lf the engine is not being used, shut it down.
Turn Switch to "Off" Position to Shut Down the Engine
The engine can be shut down completely by turning
off the switch on installations equipped with an elec
tric shut-down valve, or by turning the manual shut
down valve knob. Turning off the switch which
controls the electric shut-down valve stops the engine
unless the override button on the shut-down valve
has been locked in the open position. lf the manual
override on the electric shut-down valve is being used,
turn the button fully counterclockwise to stop the
engine. Refer to "Normal Starting Procedure". The
valve cannot be reopened by the switch until after the
engine comes to a complete stop, unless a rapid re
start valve is installed.
Caution: Never leave the switch key or the override

button in the valve open or in the run position when
the engine is not running. With overhead tanks this
would allow fuel to drain into the cylinders, causing
a hydraulic lock.
Stop Engine Immediately If Any Parts Fail

Practically all failures give some warning to the
operator before the parts fail and ruin the engine.
Many engines are saved because alert operators heed
warning signs (sudden drop in oil pressure, unusual
noises, etc.) and immediately shut down the engine.
Cold-Weather Protection
1. For cold-weather operation, use of permanent-
type antifreeze with rust inhibitor additives is
recommended. See Section 3.
2. Drain the cylinder block and heads on all engines
by opening the petcocks and removing the drain
plugs as shown in Fig's. 1-13 to 1-19. If an air com
pressor (Fig. 1-20), heat exchanger or other "water
cooled" accessory is used, open the petcock and
drain. Failure to properly drain the engine and
accessories may cause serious damage during
freezing weather.
3. lmmersion-type water and oil heaters are available
for engines used in cold-weather operations and to
maintain temperatures to permit the engine to Fig. 1-15, (OM1013L). Cooling system drain points (left bank side)
operate at full load at start-up. V7VT-555 C.I.D. Engine
Fig. 1-16, (V40033). Coolant drain point — V/VT-1710 Engine Fig. 1-19, (OM203 ). Coolant drain point — KTA-3067 Engine
Fig. 1-17,(OM1009L). Cooling system drain points—KT/KTA-1 150

C.I.D. Engine
Engine Operation in Cold Weather
Satisfactory performance of a diesel engine operating
in low ambient temperature conditions requires modi
fication of the engine, surrounding equipment, operat
ing practices and maintenance procedures. The
colder the temperatures encountered the greater
the amount of modification required and yet with the
modifications applied, the engines must still be
capable of operation in warmer climates without
extensive changes. The following information is
provided to engine owners, operators and mainte
nance personnel on how the modifications can be
applied to get satisfactory performance from their
diesel engines.
There are three basic objectives to be accomplished:
Fig. 1-18, (K21903). Coolant drain point — KT(A)-2300 Engine 1. Reasonable starting characteristics followed by
1-9
practical and dependable warm-up of the engine

and equipment.
2. A unit or installation which is as independent as
possible from external influences.
3. Modifications which maintain satisfactory operat
ing temperatures with a minimum increase in
maintenance of the equipment and accessories.
lf satisfactory engine temperature is not maintained,
higher maintenance cost will result due to the in
creased engine wear, poor performance and forma
tion of excessive carbon, varnish and other deposits.
Special provisions to overcome low temperatures are
definitely necessary, whereas a change to warmer
climate normally requires only a minimum of revision.
Most of the accessories should be designed in such a
way that they can be disconnected so there is little
effect on the engine when they are not in use.
The two most commonly used terms associated with
preparation of equipment for low temperature opera
tion are "Winterization" and "Arctic Specifications"
Winterization of the engine and/or components so
starting and operation are possible in the lowest
temperature to be encountered requires:
1. Use of correct materials.
2. Proper lubrication, low temperature lubricating oils.
3. Protection from the low temperature air. The metal
temperature does not change, but the rate of heat
dissipation is affected.
4. Fuel of the proper grade for the lowest temperature.
5. Heating to be provided to increase the engine block
and component temperature to a minimum of
—25° F [—32° C] for starting in lower temperatures.
6. Proper external heating source available.
7. Electrical equipment capable of operating in the
lowest expected temperature.
Arctic specifications refer to the design material and
specifications of the components necessary for satis
factory engine operation in extreme low temperatures
to —65° F [—54° C]. Contact Cummins Engine
Company, lnc., or the equipment manufacturer to
obtain the special items required.
Caution: "Anti-leak" antifreezes are not recommended
for use in Cummins Engines. Although these anti
freezes are chemically compatible with DCA water
treatment, the "anti-leak'' agents may clog the coolant
filters and render them ineffective.
1-10
Maintenance Instructions
Industrial Fire Pump Engines
Fire pump engines are built and applied under and review all systems for leaks or unusual condi
conditions set down by agencies such as Underwriters tions; correct as required.
Laboratory; therefore, parts originally supplied must 9. Stop the engine and install ST-1224 Adapter.
not be deviated from without qualifying agency ap
proval. The following instructions are those special 10. Check the crankcase oil level and fill it to the high
items necessary to this application, and should be mark.
used in conjunction with those previously stated.
11. Start the engine and adjust overspeed.
Initial Start-Up 12. Remove ST-1224 and replace the original adapter.
Note: Contact operating personnel responsible for fire 13. Clean the raw water strainer.
protection system before starting. Obtain approval to 14. Start the engine and adjust operating speed.
service or repair. After repair obtain authorized signa
15. Adjust the raw water pressure regulator.
ture of acceptance.
1 . Remove the heat exchanger cap, check or fill the 16. Engine is now ready for normal operation.
engine coolant supply; open the water filter inlet
Normal Operation
and outlet valves.
1. Daily or normal operation would include the
2. Prelubricate the engine with oil meeting specifica
checking of fuel, lubricating oil, coolant and cor
tions MlL-L-46152 (APl-CC/SC) viscosity 10W30.
recting any leaks or unusual conditions as required.
This includes removal of the turbocharger oil inlet
line on turbocharged engines to prelubricate the 2. Check the coolant and oil heaters to assure at least
housing by adding 2 to 3 oz [60 cc] of clean engine 120°F [49° C] water temperature has been
lubricating oil. maintained.
3. Check the crankcase oil level and fill to the high 3. Manually start the engine using the prescribed
mark on the dipstick. starting procedure.
4. Remove the fuel pump solenoid lead and crank the 4. Operate the engine the prescribed period of time
engine through both crankjng cycles. or 5 minutes after stabilization of the coolant
temperature.
5. lf the engine is equipped with a "Vernier throttle",
place it in the idle position; if not, place the MVS 5. Shut the engine down using the normal test shut
throttle in the idle position. On turbocharged down procedures.
models the delay cylinder line may be disconnected
at the block and the block opening plugged. Fire Pump Engines — Overspeed
Switch Adjustment
6. Reconnect the fuel solenoid lead and start the
(IF Engine Models)
engine; run it at idle speed.
The speed switches required for overspeed protection
7. Verify the lubricating oil pressure has been estab
on fire pump engines require high speed for the over-
lished, normally in 6 to 8 seconds.
speed adjustment. All engines are now being shipped
Note: Some automatic controllers require lubricating adjusted at the maximum overspeed. The following
oil pressure higher than the normal pessure at 600 rpm overspeed adjustments are 20 percent above the rated
idle. lncrease the idle to 800 to 900 rpm if this condition engine speed.
is encountered. All turbocharged engines should be
An adapter, ST-1224 with 2:1 ratio, in speed switch
set to 800 to 900 rpm idle.
drive only, (1, Fig. 1-21) is available to drive the speed
8. Continue to operate the engine for 3 to 5 minutes switch at twice the engine speed. This tool when
1-11
installed in place of the existing adapter permits adjust On inline engine models, this can be accomp
ment to be made to the speed switch at slightly over lished by adjusting the Vernier throttle control.
1/2 engine and pump speed. This maintains a pump
On Medium Duty V engines, the speed adjust
speed well within its safe speed range while the
ment must be made by adjusting the governor
adjustments are being made.
idle and maximum speed screws. The idle screw
is housed in the front of the MVS governor. The
maximum speed screw is mounted to the MVS
Table 1-3: Engine governor by a bracket and is on the left hand
side of the fuel pump. Engine slow down is ac
Engine Rated
Overspeed complished by turning the idle speed screw
Model Speed
counterclockwise and turning the maximum
V-378-F1 1750-2200 2100-2640 speed screw in a clockwise direction. To in-
V-378-F2 2400-3300 2880-3960 I reverse the procedure.
V-504-F1 1750-2200 2100-2640
V-504-F2 2400-3300 2880-3960 5. Set the single
N-855 1460-2100 1750-2520 a. Remove the lockwire from on

NT-855-F1 1750-2100 2100-2520 of the switch. Loosen the three (3)
NT-855-F2 1750-2300 2100-2760 b. Rotate the cover clockwise (this decreases trip
VT-1710-F 1750-2100 2100-2520 speed) until the switch actuates and stops the
c. Secure the and the locking

the present tachometer drive
d. On manual reset models, re-activate the switch
2. lnstall the service tool, ST-1224, in position of the
by pushing the reset button on top of the switch.
standard drive adapter. Connect the tachometer
and overspeed stop switch to the ST-1224 Tool. 6. Set the dual element speed switches.
Note: The overspeed stop switch cable must be con Caution: Do not break or remove the lockwire.
nected to the short adapter connection. (1, Fig. 1-21).
a. Remove the round head dust cover screw
3. Start the engine and warm to operating temperature. marked 2 from the top of the switch. Fig. 1-22.
4. Set the engine speed to one-half (1/2) the desired b. Insert a 1/16 inch Hex Allen wrench into the
engine shut-down speed as indicated by the adjusting screw located just below the surface
tachometer. of the cover.
r"7 1-21. (ST-1224). ST-1224 adapter Fig. 1-22, (CGS27). Double speed switch
c. Turn counterclockwise to lower the engine
shut-down speed. Turn clockwise to raise the
engine shut-down speed.
Caution: Do not turn the adjusting screw more than
three (3) revolutions in either direction from the
factory setting. Do not attempt to set the duel element
switch in the same manner as the single element
switch.
d. Replace the dust cover screw removed in "Step
a" above.
e. All overspeed switches must be manually reset,
reactivate the switch by pushing the reset button
on top of the switch.
7. Replace the service tool, ST-1224, with the original Fig. 1-23. (N11979). Adjusting engine speed
drive adapter and reconnect the cables.
Note: lf the stop crank adjustment is required do not
use the ST-1224 Adapter. Replace with a standard
adapter to effect the adjustment.
Fire Pump Engine Operating Speed Adjustment
All Cummins fire pump engines will be shipped
adjusted at the speeds in Table 1-4, unless prior
approval has been established for a specific speed.
Final operating speed adjustment should be made at
the time of the in-service inspection to obtain the
required fire pump operating speed.
This speed adjustment must be made with the Vernier
throttle in the full fuel position and the systems fire
pump operating at its rated condition. All speed ranges
of N-NT and V-12 models are available by adjusting
the VS high speed adjusting screw. Fig's. 1-23 and 1-24. Fig. 1-24, (N11980). Governor adjusting screw
ment is made by loosening the 7/16 inch locking nut

Table 1-4: Fire Pump Engine Operating Speed
and backing the screw out to increase the engine speed
Fuel Factory Maximum through the full speed range.
Engine Pump Adjusted Operating The V-378 and V-504 F1 and F2 models require two
Model Code Speed Speed differently calibrated fuel pumps. One pump code
V-378-F1 C-653 1750 2200 provides speeds between 1750 and 2300 rpm. A differ
V-378-F2 C-651 2400 3300 ent pump code is required for speeds between 2400
V-504 F1 C-652 1750 2200 and 3300 rpm. The required speeds on these models
V-504 F2 C-650 2400 3300 are similarly obtained by MVS adjustment within the
calibrated range as indicated above. lt normally is
N-855 8761 1750 2100
8770 1750 2100 prohibited by UL and FM to change engine ratings by
NT-855 F1
NT-855 F2 8771 1750 2300 changing fuel pumps on any models of fire pump
VT-1710 F 8784 1750 2100 engines. ln the event of fuel pump rebuild, the pump
must be calibrated to the original code and any devia
tion would be a violation to the insurance agencies
This screw requires a 1/8 inch Allen wrench and adjust- approval.
1-13
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-14
mm •a Maintenance is the key to lower operating costs. A

Iw™IIT1©I1oI1C© diesel engine requires regularly scheduled maintenance
to keep it running efficiently.
Maintenance Schedule
Preventive maintenance is the easiest and least

expensive type of maintenance. lt permits the Mainte
nance Department to do the work at a convenient time.
A Good Maintenance Schedule Depends On

Engine Application
Actual operating environment of the engine governs
the maintenance schedule. The suggested check sheet
on the following page indicates some checks have to
be performed more often under heavy dust or other
special conditions.
Using the Suggested Schedule Check Sheet

The maintenance schedule check sheet is designed
as a guide until adequate experience is obtained to
establish a schedule to meet a specific operation.
A detailed list of component checks is provided
through several check periods; also a suggested
schedule basis is given for hours of operation, or
calendar of time.
A maintenance schedule should be established using
the check sheet as a guide; the result will be a mainte
nance program to fit a specific operation.
The check sheet shown can be reproduced by any
printer. The person making each check can then
indicate directly on the sheet that the operation has
been completed. When a complete column (Under A,
B, C, etc.) of checks is indicated, the engine will be
ready for additional service until the next check is due.
Storage for Engines Out of Service

lf an engine- remains out of service and its use is not
immediately forthcoming, special precautions should
be taken to prevent rust. Contact the nearest Cummins
Distributor or consult applicable Shop Manual for
information concerning engine storage procedure.
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70° F [21° C] must also be equipped with a lubricating
oil heater. When using a lubricating oil heater im
Schedule I, Schedule II
mersed in oil , the maximum surface of heater in contact
The following maintenance schedules should be used with oil, should be less than 300° F [149° C] to minimize
to establish maintenance practices for Cummins formation of hard carbon on the heating element.
standby (GS) or continuous duty (GC) generator sets.
Recommended wattage for the heaters when the unit is
Schedule l is used with standby applications. Many of in a protected area or in an enclosure are shown in
these installations are regulated by NFPA and/or local Bulletin No. 3379009, in Section 7 Miscellaneous.
codes (reference NFPA No. 76A). Standby units should be operated once a week under a
Standby rated generator sets are for supplying electric minimum of 25% of rated KW load for at least thirty
power in the event of normal utility power failure. No minutes. During this test, the engine must reach normal
overload capability is available for this rating. This operating temperature.
rating may be used for continuous service for as long Cummins Continuous Duty Generator Sets
as the emergency may last. This rating conforms with
the BS 649:1958 overload rating and DlN "B" 6270. Continuous duty generator sets may be equipped with
a cold starting aid. Maintenance procedures for these
Schedule Il is used with continuous duty applications. devices can be found in the seasonal maintenance
Continuous duty rated generator sets are for supplying section.
electric power in lieu of commercially purchased
power. Intermittent overloads up to the standby rating
are allowable. This rating may be used for continuous
service in commercial applications and it conforms
with BS 649:1958 and DIN "A" 6270 for generator set
Using The Suggested Schedule Check Sheet

Actual operating environment of the engine governs
the maintenance schedule. The suggested check sheet
on the following page indicates some checks have to
be performed more often under heavy dust or other
special conditions.
The maintenance schedule check sheet is designed as
a guide until adequate experience is obtained to estab
lish a schedule to meet a specific operation.
A detailed list of component checks is provided
through several check periods; also a suggested
schedule basis is given for hours of operation, or
calendar of time.
A maintenance schedule should be established using
the check sheet as a guide; the result will be a main
tenance program to fit a specific operation.
Cummins Standby Generator Sets
Cummins standby generator sets may be required to
start and come on line in 10 seconds or less.
These engines must be equipped with engine coolant
heaters capable of maintaining coolant temperature
at a minimum of 100° F [38° C].
Engines subject to ambient temperatures less than
2-4
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9-2
Continuous Duty check. A B C D
Generator Set Maintenance 83
li
o» ro m C<
CtteCk: - For Leak. e e e e e
- Operation ol M Mearter e
- Engine Oil Level e • e e e
- HfdrauHc Governor ON Unl e e e e •
—
I-Hnjc — Crun
. ,11 EU
no« Elk*
rmer • e e e
— By I*— Filar e e e e
- Engine 0.1 • • •
—-—
Cooling Check: — ForLMks e e e e e
- For Radiator Ak Bcolrtcnon e e e e e
- Operation ol Coolant Heater e
Hon end Connection. e • e e e
- CMIMLml e e e e •
- «i«-Fieci« and OCA Concentration • • e •
- B*H Condition and Tanalon e e e • e
- Fan Hub. Drive Pultey, and w.l.r Pump • • e e
- Haal E.chenger Zmc Anode Plug. •
Change - OCA Water Finer e e e e
Clean: - (doling Syatem e
A'tak Check: - FoiLaaki e e • e •

- Ail Cteaner Reatrictlon • e e e e
— Piping and Connection* e e e e
Ctean: — Crankcee Brealher e e e e
- Or Change Ak Cleaner Bement e e e e
Fuel Oack: -F«L«k. • e e e e

• e e e
- Fuel Line, and Connection. • • « *
Dram: - Sediment Irom Tank! • e e • e
Change: - Fuel FlWn e e e e
Ckaan: - Float Tank Breather e g> • e
- and Calibrate Injector. e
- and/or Calibrate Fuel Pump e
Adju.l Infactor. and Valve. e e
Check - For Leak. • 1 - • • e
- For Cthau.t Restriction e e
CW-: -111! II. ft , 1 ImÔmmm
Tighten Eihaaut Manifold and Turbochargar Craaee.e«r. —i— •
Engine Check: - For Unu.ul Vibration e • e e e

Related - Vibration Damper •
- Crankahall End Pla, e
Tighten Mounting Hardware •
Cte- - Engine e
-F» HHo. Block Spring. e e e e
Electrical — Battery Charging System

— Battery Etectrolyte Laval
- Glow Plug
- And dean Magnetic Pickup Unit
— Safety Control and Alarm*
Ak Inset and Outtet ft
Windings and Etectrical Connectoin!
Operation ot Generator
Grease: — Bearing
Switchgear — Power Distribution Wking

"A" Maintenance Checks— Daily
Make a Daily Report of Engine Operation to the

Maintenance Department
The engine must be maintained in top mechanical
condition if the operator is to get optimum satisfaction
from its use. The maintenance department needs daily
running reports from the operator to make necessary
adjustments in the time allotted and to make provisions
for more extensive maintenance work as the reports
indicate the necessity.
Comparison and intelligent interpretation of the daily
report along with a practical follow-up action will
eliminate most failures and emergency repairs.
Report to the Maintenance Department any of the
following conditions:
Fig. 2-1, (K21901). Checking engine oil level
1. Low lubricating oil pressure.
2. Low power. Check Engine Coolant Level
3. Abnormal water or oil temperature. Keep the cooling system filled to the operating level.
Check the coolant level daily or at each fuel fill point.
4. Unusual engine noise. lnvestigate for causes of coolant loss. Check the
5. Excessive smoke. coolant level only when the system is cool.
6. Excessive use of coolant, fuel or lubricating oil. Check Belts

7. Any fuel, coolant or lubricating oil leaks. Visually check belts for looseness. lf there is evidence
of belt slippage adjust as follows:
Check Engine
Using the appropriate gauge, Fig's. 2-2 and 2-3, check
Check Engine Oil Level
Note: Some dipsticks have dual markings, with highl
and low-level marks: static oil marks on one side,
engine running at low idle speed marks on opposite
side. Be sure to use the proper scale.
1. Check the oil level with the dipstick oil gauge
located on the engine. Fig. 2-1. For accurate read
ings, the oil level should not be checked for approx
imately 15 minutes after the engine is shut-down.
Keep the dipstick with the oil pan with which it was
originally shipped. Keep the oil level as near the "H"
(high) mark as possible.
Caution: Never operate the engine with the oil level
below the "L" (low) mark or above the "H" (high) mark.
2. If necessary, add oil of the same quality and brand
as already in the engine. See Section 3. Fig. 2-2. (OM1014L). Checking belt tension with a Krikit gauge
2-7
Table 2-1: Belt Tension (Lbs.)
Belt New Belt* Minimum • Used Beift Installation Tension

Width Belt Tension • II Below
(lb.) ±10 (lb.) 1 10
.380 ST-1274 140-150 60 100

.440 CAN-292 140-150 60 100
1/2 140-150 60 100
11/16 160-170 60 100
3/4 ST-1138 160-170 60 100
7/8 160-170 60 100
K-Sect.
5 Rib ST-1293 125-135 60 100
V-Ribbed
K-Sect.
6 Rib ST-1293 150-160 70 120
V-Ribbed
K-Sect.
10 Rib MM 250-260 140 200
V-Ribbed
- Used belts should be retensiorted to values listed in this column.
Note: A belt is aDnsidered as used if it has been in operation for a period of time of at least 5 minutes.
and/or adjust belts to the tension as indicated in Table the side of the gauge should be flat against the edge
2-1. of the belt
Inline Engine Water Pump Beits

(No idler)
1 . Eccentric water pump adjustment.
a. Loosen the water pump clamp ring to allow the
pump body to turn.
b. Loosen the pump body by pulling up on the
belts. A sharp jerk may be required.
c. lnsert a bar in the water pump body slots and
rotate the pump body counterclockwise to
tighten the belts.
Note: Do not adjust to final tension at this time.

d. Snug the clamp ring capscrew farthest from the
Fig 2-3. (OM1015L). Adjusting belt tension with ST-1293 belts, on the exhaust side to 5 ft-lbs [7 N-m).
e. Snug the two capscrews above and below the
Note: When using the "Krikit" gauge the correct belt
first one to 5 ft-lbs [7 N^m].
tension reading for the belt tested must be read at the
point where the top of the black indicator arm crosses f. Finish tightening by alternating from side to
the bottom numbered scale. Position the gauge in the side in 5 ft-lbs [7 N.m] increments to a final
center of the belt between two pulleys. The flange at torque of 12 to 15 ft-lbs [16 to 20 N.m].
g. Check the belt tension. Inline Engine Water Pump Belts

(With Idler)
Final belt tension was not obtained by adjustment
alone. The water pump body was pulled straight by 1. Loosen the capscrews and lockwashers or locknut
snugging the capscrews in the order described, thus securing the idler pulley to the bracket or water
increasing the belt tension to the final value. pump. Fig. 2-4.
2. Adjustable (split) pulley water pumps, V-903 2. Using a pry bar (NTA) or adjusting screw (FFC)
Engines only. adjust the idler pulley until the proper belt tension
is indicated on the gauge. See Table 2-1 .
a. Remove the capscrews joining the sheave(s) of
the pulley. 3. Secure the idler pulley or bracket in position by
tightening the locknut or capscrews and lock-
Note: Clean the capscrew threads and holes in the
washers to 45 to 55 ft-lbs [61 to 75 N«m] torque.
sheaves thoroughly to avoid capscrew breakage
during reassembly. Note: The self tensioning idler on V-1710 belt driven
water pumps requires no adjustment or belt tension
b. The outer half of the pulley is screwed onto the
check.
hub extension of the inner half. Some pulleys
are provided with flats, and some with lugs for
Fan Drive Beits
barring.
1. Loosen the large locking nut on the fan hub shaft
c. Bar the engine over to roll the belt outward on
or the capscrews securing the fan hub shaft to the
the pulley as the outer half is turned in.
mounting bracket. The fan hub will fall out of line
d. Adjust the belt(s) to the tension indicated in when this is done.
Table 2-1.
2. Turn the adjusting screw to increase the belt
e. Turn the outer sheave(s) in enough to align the tension.
capscrew holes.
3. Tighten the locknut or capscrews until the fan hub
f. Start the capscrews and tighten alternately and is straight. Snug the nut to maintain the hub in
evenly. Final tension is: proper alignment with the fan hub bracket.
5/16-18 capscrew, 10 to 12 ft-lbs [14 to 16 N .m]
Caution: Do not adjust to full tension with the adjust
3/8-16 capscrew, 17 to 19 ft-lbs [23 to 26 N .m]
ing screw, as this would result in overtightening.
g. Bar the engine over one or two revolutions to
4. Belt tension should read as indicated in Table 2-1
seat the belt.
on applicable gauge.
h. Recheck the belt tension.
5. Tighten NH/NT Engines locknut to 400 to 450 ft-lbs
[542 to 610 N.m]; then back off 1/2 turn. Tighten
the four 1/2 inch capscrews, Fig. 2-5, on NTC-350
FFC Engines to 75 to 85 ft-lbs [101 to 115 N.m).
On V-903 Engines tighten capscrews to 75 ft-lbs [102
N.m] or single nut to 450 ft-lbs [610 N.m].
6. Recheck the belt tension.
7. Back out the adjusting screw one-half turn to pre
vent breakage.
Note: The self tensioning backside idler on KT/KTA-
2300 and KTA-3067 belt driven fan requires no belt
tension check.
Generator/Alternator Belts
Belt tension should be as indicated in Table 2-1 when
Fig. 2-4, (N11974). Water pump — with idler measured with the applicable gauge.
2-9
Visually check the fuel system, etc. for misadjustment
or tampering; check all connections for leaks or
Check the engine for damage; correct as
Fig. 2-5. (OM1016I). Fan hub NTC-350 FFC
Belt Installation
lf the belts show wear or fraying, replace as follows:
1 Always shorten the distance between the pulley
centers so the belt can be installed without force.
Never roll a belt over the pulley and never pry it on Fig. 2-6, (N11001).
with a tool such as a screwdriver. Either of
methods
failure.
Always replace the belts in complete
riding depth should not vary over 1/16 in [1.6 mm]
on
Pulley misalignment must not exceed 1/16 in
[1.6 mm] for each ft [0.3 m] of distance between
the pulley i
4. Belts should not bottom on the pulley grooves nor
should they protrude over 3/32 in [2.4 mm] above
the top edge of the groove.
5. Do not allow belts to rub any adjacent parts
6. Adjust belts to the proper tension.
Readjusting New Belts
All new belts will loosen after running for 5 minutes
and must be readjusted to "belt tension after run-in"
Ref. Table 2-1.
Check Oil Bath Cleaner Oil Level

Daily check oil level, Fig. 2-6, in the oil bath air cleaner
to be sure the oil level in the cup is at the indicated
mark. Refill as required.
*Cummins Engine Company, Inc. recommends the
use of dry type air <
2-10
Maintenance lnstructions
"A" Maintenance Checks— Weekly
Repeat Daily Checks
Check Air Cleaner

Clean Pre-Cleaner and Dust Pan
Under extremely dirty conditions an air pre-cleaner
may be used. Clean the pre-cleaner jar and dry-type
air cleaner dust pans daily or more often, as necessary,
depending on operating conditions.
Check Inlet Air Restriction

Mechanical Indicator
A mechanical restriction indicator is available to indi 1. Wiring 3. Vacuum Switch
cate excessive air restriction through a dry-type air 2. Piping 4. Warning Light
cleaner. This instrument can be mounted in the air
Fig. 2-8, (N21905). Vacuum switch to check air inlet
cleaner outlet or on the vehicle instrument panel. The
red flag (1, Fig. 2-7) in the window gradually rises as
the cartridge loads with dirt. After changing or replac 1. Air restriction on turbocharged engines must not
ing the cartridge, reset the indicator by pushing the exceed 25 inches [635 mm) of water or 1.8 inches
reset button (2). [46 mm] of mercury under full power conditions.
2. Naturally aspirated engine air restriction must not
exceed 20 inches [508 mm] of water or 1.5 inches
[38 mm] of mercury at air intake manifold at rated
speed.
Clean or Replace Air Cleaner Elements
The paper element in a dry-type air cleaner, Fig's. 2-9,
2-10, 2-11 and 2-12, may be cleaned several times by
using air to blow off dirt or by washing with nonsudsing
household detergent and water at 120 to 140°F [49 to
60° C], then drying with compressed air, approximately
30 psi [306 kPa]. Do not hold the air jet too close to
the paper element.
Elements that have been cleaned several times will
finally clog and air flow to the engine will be restricted.
After cleaning, check the restriction as previously
Fig. 2-7, (CGS-20). Air inlet restriction indicator
described and replace the element if necessary.
Note: Never remove the felt washer from the indicator. Caution: Holes, loose end seals, dented sealing
lt is necessary to absorb moisture. surfaces and other forms of damage render the
cleaner inoperative and require immediate element
Vacuum Indicator replacement.
Vacuum switches, Fig. 2-8, are available which actuate To change the element:
a warning light on the instrument panel when the air
restriction becomes excessive. 1. Loosen the wing nut (1, Fig. 2-9) securing the
2-11
Fig 2-9. (OM1028L). Air cleaner—dry type Fig. 2-11, (OM1029L) Air cleaner—heavy duty
Caution: Pull the cover and the element straight out

when removing them from the housing, Fig. 2-10, to
avoid damage to the element Fig. 2-12, (OMIoaOL). Air cleaner—heavy duty dual element
-12
3. Remove the gasket (5) from the outlet end (7) of

the housing.
When installing the element, make sure it seats on the
gasket at the air cleaner outlet end.
Heavy Duty Dry-Type Air Cleaners
Heavy duty air cleaners (single and dual types) com
bine centrifugal cleaning with element filtering, Fig's.
2-11 and 2-12, before air enters the engines.
Before disassembly, wipe dirt from the cover and the
upper portion of the air cleaner. To clean single or dual
types:
1 . Loosen the wing bolt, remove the band securing the
dust pan (1, Fig. 2-11), (2, Fig. 2-12).
Fig. 2-13, (N21026). Air cleaner — cartridge type (two stage)
2. Loosen the wing nut (2, Fig. 2-11 and 3, Fig. 2-12),
remove the dust shield (3, Fig. 2-11), (4, Fig. 2-12),
from the dust pan (1, Fig. 2-11), (2, Fig. 2-12), clean
the dust pan and shield.
3. Remove the wing nut (2, Fig. 2-11), (5, Fig. 2-12)
securing the air cleaner primary element (6, Fig.
2-12) in the air cleaner housing, inspect the rubber
sealing washer on the wing nut (4, Fig. 2-11), (5, Fig.
2-12).
4. Blow out the element from the clean air side with
compessed air not exceeding 30 psi [207 kPa].
5. Wash the element with nonsudsing household
detergent and water, 120 to 140° F [49 to 60° C]. Dry
with compressed air, 30 psi [207 kPa].
6. lnspect the element after cleaning.
Fig. 2-14, (V11009). Air cleaner — cartridge type (single stage)
7. lnstall a new or the cleaned primary element.
panel with the dust bin (1). To remove the pre-
8. Be sure the gasket washer is in place under the cleaner panel (2) equipped wth an exhaust aspira
wing nut before tightening. tor loosen the "U" bolt clamp securing the pre-
9. Reassemble the dust shield and dust pan, position cleaner to the aspirator tubing.
them to the air cleaner housing and secure with 2. Remove the dirty Pamic cartridge (3), by inserting
the band. your fingers in the cartridge opening (loosen all
10. On the dual element type Cyclopac cleaner: four corners of the cartridge, one at a time) and
pulling it straight out.
a. Check the air restriction indicator. lf the air
restriction is excessive, disassemble the air With the larger cartridge, it may be necessary to break
cleaner, remove the wing nut (8, Fig. 2-12), and the seal along the edges of the cartridge. After the seal
replace the safety element (9). has been broken, pull the cartridge straight out and
slightly up so the cartridge will clear the sealing frame
b. Reassemble the air cleaner as described in and edges of the air cleaner housing.
"Steps 8 and 9" above.
Cleaning and Inspection
Cartridge Type Air Cleaner Element
1. Clean the pre-cleaner openings (2) of all soot, oil
1. Loosen the wing nuts (4, Fig. 2-13or2-14)ontheair film and any other objects that may have become
cleaner housing (5) to remove the pre-cleaner lodged in the openings. Remove any dust or dirt in
2-13
the lower portion of the pre-cleaner and aspirator and wash the cup in cleaning solvent or fuel oil.
tubing. lnspect the inside of the air cleaner housing
Note: During wet weather and in winter months,
for foreign material.
changing of the oil is equally as important as during
2. lnspect the dirty cartridge for soot or oil. lf there is dusty weather since the air cleaner inlet may be located
soot inside the Pamic tubes, check for leaks in the in an air stream which carries moisture into the cleaner.
engine exhaust system, exhaust "blow-back" into
Fill the oil cup to the level indicated by the bead on the
the air intake and exhaust from other equipment.
side with clean, fresh oil of the same grade as that in
lf the cartridge appears "oily", check for fumes
the crankcase and assemble it to the cleaner. In ex
escaping from the crankcase breather. Excessive
tremely cold weather a lighter grade may be necessary.
oil mist shortens the life of any dry-type cartridge.
A straight mineral, non-foaming detergent, or non-
Troubleshooting at this point can appreciably
foaming additive oil may be used in oil bath air
lengthen new cartridge life.
cleaners.
3. lt is not recommended to clean and reuse the
Caution: Never use dirty oil or used oil.
cartridge. When returned to service, life expectancy
of a paper cartridge will be only a fraction of the Drain Air Tanks
original service life.
ln cold weather, condensed moisture in the air tanks
4. Inspect clamps and flexible hose or tubing to be and lines may freeze and make controls useless.
sure all fittings are air tight on cleaners with exhaust
aspirators. Drain the air tanks to keep all water out of the com
pressed air system.
5. The pre-cleaner dust bin is self-cleaning.
Assembly Drain Sediment from Fuel Tanks
1 . Inspect the new filter cartridge for shipping damage Loosen the fuel tank drain cock or plug, if used, and
before installing. drain approximately 1 cup of fuel to remove water and
sediment. Close the drain cock or plug.
2. To install a new cartridge, hold the cartridge (3, Fig.
2-13 and 2-14) in the same manner as when remov Fuel/Water Filter Separator
ing it from the housing. lnsert the clean cartridge lf more moisture than usual is present when checking
into the housing; avoid hitting the cartridge tubes the fuel tanks, it may be advisable to install a water
against the sealing flange on the edges of the air separator.
cleaner housing.
Contact the nearest Cummins Dealer for a Fleetguard
3. The cleaner requires no separate gaskets for seals; water separator that meets requirements.
therefore, care must be taken inserting cartridge to
insure a proper seat within the cleaner housing. Drain plugs are located in the bottom of some fuel filter
Firmly press all edges and corners of the cartridge cases and in the sump of some fuel supply tanks. More
with your fingers to effect a positive air seal against condensation of water vapor occurs in a partially filled
the sealing flange of the housing. Under no circum fuel tank than in a full one. Therefore, fuel supply tanks
stances should the cartridge be pounded or should be kept as nearly full as possible. Warm return
pressed in the center to effect a seal. ing fuel from the injectors heats the fuel in the supply
tank. lf the fuel level is low in cold weather, the fact
4. Replace the pre-cleaner panel (2) and tighten the that the upper portion of the tank is not being heated
wing nuts (4) by hand, for final tighteness turn 1-1/2 by returning fuel tends to increase condensation. ln
to 2 turns with a small adjustable wrench. Do not warm weather both the supply tank and the fuel are
overtighten. On a pre-cleaner with an exhaust warm. ln the night, however, cool air lowers the
aspirator, assemble the aspirator tube to the pre- temperature of the tank much more rapidly than the
cleaner panel and tighten the "U" bolt. temperature of the fuel. Again this tends to increase
5. Care should be taken to keep the cleaner face condensation.
unobstructed. Engine Front Trunnion
Change Oil Bath Air Cleaner Oil lf used, the engine front trunnion mount should be
Before dirt build-up reaches 1/2 inch [12.7 mm], lubricated with grease meeting specifications as out
remove the oil cup from the cleaner. Discard the oil lined in Section 3.
-14
"B" Maintenance Checks
Table 2-2: Lubricating Oil Filter Elements

At each "B" Maintenance Check, perform all the "A"
Checks in addition to the following.
of Filter Capacity Engine
Lubricating Oil Change Intervals (Element P/N) (Gals.) Family
Note: lf the lubricating oil is drained from the oil pan to Full-flow 0.93 All Engines (except
make an engine repair, new oil must be used. Do not (LF516) V-378 and V-504)
use oil after it has been drained from the oil pan. Full-flow 0.83 V-378 & V-504 Only
(LF613)
Maintaining a proper "B" maintenance check interval Full-flow 0.80 All Engines
is a very important factor in preserving the integrity spin-on (LF670) (Optional on V-555)
of an engine. Lubricating oil contamination is the direct Full-flow 0.65 Standard on All
result of engine operation and the load factor involved. (spin-on short) Small Vee
The amount of contamination generated depends (LF670-SC)
on the amount of fuel the engine consumes. Labora
Bypass, 750 in3 2.91 All Engines
tory and field tests have determined that, when using
(LF750-A) (Except Small Vee)
the recommended quality oils and filters, a turbo- Bypass, 750 in3 2.91 All Engines
charged engine in good condition and equipped with (LF750-C) (Except Small Vee)
a bypass oil filter can consume 255 gallons of fuel Bypass, 750 in3 2.91 All Engines
for each gallon of oil in the oil system before the (LF750) (Except Small Vee)
maximum level of oil contamination is reached. Based Bypass, 500 in3 2.25 Small Vee Only
on these findings, Cummins Engine Company, lnc., (LF500)
recommends that the "B" check interval be determined Bypass, spin-on 0.70 C & I Engines and
by the use of the "Chart Method". At each "B" check (LF777) Small Vee
interval it is recommended to change the full-flow Full-flow 0.50 Standard on All Small
filter and the bypass filter. spin-on Vee (Will replace
(LF734) LF670-SC)
The total lubricating system capacity in gallons can
be determined by adding the high level of the lubri
cating oil in the oil pan and the capacities of the Assume a VT-1710 engine which has the following
full-flow and bypass filters. All lubricating oil systems capacities:
must be rounded to the nearest gallon when applied
Lubricating Oil Pan Capacity 18 gallons
to the chart. Table 2-2 lists the capacities of the
full-flow and bypass filter elements. Full-Flow Filter (3) 2.79 gallons
Bypass Filter 750 in3 (2) 5.82 gallons
Chart Method
Total Lubricating Oil 26.61-27 gallons
From laboratory and field tests we know that the System Capacity
maximum contamination level for a gallon of oil is
reached when 255 gallons of fuel is consumed in a Round this capacity to the nearest whole gallon and
turbocharged engine or 280 gallons of fuel in a select the chart entitled "Off Highway Turbocharged
naturally aspirated engine. The 255 or 280 figure is the with By-Pass Filter" "Lube System Capacity-27 gallons "
constant used in the equation for the oil change period. Also assume the average fuel consumption = 17.5 gal
The following illustration is how to use the chart lons per hour and the average oil consumption = 8 hours
method to determine the recommended oil change per quart.
interval: To read the chart.
2-15
Change Period = Constant x fuel consumed x the oil available.
Oil Available = Oil system capacity + one-half the make-up oil added in a given period.
Oil Added = Change Interval
Oil Consumption Rate
Change Period = The Constant x the fuel consumed x [the system capacity + one-half (the Change Period)
(Oil Consump. Rate)
Solving this equation for the oil change period gives
the equation which is used in developing the Chart
Method.
Change Period = Constant x fuel consumed x oil consumption x system capacity
Oil consumption — one-half (constant x fuel consumed)
1. The numbers along the left side of the chart repre b. Select a group lube oil consumption for entering
sent fuel consumption in gallons per hour. Divide the chart that is halfway between the average lube
the grid between "10" and "20" in 10 equal parts to oil consumption and the lowest oil consumption
find the point for fuel consumption. in the group.
2. Beginning at "17.5" (fuel consumption), draw a 4. Read the appropriate chart for each group using
line from left to right to the curve "8". This curve the fuel consumption determined in 2b and the lube
represents oil consumption at the rate of 8 hours oil consumption determined in 3b. The oil change
per quart. interval determined in this manner should be
applied to the entire group.
3. From the point on the curve "8", draw a line perpen
dicular to the bottom of the chart. The numbers 5. Since some will have more than one group of
across the bottom of the chart represent the oil engine models, a change interval should be deter
change interval in hours. mined for each group. In some cases it may be
wise to divide some groups into sub-groups (such
4. The perpendicular line from the curve "8" intersects
as older NTC-290's and newer Formula 290's) for
the bottom line of the chart between "500" and
which a change interval is determined.
"600". Divide the grid in 5 equal parts to find the
point for the recommended oil change interval. ln 6. Practically, now, a manager must review the oil
this example the recommended oil change interval change intervals determined for each group or
is 505 hours.
LUBE SYSTEM CAPACITY - 27 GALLONS
Since it is not practical with a group of engines to use a
different oil change interval for each engine based
on the chart method, Cummins recommends that
you use the chart method in the following manner:
1. Divide the engines into groups by engine model
(engines with the same lube system capacity).
2a. Determine the average fuel consumption for all
the engines in each group.
b. Select a group fuel consumption, for entering the
chart, that is halfway between the average fuel
consumption and the highest fuel consumption
in the group.
10 I ' ■ II 1
3a. Determine the average lube oil consumption for all 200 300 400 500 600
the engines in the group. OIL CHANGE INTERVAL (HOURSI
?-16
subgroup; consider the other items in his preventa

tive maintenance schedule; consider his own past
practice; and select an oil change interval which
he feels is the best compromise.
Note: Cummins Engine Co., lnc., does not recom
mend exceeding 25,000 miles and/or 600 hours on oil
change intervals. Therefore, the charts or limited to
25,000 miles or 600 hours and must not be extended.
The charts for determining the recommended oil
change intervals are included in the following pages.
Chart Method Alternative
As an alternative to the Chart Method for determining
the "B" maintenance check interval, Cummins Engine
Co., lnc., recommends that the "B" check be performed
every 10,000 miles, 250 hours or 6 months.
Note: Perform the "B" check in 6 month intervals for
engiens in emergency or standby operations and any
other operation where less than the recommended
miles or hours have been accumulated in a 6 month
interval.
2-17
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Lubricating Oil Analysis analytical results should be done as quickly and
carefully as possible to prevent serious engine damage.
An alternate method for determining when to change
lubricating oil and filters is by used oil analysis using
laboratory tests. The analyses used are for the purpose
of determining the amount of contamination in the Table 2-3: Lubricating Oil Condemnation Limits
oil; not for predicting potential engine failures. It is
recommended that new engines be operated through Property (ASTM Method*) Condemnation Limit
at least one oil change interval determined by the
chart method prior to initiating a used oil analysis Viscosity @ 100* C ±1 SAE Viscosity grade"
program. (D-445) from the new oil
ln order to initiate a used oil analysis program for a Insolubles, pentane. 1.0% maximum
large number of engines they should be grouped by noncoagulated
basic model, rated horsepower and type of service. (D-893)
The horsepower range of a group should not exceed Insolubles, toluene. 1.0% maximum
25; in other words NTC-270 and NTC-290 engines
could be placed in the same group, however, NTC-290
and NTC-350 engines should be in separate groups.
Small vee, medium vee, NH and K models should be
in separate groups. After the engines have been
grouped, a sub-group consisting of 10 percent of the
total engines in each group should be selected for (D-664)
the used oil analysis program. lf a group consists of Water content 0.2% maximum
less than 50 engines but more than 25 engines the (D-95)
sub-group size should be 5 engines. For groups of
less than 25 engines the sub-group size should be 8 Additive metal content 75% of new oil level,
(AES or AAS**) minimum
engines. The selecting of the engines for each sub
group should be completely random.
"ASTM (The American Society for Testing and
Each group of engines should be set up on oil change Materials) publishes these methods in their Annual
intervals as described under the "Chart Method". Book of Standards, Part 23. Other methods should
When the engines reach the end of the second chart not be used without consulting Cummins.
method oil change interval, an oil change should be
"SAE Viscosity grades are published by the Society
performed on all units in the group except those
of Automotive Engineers in their annual SAE
engines selected for the sub-group. The engines in
Handbook as SAE Recommended Practice J300d.
the sub-groups should only have an oil sample taken. and are shown in Table 1 of thsi bulletin.
Additional oil samples should be taken from each of
the engines in the sub-groups at every 48-operating- ***AES (Atomic Emission Spectroscopy) and AAS
hour interval after the first sample. This sampling (Atomic Absorption Spectroscopy) are not stan
frequency may be varied somewhat as dictated by the dard ASTM methods, however most used oil
operation. The sampling frequency should not be analysis laboratories are capable of determining
additive metal concentration by one of these
extended beyond 60 hours for equipment safety
methods and sample results determined by the
reason or reduced below 40 hours because of the same laboratory using the same method can be
added analytical costs. safely compared.
This sampling process should continue until the results
of the analyses of the samples indicate that any one
of the condemnation limits listed in Table 2-3 has To determine whether the maximum oil change inter
been reached or exceeded until the desired oil change val has been reached the properties in Table 2-3 should
interval extension is reached. This process should be be determined by the laboratory methods specified.
continued cautiously since the engines in the sub This table also specifies condemnation limits to be
groups are subject to permanent damage because used for determining the lubricating oils' useful life.
of the over-extended oil change interval. The analytical This group of analyses and the methods are not
work on the samples and the examination of the generally part of the oil analyses offered by most
?-26
commercial used oil analysis laboratories. These in Section 3, and genuine Cummins filters on
analyses are not low cost, generally costing between equipment.
$50 and $135 per sample.
Change Spin-On Lubricating Oil Filter Elements
When any one of the condemnation limits is exceeded
1 . Unscrew combination case and elements, Fig. 2-15,
on any one sample an oil change should be performed
discard elements.
on all engines in the sub-group. The hours at which
the sample for which a condemnation limit was ex
ceeded is the oil change interval at which 10% or more
(depending on sub-group size) of the group are using
lubricating oil which has exceeded its useful life. This
sampling and analysis process should be repeated
once to confirm the oil change interval. When this
process is complete the entire group of engines can
be placed on the new oil change interval.
This method of establishing an oil change interval
will determine a different interval for each group of
engines. lt is not possible to provide maintenance
on several different schedules or if one desires to
schedule the oil change to coincide with other mainte
nance, the more conservative (or shorter) maintenance
schedule should be used.
Please contact your Cummins Service Representative Fig. 2-15(OM1018L). Installing lubricating oil filter cartridge
if you need assistance or have any questions about
utilizing this method of determining an oil change
interval. Note: At each filter change check torque of adapter
mounting capscrew; it should be 25 to 35 ft-lbs [34 to
Change Engine Oil 47 N.m]. lf the capscrew is not within torque range,
the adapter may rotate when the spin-on filter is
Factors to be checked and limits for oil analysis are removed. Replace the adapter to the filter head gaskets
listed below. Oil change at "B' Check, as shown in at each "C" maintenance check.
the maintenance chart on Page 2-2, is for average
conditions. 2. Fill the filter with lubricating oil. Apply a light even
coat of lubricating oil to the gasket sealing surface
1. Bring engine to operating temperature, shut down prior to installing the filter.
engine, remove drain plug from bottom of oil pan,
and drain oil.
2. lnstall drain plug in oil pan. On 855, V-903, KT(A)-
1150, KT(A)-2300 and KTA-3067 Engines torque
to 60 to 70 ft-lbs [81 to 95 N.m]. On V-378, V-504
and V-555 Engines torque to 35 to 40 ft-lbs [47 to 54
N.m]. On V-1710 Engines torque to 45 to 55 ft-lbs
[61 to 75 N.m].
3. Fill the crankcase to "H" (high level) mark on the
dipstick.
4. Start engine and visually check for oil leaks.
5. Shut down the engine; allow 15 minutes for oil to
drain back into the pan; recheck the oil level with
the dipstick. Add oil, as required.
Fig. 2-16, (K21907). Installing "spin-on" lubricating oil filter —
Note: Use lubricating oil meeting specifications listed KT(A)-2300 Engine
2-27
3. Position element to the filter head, Fig. 2-16. Change Lubricating CM By-Pass Filter Element
Tighten by hand until the seal touches the filter
Note: By-pass filters may be mounted either vertically,
head, tighten an additional one-half to three-
horizontally or inverted; all are serviced in like manner.
fourths turn.
1. Remove the drain plug (5, Fig. 2-17) and drain oil.
2. Remove the clamping ring capscrew (1) and lift
off the cover.
4. Run the engine, check for leaks, recheck engine
oil level; add oil as necessary to bring the oil level 3. Unscrew the support hold-down assembly (3); lift
to "H" mark on the dipstick. out the element (4) and the hold-down assembly.
Discard the element
Note: Always allow oil to drain back to the oil pan
before checking the level. This may require 15 minutes. 4. Clean the housing and hold-down assembly in
solvent.
Change the LF—777 Lubricating CM Spin-On
By-pass Filter. 5. Inspect the hold-down assembly spring and seal.
Replace if damaged.
1. Unscrew the spin-on filter from the filter head;
discard the filter. 6. Inspect the drain plug and connections. Replace
if damaged.
2. Apply a light even coat of lubricating oil to the
gasket sealing surface, prior to installing the filter. 7. Check the orifice plug (6) inside the oil outlet con
nection or standpipe; blow out with air to open
3. Position the filter to the filter head. Tighten by hand
and clean.
until the seal touches the filter head; tighten an
additional one turn. 8. Check the filter cover O-ring (7). Replace if
necessary.
4. Run the engine, check for leaks, shut-down the
engine. Add oil as necessary to bring the oil level 9. Install the new element in the housing. Fig. 2-1 &
to the "H" mark on the dipstick.
10. Replace the support hold-down assembly in the
filter and tighten down to stop.
11. Position the O-ring seal on the housing flange.
12. Install the cover and clamping ring; tighten the cap-
screws until the clamping lugs are indexed.
13. Run the engine, check for leaks; add enough extra
oil to the crankcase to fill to the "H" (high) mark
on the dipstick.
cig. 2-17, (V41908). By-pass filter cross section Fig. 2-18, (K21908). Installing by-pass filter element
28
Caution: Never use a by-pass filter in place of a full-flow Replaceable Element

filter. 1. Open the drain cock(s) and drain the contents.
Change Fuel Filter Element 2. Loosen thenut(s) atthetopofthefuelfilter(s).Take
out the dirty element, clean the filter case(s) and
Spin-On Type Filter install new element(s). Fig. 2-20.
1. Unscrew the combination case and element. Fig.
3. lnstall new gasket(s) in the filter(s) and assemble
2-19, discard the element.
the case(s) and element(s). Tighten center bolt(s)
2. Fill the new filter with clean fuel and apply a light to 20 to 25 ft-lbs [27 to 34 N.m] with a torque
even coat of lubricating oil to the gasket sealing wrench. Fill the filter case(s) with clean fuel to aid
surface prior to installing the filter. in faster pick-up of fuel.
3. lnstall the filter; tighten by hand until the seal 4. Check the fittings in the filter head(s) for leaks.
touches the filter head. Tighten an additional one- Fittings should be tightened to 30 to 40 ft-lbs [41 to
half to three-fourths turn. 54 N.m].
Check Engine Coolant

Periodic tests of the engine coolant should be made
to ensure that the frequency of water filter servicing
or concentration of DCA inhibitor is adequate to
control corrosion for any specific condition of opera
tion. ln cases where "make-up" water must be added
frequently, we suggest that a supply of water be treated
and added as necessary.
The concentration of effective inhibitor dissolved in
Fig. 2-19, (V11909). Changing "spin-on" type fuel filter
Caution: Mechanical tightening will distort or crack

the filter head.
Fig. 2-20,(OMl021L). Installing replaceable fuel filter element Fig. 2-21, (N12021). DCA coolant test kit
2-29
the coolant can be measured by a Fleetguard DCA

Coolant Checking Kit Part No. 3300846-S or Cummins
3375208 which is available from Cummins Distributors
for this check. Fig. 2-21.
The test kit indicates DCA concentration by measuring
the total nitrite of a coolant sample, which provides
cylinder liner cavitation protection.
When antifreeze is present, it may contribute to the
total nitrite, but most of the nitrite protection is ob
tained from the DCA inhibitor. ln general, a good nitrite
reading indicates that the combined inhibitor packages
contained in the antifreeze (if used) and in DCA are
sufficient to ensure complete cooling system
protection.
Fig. 2-22. (V12022). Mixing
1. Rinse the plastic dropper pipet several times with
the engine coolant Fill the dropper exactly to the 5. Continue adding drops of solution A, keeping
1.0 ml. mark. Discharge into the empty vial. count of the number of drops and swirl between
each drop until the color changes from red to a pale
2. Fill the vial to the 10 ml. scribe mark with tap water
grey, green, or blue.
and mix well. (This dilution step is necessary to
minimize the differing colors of antifreeze.) 6. Record the number of drops required for the color
change and consult Table 2-4 for coolant condition
3. Add two or three drops of Solution B and swirl to
and recommended i
form a uniform red color.
4. Add one drop of Solution A to the vial, being careful
to hold the dispenser provided in a vertical postion. 1. Test the coolant for DCA according to the nitrite
Swirl. test procedure "With or Without Antifreeze"
Table 2-4: Nuniber of Drops of Test S olution "A"
Coolant With Coolant Without1

Maintenance r
0-12 0-6 Dangerous (0 to 0.6 oz. per Precharge system or add
gallon DCA) make-up DCA to top tank
12-17 7-12 Borderline (0.7 to 1.2 oz. per Replace service filter and/or
gallon DCA) add make-up DCA to top tank.
18-25 13-20 Acceptable (1.3 to 2.0 oz. per None.
gallon DCA)
25-30 20-30 Tolerable (2.0 to 3.0 oz. per None.
gallon DCA)
Over 30 Over 30 Overrated (over 3.0 per gallon Drain part of coolant and
DCA) make-up with plain antifreeze
and water.
Note: Ethylene glycol/water solutions should not contain more than 3.0 oz. DCA or Dowtherm 209/water solutions
should not contain more than 2.0 oz. per gallon DCA. Concentrations in of the above can cause sludge to form
in the water filter.
depending on the presence or absence of anti 500 gallons [1892 l] yields a total DCA requirement
freeze in the cooling system. of 750 oz. [46 lb. 14 oz.) [21.3 kg].
2. Estimate the make-up DCA. For example, if a fifteen 4. Add the water to the holding tank. Agitating con
gallon cooling system contains only 0.5 oz/gal. tinuously, add the DCA to the water in small
[4 ml per l] DCA, and 1.5 oz/gal. [12 ml per l] is amounts until all of the chemical has dissolved.
required, 15 ounces [426 g] of DCA should be The water should be above 50° F [10°C].
added to the make-up coolant.
5. Add the antifreeze last, if used, maintaining agita
Note: A one pint bottle of DCA-4L liquid (P/N 3300858) tion to bring and keep the finished coolant in
contains six dry ounces of DCA chemical in Step 2, solution. Both antifreeze and DCA will settle to the
concentrations are in dry ounces of chemical per bottom of the tank unless constant mixing or recir
gallon of coolant. culation is provided. An example of recirculation is
the use of a small pump operating continuously
3. Estimate the total amount of make-up coolant
to draw DCA and antifreeze off the bottom of the
required (gallons), and calculate the proportions
tank and discharging the solution at the top.
of water and antifreeze, if used, required. For
Samples of coolant can be drawn off the top, middle
example, one gallon of 50-50 antifreeze/water
and bottom of the storage tank and tested for anti
solution will require two quarts of antifreeze and
freeze and/or DCA concentration if inadequate
two quarts of water.
mixing is suspected.
4. Add the required amount of water to a mixing
Change DCA Water Filter
container and dissolve the number of ounces of
DCA obtained in Step 2 in the water. lf negative Change the filter or element at each "B" Check; selec
or zero results were obtained in Step 2, do not add tion of element to be used should be based upon the
DCA. (For DCA to dissolve, water should be above size of the system. See "Coolant Specifications",
50° F [10° C].) Section 3.
5. Add the required amount of antifreeze, if used, to Note: Whenever the coolant supply is changed the
the water solution and mix thoroughly. system must be drained, flushed, and precharged. See
"Coolant Specifications", Section 3 for DCA compati
6. Add the make-up coolant to the cooling system.
bility with different brands of antifreeze.
Note: lf the DCA concentration is low, and the coolant
level high, DCA may be added directly to the radiator Spin-On Element
in the amount indicated in Step 2. The engine should 1 . Close the shut-off valves on the inlet and drain lines.
be running and warm enough to permit coolam circu
2. Unscrew the element and discard.
lation throughout the entire system.
3. Apply a light even coat of lubricating oil to the
Bulk Storage of Make-Up Coolant
If make-up coolant is stored in bulk, the following
recommendations are provided for mixing and storing
the coolant.
1. Drain and clean the bulk storage tank to remove
any possible contaminants.
2. Krowing the total capacity of the holding tank,
calculate the proportions of water and antifreeze,
if used, required. For example, a 500 gallon [1892 1]
tank will hold 250 gallons [946 l] of water and 250
gallons [946 l] of antifreeze for a 50-50 mixture.
3. Multiply the desired DCA concentration by the
total capacity of the holding tank in gallons. ln the
example above, 1.5 oz. DCA per gallon [12 ml per l]
of coolant can be used in the 50-50 mixture. Multi
plying 1.5 oz. DCA per gallon [12 ml per l] times Fig. 2-23, (OM1023L). Installing DCA water filter cartridge
2-31
Operation and l
gasket sealing surface prior to intalling the filter.

lnstall a new element, tighten until the seal touches
the filter head. Tighten an additional one-half to
three-fourths turn. Fig. 2-23. Open the shut-off
valves.
Caution: Mechanical will distort or crack
Check Oil Levels

Check Aneroid Oil
1. Remove the pipe plug from the hole marked "Lub
Oil".
2. Fill with engine lubricating oil to the level of the
pipe plug hole. Reinstall the pipe plug.
Check Hydraulic Governor Oil Level
Keep the level half-way up on the inspection glass or
to the high-level mark on the dipstick. Use the i
grade oil as used in the engine.
1 . Remove the wing nut (6, Fig. 2-24), flatwasher and

rubber washer securing the cover (1), to the
breather body (5).
2. Lift off the cover and life out the breather element
(2), vapor element (3), and gasket (4).
3. Clean all metal and rubber parts in an approved
cleaning solvent. Dry thoroughly with compressed
air.
4. lnspect the rubber gasket; replace it if necessary.
lnspect the body and cover for cracks, dents or
breaks; discard all unserviceable parts.
5. lnstall a cleaned or new breather element (2, Fig.
2-24) and cleaned vapor element (3) to the
breather body (5).
6. lnstall the rubber gasket (4) in the cover (1); posi
tion the cover assembly to the body (5). Fig. 2-25, (N11934) Crankcase breather — type
7. Install the rubber washer, flatwasher and wing nut

(6); tighten securely. 3. Clean the vent tube, screens and baffle in an
approved cleaning solvent. Dry with compressed
Screen Element Breather — Cleaning and Inspection air. Wipe out the breather housing.
1. Remove the vent tube if not previously removed. 4. Assemble the baffle and screens, if used, and a new
gasket in the body.
2. Remove capscrews, washers, cover, screens and
baffle if used, from the breather body. Fig. 2-25. 5. Replace the cover with the cover boss resting
32
securely on the point of the screen, if used; secure

with washers and capscrews.
6. Replace the vent tube.
Clean Air Compressor Breather

When used, service breathers regularly as follows:
Bendix-Westinghouse Paper Element
Remove the breather cover and element. Fig. 2-26.
Clean by reverse flushing with compressed air; reas
semble on the compressor. Discard the element if
it is damaged or unsuitable for cleaning.
Fig. 2-27, (V414209). Cummins air compressor breather — paper

element
Note: At any time the three-prong unloader hat is used,

it will set up air pulsations across the compresor intake
which can destroy the paper element. Pipe intake air
for Cummins compressors from the engine air mani
fold when the three-prong unloader hat is applied;
current factory-installed compressors are so equipped.
This same procedure may be used for any Cummins
Compressor in the Field.
Clean Tray Screen

Fig. 2-26. (V41420). Bendix-Westinghouse air compressor breather Clean the tray screen in kerosene or cleaning solvent.
Dry with compressed air, reassemble to the cleaner.
Bendix-Westinghouse Sponge Note: lf the tray screen is extremely dirty, it may be
Remove the breather from the air compressor. Dis necessary to singe the screen with a flame. Do not melt
assemble the breather, wash all metal parts in solvent the tin plate on the screen.
and blow dry with compressed air. Wash the element
in solvent; remove all solvent from the element; dip it in
clean engine oil and squeeze excess oil from the
element.
Cummins Paper
Clean the element at each "D" maintenance check.
Remove the wing nut securing the front cover to the
body. Lift off the front cover and element. lnspect the
paper element before cleaning by reverse flow of
compressed air; discard the element if it is damaged
or unsuitable for cleaning. Fig. 2-27.
Caution: Do not rupture the filter element.
Clean the body and front cover with a clean cloth. With
the rubber gasket on center bolt, place the element in
the front cover and assemble over the center bolt;
secure with the wing nut.
2-33
"C" Maintenance Checks
At each "C" Maintenance Check, first perform all A", Valve Set Mark Alignment
and "B" Checks in addition to those following:
1. Turn the crankshaft in direction of rotation until
No. 1 "VS" mark appears on the vibration damper
Adjust Injectors and Valves
or crankshaft pulley. See Fig. 2-28 for the location
lt is essential that the injectors and valves be in correct of the valve set marks. ln this position, both intake
adjustment at all times for the engine to operate and exhaust valves must be closed for cylinder
properly. One controls engine breathing; the other No. 1 ; if not, advance the crankshaft one revolution.
controls fuel delivery to the cylinders. See Fig. 2-29, Fig. 2-30 and Table 2-5 for firing
order.
Final operating adjustments must be made using
correct values as stated.
Caution: Be sure the injector and valve set markings,
wherever located, are in proper alignment with the
indicator mark.
The following temperature conditions provide the

necessary stabilization of engine components to allow
for an accurate valve and injector adjustment.
Cummins Engine Company, lnc. recommends that
valve and injector plunger adjustments be made when
the engine is cold. The engine must be at any stabilized
temperature of 140° F [60° C) or below.
A second setting or resetting after the engine is warm
is not recommended.
Fig. 2-28, (OM1035L). Valve set marks—V/VT-555, C.I.D. Engine
Injector Plunger Adjustment Using Torque
Method, V/VT-378, V/VT-504, V/VT-555 Engines
The injectors and valves must be in correct adjustment
at all times for the engine to operate properly. This
controls engine breathing and fuel delivery to the
cylinders. Final adjustment must be made when the
engine is at operating temperature. The injectors must
always be adjusted before the valves. The procedure
is as follows:
Fig. 2-29. (V11461). V6 firing order

2-34
contacts the cup and advance an additional 15

degrees to squeeze the oil from the cup.
Fig. 2-30, (V11462) V8 firing order
Note: Do not use the fan to rotate the engine.

Fig. 2-31, (OM1037L). Adjusting injector plunger
2. Adjust the injector plunger, then the crossheads
and valves of the first cylinder as explained in suc
ceeding paragraphs. Turn the crankshaft in the 2. Loosen the adjusting screw one turn. Using a
torque wrench calibrated in in-lbs and a screw
direction of rotation to the next "VS" mark corres
driver adapter, tighten the adjusting screw to the
ponding to the firing order of the engine and the
values shown in Table 2-6 for cold setting and
corresponding cylinder will be ready for adjust
tighten the locknut.
ment. See Table 2-5.
3. Continue turning the crankshaft in the direction of
rotation and making adjustments until all injectors Table 2-6: Injector Plunger Adjustment Torque
and valves have been correctly adjusted. V/VT-378, V/VT-504, V/VT-555 Engines
Oil Temperature Oil Temperature

Table 2-5: Engine Firing Order V Engines Cold Hot
Right Hand V8 1-5-4-8-6-3-7-2 60 in-lbs [6.8 N .m] 60 in-lbs [6.8 N -m]

Right Hand V6 1-4-2-5-3-6
Note: Two complete revolutions of the crankshaft are

needed to set all injector plungers and valves. The
injector and valves can be adjusted for only one cylin
der at any one "VS" setting.
Injector Plunger Adjustment
Before adjusting the injector, tighten the injector hold-
down capscrew to 30 to 35 ft-lbs [41 to 47 N am].
The injector plungers of all engines must be adjusted
with an in-lb torque wrench to a definite torque setting.
Snap-On Model TQ12B or equivalent torque wrench
and a screwdriver adapter can be used for this adjust
ment. Fig. 2-31.
1. Turn the adjusting screw down until the plunger Fig 2-32 (OM1038L). Tighten injector adjusting screw locknut
3-
Note: After all the injectors and valves are adjusted and 3. Turn down the crosshead adjusting screw until rit
the engine has been started and warmed up to 140° F touches the valve stem. Fig. 2-33.
[69° CJ oil temperature, reset the injectors to the warm
4. Hold the adjusting screw in this position and torque
setting. This is only necessary if the injectors, lever
the locknut to the values listed in Table 2-8.
assemblies, or push rods have been changed.
5 Check the clearance between the crosshead and
3. Hold the injector adjusting screw and tighten the
the valve spring retainer with a wire gauge. There
injector adjusting screw locknut to the values indi
must be a minimum of 0.025 inch (0.64 mm] clear
cated in Table 2-7.
ance at this point.
When an ST-669 Adapter is used, nut torque is reduced
Valve Adjustment
to compensate for additional torque arm length. Fig.
2-32. The same crankshaft position used in adjusting the
injectors is used for setting the intake and exhaust
valves.
Table 2-7: Injector and Valve Locknut Torque
V/VT-378, V/VT-504, V/VT-555 Engines
Table 2-8: Crosshea d Locknut Torque
Without ST-669 With ST-669
Without ST-669 With ST-669
40 to 45 ft-lbs. 30 to 35 fl-lbs.
[54 to 61 N -m] [41 to 47 N -m] 25 to 30 ft-lbs. 22 to 26 ft-lbs
[34 to 41 N-rn] [30 to 35 N -m]
Crosshead Adjustment
1. Loosen the locknut and back off the adjusting
Crossheads are used to operate two valves with one
screw. Insert a feeler gauge between the rocker
rocker lever. The crosshead asjustment is provided to
lever and the top of the crosshead. Valve clearances
assure equal operation of each pair of valves and
are shown in Table 2-9. Turn the screw down until
prevent strain from misalignment.
the lever just touches the gauge and lock the
1 . Loosen the valve crosshead adjusting screw lock- adjusting screw in this position with the locknut.
nut and back off the screw one turn. Fig. 2-34. Torque the locknut to the values indicated
in Table 2-7; note Step 2 under "Injector Plunger
2. Use light finger pressure at the rocker lever contact
Adjustment".
surface to hold the crosshead in contact with the
valve stem (without the adjusting screw).
Table 2-9: Valve Clearances — Inch [mm]

V/VT-378, V/VT-504, V/VT-555 Engines
lntake Valve Exhaust Valve

Oil Temperature Oil Temperature
Cold Cold
0012 0 022
[0.30] [0.56]
V-903 Engines Injector Adjustment,

Using Dial Indicator Method
This method involves adjusting the injector plunger
Fig 2-33. (OM1039L). Adjusting crossheads
2-36
"VS" mark for cylinder 2-8 is aligned with the pointer.

ln this position both the intake and exhaust valve
rocker levers for No. 2 cylinder should be free and can
be moved up and down. lf not, bar the engine another
360 degrees in the direction of rotation and realign the
2-8 "VS" mark.
Fig. 2-34, (OM1040L). Adjusting valves
travel with an accurate dial indicator rather than

tightening the adjusting screw to a specified torque.
The "indicator method" eliminates errors in adjustment
caused by friction in the screw threads and distortion
from overtightening the adjusting screw locknut. A Fig 2-35, (OM1041L). Barring V-903 Engine
check can be made of the adjustment without disturb
ing the locknut or screw setting. The valves can also
be checked or set while adjusting the injectors by this The timing mark locations (Fig's. 2-36 and 2-37) are
method. See Table 2-10 for specifications. used with the dial indicator method of setting the
injectors and valves. Alignment, in either location,
should be held to within one-half inch [12.7 mm] of
Table 2-10: Adjustment Limits Using Dial lndicator the pointer.
Method Inch [mm] V-903 Engines
lnjector Plunger Valve Clearance

Travel lntake Exhaust
1 to 1 Rocker Lever Ratio — lnjector Lever P/N 211319
0.187 ± 0.001 0.012 0.025

[4.75 ± 0.03] (0.30] [0.64]
Before adjustment, tighten the injector hold-down

capscrew to 30 to 35 ft-lbs [41 to 47 N .m) torque.
Note: Remove the key, and using either a 3/8 inch hex
drive for female type barring device or a 5/8 inch six-
point socket for the male type barring device, press
inward until the barring gear engages the drive gear;
then advance. Fig. 2-35. After completion of adjust Fig. 2-36, (OM1042L) Location of timing marks on front cover and
ment, be sure the drive retracts and install the key into vibration damper
the safety lock groove.
Note: No. 2 cylinder is selected for the purpose of
Using the regular engine barring device, Fig. 2-35, illustration only. Any other cylinder could be used, if
rotate the engine in the direction of rotation with the so desired.
2-37
Using ST-1251 Rocker Lever Actuator, bottom the
injector plunger, check the zero (0) setting. Fig.
2-39. Allow the plunger to rise slowly, the indicator
must show the plunger travel to be within the range
specified in Table 2-10.
Fig. 2-37. (V514127). Valve set mark on accessory drive — V-903
1. Set up the ST-1270 lndicator Support with the •

indicator extension atop the injector plunger flange
at No. 2 cylinder, Fig. 2-38.
Fig. 2-39. (V514128). Bottoming injector plunger in cup — V-903
5. Using ST-669 Torque Wrench Adapter to hold the

adjusting screw in position, torque the locknut
30 to 35 ft-lbs [41 to 47 N .m]. lf the torque wrench
adapter is not used, hold the adjusting screw with
a screwdriver, torque the locknuts 40 to 45 ft-lbs
[54 to 61 N.mJ.
6. Actuate the injector plunger several times as a
check of the adjustment. Remove the dial indicator
assembly.
7. Adjust the valves on the appropriate cylinder as
determined in Step 1 and Table 2-10. Tighten the
locknuts the same as the injector locknut.
Fig. 2-38, (V514114). Dial indicator in place — V-903
2. Screw the injector lever adjusting screw down until

the plunger is bottomed in the cup, back off approx
rocker lever. The crosshead adjustment is provided to
imately 1/2 turn then bottom again, set the dial
indicator at zero (0).
Note: Care must be taken to assure the injector plunger
1. Loosen the valve crosshead adjusting screw lock-
is correctly bottomed in the cup, without overtighten
nut and back off the screw one turn.
ing the adjusting screw, before setting the dial
indicator. 2. Use light finger pressure at the rocker lever contact
surfgace to hold the crosshead in contact with the
3. Back the adjusting screw out until a reading of
valve stem (without adjusting screw). Fig. 2-40.
0.187 inch [4.75 mm], reference Table 2-10, is
obtained on the dial indicator. Snug tighten the 3. Turn down the crosshead adjusting screw until it
locknut. touches the valve stem.
2-38
lever and the top of the crosshead. Fig. 2-41 . Valve

clearances are shown in Table 2-10. Turn the screw
down until the lever just touches the gauge, and
lock the adjusting screw in position with the lock-
nut. Torque the adjusting screw locknuts to 40 to
45 ft-lb [54 to 61 N .m] or 30 to 35 ft-lb [41 to 47
N.m] when using an ST-669 Adapter.
2. Always make the final valve adjustment after the
injectors are adjusted.
NH-743, N-855, C.I.D. Engines, Injector and

Valve Adjustment (Dial Indicator Method)
Note: Before adjusting the injectors and valves be sure
to determine if the rocker housings are cast iron or
aluminum and use the appropriate setting.
Fig. 2-40. (V51490). Adjusting crossheads — V-903
Before adjusting the injectors, torque the cylindrical
injector, hold-down capscrews in alternate steps to
4. Hold the adjusting screw in position and torque the 10 to 12 ft-lbs [14 to 16 N.m]. With flange injectors
locknut to the values listed in Table 2-8. torque the hold-down capscrews in alternate steps to
Note: Be sure that the crosshead retainer on the ex 12 to 14 ft-lbs [14.6 to 18 N.m]. Tighten the fuel inlet
haust valves, if used, are positioned equally on both and drain connections to 20 to 25 ft-lbs [27 to 34 N .m]
sides of the spring over the crossheads and valve in the flange injectors.
springs properly. Maintenance Adjustment
5. Check the clearance between the crosshead and 1. Bar the engine until "A" or 1-6 "VS" mark on the
the valve spring retainer with a wire gauge. There pulley, Fig. 2-42, is aligned with the pointer on the
must be a minimum of 0.025 inch [0.64 mm] clear gear case cover. ln this position, both valve rocker
ance at this point. levers for cylinder No. 5 must be free (valves
Valve Adjustment closed). The injector plunger for cylinder No. 3
must be at top of its travel; if not, bar the engine
The same engine position used in adjusting injectors 360 degrees, realign the mark with the pointer.
is used for setting intake and exhaust valves.
2. SetupST-1170 lndicator Support with the indicator
1. Loosen the locknut and back off the adjusting extension on the injector plunger top at No. 3
screw. lnsert a feeler gauge between the rocker
16 TC
Borl
25 VS
Fig. 2-42, (N1 14230). Accessory drive pulley marking —

Fig. 2-41. (V51492). Adjusting valves — V-903 N-855
2-39
Fig. 2-43, (OM1051L). Extension in contact with plunger Fig 2-44. (OM1052L). Actuating rocker lever
several times as a check of the adjustment. Tighten

cylinder, Fig. 2-43. Make sure the indicator exten to 30 to 35 ft-lbs [41 to 47 N • m] when using ST-669
sion is secure in the indicator stem and not against Adapter.
the rocker lever.
Note: Cylinder No. 3 for injector setting and cylinder Table 2-12: Adjustment Limits 1Jsing Dial Indicator
No. 5 for valve setting are selected for illustration pur Method Inch [mm] N-855 Engim
poses only. Any cylinder combination may be used as
a starting point. See Tabel 2-11. Injector Plunger
OH Travel Valve Clearance
Temp. Inch [mm] Inch [mm]
Table 2-11: Injector and Valve Set Position
Adj. Value Intake Exhaust
N-855 Engines
Aluminum Rocker Housing
Bar in Pulley Set Cyiind
Direction Position Valve Cold 0.170 0.011 0.023
[4.32] [0.28] [0.58]
Start A or 1-6VS 3 5 Hot 0.170 0.011 0.023
Adv. To B or 2-5VS 6- 3 [4.32] [0.28] [0.58]
Adv. To C or 3-4VS 2 6
A or 1-6VS 4 2 fôct
oasi Imn
iron Dn
Adv. To
Adv. To B or 2-5VS 1 4 0.013 0.025
Cold 0.175
Adv. To C or 3-4VS 5 1 [0.63]
[4.45] [0.32]
Hot 0.170 0.011 0.023
[4.32] [0.28] [0.58]
3. Using ST-1 193 Rocker Lever Actuator. Fig. 2-44, or
equivalent, bar the lever toward the injector until NT-855 (Big Cam only - N on Top-Stop)
the plunger is bottomed to squeeze the oil film
0228 0 011 0.023
from the cup. Allow the injector plunger to rise, [0.58]
[5.79] [0.28]
then bottom again. Set the indicator at zero (0).
Check the extension contact with the plunger top. Note: Check engine dataplate for injector and valve setting.
4. Bottom the plunger again, release the lever; the Adjust Injectors and Valves (Torque Method)
indicator must show travel as indicated in Table V-1710, NH-743, N-855 C.I.D. Engines
2-12. Adjust as necessary.
Timing Mark Alignment
5. lf loosened, tighten the locknut to 40 to 45 ft-lbs
[54 to 61 N.m] and actuate the injector plunger 1 . lf used, pull the compression release lever back and
2-40
block in the open position only while barring the valves closed; this is the cylinder to be adjusted.
engine.
5. Adjust the injector plunger first, then the cross-
2. Loosen the injector rocker lever adjusting nut on all heads and valves to the clearances indicated in the
cylinders. This will aid in distinguishing between following paragraphs.
cylinders adjusted and not adjusted.
6. For the firing order See Table 2-13 for lnline
Note: Before adjusting the injectors and valves be sure Engines and Tabel 2-14 and Fig. 2-47 for V-1710
to determine if the rocker housings are cast iron or Engines.
aluminum and use the appropriate setting.
3. Bar the engine in the direction of rotation until a
valve set mark (Fig's. 2-45, 2-46 and 2-47) aligns
with the mark or pointer on the gear case cover. "V
Example: A or 1-6 "VS" on lnline Engines or 1-6R
"VS" on V-1710 Engines. ©0© ©0©
4. Check the valve rocker levers on the two cylinders
aligned as indicated on the pulley. On one cylinder
of the pair, both rocker levers will be free and the
000 00©
Fig 2-47. (V414231). V-1710 piston position
Table 2-13: Engine Firing Order N-855 Engines
Right Hand Left Hand

Rotation Rotation
1-5-3-6-2-4 1-4-2-6-3-5
Fig. 2-45, (V41484). Valve set mark — V-1710 Table 2-14: Firing Order V-1710 Engines
Right Hand —
1 L-6R-2L-5R-4L-3R-6L-1 R-5L-2R-3L-4R
Left Hand —
1 L-4R-3L-2R-5L-1 R-6L-3R-4L-5R-2L-6R
7. Continue to bar the engine to the next "VS" mark

and adjust each cylinder in the firing order.
Only one cylinder is aligned at each mark. Two
complete revolutions of the crankshaft are required to
adjust all cylinders.
lnjector Plunger Adjustment
The injector plungers must be adjusted with an inch-
Fig. 2-46. (N114220-A). Valve set mark — N-855 pound torque wrench to a definite torque setting.
2-41
Construction and lndustrial
Adjustment
Crosseheads are used to operate two valves with one
rocker lever. The crosshead adjustment is provided to
1 . Loosen the valve crosshead adjusting screw lock-
nut and back off the screw (4, Fig. 2-50) one turn.
Table 2-15: Injector Plur *— nt —

Inch-lbs [N -m]
Cold Set Hot Set
V-1710 Engines
Fig 2-48. (V414190). Adjusting injector plunger — V-1710
50 [0.6]
NH-NT-743 and 855 Engines
Cast lron Rocker Housing
48 [5.4] 72 [8.1]
71 [81] 72 [8.1]
Fig. 2-49. (OM1037L). Adjusting injector plunger
Snap-On Model TE-12 or equivalent torque wrench

and a screwdriver adapter can be used for this adjust
ment. See Fig's. 2-48 and 2-49.
1 . Turn the adjusting screw down until the plunger
contacts the cup and advance an additional 15
degrees to squeeze the oil from the cup. Fig 2-50. (N21461) Valve crosshead
Note: Number one L and one R cylinders on V-1710
Engines are at the gear case of the engine. 2. Use light finger pressure at the rocker lever contact
surface (1) to hold the crosshead in contact with
2. Loosen the adjusting screw one turn; then using a the valve stem (2).
torque wrench calibrated in inch-pounds and a
screwdriver adapter tighten the adjusting screw to 3. Turn down the crosshead adjusting screw until it
the value shown in Tabel 2-15 and tighten the touches the valve stem (3).
locknut to 40 to 45 ft-lbs [54 to 61 N.m] torque. 4. Using ST-669 Torque Wrench Adapter, tighten
lf ST-669 Torque Wrench Adapter is used, torque to the locknut to 22 to 26 ft-lbs [30 to 35 N.m]. If
30 to 35 ft-lbs [41 to 47 N.m]. ST-669 is not available, hold the screws with a
-42
screwdriver and tighten the locknuts to 25 to 30 set while adjusting the injectors by this method. See
ft-lbs [34 to 41 N.m]. Table 2-17.
5. Check the clearance between the crosshead and 3375004 lnjector Adjustment Kit is used to adjust the
the valve spring retainer with a wire gauge. There injectors with or without Jacobs Brake units installed.
must be a minimum of 0.020 inch [0.51 mm] clear
lt is essential that the injectors and valves be in correct
ance at this point.
adjustment at all times for the engine to operate
Valve Adjustment properly.
The same engine position used in adjusting the
injectors is used for setting the intake and exhaust
Table 2-1 7: Injector and Valve Set Position KT(A)-1 1 50
valves.
1 . While adjusting the valves, make sure that the com Bar in Pulley Set Cylinder
pression release, on those engines so equipped, Direction Position Injector Valve
is in the running position. Start A 3 5
2. Loosen the locknut and back off the adjusting Adv. To B 6 3
screw. lnsert a feeler gauge between the rocker Adv. To C 2 6
lever and crosshead. Turn the screw down until the Adv. To A 4 2
Adv. To B 1 4
lever just touches the gauge and lock the adjusting
Adv. To C 5 1
screw in this position with the locknut. Tighten the
locknut to 40 to 45 ft-lbs [54 to 61 N.m] torque. Firing Order 1-5-3-6-2-4
When using ST-669 torque to 30 to 35 ft-lbs [41 to
47 N.m).
One controls engine breathing; the other controls
3. Always make final valve adjustment at stabilized fuel delivery to the cylinders.
engine lubricating oil temperature. See Table 2-16
Operating adjustments must be made using the
for the appropriate valve clearances.
correct values as stated.
Injector and Valve Adjustment
Table 2-16: Valve Clearances — Inch [mm] Note: Do not use the fan to rotate the engine. Remove
the shaft retainer key. Fig. 2-51, and press the shaft
Intake Valves Exhaust Valves inward until the barring gear engages the drive gear;
Cold Set Cold Set then advance. After the adjustments are complete
retract the shaft and install the retainer key into the
V-1710 Engines safety lock groove.
0.014 [0.36] 0.027 [0.69]
NH-NT-743 and 855 Engines
Cast lron Rocker Housing
0.016 [0.41] 0.029 [0.74]
0.014 [0.36] 0.027 [0.69]
Injector and Valve Adjustment Using 3375004

Dial Indicator Kit KT(A)-1150 Engines
This method involves adjusting the injector plunger
travel with an accurate dial indicator. A check can be
made of the adjustment without disturbing the locknut
or screw setting. The valves can also be checked or Fig. 2-51. (K11919). Engine barring arrangement — KT(A)-1150
2-43
Operation and
Caution: The barring mechanism gear must be

completely engaged when barring the engine to avoid
damage to the teeth of the gear.
1 . Bar the engine in the direction of rotation until "B"
mark on the pulley, Fig. 2-52, is aligned with pointer
on the gear case cover. ln this position, both valve
rocker levers for cylinder No. 3 must be free (valves
closed). The injector plunger for cylinder No. 6
must be at top of travel; if not, bar the engine 360
degrees, realign the marks with the pointer.
Fig. 2-53. (OM1061L). Dial indicator in place—extension in contact

with plunger
5. Using 3375009 Rocker Lever Actuator Assembly

and Support Plate, bottom the injector plunger,
check the zero (0) setting. Fig. 2-54. Allow the
plunger to rise slowly; the indicator must show the
plunger travel to be within the range specified in
Table 2-18.
Table 2-18: Adjustment Limits Using Dial

Fig. 2-52, (K11920). Accessory drive pulley marking — KT(A)-1150 Method Inch [mm] KT(A)-1150 Engines
Note: The injector and valves on any one (1) cylinder Injector PlunQcr
Travel Intake Exhaust
can not be set at the same valve set position. Example:
lf the rocker levers on No. 3 cylinder are free (valves 0.304 ± 0.001 0.014 0.027
closed) the injector plunger travel on No. 6 cylinder is [7.72 ± 0.03] [0.36] [0.69]
to be adjusted. Any valve set position may be used as
a starting point. See Table 2-17.
2. lnstall 3375004 Dial Indicator Assembly to the
rocker housing, extension (3375005) must go
through the opening in the Jacobs Brake housing
and contact the injector plunger top, Fig. 2-53.
3. Screw the injector lever adjusting screw down until
the plunger is bottomed in the cup, back off approx
imately 1/2 turn then bottom again, set the dial
indicator at zero (0).
Note: Care must be taken to assure the injector plunger
is correctly bottomed in the cup, without overtighten
ing the adjusting screw, before setting the dial indicator.
4. Back the adjusting screw out until a reading of
0.304 inch [7.72 mm], reference Table 2-18, is ob
tained on the dial indicator. Snug tighten the
locknut. Fig 2-54. (K1 14104). Actuating rocker lever
6. Using ST-669 Torque Wrench Adapter to hold the 1 1 . See Table 2-18 for valve clearance values.
adjusting screw in position, torque the locknut
1 2. Repeat the adjustment procedure for each cylinder.
to30to35ft-lbs[41 to47N.m]. lf the torque wrench
See Table 2-17 for firing order and injector and
adapter is not used, hold the adjusting screw with
valve set positions.
a screwdriver, torque the locknuts to 40 to 45 fl-lbs
[54 to 61 N.m]. Crosshead Adjustment
7. Actuate the injector plunger several times as a Crossheads are used to operate two valves with one
check of the adjustment. Remove the dial indicator rocker lever. The crosshead adjustment is provided to
assembly. assure equal operation of each pair of valves and pre
vent strain from misalignment.
Caution: If Jacobs Brake is not used, be sure the cross-
heads are adjusted before setting the valves. See 1 . Loosen the valve crosshead adjusting screw lock-
Crosshead Adjustment following. nut and back off the screw (4, Fig. 2-56) one turn.
8. Adjust the valves on the appropriate cylinder as
determined in Step 1 and Table 2-18. Tighten the
locknuts the same as the injector locknut.
9. lf Jacobs Brake is used, use 3375012 (0.018 inch
[0.46 mm] thick) Feeler Gauge and 3375008 Torque
Wrench Adapter, set the exhaust valve crosshead
to Jacobs Brake slave piston clearance. Fig. 2-55.
Fig 2-56. (K21924). Valve crosshead

surface (1) to hold the crosshead in contact with
the valve stem (2) (without adjusting screw).
3. Turn down the crosshead adjusting screw until it
touches the valve stem (3).
Fig 2-55. (OM1063L). Adjusting crosshead to slave piston
clearance 4. Using ST-669 Torque Wrench Adapter, tighten
the locknuts to 22 to 26 ft-lbs [30 to 35 N.m]. lf
ST-669 is not available, hold the screws with a
Note: Turn both adjusting screws alternately and
screwdriver and tighten the locknuts to 25 to 30
evenly until the crosshead and feeler gauge contact
ft-lbs [34 to 41 N.m].
the slave piston and the adjusting screws are bottomed
on the valve stem. Back the adjusting screws out one- 5. Check the clearance (6) between the crosshead
fourth (1/4) to one-half (1/2) turn. Starting with the and valve spring retainer with a wire gauge. There
outer adjusting screw (next to water manifold), then must be a minimum of 0.025 inch [0.64 mm] clear
moving to the screw under the rocker lever, retighten ance at this point.
gradually until the crosshead and feeler gauge contact
the slave piston. Snug tighten the locknuts. Injector and Valve Adjustment Using 3375004
Dial Indicator Kit (KT(A)-2300 and KTA-3067
10. Hold the crosshead adjusting screws with a screw
Engines
driver, torque the locknuts 22 to 26 ft-lbs [20 to 35
Nam] using 3375008 Adapter and torque wrench. Valve Set Mark Alignment
2-45
Operation and I
Note: KT(A)-2300 and KTA-3067 injectors, cross- the barring mechanism must be removed when viewing
heads and valves are adjusted to the same values. the timing marks at the flywheel housing.
Refer to Fig's. 2-57 and 2-58 for specific cylinder 1 . When viewing the engine at the vibration damper.
arrangement and engine firing order. Fig. 2-59, align the timing marks on the damper
with the pointer on the gear case cover.
®®®®®®
LB ( u ;
®®®®®
Fig 2-57, (K21916). Cylinder arrangement and firing order - Fig 2-59. (K21917)
KT(A)-2300 KT(A>-2300
When barring the engine from the right bank at the

flywheel housing "A" VS timing marks on the fly
wheel .(1 , Fig. 2-60) must align with the scribe mark
RB (2) when viewed through the opening marked "A"
on the flywheel housing.
LB
Firing Order
V 16 -1R 1L 3R 3L-7R-7L-5R4L-8R-8L-6R-6L-2R-2L-4R-4L
Fig 2-58. (OM204). Cylinder arrangement and tiring order —

KTA-3067
Three locations are provided where valve and injector

alignment marks may be viewed. Injector plunger
travel and valves both may be set on one cylinder at the
same valve set location. The crankshaft must be turned Fig. 2-60, (K21918) Valve set marks on right bank flywheel and
through two (2) complete revolutions to properly set housing — KT(A)-2300
all injector plunger travel and valves.
Note: The barring mechanism may be located on either 3. When barring the engine from the left bank at the
the left bank or right bank at the flywheel housing. flywheel housing "C VS timing mains on the fly
The cover plate on opening "A" or "C" directly above wheel (1, Fig. 2-16) must align with the scribe mark
(2) when viewed through the opening marked "C"

on the flywheel housing.
Caution: When aligning valve set marks at either fly
wheel housing location, care must be taken to assure
that "A" or "C" valve set marks on the flywheel match
"A" or "C marks on the flywheel housing opening.
Fig 2-61, (K21919) Engine barring device
Injector Plunger Adjustment

1 . Bar the engine in the direction of rotation until the
appropriate valve set mark is algined with the scribe
mark on the flywheel housing or until a valve set
mark on the vibration damper is aligned with the
pointer on the gear case cover.
Note: Any valve set position may be used as a starting
point when adjusting the injectors, crossheads and Fig. 2-63, (K21921). Bottoming injector plunger in cup
valves. Determine which of the two (2) cylinder indi
cated have both valves closed (rocker levers free).
This cylinder is in position for injector plunger travel, 4. Allow the plunger to rise then bottom the plunger
crosshead and valve adjustment. again, release the lever, the indicator must show
travel as indicated in Table 2-19. Adjust as necessary.
2. Set up 3375007 lndicator Support on the rocker
lever housing, of the cylinder selected, with the 5. lf the adjusting screw locknuts were loosened for
indicator extension 3375005 on the injector plunger adjustment, tighten to 40 to 45 ft-lbs [54 to 61 N • m]
top. Fig. 2-62. torque and actuate the plunger several times as a
Note: Make sure the indicator extension is secure in

the indicator stem and is not touching the rocker lever.
Table 2-19: Adjustment Limits Using Dial Indicator
3. Using the rocker lever actuator, Fig. 2-63, depress Method Inch [mm] KT( A)-2300 and KTA-3067 Engines
the lever toward the injector until the plunger is
bottomed in the cup to squeeze the oil film from the Injector Plunger Valve Clearance
cup. Allow the injector plunger to rise, bottom Travel lntake Exhaust
again, hold in the bottom position and set the indi 0.308 + 0.001 0.014 0.027
cator at zero (0). Check the extension contact with [7.82 ± 0.03] [0.36] [0.69]
the plunger top.
2-47
Operation and
check of the adjustment. Tighten the lockouts to and valve adjustment on this cylinder bar the engine in
30 to 35 fHbs [41 to 47 N.m] torque when using the direction of rotation until the next valve set mark
ST-669 Torque Wrench Adapter. is aligned with the scribe mark at the flywheel housing
or the pointer on the gear case cover, repeat the pro
6. Remove 3375004 Kit
cedure. See Fig s. 2-57 and 2-58 I
ment and engine firing order.
rocker lever, an adjusting screw is provided to assure
equal operation of each pair of valves and prevent
strain from misalignment Crosshead adjustment
1 . Remove fill plug ( 1 . Fig. 2-64) from the hole marked
changes as a result of valve and seat wear during
"Lub oif.
1. Loosen the adjusting screw locknut, back off the

screw (4. Fig. 2-56) one turn.
surface (1 ) to hold the crosshead in contact with
the valve stem (2). The adjusting screw should not
touch the valve stem (3) at this point
3. Turn down the adjusting screw until it touches the
valve stem (3).
4. Using 3375006 Troque Wrench Adapter to hold the
adjusting screw in position, tighten the locknut to
22 to 26 ft-lb (30 to 35 N.mJ torque. lf the torque
wrench adapter is not used, hold the adjusting
screw with a screwdriver, tighten the locknut to
25 to 30 ft-lb [34 to 41 N.m] torque.
Fig 2-64, (N10503) Aneroid
5. Check the clearance (6) between the crosshead
and the valve spring retainer with a gauge. There
must be a minimum of 0.025 inch [0.64 mm] clear 2. Remove the drain plug (2) from the bottom of the
ance at this point aneroid.
Valve Adjustment 3. Replace the drain plug (2). fill the aneroid with clean
engine lubricating oil. Replace the fill plug (1).
t. lnsert the correct thickness feeler gauge between
the rocker lever and the crosshead for the valves
being adjusted. See Table 2-19 for valve clearance.
Remove and replace the aneroid breather (3. Fig. 2-64).
Note: Exhaust valves are toward the front of the engine
Oil
in each cylinder head on the LB side and are toward
the rear of the engine in each cylinder head on the Change oil in the hydraulic governor sump at each
RB side. "C" Check.
2. lf adjustment is required, loosen the locknut and Use the same grade of oil as used in the engine. See
turn the adjusting screw down until the rocker lever "Lubricating Oil Specifications"
just touches the feeler gauge; lock the adjusting
Note: When temperature is extremely low, it may be
screw in this position with the locknut.
necessary to dilute the lubricating oil with enough fuel
3. Tighten the locknut to 40 to 45 ft-lb [54 to 61 N • m] oil or other special fluid to ensure free flow for satis
torque. When using ST-669 Torque Wrench factory governor action.
Adapter tighten the locknuts to 30 to 35 ft-lb [41 to
47 N.m] torque. Backside Idler Fan Drive
completing the injector plunger travel, crosshead lnspect the idler assembly to be sure the pivot arm is
-3
not binding. Use the following procedure. Clean Complete Oil Bath Air Cleaner
1 . Check the idler arm for freedom of movement. Steam
a. Grasp the pulley and move the pulley and arm Steam clean the oil bath cleaner main body screens.
away from the fan belt until the arm is nearly Direct the stream jet from the air outlet side of the
vertical. cleaner to wash dirt out in the opposite direction of
air flow.
b. Release the arm and pulley and allow them to
move back to their original position against Solvent-Air Cleaning
the belts.
1 . Steam clean the exterior of the cleaner.
c. The motion of the arm and pulley assembly
2. Remove the air cleaner oil cup.
should be free with no binding.
3. Clamp the hose with the air line adapter to the air
2. lf the arm appears to be binding or tight, release the cleaner outlet.
spring tension by placing a box end wrench over
the square knob on the end of the pivot arm cap and 4. Submerge the air cleaner in solvent.
while holding up on the box end wrench, remove 5. lntroduce air into the unit at 3 to 5 psi [21 to 34 kpa]
the capscrew which holds the cap in place and and leave it in the washer 10 to 20 minutes.
allow the spring to unwind by allowing the box end
wrench to rotate counterclockwise. 6. Remove the cleaner from solvent and steam clean
thoroughly to remove all traces of solvent. Dry with
a. With the spring unloaded, rotate the cap until compressed air.
the slots inside the cap align with the roll pins Caution: Failure to remove solvent may cause engine
in the pivot arm, and remove the cap by pulling to overspeed until all solvent is sucked from the cleaner.
away from the engine.
7. lf the air cleaner is to be stored, dip it in lubricating
b. With the torsion spring unloaded, the pivot arm oil to prevent rusting of the screens.
should rotate freely. lf it does not appear free,
Note: lf screens cannot be thoroughly cleaned by
then the bushings require replacement or re
either method, or if the body is pierced or otherwise
packing with lubricant.
damaged, replace with a new air cleaner.
3. To inspect the bushings, loosen and remove the
large hex head capscrew in the center of the pivot
arm and remove the pivot arm from the pivot arm
support.
a. lnspect the shaft for corrosion and clean it as

necessary with fine grade emery cloth.
b. lnspect the bushings and thrust washers, clean

and repack them with a good grade of lubricant
such as:
— lubriplate
— moly-disulfide grease
c. lnspect the O-ring on the pivot arm and replace

it as necessary. Lubricate the O-ring prior to
installation.
d. Reassemble the pivot arm assembly cap using a
new spring.
e. Retension the new spring and lock the cap in

place. lnstall a new fan belt and test the unit.
2-4Q
"D" Maintenance Checks
At each "D" Maintenance Check, perform all "A", "B" Clean and Calibrate Fuel Pump
and "C" checks in addition to those following. Most of
Check the fuel pump calibration on the engine if re
these checks should be performed by a Cummins
quired. See the nearest Cummins Distributor or Dealer
Distributor or Dealer and where Cummins Shop
for values.
Manuals are available for complete instructions.
Clean and Calibrate Injectors Clean and Calibrate Aneroid
Clean and calibrate the injectors regularly to prevent 1 . Remove the flexible hose or tube from the aneroid
restriction of fuel delivery to the combustion chambers. cover to the intake manifold.
Because of the special tools required for calibration, 2. Remove the lead seal (if used), screws and aneroid
most owners and fleets find it more economical to let cover.
a Cummins Distributor do the cleaning and calibra
tion operations. 3. Remove the bellows, piston, upper portion of the
two piece shaft and the spring from the aneroid
To clean and calibrate the injectors, refer to Bulletin body.
No. 3379071 and revisions thereto.
Note: Count and record the amount of thread turns
After removing the injectors from KT(A)-1150, KT(A)- required to remove the upper shaft, piston and bellows
2300 or KTA-3067 Engines for cleaning the seal seat from the lower shaft
should be removed from the injector (1, Fig. 2-65) or
injector "well" for cleaning, examination and/or 4. Race the hex portion of the shaft in a vise, snug
replacement as necessary. tighten the vise, remove the self-locking nut, retain
ing washer and bellows.
5. Clean the parts in an approved cleaning solvent.
6. Position the new bellows over the shaft to the
piston, secure with retaining washer and self-
locking nut. Tighten the self-locking nut to 20 to 25
ft-lb [2.3 to 2.8 N.mJ torque.
7. lnstall the spring, shaft, piston and bellows assem
bly into the aneroid body. As the two piece shaft is
re-assembled, turn the upper portion of the shaft
the same amount of thread turns as recorded
during disassembly.
Caution: The amount of thread turns during installation
must correspond with turns during removal to avoid
changing the aneroid setting.
8. Align the holes in the bellows with the correspond
ing capscrew holes in the aneroid body.
Fig 2-65, (K11918). Injector seal seat — all KT Engines
9. Position the cover to the body; secure with flat-
washers, lockwashers and fillister head screws.
Caution: There must be only one (1) seal seat used 10. lnstall a new seal. Refer to Bulletin No. 3379084
in each injector "weir. Use of more than one seal seat for sealing instructions and calibration procedure.
per injector will change the injector protrusion and Calibration, if required, must be performed by a
cause combustion inefficiency. Cummins Distributor on a fuel pump test stand.
-50
11. Reinstall the flexible hose or tube from the aneroid 2. Remove one capscrew from the front plate (com
cover to the intake manifold. pressor wheel end) and replace it with a long
capscrew. Attach an indicator to the long capscrew
Inspect/Install Rebuilt Unit as Necessary and register the indicator point on the end of the
rotor shaft. Push the shaft from end-to-end making
The following assemblies should be inspected at this
note of the total indicator reading. Fig. 2-66. On
time. The options are: inspect and reuse, rebuild per
T-50, ST-50 and VT-50 the end clearance should be
shop manual instructions, replace with a new or
0.006 to 0.018 inch [0.15 to 0.46 mm].
Distributor/Dealer exchange unit or Cummins Diesel
ReCon lnc. unit. a. Push the wheel toward the side of the bore.
Inspect Water Pump and Fan Hub b. Using a feeler gauge, check the distance be
tween the tip of the wheel vanes and the bore.
lnspect the water pump and fan hub for wobble and
On T-50, ST-50 and VT-50 the clearance should
evidence of grease leakage. Replace with rebuilt pre-
be 0.003 to 0.033 inch [0.08 to 0.84 mm].
lubricated units as necessary.
3. Check the radial clearance on the compressor
Idler Pulley
wheel only.
lnspect, rebuild and repack the idler pulley with correct
4. lf end clearances exceed the limits, remove the
grease. Refer to the Engine Shop Manual for the
turbocharger from the engine and replace it with
rebuild and lubricating procedure for the idler pulley.
a new or rebuilt unit.
Inspect Turbocharger 5. Check T-18A turbochargers as follows.
Check Turbocharger Bearing Clearance a. For checking procedures refer to Service
Manual Bulletin No. 3379055.
Check bearing clearances. This can be done without
removing the turbocharger from the engine, by using a b. End clearance should be 0.004 to 0.009 inch
dial indicator to indicate the end-play of the rotor shaft [0.10 to 0.23 mm], radial clearance should be
and a feeler gauge to indicate the radial clearance. 0.003 to 0.007 inch [0.08to0.18mm]. lf the clear
Fig. 2-66. ances exceed these limits, remove the turbo-
charger(s) from the engine and replace them
with new or rebuilt units.
6. lntall the exhaust and intake piping to the
turbocharger(s).
Inspect Vibration Damper

Rubber Damper
The damper hub (1, Fig. 2-67) and the inertia member
(2) are stamped with an index mark (3) to permit the
detection of movement between the two components.
There should be no relative rotation between the hub
and the inertia member resulting from engine
operation.
Check for extrusion or rubber particles between the
Fig 2-66, (OM1065L). Check turbocharger bearing end clearance hub and the inertia member.
lf there is evidence of inertia member movement and
rubber extrusion, replace the damper.
Checking Procedure
Viscous Dampers
1. Remove the exhaust and intake piping from the
turbocharger to expose the ends of the rotor Check the damper for evidence of fluid loss, dents and
assembly. wobble. Visually inspect the vibration damper's thick
recommended change interval** regardless of condi

tion. Gellation of the damper's silicon fluid occurs after
extended service because of the high shear rates and
resulting high temperatures imposed on the fluid
during normal damper operation and, if the damper
has not failed at this time, its failure is imminent.
Table 2-20: Viscous Vibration Damper Thickness

Sepcifications — Inch [mm]
Damper Allowable "Recommended

Part Number Thickness Change Interval
20633-1 1.981 [50.32] 9000

Fig. 2-67. (OM1066L). Vibration damper alignment marks 20634- 1 1.644 [41.76] 9000
20835-1 1.142 [29.01] 9000
ness for any deformation or raising of the damper's 145789 1.663 [42.24] 6000
front cover plate. 190213 1.663 [42.24] 6000
207531 2.574 [65.38] 18000
1 . lf a lack of space around the damper will not permit 210758 1.550 [39.37] 6000
a visual inspection, run a finger around the inside 211268 1.663 [42.24] 6000
and the outside of the front cover plate. lf any 211914 1.981 [50.32] 9000
variations or deformations are detected, remove the 211915*
vibration damper and check as follows. 211916 1.663 [42.24] 6000
217321 1.663 [42.24] 15000
2. Remove paint, dirt and grime from the front and 217322 1.663 [42.24] 15000
rear surface of the damper in four (4) equal spaced 217323 1.663 [42.24] 15000
areas. Clean the surface with paint solvent and fine 218755 1.663 [42.24] 15000
emery cloth. 3005973 2.574 [65.38] 18000
3015464 2.574 [65.38] 18000
3. Using a micrometer measure and record the thick
ness of the dampers at the four (4) areas cleaned
*Due to vendor manufacturing differences 211915
in Step 3. Take the reading approximately 0.125
Vibration Damper maximum allowable thickness
inch [3.18 mm] from the outside edge of the front
depends upon the style of damper installed on the
cover plate.
engine. Fabricated type 211915 Vibration Dampers,
4. Replace the damper if the variation of the four (4) identified by a weld bead on the inside of the damper
readings exceed 0.010 inch [0.25 mm]. where the mounting flange joins the housing and
vendor Part Number 709555, have a maximum allow
Viscous vibration dampers should be checked under
able thickness of 1.570 inch [39.88 mm]. The recom
the following conditions:
mended change interval for this damper is 12,000
1 . At any time the damper is removed fiom the engine. hours. Cast and machined type 211915 Vibration
Dampers (vendor Part Number 707843) have a maxi
2. At any time the engine experiences the following
mum allowable thickness of 1.550 inch [39.37 mm].
problems:
The recommended change interval for this damper
a. Gear train failure is 6,000 hours.
b. Accessory drive shaft failure
c. Crankshaft failure Air Compressor
d. Damper mounting capscrew failure lnspect the air compressor, check for evidence of oil
or coolant leakage. Drain the air tank and check for air
e. Flywheel mounting capscrew failure
compressor lubricating oil carry over. Replace with
Viscous vibration dampers should be replaced at our a rebuilt unit as necessary.
52
Backside Idler Fan Drive

Remove the pivot arm assembly, disassemble and
clean. Replace the Teflon bushings. lnspect the thrust
washers and replace as necessary. Pack Teflon bush
ings with Aeroshell No. 5 Lubriplate (type 130AA) or
Moly-disulfide grease, reassemble and install the idler
assembly.
Clean Crankcase Breathers

(KT(A)-2300 and KTA-3067 Engines
Remove the crankcase breathers from the right bank
front and left bank rear of the cylinder block. Clean
in an approved cleaning solvent, dry with compressed
air, install the breather.
2-53
may not fai exactly into suggested mawrterarce
. due to miles or hours operawan but are per-
Replace Hose (As Required)
Cooftng System (Fall) Inspect the oil ''iter and coofing system hose and hose
connections for leaks and/or deter crater Parties
The cooling system must be dean to do its work of deteriorated hose can be carried through the cooling
system or lubricating system and rested or dog smafl
tort from water jackets and heat rejection from toe passages, especially radiator core, and lubncatmg
radiator Use clean water toat wif not dog any of me oi
hundreds of smaff passages in the radiator or water
c^ssages m toe block. CIean toe radiator cores, heater
cores, oil cooler ard tmx> passages that have become
tby<
Remove the 1/8 inch pipe plug from the manifold, near
the glow plug, and check the operation of the preheater
1.
r? r.jsf and scale rave collected, the system must be
cftermcafty cleaned. Use a good cooling system
(Fall)
or
and therrnaoc fans must be set to operate
in the same range as the thermostat with which they are
used. Table 2-21 gives the settings for shutterstats and
Flush the radiator and the block before ruling with thermatjc fans as normally used. The 180 to 195° F [82
antifreeze, or installing a water filter on a used or rebuilt to 91° C] thermostats are used only with shutterstats
that are set to close at 187° F [86° C] and open at
19S*F [91° C].
//hen pressure flushing the radiator, open the upper
and lower hose connections and screw the radiator cap
on tight. Use the hose connection on both the upper
and lower connections to make the operation ea§ier. Remove the thermostats from the thermostat housings
Attach a flushing gun nozzle to the lower hose con and check for proper opening and dosing temperature.
nection and let water run until the radiator is full. When
Most Cummins Engines are equipped with either
full, apply air pressure gradually to avoid damage to the
medium 170 to 185° F [77 to 85° C] or low 160 to 175°F
core Shut off the air and allow the radiator to refill; then
[71 to 79° C] and in a few cases high-range 180 to
apply air pressure. Repat until the water coming from
195° F [82 to 91° C] thermostats, depending on engine
the radiator is clean.
application.
Caution: Do not use excessive air pressu
flow. This could split or Clean Engine (Spring)
Steam is the most satisfactory method of cleaning a
Sediment and dirt settle into pockets in the block as dirty engine or piece of equipment. lf steam is not
well as the radiator core. Remove the thermostats available, use an approved solvent to wash the engine.
from the housing and flush the block with water
Partially restrict the lower opening until the block fills. All electrical components and wiring should be pro
Apply air pressure and force water from the lower tected from the full force of the cleaner spray nozzle
Table 2-21: Thermal Control Settings
Setting With Setting With Setting With

160 to 175° F 170 to 185° F 180 to195°F
Control [71 to79°C] [77 to 85° C] [82 to 91 °C]
Open Close Open Close Open Close

Thermatic Fan 185°F 170° F 190°F 182° F
[85° C] [77° C] [88° C] [82° C]
Shutterstat 180°F 172° F 185° F 177°F 195° F 187° F
[82° C] [78° C] [85° C] [81° C] [91° CJ [86° CJ
Modulating 175°F 185° F
Shutters Open [79° C] [85° C] [91° C]
Checking Mountings (Spring) the capscrews as necessary. Check the fan for wobble
or bent blades.
Tighten Mounting Bolts and Nuts (As Required)
Check the fan hub and crankshaft drive pulley to be
Engine mounting bolts will occasionally work loose
sure they are securely mounted. Check the fan hub
and cause the engine supports and brackets to wear pulley for looseness or wobble; if necessary, remove
rapidly. Tighten all mounting bolts or nuts and replace the fan pilot hub and tighten the shaft nut. Tighten the
any broken or lost bolts or capscrews. fan bracket capscrews.
Tighten Turbocharger Mounting Nuts
Check Crankshaft End Clearance (Spring)
(As Required)
The crankshaft of a new or newly rebuilt engine must
Tighten all turbocharger mounting capscrews and nuts
have end clearance as listed in Table 2-22. A worn
to be sure that they are holding securely. Tighten the
engine must not be operated with more than the worn
mounting bolts and supports so that vibration will be
limit end clearance shown in the same table. lf the
at a minimum. Fig. 2-68.
engine is disassembled for repair, install new thrust
rings.
Check Fan and Drive Pulley Mounting (Spring)
Check the fan to be sure it is securely mounted; tighten
Table 2-22: Crankshaft End Clearance — Inch [mm]
Engine New New Worn

Series Minimum Maximum Limit
H, NH. 0.007 0.017 0.022

NT [0.18] [043] [0.56]
V-903. 0.005 0.015 0.022
VT-903 [0.13] [0.38] [0.56]
V-378, V-504 0.004 0.014 0.022
V-555 [0.10] [0.36] [0.56]
V-1710 0.006 0.013 0.018
[0.15] [0.33] [0.46]
KT(A)-1150 0.007 0.017 0.022
[0.18] [0.43] [0.56]
KT(A)-2300 0.005 0.015 0.022
KTA-3067 [0.13] [0.38] [0.56]
Fig. 2-68, (N11953). Tightening turbocharger mounting marks
2-55
Do not pry against the outer damper ring.

The check can be made by attaching an indicator to
rest against the damper or pulley, while prying against
the front cover and inner part of the pulley or damper.
End clearance must be present with the engine
mounted in the unit and assembled to the transmission
or converter.
Check Heat Exchanger Zinc Plugs (Spring)

Check the zinc plugs in the heat exchanger and change
if they are badly eroded. Frequency of change depends
upon the chemical reaction of raw water circulated
through the heat exchanger.
2-56
Specifications and Torque
^ . Providing and maintaining an adequate supply of

SpQCIf ICAllOnS clean, high-quality fuel, lubricating oil, grease and
TOIXIUO coolant in an engine is one way of ensuring long life
^ and satisfactory performance.
Lubricant, Fuel and Coolant
The Functions of Lubricating Oil Dirt entering the engine through the combustion air,
fuel, while adding or changing lubricating oil.
The lubricating oil used in a Cummins engine must
be multifunctional. It must perform the primary The oil must have an additive package to combat
functions of: these contaminates. The package generally con
Lubrication by providing a film between the moving sists of:
parts to reduce wear and friction. Detergents/Dispersants which keep insoluble matter
in suspension until they are filtered from the oil or
Cooling by serving as a heat transfer media to carry
are removed with the oil change. This prevents sludge
heat away from critical areas.
and carbon deposits from forming in the engine.
Sealing by filling in the uneven surfaces in the cylinder
Inhibitors to maintain the stability of the oil, prevent
wall, valve stems and turbocharger oil seals.
acids from attacking metal surfaces and prevent rust
Cleaning by holding contaminants in suspension to during the periods the engine is not operating.
prevent a build up of deposits on the engine surfaces.
Other Additives that enable the oil to lubricate highly
In addition, it must also provide: loaded areas, prevent scuffing and seizing, control
foaming and prevent air retention in the oil.
Dampening and cushioning of components that
operate under high stress, such as gears and push
tubes. Oil Performance Classification System
Protection from oxidation and corrosion. The American Petroleum lnstitute (APl), The Ameri
can Society for Testing and Materials (ASTM) and
Hydraulic Action for components such as Jacobs
the Society of Automotive Engineers (SAE) have
Brake and hydraulic controls.
jointly developed and maintained a system for classi
Engine lubricating oil must be changed when it can fying lubricating oil by performance categories. The
no longer perform its functions within an engine. Oil following are brief descriptions of the APl categories
does not wear out, but it becomes contaminated to used in the Cummins oil performance recommen
the point that it can no longer satisfactorily protect dations.
the engine. Contamination of the oil is a normal result
CC (Equivalent to MlL-L-2104B.) This category des
of engine operation. During engine operation a wide
cribes oils meeting the requirements of the military
variety of contaminants are introduced into the oil.
specification MlL-L-2104B. These oils provide low
Some of these are:
temperature protection from sludge and rust and are
Byproducts of Engine Combustion — asphaltenes, designed to perform moderately well at high tempera
soot and acids from partially burned fuel. ture. For moderate-duty service.
Acids, varnish and sludge which are formed as a CD (Equivalent to Series 3 and MlL-L-45199B.) This
result of the oxidation of the oil as it breaks down category described oils meeting the requirements of
or decomposes. the Series 3 specification and MlL-L-45199B. These
3-1
oils provide protection from deposits and oxidation light-duty service including standby and
at high temperature. For severe-duty service. operation.
SC (Equivalent to 1964 MS Oils). This category des are used where more protection is
cribes oils meeting the 1964-1967 requirements of required than is provided by a single category.
automobile manufacturers. Primarily for use in CC/CD and CC/SC categories indicate that the oil is
automobiles, it provides low temperature anti-sludge blended to meet the performance level required by
and anti-rust protection required in a light-duty each single category.
diesel service such as a stop-and-go operation.
A sulfated ash limit has been placed on lubricating
SD (Equivalent to 1968-1971 MS Oils.) This category oil for use in Cummins engines. Past experience has
describes oils meeting the 1964-1967 requirements shown that oils with a high ash content may produce
of automobile manufacturers. Primarily for use in deposits on valves that can progress to guttering
automobiles, it provides low temperature anti-sludge and valve burning. A maximum sulfated ash content
and anti-rust protection required in a fight-duty diesel of 1.85 mass % is recommended for all oil used in
service such as a stop-and-go operation. It may be Cummins engines except engines fueled with natural
substituted for SC category. gas. For natural gas engines a sulfated ash range
of 0.03 to 0.85 mass % is recommended. Cummins
SE (Equivalent to 1972 MS Oils.) This category
Engine Co., Inc., does not recommend the use of
describes oils meeting the 1972 requirements of
ashless oils for natural gas engines. When the ash
automobile manufacturers. Primarily for use in auto
content is below .15 mass %, the ash should
mobiles, it provides protection from high tempera
ture oxidation and low temperature anti-sludge and
anti-fust as require
as a stop-and-go »
SC category. Special "break-in" lubricating ofls are not recom
CB (No equivalent Specification.) These oils mended for new or rebuilt Cummins engines Use the
usually referred to as Supplement 1 iIs used in i
gory describes oils which met the requirements of
the military specification MIL-L-2104A where the
The viscosity of an oil is a measure of its resistance to
sulphur content For moderate duty service. Oils in flow. The Society of Automotive Engineers hast
this performance category should not be used In tied engine oils in viscosity grades; Table 3-1
the viscosity range for these grades Otis #ia
The Engine Manufacturers Association (EMA) pub the low temperature (0° F [—18° C]) requirement
lishes a book entitled "Lubricating Oils Data Book". carry a grade designation with a "W* suffix. Oils that
Copies may be purchased from the Engine Manufac meet both the low and high temperature requirements
turers Association, 111 E Wacker Drive, Chicago, 111. are referred to as multigrade or i
60601. This book lists commercially available oils by oils.
oil company and brand name with the APl perform-
ning effects a low viscosity base oil will experience

at engine operating temperatures. Multigraded oils
that meet the requirements of the API '
are recommended for use in
Cummins Engine Co., lnc. does not recommend the
use of any specific brand of engine lubricating oil. Cummins recommends the use of multigraded lubri
Cummins recommends the use of oil designed to cating oil with the viscosity grades shown in Table 3-2.
meet the following APl Table 3-2 shows Cummins viscosity grade recom
mendations at various ambient temperatures. The
CC for use in naturally aspirated engines.
only viscosity grades recommended are those shown
CC/CD for use in turbocharged engines. in this table.
"C/SC for use only in engines that operate in a Cummins has found that the use of multigraded lubri
eating oil improves oil consumption control, improved The primary criterion for selecting an oil viscosity
engine cranking in cold conditions while maintaining grade is the lowest temperature the oil will experience
lubrication at high operating temperatures and may while in the engine oil sump. Bearing problems can
contribute to improved fuel consumption. Cummins be caused by the lack of lubrication during the crank
does not recommend the use of single grade lubricat ing and start up of a cold engine when the oil being
ing oils. In the event that the recommended multi- used is too viscous to flow properly. Change to a
grade oil is not available, single grade oils may be lower viscosity grade of oil as the temperature of the
substituted. oil in the engine oil sump reaches the lower end of
the ranges shown in Tatle 3-2.
Caution: When single grade oil is used, be sure that
the oil wiH be operating within the temperature ranges
shown in Table 3-3.
Table 3-1: SAE Viscosity Numbers for Lubricating Oils

Viscosity Range
SAE mlllipascal-second, mPa»s millimetre/second, mmVs
Viscosity (centlpoise, cP) @ 0° F [-18° C] (centistoke, cSt) @ 212° F [100° C]
Grade maximum minimum maximum
5W 1250 3.8
10W 2500 4.1
15W 5000 5.6
20W 10000 5.6
20 5.6 less than 9.3
30 9.3 less than 12.5
40 12.5 less than 16.3
50 16.3 less than 21.9
1. SAE Recommended Practice J300d

2. 1 mPa»s = 1 cP
3. 1 mmVs = 1 cSt
Table 3-2: Cummins Recommendations for Table 3-3: Alternate Oil Grades
Viscosity Grade vs. Ambient Temperature 10W -13°Fto32oF[-25oCto0oC]
SAE Viscosity Ambient 20W 23° F to 68° F [-5° C to 20° C]
Grade* Temperature' 20W-20* 23° F to 68° F [-5° C to 20° C]
20 23° F to 68° F [-5° C to 20° C]
Recommended 30 39° F and above [4° C and above]
10W - 30 -13° F to 95° F [-25° C to 35° C] 40 50° F and above [10° C and above]
15W - 40 14°F and above [-10°C and above)
20W - 40 32° F and above [0° C and above] *20W-20 is not considered a multigradeeven though it meets
two grades.
*SAE-5W mineral oils should not be used.
"For temperatures consistently below -13°F [-25°C] See
Table 4.
3-3
may be used provided they meet the minimum

at 212° F [100° C].
Synthetic oils for use in diesel engines are primarily
blended from synthesized hydrocarbons and esters.
These base oils are manufactured by chemically
reacting lower molecular weight materials to produce
a lubricant that has planned predictable properties.
Synthetic oil was developed for use in an extreme
environment where the ambient temperature may be
as low as —50° F [—45° C] and extremely high engine
temperatures at up to 400° F [205° C]. Under these
extreme conditions petroleum base stock lubricants
(mineral oil) do not perform satisfactorily.
Cummins Engine Co., lnc. recommends synthetic
lubricating oil for use in Cummins engines operating
in areas where the ambient temperature is consistently
lower than —13° F [—25° C]. Synthetic lubricating
oils may be used at higher ambient temperatures
provided they meet the appropriate APl Service
categories and viscosity grades.
Cummins Engine Co., lnc. recommends the same oil
change interval be followed for synthetic lubricating
oil as that for petroleum based lubricating oil.
Arctic Operations
For engine operation in areas where the ambient
temperature is consistently below —13° F [—25° C]
and where there is no provision to keep the engine
warm when- it is not operating, the lubricating oil
should meet the requirements in the following table.
Oil meeting these requirements usually have synthetic
base stocks. SAE 5W viscosity grade synthetic oils
Table 3-4: Arctic Oil
Parameter
(Test Method) Specifications
Performance APl Classification CC/SC

Quality Level API Classification CC/CD
Viscosity 10,000 mPa»s Max. at
—31° F (—35° C]
4.1 mmVs Min. at
212° F [100° C)
Pour Point Min. of 9° F [5° C) Belpw the
(ASTM D-97) Lowest Expected Ambient
Temperature
Sulfated Ash Content 1.85% by Weight Maximum
(ASTM D-874)
4
Rubber Swell *FTM 3603

Cummins Engine Company, lnc., recommends use of 10 max.
grease meeting the specifications of MlL-G-3545, * Federal Test Method Standard No. 791a.
excluding those of sodium or soda soap thickeners.
Caution: Do not mix brands of grease. Damage to
Contact the lubricant supplier for grease meeting
the bearings may result Excessive lubrication is as
these specifications.
harmful as inadequate lubrication. After lubricating
the fan hub, replace both pipe plugs. Use of fittings
TEST TEST PROCEDURE
will allow the lubricant to be thrown out, due to
High-Temperature Performance
Dropping point, ° F. ASTM D 2265

350 min.
Bearing life, hours at 300° F *FTM 331
10,000 rpm 600 min.
Low-Temperature Properties
Torque, GCM ASTM D 1478

Start at 0° F 15,000 max.
Run at 0° F 5,000 max.
Rust Protection and Water
Rust Test ASTM D 1743

Pass
Water resistance, % ASTM D 1264
20 max.
Stability
Oil separation, % *FTM 321

30 hours® 212° F 5 max.
Worked ASTM D 217

250-300
Bomb Test, PSI Drop ASTM D 942

100 Hours 10 max.
500 Hours 25 max.
Copper, Corrosion *FTM 5309

Pass
Dirt Count, Partlcles/cc *FTM 3005
25 Micron + 5,000 max.

75 Micron + 1 ,000 max.
125 Micron + None
3-5
Operation and Maintenance Manual
Fuel Oil
Cummins diesel engines have been developed to take
advantage of the high energy content and generally
lower cost of No. 2 Diesel Fuels. Experience has shown
that a Cummins diesel engine will also operate satisfac
torily on No. 1 fuels or other fuels within the following
specifications.
Recommended Fuel Oil
Viscosity 1.3 to 5.8 CenttStoke

(ASTM D-445) [1.3 to 5.8 mm* Per Second)
at 104° F [40° CJ.
Cetane Number 40 minimum except in cold
(ASTM D-613) weather or in service with
prolonged low loads, a higher
cetane number is desirable.
Sulfur Content Not to exceed 1% by weight.
Water and: Not to 0.1% by weight.

(ASTM D-1796)
Carbon Residue Not to exceed 0.25% by
(Ransbottom ASTM weight on 10% residue.
D-524 or CM89)
Rash Point 125°F [52° C] minimum.
Certain marine registries
require higher flash points.
30 to 42° F [—1 to 6°C] AP l.
(ASTM D-287) at 60° F [16° C] (0.816 to 0.876
Sp. Gr.)
Cloud Point 10°F (—12°C] below lowest
temperature expected to
operate at.
Active Sulfur-Copper Not to exceed No. 2 rating
Strip-Corrosion after 3 hours at 122° F [50° CJ.
(ASTM D-130)
Not to exceed 0.02% by
I weight.
Distillation The distillation curve should
(ASTM D-86) be smooth and continuous.
At least 90% of the fuel should
evaporate at less than 680° F
[360° CJ. All of the fuel should
evaporate at less than 725° F
[385° CJ.
3-6
Coolani antifreeze except Methoxy Propanol. See Table

3-5 for Methoxy Propanol precharge instructions.
Water should be clean and free of any corrosive
chemicals such as chloride, sulphates and acids. lt 2. At the first "B" Check (oil change period) the DCA
should be kept slightly alkaline with a pH value range precharge element should be changed to DCA
of 8.5 to 10.5. Any water which is suitable for drinking Service Element. See Table 3-5.
can be treated as described in the following paragraphs
3. Replace the DCA Service Element at each succeed
for use in an engine.
ing "B" Check.
Maintain the Fleetguard DCA Water Filter on the
a. lf make-up coolant must be added between
engine. The filter bypasses a small amount of coolant
element changes, use coolant from a pre-
from the system via a filtering and treating element
treated supply, see "Make-Up Coolant
which must be replaced periodically.
Specifications", Section 2.
1. ln summer, with no antifreeze, fill the system with
b. Each time the system is drained, precharge per
water.
coolant specifications, Table 3-5.
2. In winter, select an antifreeze and use with water
4. The service element may be changed at the "C"
as required by temperature.
Check if 3300858 (DCA-4L) direct chemical addi
Note: Some antifreeze also contains anti-leak additives tive is added to the cooling system at each "B"
such as inert inorganic fibers, polymer particles or Check between service element changes. One
ginger root. These types of antifreeze should not be bottle of direct additive should be used for every
used in conjunction with the water filter. The filter 10 gallons of cooling system capacity. Add one
element will filter out the additives and/or become bottle for every 15-gallon capacity if methoxy
clogged and ineffective. propanol antifreeze is used in the cooling system.
3. lnstall or replace the DCA Water Filter as follows 5. To ensure adequate corrosion protection, have
and as recommended in Section 2. the coolant checked at each third element change
or more often. See "Check Engine Coolant",
New Engines Going Into Service Equipped Section 2.
With DCA Water Filters
1. New engines shipped from Cummins Engine
Company are equipped with water filters contain
ing a DCA precharge element. This element is
compatible with plain water or all permanent-type
Table 3-5: Spin-on Type DCA Water Filter
Cooling System Ethylene Glycol Base Antifreeze Methoxy Propanol Base Antifreeze
Capacity (U.S. DCA-4L Precharge Service DCA-4L Precharge Service

Gallons) (P/N 3300858) Element(s) (P/N 3300858) Element(s)
0-8 1 WF-2010 1 WF-2011

(P/N 299080) (P/N 3300721)
9-15 2 WF-2010 2 WF-2011
16-30 5 WF-2010 4 WF-2011
31-60 10 (2) WF-2010 8 (2) WF-201 1
35-90 12 (2) WF-2016 8 (2) WF-201 7
(V-1710) (P/N 299086) (P/N 3300724)
70-90 16 (2) WF-2010 16 (2) WF-2011
(KT-2300
3-7
Capscrew Markings and Torque Values
Current Usage Much Used Much Used Used at Times Used at Times
Minimum Tensile To 1/2-69,000 [476] To 3/4-120,000 [827] To 5/8-140,000 [965] 150,000 [1 034]
Strength PSI To 3/4-64,000 [421] To 1-115,000 [793] To 3/4-133,000 [917]
MPa To 1-55,000 [379]
Quality of Material 1 ndeterminate Minimum Commercial Medium Commercial Best Commercial
SAE Grade Number 1 or 2 5 ■ or 7 8
Head Markings
Manufacturer's marks
may vary
These are all SAE
Grade 5 (3 line)
7
Capscrew Body Size Torque Torque Torque Torque

(Inches) - (Thread) Ft Lbs [N.m] Ft- Lbs [N.m] Ft- Lbs [N.m] Ft-Lbs [N.m]
1/4 - 20 5 [7] 8 [11] 10 [14] 12 [16]
- 28 6 [8] 10 [14] 14 [19]
5/16 - 18 11 [15] 17 [23] 19 [26! 24 [33]
- 24 13 [18] 19 [26] 27 [37]
3/8 - 16 18 [24] 31 [42] 34 [461 44 [60]
- 24 20 [27] 35 [47] 49 [66]
7/16 - 14 28 [38| 49 [66] 55 [75] 70 [95]
- 20 30 [41] 55 [75] 78 [106]
1/2 - 13 39 |53| 75 [102] 85(115] 105 [142]
- 20 41 (561 85 [115] 120 [163]
9/16 - 12 51 [691 110 [149] 120 [163] 155 [210]
- 18 55 [75] 120 [163] 170 [231]
5/8 - 11 83 |113| 150 [203] 167 [226] 210 [285]
- 18 95 [129] 170 [231] 240 [325]
3/4 - 10 105 [142] 270 [366! 280 [ 380) 375 [508]
- 16 115 ( 156] 295 [400! 420 [569]
7/8 - 9 160 [2171 395 [536 1 440 |597| 605 [820]
- 14 175 [237] 435 [590 l 675 [915]
1 - 8 235 [319] 590 [ 800 1 660 [895] 910 [1234]
- 14 250 [339 1 660 [895| 990 [1342]
1. Always use the torque values listed above when specific torque values are not available.
2. Do not use above values in place of those specified in other sections of this manual; special attention should be observed
when using SAE Grade 6. 7 and 8 capscrews.
3. The above is based on use of clean, dry threads.
4. Reduce torque by 10% when engine oil is used as a lubricant.
5. Reduce torque by 20% if new plated capscrews are used.
6. Capscrews threaded into aluminum may require reductions in torque of 30% or more of Grade 5 capscrews torque and
must attain two capscrew diameters of thread engagement.
Caution: lf replacement capscrews are of a higher grade than originally supplied, adhere to torque specifications for
.r placement.
Troubleshooting
. Troubleshooting is an organized study of the problem

TrOUDlOStlOOXinCJ and a planned method of procedure for investigation
and correction of the difficulty. The chart on the
following page includes some of the problems that an
operator may encounter during the service life of a
Cummins diesel engine.
Cummins Diesel Engines
The chart does not give all the answers for correction pressure. Too often, engines are completely disas
of the problems listed, but it is meant to stimulate a sembled in search of the cause of a certain complaint
train of thought and indicate a work procedure directed and all evidence is destroyed during disassembly
toward the source of trouble. To use the trouble operations. Check again to be sure an easy solution
shooting chart, find the complaint at the top of the to the problem has not been overlooked.
chart; then follow down that column until you come to
Find And Correct Basic Cause Of Trouble
a black dot. Refer to the left of the dot for the possible
cause. After a mechanical failure has been corrected, be sure
to locate and correct the cause of the trouble so the
Think Before Acting
same failure will not be repeated. A complaint of
Study the problem thoroughly. Ask these questions: "sticking injector plungers" is corrected by replacing
the faulty injectors, but something caused the plungers
1. What were the warning signs preceding the
to stick. The cause may be improper injector adjust
trouble?
ment, or more often, water in the fuel.
2. What previous repair and maintenance work has
Tools And Procedures To Correct A Complaint
been done?
Tools and procedures to correct the complaints found
3. Has similar trouble occurred before?
in this Troubleshooting section are available from
4. lf the engine still runs, is it safe to continue running Cummins distributors and dealers. A list of publica
it to make further checks? tions, by bulletin numbers, is included in the back of
this manual in the form of a purchase order. This list
Do Easiest Things First
includes all engine model shop and and engine repair
Most troubles are simple and easily corrected; ex and rebuild manuals.
amples are "low-power" complaints caused by loose
AFC Fuel Pump Adjustments
throttle linkage or dirty fuel filters, "excessive lube
oil consumption" caused by leaking gaskets or All AFC fuel pump adjustments are specified for
connections, etc. calibration on a fuel pump test stand and not to be
made on the engine. Contact your nearest authorized
Always check the easiest and obvious things first.
Cummins distributor to perform maintenance, if
Following this simple rule will save time and trouble.
required.
Double-Check Before Beginning
Disassembly Operations
The source of most engine troubles can be traced not
to one part alone but to the relationship of one part
with another. For instance, excessive fuel consumption
may not be due to an incorrectly adjusted fuel pump,
but instead to a clogged air cleaner or possibly a
restricted exhaust passage, causing excessive back
4-1
Trouble
i?s»»/«/J
Shooting Mil
Cummins Engines HI
WffllltMM
CAUSES
Restricted Ak Intake • •• • •
H.gh Eihausl Back Pressure •; * * [ •
Air TMn Alt In Hot Weather or High •: •m t
• j Ak Le°ks 8«,"»" Cte""" Engine •ii i»i • •
* Dkly Turbocharger Compressor la] mm m •
Improper Use of Starter AloVAk temp •1 •1 " L - ♦
Stuck Dram «*t 1 M • § ••
Out of Fuel or Fuel Shut Off Cloeed A • -
Poor OusWy FueUGrade Fuel • • •| • • •• •
Ak Leeks m Suction Lines •• • • ••• • •j
Restricted Fuel Lines ••• f •• | •• _
Ejrtsmsl or keemai Fuel Leeks • • • J •LI
Plugged Injector Spray Hotes •
Broken Fuel Pump Drive Shaft • •
Scored Geer Pump or Worn Gears • •
Wrong Injector Cups •• •
Cracked Inksctor Body or Cup ncnnn • • • • I -
FiipI Damaged • •• •
m seiiietnIactor
as>intkO-Fttng
mirt- *t" ■ r-Tr •
SySteiTI Throttte Linkage or AJkiilwewl •• -
trasorrectfy AsssariMed lees Sprtrrrraa •••
IncorrecSly senielllilt Gumieui WaiuMn •••
High-Spaed Govsrnor Set TOO Low ••
Water In Fuel snOVor WksksJ •• • ••
AFC Cakbraoon Incorrect • •• •
Ckjrrresjed/Worn AFC Plunger Seal/Barrel
Fuel Pump Calibration Incorrect • •• • •
Injector Flo. Incorrect AfA
w At*. •
•• w''
Plugged ASA •
ASAJAFC Aw Leak. Bellows •
ASA 1MB Flo- V—r Stuck Opar. 1 • •
Ejflarnel awl kaatias Oil Lasts • c
Dirty OS FkSar • -
Lubricating Faulty Cylmder CM Control • • •■
Clogged Oil Dr«tkngs c •
System o» suction Line Bestrictton - r. - •
Faulty Oil Pressure Regulator c -
Crankcase Low or Out of Oil - C - •• •
Wrong Grade Ok lor Weather Condttrons • -
Oil Lass* IboHrgh • • 1 .. •
Darnagad Hoa»Vt-O0«M E
Radiator Shutters Stuck C
La*Coo*nlCapmc*rfUrtv Radtoeor
Coolant Temperature Low
Operation Dmy
Oil Weeds Changing

Efpgin* Exterior Dkty
Gaalie Blow By or t^taga mm
Broken or Worn Piston Rasas mm

Mechanical Incorrect
Adjustments Broken Cam Lobes
Main Bearing Bore Out of Alignment
Engine Due tor Overhaul
Damaged Main or Rod Bearings
Geartrain Backtatvh^roken tooth
e lo Driven Unit
Looae Mounttng Bolts/Head Capacnw
fatcorrac. Vm+m and Infactlon Timing
Worn or Scored Liners or Pistons
Injectors | mi
Broken/Bent Push Rod or Cam Box
Timing
System
System Stuck In Advance
Plugged Alrtine lo aTVT Actnrator
Index
Air Cleaner Cleaning (Oil Bath Type) 2-49 Fuel Filter Element Changing
Air Cleaner Element — Cartridge Type 2-11 (Spin-On Type) 2-29
Air Cleaner Element Cleaning Fuel Filter Sediment Draining 2-14
(Single and Dual Type Elements) 2-11 Fuel Oil Leaks 2-10
Air Cleaner Element Cleaning (Dry Type) 2-13 Fuel Oil Specifications 3-6
Air Cleaner Oil Changing 2-11 Fuel Pump Calibration 2-50
Air Cleaner Oil Level 2-14 Fuel System Priming 1-1
Air Cleaner Tray Screen Cleaning 2-30 Fuel Tank Sediment Draining 2-14
Air Compressor 2-52
Air Compressor Breather 2-33 Governed Engine Speed 1-6
Air Connections 1-3 Grease Specifications 3-5
Air lnlet Restriction at Air Cleaner 2-11
Air Inlet Restriction at Engine 2-11 High Altitude Operation 1-7
Air Tank Draining 2-14 Hose Checking 2-54
Aneroid Oil Level, Check 2-32 Hydraulic Governor 1-3
Aneroid Change Oil 2-48 Hydraulic Governor Oil Change 2-48
Aneroid — Clean and Calibrate 2-50 Hydraulic Governor Oil Level 2-32
Aneroid — Replace Breather 2-48
ldler Pulley 2-51
Belt Tersion — Checking and Adjusting 2-7 ldling the Engine 1-7
By-Pass Oil Filter Changing 2-28 lndustrial Fire Pump Engines 1-11
Back Side ldler Fan Drive 2-48 lnjectors, Clean and Calibrate 2-50
lnjector Plunger
Cold-Starting Aid Checking 2-54 Adjustment 2-35, 2-38, 2-39, 2-41, 2-43, 2-47
Cold-Starting Aids 1-4
Cold-Weather Protection 1-8 Lubricating Oil Change lntervals 2-15
Cold-Weather Starting 1-4 Lubricating Oil Analysis 2-26
Coolant Check 2-29 Lubricating Oil Specifications 3-1
Coolant Leaks 2-7 Lubricating System Priming 1-1
Coolant Level 1-3, 2-7
Coolant Specifications 3-7 Maintenance Check Sheet 2-3
Cooling System Cleaning 2-54 Maintenance Operation 2-1
Crankcase Breather Cleaning 2-32, 2-53 Maintenance Schedule 1-14, 2-2, 2-5, 2-6
Crankshaft End Clearance 2-55 Mounting Bolt and Nut Tightening 2-55
Crosshead Adjustment . . 2-36, 2-38, 2-42, 2-45, 2-48
Oil Change Charts 2-18
Daily Checks 2-7 Oil Change Limits 2-15
Drive Pulley 2-55 Oil Filter Element Changing 2-27
Oil Level 1-1.2-7
Engine Break-In 1-1 Oil Pressure Gauge 1-7
Engine Coolant 1-3 Oil Temperature Gauge 1-6
Engine Exhaust 1-7 Operating lnstructions 1-1
Engine Oil Changing 2-15 Operator's Daily Report 2-7
Engine Oil Level. Check 2-7
Engine Shut-Down 1-7 Power Take-Off Applications 1-7
Engine Speeds 1-6 Pressure Flushing 2-54
Preheater — Cold Starting 2-54
Fuel Filter Water Separator 2-14 Pre-Cleaner and Dust Pan 2-11
Fan Hub lnspection 2-48 Pre-Startmg 1-1
Index
Rebuild Units — lnspection and lnstalling 2-51
Specifications and Torque 3-1

Shutterstat Checking 2-54
Starting Procedure 1-3
Steam Clean Engine 2-54
Storage for Engine Out of Service 2-1
Temperature Settings 2-54

Thermal Control Settings 2-54
Thermatic Fan Checking 2-54
Thermostat and Seal Checking 2-54
Throttle 5-5
Torque Specifrcations 3-8
Trouble-Shooting -4-1
Trouble-Shooting Chart 4-2
Turbocharger Bearing Clearance 2-51
Turbocharger Mounting Nut Tightening 2-55
Valve Adjustment 2-36. 2-39. 2-43. 2-48

Vibration Damper lnspection 2-51
"Warming Up" Engine 1-6

Water Filter Changing 2-31
Water Pump lnspection 2-51
Water Temperature Gauge 1-6
Weekly Checks 2-11
Zinc Plugs 2-56
Index 2
Part 2
REPAIR
Foreword
This NH/NT/NTA-855 C.l.D. Engine Rebuild Man How to use this Manual
ual is written and organized in a way which allows
The manual is divided into 22 groups. These
a user, no matter his familiarity with Cummins
groups are listed in the Table of Contents.
engines, to follow the procedures necessary to
rebuild that engine. For this reason, we have at The disassembly of the engine is covered in Group 0,
tempted to use as few technical terms as possible The disassembly, inspection and assembly of
and have divided procedures into the basic steps. components are covered in the appropriate group.
For example, Group 0 contains the instructions
This NH/NT/NTA Manual contains these instruc
for removing the lubricating oil pump from the
tions and specifications:
engine. Group 7, Lubricating System, contains the
• Disassembly of the engine instructions for disassembly, inspection and
• Disassembly of some components and assembly of the lubricating oil pump itself.
most assemblies
• Cleaning and inspection of the Note: Some components are not included in the
engine and parts engine manual. They are: (1) the fuel pump, (2) air
• Repair and/or replacement of parts compressor, (3) injectors and (4) turbochargers.
• Assembly of components and assemblies At the beginning of each group is an exploded
• Assembly and testing of the engine view of the components covered in that group.
• Worn limits These exploded views show the relationship be
• Torque values tween all parts in a component.
Some information that is specific to particular Also at the beginning of each group is a list of
engine models is included. You should determine tools either required or recommended to do the
what engine model an engine is before doing any procedures described in that group. Many of
work on that engine. The dataplate on the engine these tools were designed by Cummins Engine
will identify the engine model. This model number Company to perform a specific procedure and are
provides information on the design, aspiration, available from your Cummins Distributor. Other
cubic inch displacement, application (equipment tools are standard tools which are generally
for which the engine was designed) and maximum available.
rated horsepower.
At the end of each group is a table which includes
Example: NTA-855-C360 the worn limits, and dimensions of the parts con
tained in that group. (Worn limits indicate that a
N = NH Engine Series part can be used if its dimensions are within the
T = Turbocharged (if there is no "T", the dimensions given and if it is not damaged.)
engine is naturally aspirated) Torque values are also included in this table.
A = Aftercooled
855 = Cubic Inch Displacement Group 18 includes the specifications contained in
C = Construction Application all other groups and the following additional
360 = Maximum Rated Horsepower specifications:
1. Oil Recommendations
Application Designations 2. Fuel Recommendations
3. Coolant Recommendations
C = Construction
G = Generator (GS = Standby, There is an alphabetical index at the end of the
GC = Continuous Duty) manual to allow you to find the page number for
P = Power Unit specific information without having to read
M = Marine through an entire group. This index is intended to
L = Locomotive match the headings used in the text. For example,
R = Railcar if you are looking for disassembly of the lubricat-
b
ing oil pump, look up "Lubricating Oil Pump" in
the index. The entry would appear as follows:
Lubricating Oil Pump
Assembly 7-4
Disassembly 7-2
lnspection 7-2
Repair 7-2
Replacement 7-2
Note: The pages in this manual are numbered in
sequence within the group. That is, the first page
in Group 0 is 0-1; the first page in Group 1 is 1-1.
The last page in this manual is a list of other
Cummins Engine service publications on related
subjects.
The pages of the manual can be removed by bend
ing the manual back at the beginning and end of
each group. The pages can then be easily pulled
out and put in a three-ring binder.
This manual includes Service/Parts Topic infor
mation concerning the NH/NT/NTA-855 from Feb
ruary, 1979 to September, 1981 and supersedes
Bulletin Number 3379076-04. As it is the policy of
Cummins Engine Company, lnc. to improve its prod
ucts, design changes will occur after publication
of this manual which can affect the procedures
described in this manual. lf you have any ques
tions about your engine, check with your local
Cummins Distributor or Dealer.
To make sure that this manual provides the infor
mation you need in a way that allows you to make
the best use possible of that information, we need
to hear from you about any problems you encounter.
Please send your comments to:
NH Technical Writer — 80203
Service Operations
Cummins Engine Company, lnc.
Box 3005
Columbus, lN 47201
The Contents of this manual are based on infor
mation in effect at time of printing and are subject
Table of Contents to change without notice.
Group 0 — Engine Disassembly 0-1 Group 4 — Cam Followers 4-1

General Information 0-1 Cam Followers 4-2
Disassembly Of The Engine 0-4 Mechanical Variable Timing 4-7
Push Rods 4-17
Group 1 — Cylinder Block 1-1
The Cylinder Block 1-2 Group 5 — Fuel System 5-1
The Camshaft Bushing 1-2 PT Fuel Pumps 5-1
The Cylinder Liner Counterbore 1-4 Group 6 — Injectors 6-1
The Cylinder Liner Bore 1-10 Injectors and Connections 6-1
The Water Passages 1-13
Salvage Of The Cylinder Head Group 7 — Lubricating System 7-1
Capscrew Holes 1-15 The Lubricating Oil Pump 7-2
Refinishing Of The Top Surface Demand Flow and Cooling (DFC) 7-8
Of The Cylinder Block 1-16 Lubricating Oil Filters 7-11
Main Bearing Caps 1-17 Lubricating Oil Lines 7-12
Main Bearing Bore 1-17 The Lubricating Oil Pan 7-14
The Cylinder Liners 1-24 The Lubricating Oil Dipstick 7-14
Crankshaft 1-24 The Lubricating Oil Cooler 7-14
Bearings 1-25 NTE (European) Oil Cooler 7-20
Crankshaft Thrust Bearings 1-26
The Vibration Damper 1-26 Group 8 — Cooling System 8-1
The Mounting Flange For The Eccentric Water Pump 8-2
The Vibration Damper 1-27 The Water Pump For The
The Connecting Rod 1-27 NTA Engine 8-6
Piston Rings 1-31 The FFC Water Pump 8-12
Pistons 1-31 The Fan 8-18
Assemble The Piston To The Fan Hub 8-18
The Connecting Rod 1-32 The Thermostat and Housing 8-21
The Rear Cover 1-32 The Raw Water or Sea Water Pump 8-22
The Camshaft 1-33 Group 9 — Drive Units 9-1
The Camshaft Support 1-33 General Information 9-1
The Gear Cover 1-33 Accessory Drive 9-2
Hydraulic Governor Drive 9-3
Group 2 — Cylinder Head 2-1
Drive Pulleys 9-4
Cylinder Head 2-2
The Valve Guides 2-8 Group 10 — Air Intake System 10-1
Valves 2-9 The Intake Manifold and Connection 10-1
The Valve Springs 2-11 The Aftercooler 10-1
The Crosshead Guides 2-11
Crossheads 2-12 Group 11 — Exhaust System 11-1
Water Holes 2-12 Exhaust Manifolds 11-1
lnjector Sleeve 2-14 Group 12 — Air Equipment 12-1
Assembly and Testing 2-16 Air Compressor 12-1
Vacuum Pump 12-1
Group 3 — Rocker Levers 3-1 Air Cranking Motor 12-1
Rocker Levers and Housing 3-2
Rocker Levers 3-2 Group 13 — Electrical Equipment 13-1
Crankcase Breather 3-5 Wiring Diagram 13-1
Rocker Housing Cover 3-5 Electrical Components 13-1
Group 14 — Engine Assembly and Testing . . . 14-1 Cam Follower Specifications 18-7
Engine Assembly 14-3 Lubricating Oil Pump Specifications 18-8
To Test The Engine 14-44 Oil Pan Capacity 18-11
Paint The Engine 14-48 Cooling System Specifications 18-13
Preparing An Engine From Storage Drive Unit Specifications 18-14
To Service 14-50 Assembly Specifications 18-15
Capscrew Markings and Torque Values 18-18
Group 16 — Mounting Adaptations 16-1 Lubricating Oil 18-19
The Flywheel 16-1 Grease 18-22
The Flywheel Ring Gear 16-1 Fuel Oil 18-22
Coolant 18-24
Group 18 — Wear Limits, Specifications
And Torque 18-1 Group 20 — Vehicle Braking 20-1
Cylinder Block Specifications 18-1 The Compression Brake 20-1
Cylinder Head Specifications 18-5 Maintenance Of The Engine Brake 20-1
Rocker Lever Specifications 18-6 The Exhaust Brake 20-9
e/(f Blank)
01
f
Engine Disassembly
f% rftiaB1 f% During unit removal, time and labor will be saved

**iOlip " if the steps outlined are followed. Precautions are
included that may help prevent accidents and/or
damage to the parts.
Engine Disassembly
Service Tool List General Information

The following service tools or tooIs of equal
quality are required to disassemble the 855 C.I.D. Engine Dataplate
(Cubic Inch Displacement) Series Diesel Engines. The engine dataplate is located on the mounting
flange for the gearcase, Fig. 0-1.
Service Tools (Or Equivalent) Required

Service Tool Tool
Number Name
ST-125 Lifting Fixture
ST-548, 1317 or 3375193 Engine Rebuild Stand
ST-805 or 3375013 Engine Stand Adapter
3376028 MVT Fixture
3376029 Bracket and Studs
Desirable (Or Equivalent) Service Tools
ST-163 Engine Support
ST-647 Puller (Pulley)
ST-845 Fan Hub Wrench
ST-687 Crankshaft Flange Puller
ST-893 Fan Hub Wrench
ST-1178 Main Bearing Cap Puller
ST-1201 Liner Puller Bridge
ST-1202 Liner Puller Assembly Fig. 0-1. Engine Dataplates
ST-1259 Seal Mandrel
ST-1297 lnjector Puller
3375049 Always write the serial number of the engine, the
Filter Wrench (Spin-On)
3375161 Top Stop Injector Puller CPL number and the engine Model number on all
3375268 Camshaft Pilot orders for parts. This lnformation is important for
3375602 Nylon Guide Screws fuel pump calibration and ordering parts.
3376015 Cylinder Liner Puller Note: The Engine Dataplate must not be changed
Standard Tools — Obtain Locally unless approved by Cummins Engine Co., Inc.
Hoist (Power or Chain)
Inspect the engine before disassembly. Check the
Steam Cleaner
Cleaning Tank locations of the parts on the outside of the
Rinsing Tank engine.
lmpact Wrench During disassembly, check the length of the
Glass Bead Cleaner capscrews when they are removed. Keep the
0-1
NT/NTA 855 C.I.D. Engine Shop Manual
capscrews separate according to their use on the

engine. This will help you find the correct
capscrews during assembly.
Discard the seals, gaskets, lockplates, O-rings
and other sealing parts after they have been
removed from the engine. Check the hoses and
belts for damage.
To prepare the engine for disassembly, remove all
fluids from the engine.
To Drain The Fluids

1. Drain the oil from all the components on the
engine, Fig. 0-2.
Fig. 0-3. Drain The Coolant From The Engine.
Fig. 0-2. Oil Drain Plug
2. Drain the diesel fuel from the fuel pump, fuel Fig. 0-4 (N10074). Remove The Starting Motor.
filters and fuel lines.
3. Drain the cooling fluid from the cylinder block
(Fig. 0-3) and all the components on the
engine.
4. If the engine has a compressed air system,
vent the compressed air.
Cleaning
To Clean The Engine
Before you clean the engine, remove the electrical
equipment (Fig. 0-4 and Fig. 0-5) and controls. Put
a label on the wiring as it is removed. Put a cover
or tape on the openings of the engine to prevent
moisture from entering the engine. Clean the
engine with any standard steam cleaner or with
hot water under high pressure. Fig. 0-5 (N10075). Remove The Alternator.
Engine Disassembly
To Clean Parts And Assemblies Caution: Do not damage the gasket surfaces of
Most of the parts can be cleaned with steam or the parts.
hot water. Use steam to clean the pistons. Then 1. Heat the solution of solvent or acid to approx
use a solvent so that all of the carbon is removed imately 180° to 200 °F [82° to 93 °C]. Mix the
from the ring grooves of the piston. lf the part will solution continuously.
be damaged by moisture or does not come clean,
use another method. lf a part is to be put in 2. After disassembly, put the small parts in a
storage, dry it with compressed air and coat it wire container and clean them with steam.
with a rust inhibitor. The parts must be cleaned as After steam cleaning, put the parts in the
soon as possible after disassembly. heated solution. Use a hoist to lower the large
parts into the cleaning solution.
To Clean Parts With Glass Beads
3. Make sure all the pipe plugs are removed from
Use glass beads to clean valves and cylinder the oil passage in the cylinder block. To clean
heads. the passage, push a rod with a brush attached
Follow These Recommendations: to one end through all the passages in the
cylinder block. Remove all the deposits from
1. Size of the glass beads: Use U.S. sieve size the bore for the cylinder liner. Use a wire brush
Number 60. installed in an air drill to clean the counter-
2. Pressure: Use 80 psi [551 kPa] pressure. Or bore for the cylinder liner. Remove any scrat
follow the Manufacturers instructions. ches or damage.
3. Do not let the glass beads hit the part for more Note: lf the engine has piston cooling, make sure
time than is necessary. Be careful when you the spring and plug under the pipe plug for the
clean parts made of aluminum. piston cooling oil passage is removed before
4. After using the glass beads, use steam and cleaning the cylinder block.
compressed air to remove the glass beads 4. To remove thick mineral deposits other than
from the parts. Then, wash the parts in solvent dirt, use a solution of acid.
and dry with compressed air. Make sure all the
parts are clean and all glass beads are re Warning: Acid can cause an injury to you or
moved before the parts are assembled. damage machinery. Always have a tank of strong
soda water ready for use.
Note: Use a different container of solvent to wash
parts that have been cleaned with glass beads. 5. Wash all the parts in hot water and dry with
compressed air. Use the compressed air to
To Clean Parts With Solvent Or Acid remove the cleaning fluid or water from the
Warning: The use of acid is dangerous to both a holes for the capscrews. This will prevent
person and a machine. Always have a tank of damage when the capscrews are installed.
strong soda water to control the acid. Wear safety 6. lnstall the spring and plug for the oil passage.
glasses and gloves. lnstall the pipe plugs in the oil passages and
Always read the instructions given on the con tighten them to the correct torque.
tainers of cleaning solvents and acids. Follow Note: lf a part requires repair with a machine tool,
these instructions. do not install the pipe plugs in the part until the
Caution: Cleaning solvents can damage the bear repairs are completed. Clean all metal particles
ing shells and aluminum parts. Always read the from the part. Then install the pipe plugs.
instructions for cleaning these parts before you 7. lf the parts are not used immediately after
clean them. cleaning, apply a coating of rust protection
Caution: Do not damage the surface of the parts. compound to protect the parts from rust.
Before you put the parts into a container of sol Note: You must remove the rust protection com
vent solution, make sure you remove all gaskets pound from the parts before you assemble them
and deposits. in the engine.
0-3
Disassembly of the Engine 3. Disconnect the inlet line and the outlet line
from the head of the water filter.
Before you install the engine on the engine stand,
remove the following items: 4. Remove the capscrews, lockwashers and flat-
washers that hold the bracket and head of the
The Oil Gauge and Bracket filter to the cylinder block.
1. Remove the capscrews and lockwashers that
hold the bracket to the cylinder block, Fig. 0-6. The Mechanical Controls and Supply Lines
for Fuel, Air and Water
2. Remove the bracket for the oil gauge from the
cylinder block. 1. Remove the linkages that control the throttle
and clutch. Remove any other controls that
are mounted to the engine.
2. Remove all water connections and hoses.
3. Remove the fuel lines from the drain for the
fuel injectors and the inlet. lf the engine has
one, remove the fuel filter. Remove the line
that returns the fuel from the fuel'pump to the
fuel tank.
Note: When an engine is a dual diesel, there are
two sets of fuel lines and additional valves to con
trol the fuel.
4. Remove the air lines from the air compressor.
5. Remove the hoses and tubes that connect the
air cleaner and the turbocharger.
Caution: During disassembly of the engine, put a
Fig. 0-6. Remove The Oil Gauge Bracket. cover tape over the inlet and outlet to the turbo-
The Water Filter
1. Close the shutoff valves for the inlet line and
the outlet line. 1. Remove the air crossover from the turbo-
2. Remove the element from the water filter and charger and aftercooler or intake manifold,
discard, Fig. 0-7. Fig. 0-8.
Fig. 0-7 (N 11976). Remove The Water Filter. Fig. 0-8. Remove The Air Crossover.
Engine Disassembly
2. Remove the oil drain line from the turbo- 3. Remove the vent tube and clip from the
charger and cylinder block. Remove the oil engine.
supply line from the turbocharger and the oil
cooler, Fig. 0-9. The Oil Cooler and Filter
1. Remove the capscrews holding the water con
nection to the cylinder block, Fig. 0-11.
Fig. 0-9. Remove The Turbocharger Oil Supply Line.

3. Before you remove the turbocharger, remove
all heat shields for the turbocharger. Remove
the locknuts that hold the turbocharger to the
exhaust manifold. Lift the turbocharger from
the flange on the exhaust manifold, Fig. 0-10. Fig. 0-11. RemoveThe Capscrews Holding The Water Connection.
2. Loosen the clamp that holds the transfer tube

to the oil cooler. Remove the transfer tube and
water connection, Fig. 0-12.
Fig. 0-10. Remove The Turbocharger.

The Crankcase Vent
1. Loosen the clamps and remove the hose for
the vent tube from the breather.
Fig. 0-12 (N100141) Remove The Water Connection And
2. Remove the capscrews and lockwashers that Transfer Tube.
hold the clip for the vent tube to the cylinder
block. 3. Remove the oil filter and discard it, Fig. 0-13.
0-5
Fig. 0-13. Remove The Oil Filter. Fig. 0-15. Remove The Oil Cooler Housing.
4. Remove the capscrews, lockwashers and flat- The Water Pump Inlet
washers that hold the bracket for the oil
cooler to the cylinder block. 1. Remove the capscrew, lockwashers and flat-
washers that hold the bracket for the water in
5. Remove the capscrew, lockwasher and flat- let connection to the cylinder block.
washer that hold the water transfer tube to the
housing for the thermostat, Fig. 0-14. Remove 2. Remove the capscrews, lockwashers and flat-
the water transfer tube and discard the washers that hold the inlet for the water to the
O-rings. water pump. Remove the inlet and discard the
gasket, Fig. 0-16.
Fig. 0-14. Remove The Capscrew That Holds The Transfer Tube.
Fig. 0-16 (N100142). Remove The Water Pump lnlet.
6. Remove the capscrews, lockwashers and flat-
washers that hold the support for the oil cooler The Piston Cooling Nozzles
to the cylinder block. lnstall a dowel into one of
the capscrew holes to hold the support until all Remove the capscrews and lockwashers that hold
the capscrews are removed. Remove the oil the nozzles in the cylinder block. Remove the
cooler, Fig. 0-15. Remove the dowel. nozzles, Fig. 0-17.
0-6
Engine Disassembly
3. Put the engine in the correct position on the

engine stand. lnstall the lockwashers and
capscrews to hold the engine to the stand.
4. After the engine is tightly installed to the
engine stand, Fig. 0-19, remove the following
items.
Fig. 0-17 (N100140). Remove The Piston Cooling Nozzle.
The Exhaust Manifold

1. Bend the tabs on the lockplate away from the
capscrews for the exhaust manifold.
2. Remove the capscrews, lockwashers and
lockplates that hold the exhaust manifold to
the cylinder block, Fig. 0-18. Fig. 0-19. The Engine Installed To The Engine Stand.
The Aftercooler
1. Loosen the clamps and remove the water
crossover tube from the front of the after-
cooler, Fig. 0-20.
Fig. 0-18. Remove The Capscrews From The Exhaust Manifold.
3. Remove the exhaust manifold.
To Install the Engine on the Engine Stand

Fig. 0-20. Remove The Water Crossover Tube.
1. Replace the rear water header cover with the
adapter plate for the engine stand.
2. Loosen the clamps and remove the water
2. Install the adapter plate for the engine stand crossover tube from the rear of the after-
to the engine stand. cooler, Fig. 0-21.
0-7
Fig. 0-21. Remove The Tube From The Rear Of The Aftercooler. Fig. 0-23. Remove The Capscrews From The Aftercooler.
3. Remove the air supply tube for the air com

The Fuel Pump
pressor from the aftercooler, Fig. 0-22.
1. Remove the capscrews that hold the fuel

pump the the air compressor, Fig. 0-24.
Remove the support brackets.
Fig. 0-22. Remove The Air Supply Tube From The Air Compressor.

hold the aftercooler to the engine, Fig. 0-23. Fig. 0-24. Remove The Capscrews That Hold The Fuel Pump.
lnstall two dowels, one at each end of the
aftercooler, into capscrew holes to hold the
aftercooler. 2. Remove the fuel pump from the air com
pressor, Fig. 0-25. Remove the fuel pump drive
spider coupling.
5. Remove the aftercooler. The aftercooler is
heavy. Use a hoist or another person to help
you to remove the aftercooler. Remove the 3. Put a cover over the connections on the fuel
dowels. pump so dirt will not enter the fuel pump.
0-8
Engine Disassembly
Fig. 0-25. Remove The Fuel Pump. Fig. 0-27. Remove The Spline Coupling.
The Air Compressor

hold the air compressor to the accessory drive.
2. Remove the air compressor from the
accessory drive, Fig. 0-26.
Fig. 0-28. Loosen The Water Pump Belt.
2. Loosen the adjusting screw for the fan hub to

release tension on the belt for the fan hub.
3. Remove the belts for the fan hub and water
pump.
Fig. 0-26. Remove The Air Compressor.
hold the adjusting bracket for the fan hub to
the water pump body and the rocker lever
3. Remove the spline coupling from the
housing, Fig. 0-29.
accessory drive, Fig. 0-27.
5. Remove the fan hub and adjusting bracket.
The Fan Hub Water Pump 6. Loosen the clamps that hold the water bypass
tube to the thermostat housing.
1. Loosen the nut on the end of the idler shaft.
Loosen the adjusting screw for the idler 7. Remove the water bypass tube from the ther
pulley. This releases the tension on the belt mostat housing and the water pump body, Fig.
for the water pump, Fig. 0-28. 0-30. Discard the O-rings.
0-9
Fig. 0-29. Remove The Capscrews That Hold The Bracket. Fig. 0-31. Remove The Capscrews From the Water Pump.
Fig. 0-32. Remove The Water Pump.

Fig. 0-30. Remove The Water Bypass Tube.

hold the water pump body to the cylinder
block, Fig. 0-31.
9. Remove the water pump and discard the
gasket, Fig. 0-32.
The Accessory Drive Pulley

1. Remove the locknut and washer.
Note: When a flanged locknut is used to hold the
pulley on the shaft, you must not let the
accessory driveshaft turn when the locknut is
removed. When the flanged locknut is installed, it
is tightened to 270 to 340 ft.-lbs. [366 to 461 N»m]
torque. Fig. 0-33. Remove The Accessory Drive Pulley.
0-10
Engine Disassembly
2. Use the ST-647 Puller to remove the pulley,

Fig. 0-33. lf the threads in the capscrew holes
are distorted, install a tap with the same
thread size into the holes. Remove the tap. ln
stall the ST-647. Be careful and do not let the
capscrews damage the gear cover.
3. Remove the pin and oil seal from the shaft.
The Accessory Drive

hold the accessory drive to the cylinder block.
2. Use a rubber hammer to loosen the drive.
3. Remove the drive and discard the gasket, Fig.
0-34.
Fig. 0-35. Remove The Rocker Lever Covers.
Fig. 0-34. Remove The Accessory Drive.
The Rocker Lever Cover Fig. 0-36. Remove The Rocker Lever Housings.
1. Remove the capscrews, lockwashers and flat- The Push Rods
washers that hold the rocker lever cover to the
rocker lever housing. Lift all the push rods from their sockets. Put a
mark on each push rod as it is removed to identify
2. Remove the covers and discard the gaskets, its location in the engine.
Fig. 0-35.
The Rocker Housing The Valve Crossheads
1. Loosen the locknut and adjusting screw for 1. Loosen the crosshead adjusting nuts.
the rocker levers. Turn the adjusting screws 2. Remove all of the crossheads for the valves,
counterclockwise two times. Fig. 0-37.
2. Remove the capscrews and washers that hold
the rocker housings to the cylinder heads. The Water Manifold and Thermostat Housing
3. Remove the rocker lever housing and discard 1. Remove the capscrews and lockwashers that
the gaskets, Fig. 0-36. Put a mark on each hold the water manifold to the cylinder head.
housing as it is removed to identify its loca 2. Remove the water manifold and thermostat
tion on the engine. housing, Fig. 0-38. Discard the O-rings.
0-11
Fig. 0-37. Remove The Crossheads Fig. 0-39. Remove The Injectors.
Fig. 0-38. Remove The Water Manifold. Fig. 0-40 (N100149). Remove The Fuel Crossover.
The Injectors The Cylinder Head
1. Remove the capscrews that hold the injector 1. Remove the capscrews and washers that hold
clamps. Remove the clamps. Remove the the cylinder head to the cylinder block. Be
injector links. careful and do not damage the capscrews.
2. Use the Part No. 3375161 injector Puller to Note: Remove the capscrews in the opposite
remove the top stop injectors from the cylinder sequence as that used for installing the cylinder
head. Use the ST-1297 injector puller to remove heads, Fig. 0-41.
the "PTD" injectors from the cylinder head.
2. Lift each cylinder head from the cylinder
3. Remove the injectors, Fig. 0-39. Put the in block, Fig. 0-42. Put a mark on each cylinder
jectors in a rack that will protect them from head as it is removed to identify its location
damage and dirt. on the engine.
The Fuel Crossover 3. Remove and discard the gaskets.
1. Remove the screws that hold the fuel cross
over connectors to the cylinder head. The Lubricating Oil Pump
2. Lift the fuel crossover from the cylinder head 1. Disconnect the oil lines to the inlet and outlet
and discard the O-rings, Fig. 0-40. of the oil pump.
-12
Engine Disassembly

hold the oil pump to the cylinder block.
3. Remove the oil pump from the gear case, Fig.
0-43. Discard the gasket.
The Cam Follower Housings

hold the cam follower housings to the cylinder
block.
2. Lift and remove the housings from the
cylinder block.
Note: Do not discard the metal spacer that is used
on some engines. Measure and make a record of
Fig. 0-41 (N11427). Tightening Sequence For The Cylinder the total thickness of the gaskets. The thickness
Head Capscrews. of the gaskets between the cam follower housing
and the cylinder block controls the injection
timing.
The MVT Cam Follower Housing

The cam follower housings with mechanical
variable timing (MVT) are installed on the engine
as an assembly and must be removed as an
assembly. Follow these instructions.
1. Remove two capscrews and lockwashers as

shown in Fig. 0-44, from the first and third
housing of the assembly.
2. lnstall the Part No. 3376028 MVT Fixture to the
housings.
Fig. 0-42. Remove The Cylinder Heads.
Fig. 0-44. Remove These Capscrews From The First And

Fig. 0-43. Remove The Oil Pump. Third Housing.
0-13
Remove the remaining capscrews and 2. Remove the vibration damper and pulley, Fig.
lockwashers that hold the housings to the 0-46.
cylinder block. Then, install the 3376029 Caution: Do not use a hammer or screwdriver to
bracket to the 3376028 fixture. remove a viscous damper. These tools can
Remove the cam follower housing assembly,
Fig. 0-45.
Fig. 0-46. Remove The Vibration Damper and Pulley.

Fig. 0-45. Remove The Cam Follower Assembly. The Front Engine Support
5. Remove and discard the gasket.
hold the support to the engine.
Note: The cam follower assembly with
2. Remove the front engine support, Fig. 0-47.
mechanical variable timing requires only one
gasket.
The Vibration Damper

The Vibration Damper and Flange
(Tapered End Crankshaft)
1 . Remove the capscrews that hold the vibration
damper to the flange. Do not let the crank
shaft turn when you remove the capscrews
from the flange.
2. To remove a rubber element vibration damper,
use a rubber hammer. Do not use a metal
hammer.
3. Use the Part No. ST-887 Crankshaft Flange
Puller to remove the flange from the crank
shaft.
Fig. 0-47. Remove The Front Engine Support.
The Vibration Damper and Pulley
(Straight End Crankshaft) The Flywheel
1 . Remove the capscrews that hold the vibration 1. Cut and remove the lockwires for the cap-
damper and pulley to the crankshaft adapter. screws. Remove the capscrews, washers and
Do not let the crankshaft turn when you lockwashers that hold the flywheel to the
^move the capscrews. crankshaft.
Engine Disassembly
2. lnstall two studs with 5/8"-18 threads and 6 2. Remove the capscrews, lockwashers and flat-
inches [152 mm] long in the crankshaft to sup washers that hold the flywheel housing to the
port the flywheel during removal. cylinder block, Fig. 0-50. lnstall two dowel
bolts to hold the housing.
3. lnstall two capscrews into the flywheel puller
holes. The capscrews must have a 1/2 "-13
thread for their complete length. Turn the
capscrews slowly to push the flywheel from
the crankshaft, Fig. 0-48.
4. Lift the flywheel from the crankshaft, Fig. 0-49.
Fig. 0-50. Remove The Capscrews That Hold The Flywheel

Housing.
3. Hit the housing with a rubber hammer to push

the housing from the dowels in the cylinder
block. Remove the dowel bolts.
Fig. 0-48 (N100113). Push The Flywheel From The Crankshaft.
The Oil Pan
1. Remove the bolts, capscrews, lockwashers
and flatwashers that hold the oil pan to the
cylinder block and gear cover.
2. Remove the capscrews that hold the oil pan to
the rear cover.
3. Remove the oil pan and discard the gasket,
Fig. 0-51.
The Rear Cover and Oil Seal

1. When a wet type flywheel housing is used,
remove and discard the O-ring.
hold the cover to the cylinder block.
3. Lift the cover and seal from the crankshaft
Fig. 0-49. Remove The Flywheel. flange, Fig. 0-52. Remove the seal from the
housing.
The Flywheel Housing
1. Remove the capscrews, lockwashers and flat- The Gear Case Cover
washers that hold the oil pan to the flywheel 1. Remove the Camshaft support bearings. Do
housing. not discard the shims. Remove the capscrews
0-15
Fig. 0-51. Remove The Oil Pan. Fig. 0-53 (N100152). Use The 3375268 Pilot To Prevent Damage
To The Camshaft.
2. Remove the cup plug at the rear of the cam

shaft bore.
The Connecting Rod and Piston Assembly

1. Clean the carbon from the upper inside wall of
each cylinder liner, Fig. 0-54. Use an emery
cloth to polish the liners. Do not damage the
liners when you polish them.
Fig. 0-52. Remove The Rear Cover And Seal.
and lockwashers that hold the cover to the

cylinder block.
2. lnstall two 4 inch [101.6 mm] studs. Put one on
each side of the cover for support during
removal.
3. Remove the cover and discard the gasket.
The Camshaft
Fig. 0-54 (N100153). Remove The Carbon From The Cylinder
Before you remove a 2-1/2 inch camshaft, install Liner
the Part No. 3375268 Camshaft Pilot, Fig. 0-53.
This will prevent damage to the camshaft journals 2. Remove the caps from the connecting rods:
and bearings. a. For connecting rods that have capscrews,
1. Turn the camshaft gear slowly while you pull loosen the capscrews approximately 3/8
the camshaft from the engine. Do not remove inch [9.5 mm]. Hit the heads of the
the gear from the camshaft. capscrews with a soft hammer to push the
0-16
Engine Disassembly
cap from the dowels in the connecting rod.

Remove the capscrews and the cap.
b. For connecting rods that have bolts,
remove the nuts and washers. Pull the cap
from the connecting rod. Use a soft ham
mer to push the bolts from the rod.
Caution: Do not use a hammer or screwdriver to
remove the caps from the connecting rods.
3. lnstall Part No. 3375601 Nylon Guide Screws
in the connecting rod to prevent damage to
the cylinder liner. Push the connecting rod
and piston assembly from the cylinder liner,
Fig. 0-55. Make sure each connecting rod and
cap has a label or mark for identification.
Fig. 0-56. Remove The Main Bearing Capscrews.
2. Use the Part No. ST-1178 Main Bearing Cap

Puller to pull the main bearing caps from the
dowels in the cylinder block, Fig. 0-57. Make
sure all the bearing caps have a mark so that
they can be installed in the correct position.
Tig. 0-55 (N100154). Remove The Connecting Rod And Piston

Assembly.
4. Remove and discard the piston rings. Remove

the retaining rings that hold the piston pin.
5. To remove the pin from the piston, heat the
piston for two minutes with boiling water.
Fig. 0-57. Remove The Main Bearing Caps.
Then push the pin from the piston with your
fingers. 3. Remove the bearing caps and bearing shells.
Warning: Wear rubber gloves to prevent injury
4. Use a hook protected with a rubber hose or a
from the boiling water.
lifting strap to remove the crankshaft, Fig.
Caution: Do not use a hammer or other tools to 0-58. Be careful not to damage the surface of
remove the piston pin. the crankshaft.
5. Remove the bearing shells from the cylinder
The Crankshaft and Main Bearings block . Remove the ring dowels from the
1. Remove the capscrews and lockplates that cylinder block. Put a mark on the bearing
hold the main bearing caps to the cylinder shells showing the position from which they
block, Fig. 0-58. were removed.
0-17
The Cylinder Liners

Use the Part No. 3376015 Cylinder Liner Puller to
pull the cylinder liners from the cylinder block.
Discard the O-rings and crevice seals. lf shims are
used under the liners, do not discard the shims.
Fig. 0-58. Remove The Crankshaft.
0-18
Cylinder Block
This section includes the cylinder block, cylinder

GrOUp 1 liners, crankshaft, bearing shells, connecting
rods, pistons, camshaft, rear cover, gear cover
and vibration damper.
Cylinder Block
1. Camshaft Bushing Bore 5. Cylinder Liner 9. Crankshaft Thrust Ring 13. Piston Pin
2. Cylinder Liner Counterbore 6. Crankshaft 10. Crankshaft End Clearance 14. Piston Ring
3. Main Bearing Bore 7. Main Bearings 11. Connecting Rod 15. Camshaft
4. Cylinder Block 8. Rod Bearings 12. Piston 16. Gear Case Cover
Fig. 1-1, (N101113). Cylinder block — exploded view.

1-1
Service Tool List The Cylinder Block

To repair the cylinder block and components ac
Inspection
cording to the instructions given in this group, the
following service tools or tools of equal quality Carefully inspect any parts that are to be dis
are required. carded or used again. lnspect all surfaces for
wear or damage. Discard any damaged parts.
Note: lnspect the cylinder block on a flat surface
Service Too Is (Or Equivalent) Required to prevent distortion. Do not inspect the cylinder
Service Tool Tool block on the engine stand.
Number Name
ST-1010 Counterboring Tool (Water Hole)
ST-1065 Tool Holder Use the Dye to find the Cracks in the Cylinder Block
ST-1168 Counterbore Salvage Tool
ST-1177 Boring Tool (Main Bearing Bore) 1. Clean the area that is to be checked with
ST-1228 Camshaft Bushing Drive Kit Kerosene or cleaning solvent.
ST-1250 Cylinder Liner Bore Salvage Tool
ST-1252 Concentricity Gauge 2. Use the Part No. 3375432 Crack Detection Kit
ST-1287 Boring Tool (Lower Cylinder Liner Bore) to help you find cracks. Apply the dye to the
ST-1295 Counterboring Toot (Cylinder Liner) area. Wait approximately 15 minutes. This will
ST-1295-18 Adapter Plate give the dye enough time to enter a crack if
ST-1318 Chamfer Tool
3375115 Boring Machine there is one. Do not use compressed air to dry
3375151 Oil Seal Installation Tool the dye.
3375153 2% " Cam Cup Plug Driver
3375154 2% " Cam Bushing Drive Kit 3. Remove the extra dye from the area with a
3375268 2% ' Cam Installation Sleeve clean dry cloth.
4. Apply the developer so that the crack will
show. Cracks will show as a solid or broken
The following Service Tools or equivalent toots line. A joint in the forging will also show as a
can be used to complete the repairs to the solid or broken line. You must be able to know
the difference between a crack and a joint in
(Cavitation in the casting will

Service Tool Tool
Number Name
ST-205 Plug Gauge (Connecting Rod) Corrosion frequently occurs on the parts of the
ST-560 Ring Groove Gauge cylinder block nearest to the cylinder liners.
ST-561 Checking Fixture (Connecting Rod) Discard the cylinder block if the area cannot be
ST-563 Locating Mandrel (Connecting Rod)
Bushing Mandrel (Gear Cover) cleaned, or if the area has a distortion. Also, the
ST-598
ST-861 Chamfering Tool (Connecting Rod) cylinder block must be discarded if the damage
ST-896 Ring Gauge (Connecting Rod)
ST-897 Ring Gauge (Connecting Rod)
ST-903 Ring Gauge (Main Bearing Bore)
ST-1171 Bushing Mandrel (Accessory Drive)
ST-1178 Puller (Main Bearing Cap)
ST-1184 Cylinder Liner Hold Down Tool
ST-1242 Mandrel Set
ST-1259 Front Oil Seal and Wear
Sleeve Driver/Puller
3375151 Oil Seal Expander Use a bore gauge or a micrometer that
3375053 Thrust Surface Cutter the inside diameter of a bore to measure the in
3375361 Heating Oven side diameter of the camshaft bushing, Fig. 1-2.
3375840 Gear Puller
3375432 Crack Detection Kit Replace the bushings if they are worn
3376220 Gauge Block the limit in Table 1-1 (Ref. No. 1).
1-2
Cylinder Block
ST-1 228-4 Shaft Assembly

ST-1 228-5 Guide
ST-1 228-9 Driver
1. Assemble the tool components.
2. lnsert the tool assembly through the camshaft
bore until the driver is against the camshaft
bushing.
3. Hit the slide hammer against the shaft
assembly until the bushing is removed from
the camshaft bore.
4. lf the flywheel housing is mounted to the
cylinder block, use the Part No. ST-1 228-1 3
Puller Assembly instead of the Part No.
ST-1228-9 Driver to remove the rear bushing.
Fig. 1-2. Measure the Camshaft Bushing. lnsert the assembly through the bore until the
pins of the puller assembly are engaged
Replacement behind the bushing. Hit the slide hammer
Replace the bushings if they have scratches or against the T-handle until the bushing is
damage. Also replace the bushings if they have removed from the bore.
moved inside the bore in the cylinder block. lf the The first engines assembled with a 2-1/2 inch
bushings have moved inside the bore, check the camshaft used a camshaft bushing with a wall
size of the bore. The size of the bore is listed in thickness of 1/16 inch [1.59 mm]. The engines now
Table 1-1 (ref. No. 1). lf the bushings do not need assembled with a 2-1/2 inch camshaft use a bush
to be replaced, make sure the oil holes in the ing with a wall thickness of 3/32 inch [2.38 mm].
bushings and the oil passages in the cylinder The inside diameter of the bushings are the same.
block are aligned correctly. The bore in the cylinder block for the bushing with
To remove the bushings for the 2 inch camshaft, the thicker wall is larger. Different tools are re
use the following tools from the Part No. ST-1228 quired to remove and install these two bushings.
Camshaft Bushing Driver Set, Fig. 1-3. To find which bushing is in the cylinder block,
measure the bore for the camshaft bushing. The
ST-1 228-1 Slide Hammer
bore in the cylinder block for the bushing with the
ST-1 228-2 Rod
thinner wall measures 2.6245 to 2.6255 inch [66.66
ST-1 228-3 Mandrel Shank
to 66.68 mm]. The bore in the cylinder block for the
bushing with the thicker wall measures 2.6865 to
2.6875 inch [68.23 to 68.26 mm].
To remove the thinner bushings for the 2-1/2 inch
camshaft, use the same procedure as for the 2
inch camshaft and the following tools.
ST-1 228-1 Slide Hammer
ST-1 228-2 Rod
ST-1 228-3 Mandrel Shank
ST-1 228-4 Shaft Assembly
ST-1228-10 Driver
3375154 Guide
If the flywheel housing is mounted to the cylinder
block, follow the procedure in Step 4 for the 2 inch
camshaft. Use Part No. 3375863 Puller instead of
Fig. 1-3. ST-1228 Camshaft Bushing Drive the Part No. ST-1228-10 Driver.
1-3
To remove the thicker bushings for the 2-1/2 inch the bushing for the No. 7 bore must align with the
camshaft, use the procedure for the 2 inch cam oil drain in the bore.
shaft and the following tools.
The Cylinder Liner Counterbore
ST-1228-1 Slide Hammer
ST-1 228-2 Rod Inspection
ST-1 228-3 Mandrel Shank 1. The top of the cylinder block must be flat and
ST-1 228-4 Shaft Assembly without damage or distortion. Use a straight
ST-1228-6 Guide edge and a 0.002 inch [0.05 mm] feeler gauge
3375861 Driver to check the surface.
lf the flywheel housing is mounted to the cylinder 2. Check the upper counterbore for the cylinder
block, follow the procedure in Step 4 for the 2 inch liner. Remove any dirt or rough edges so that
camshaft. Use Part No. 3375863 Puller Assembly the liner can enter the cylinder block without
instead of the Part No. 3375861 Driver distortion. Measure the diameter of the
counterbore (A) Fig. 1-5. If the diameter is
To Install the Bushings for the Camshaft. more than 6.5635 inch [166.713 mmj, or if the
Caution: The Big Cam (2Vk inch) anginas that use depth of the counterbore (B) Fig. 1-5 is more
the thicker wall (3/32 inch) camshaft bushings than 0.412 inch [10.466 mm], the counterbore
must have the bushings installed as shown in Fig. must be repaired by installing a sleeve.
1-4. The engine will be damaged if the bushings
are not installed into the correct location.
1. Make sure the holes for oil are open in the
bore for the bushings.
2. Use the tool assembly that was used to
remove the bushings.
3. Slide the bushing on to the driver and align the
oil holes in the bushing with the oil holes in
the bore.
4. Hit the slide hammer against the shaft until
the bushing is in position in the bore.
5. Make sure the oil holes in the bushing and the A Upper Liner Counterbore
bore are in alignment. The alignment notch in B. Counterbore Depth
Fig. 1-5 (N 10103). Cross-Section of The Counterbore for The

Cylinder Liner
Part No.
Part No. 3028075 3011951 3. Make sure the counterbore meets the follow
ing conditions. lf it does not meet these condi
tions, the counterbore must be repaired.
a. Measure the depth of the counterbore at
four equaly spaced points at the edge of
the bore, Fig. 1-6. There must not be more
than a total of 0.001 inch [0.03 mm] dif
ference in the measurements around the
circumference of the counterbore.
b. The ledge must be flat with the top of the
block within 0.0014 in [0.036 mm] overall.
Fig. 1-4. Install The Thicker Wall Bushings Into These c. The counterbore must not have any
Locations (Big Cam Engines). damage.
1-4
Cylinder Block
Fig. 1-6 (N10105). Measure The Depth of The Counterbore. Fig. 1-7. Measure the Cylinder Liner Protrusion.
4. To check the protrusion of the cylinder liner:
a. Install the liner in the cylinder block. Do

not put the O-rings on the cylinder liner.
Use the Part No. ST-1184 Cylinder Liner
Hold-Down clamps to hold the liner in the
cylinder block. Make sure the clamps are
installed so that there is equal pressure on
the liner. Tighten the clamps to 50 ft.-lb.
[68 N»m) torque.
Note: You do not need to use shims for the
cylinder liner unless the counterbore .has been
repaired. lf the counterbore has been repaired,
shims are available in the following thicknesses:
0.007, 0.008, 0.009, 0.020, 0.031 and 0.062 inch
[0.18, 0.20, 0.34, 0.51, 0.79 and 1.57 mm]. Fig. 1 -8. Check The Clearance Between The Cylinder Liner Ana
Lower Bore.
b. Use the Part No. 3376220 Gauge Block to
measure the iiner protrusion, Fig. 1-7. "F" and "G". Measure each point in the di
Shims can be placed under the flange of rection "AA" and "BB" as shown in Fig. 1-9.
the cylinder liner to make the liner protru
c. At the point "C" which is approximately 1
sion the required 0.003 to 0.006 inch [0.08
inch [25.4 mm] below the top of the liner,
to 0.15 mm].
the liner bore can not be more than 0.003
5. Measure the clearance between the liner and inch [0.08 mm] out-of-round.
the lower bore, Fig. 1-8. The clearance must d. At points "D", "E", "F" and "G", the liner
not be more than 0.006 inch [0.15 mm]. The bore can not be more than 0.002 inches
liner can touch the lower bore if touching the [0.05 mm] out-of-round.
lower bore does not cause the liner bore to be
7. Another method of checking the protrusion of
out-of-round.
the cylinder liner is:
6. Measure the liner bore for out-of-round: a. Measure the thickness of the flange on the
liner. Do not include the bead on the top of
a. Use a dial bore gauge to measure the bore.
the flange when you measure the flange,
b. Measure the bore at points "C", "D", "E", Figs. 1-10 and 1-11.
1-5
b. Measure the depth of the counterbore for

the cylinder liner with the Part No. 3376220
Gauge Block.
c. Subtract the depth of the counterbore
from the thickness of the liner flange. The
remainder is the amount of protrusion of
the liner will have when it is installed in
the cylinder block. lf the remainder is not
equal to 0.003 to 0.006 inch [0.08 to 0.15
mm], add shims under the flange of the
liner.
Repair
The counterbore for the cylinder liner must be
Fig. 1-9 (V401105). Cylinder Liner Check Points. repaired if:
1. Material has been cut from the top surface of
the cylinder block.
2. The ledge of the counterbore is not flat or
even.
3. The protrusion of the cylinder liner is not
correct.
v t y i
Cut the Bore
Use the following tools from the Part No. 3375455
Cylinder Block Counterbore Tool to cut the
counterbore.
ST-1295 Drive Unit Assembly
ST- 1065 Cutter Plate
Note: lf the Part No. 3375455 is not available, the
Fig. 1-10 (V401104). The Cylinder Liner Flange.
Part No. ST-1255 Tool may be used to cut the
counterbore.
1. Measure the depth of the counterbore with the
Part No. 3376220 Gauge Block. Take four
measurements, equally spaced, around the
counterbore. This will help you to find how
much material to cut from the counterbore.
This will also show if the surface of the
counterbore is not even.
2. Assemble The Counterbore Tool.
a. lnstall the Part No. ST-1065 Cutter Plate on
the ST-1295 Driver Assembly. Make sure
the keyway in the cutter plate engages the
key in the drive assembly.
b. Tighten the capscrew to hold the cutter
Fig. 1-11 (V40123). Measure The Cylinder Liner Flange. plate to the drive assembly.
1-6
Cylinder Block
3. lnstall the cutting tool.

a. The tool must have a radius of 0.008 to
0.012 inch [0.20 to 0.30 mm] as shown in
Fig. 1-12.
b. The side of the tool must be smooth and flat.
c. The tool must cut the counterbore ledge tc
the dimensions shown in Fig. 1-13.
d. Put the cutting tool in the tool holder.
Make sure the cutting tool is put correctly
in the holder set so that it will cut when
rotated clockwise.
e. Hold a 0.010 inch [0.25 mm] thick feeler
gauge around the edge of the cutter plate
and over the end of the slot for the cutting
Fig. 1-12 (N20148). Counterbore Tool Bit Radius.
tool, Fig. 1-14.
f. Push the cutting tool out until it touches
the feeler gauge. Tighten the setscrew for
the cutting tool.
4. lnstall the assembled counterbore tool on the
cylinder block.
a. Extend the cutter plate into \>e counterbore.
b. Align the adapter plate with the capscrew
holes in the cylinder block. Fasten the
adapter plate with capscrews and flat
washers. Tighten the capscrews with your
fingers.
c. Rotate the cutter plate clockwise to make
sure the cutter plate is correctly aligned in
the counterbore.
d. Tighten the capscrews for the adapter Fig. 1-13 (N10111). Cross-Section Of The Counterbore.
plate to 50 ft.-lb. [68 N»m] torque.
5. Set the depth of the cut.
a. Loosen the adjusting collar on the drive
assembly.
b. Put a feeler gauge of the same thickness
as the material to be cut from the counter
bore between the body of the drive as
sembly and adjusting collar, Fig. 1-15.
Note: Do not remove more than 0.004 inch [0.10
mm] material per cut.
c. Rotate the adjusting collar until it touches
the feeler gauge. Remove the backlash
from the threads in the collar. Tighten the
locking screw in the collar.
d. Remove the feeler gauge. Fig. 1-14. Install The Cutting Tool.
1-7
Fig. 1-15. Set The Depth Of The Cut Fig. 1-16 (V40173). Remove The Cutting Tool.
6. Rotate the bar in the drive assembly in a clock

wise direction to cut the counterbore. Apply 1. Remove the cutting tool from the guide |
even pressure on the bar as you rotate it
Fig. 1-16.
7. After the tool has cut the depth set on the ad
2. Put the counterbore tool on the cylinder block
justing collar, rotate the bar two more times to
over the counterbore to be cut. Fasten the tool
make sure the counterbore is smooth.
to the cylinder block with capscrews and
8. Measure the depth of the counterbore before spacers. Tighten the capscrews with your
Align the tool in the counterbore by using the

guide plate. Turn the knob on the body coun
A cylinder liner counterbore that has a crack in terclockwise to unlock the drive mechanism.
the ledge or other damage can be repaired. Use Push down on the knob until the guide plate is
the'Part No. ST-1168 Liner Counterbore Tool to cut in the counterbore, Fig. 1-17. Rotate the guide
the counterbore larger so that you can install a plate to make sure it is aligned and <
repair sleeve. To cut the counterbore for a i touch the sides of the *
you need the following tools:
ST-1 168-1 Main Body
ST-1 168-19 Cutting Tool
ST-1 168-28 Base Plate
ST-1 168-39 Guide Plate
ST-1 16848 Adapter
ST-1 168-52 Micrometer Standard
ST-1 168-74 Micrometer
ST-1 16836 Driver Plate
ST-1 168-38 Jam Nut
ST-1 16837 Driver Handle
1. Assemble the base plate to the main body.

2. Install guide plate onto the shaft in the main
body. Tighten the nut and washer to hold the
guide plate. Fig. 1-17 (N101104). Align The Tool In The Counterbore.
Cylinder Block
4. Tighten the capscrews to 25 to 35 ft.-ib. [34 to

47 N»m] torque.
5. Raise the guide plate from the counterbore by
pulling up on the knob. Turn the knob
clockwise to lock the feed mechanism.
6. Adjust the micrometer to 6.750 inch [171.45
mm].
7. Loosen the setscrew in the cutting tool. Push
the adjustable set pin all the way in the cut
ting tool. Tighten the setscrew.
8. Put the cutting tool in the tool gauge. Make
sure the cutting tip of the tool is not against
the micrometer spindle. The cutting tip of the
tool must be against the hardened pad ln the Fig. 1-19. lnstall The Cutting Tool.
tool gauge.
9. Hold the tool against the hardened pad.
Loosen the setscrew to let the pin in the cut
ting tool come out against the micrometer
spindle, Fig. 1-18. Tighten the setscrew.
Fig. 1-20. Adjust The Depth Of The Cutter.
block. Lower the cutting tool on to the feeler

gauge by pulling up on the knob while pushing
down on the set collar, Fig. 1-20.
Fig. 1-18. Adjust The Length Of The Cutting Tool
Note: The feeler gauge is used to make sure that
10. Make sure the length of the cutting tool is set the sleeve will not be below the top of the cylinder
correctly. Turn the micrometer thimble coun block. After the sleeve is installed, any excess
terclockwise until the spindle touches the material can be removed.
tool. Check the reading on the micrometer.
13. Loosen the setscrew until the part No. 202226
11. lnstall the cutting tool in to the guide plate salvage sleeve will fit between the collar and
and tighten the setscrew to hold the tool, Fig. the main body of the boring machine, Fig.
1-19. Make sure the cutting tool is all the way 1-21. Tighten the setscrew in the collar.
in the guide plate. 14. Remove the 0.004 inch [0.10 mm] feeler gauge.
12. Put a 0.004 inch [0.10 mm] thick feeler gauge 15. lnstall the drive adapter in a 1/2 or 3/4 inch
between the cutting tool and the cylinder heavy duty electric drill.
1-9
counterbore to a depth of 0.350 to 0.352 inches

[8.89 to 8.94 mm].
The Cylinder Liner Bore

Inspection
lf the engine has had a piston seizure or the upper
counterbore repaired, check the alignment be
tween the counterbore and the lower bore.
The cylinder liner must be removed from the
cylinder block before you check the alignment
between the counterbore and the lower bore. Use
the Part No. ST-1252 concentricity gauge to check
the alignment. The alignment must be within
0.005 inch [0.13 mm] of the total indicator reading.
Fig. 1-21. Adjust The Cutting Travel Of The Tool.
Repair
Caution: Do not use an electric drill that Is rated
for less than 10 amperes. The drill must not Use the Part No. ST-1287 Boring Tool to cut the
operate at more than 450 rpm. lower bore for the cylinder liner.
16. Engage the drill and adapter with the 1/2 inch
The boring tool includes:
drive on the boring machine. Cut the bore until
the drill turns freely. Stop the drill immediately A tapered centering ring to align the tool with the
when it begins to turn freely. counterbore and lower bore.
Note: Approximately halfway through the cut, the A gauge rod to set the cutting depth of the tool.
tool will begin to cut the counterbore ledge. You A micrometer set-block to set the cutting tool.
must be prepared for the added load on the drill After the bore has been cut, a repair sleeve can be
when the counterbore ledge is being cut. installed in the bore.
17. -Raise the cutting tool from the bore by pulling
up on the knob. Remove the cutting tool from To Operate the Boring Tool
the guide plate. Remove the boring machine 1. Use the centering ring that will fit in the
from the cylinder block. counterbore for the cylinder liner. Remove the
18. Clean the bore of all metal particles. Remove O-ring from the boring tool. Install the center
the sharp edges with an emery cloth. ing ring on the boring tool. Make sure the
taper in the ring is toward the tool to hold the
Install the Salvage Sleeve ring on the tool, Fig. 1-22.
1. Clean the bore with a solvent. Do not use a 2. Adjust the cutting tool.
solvent that has a petroleum base.
a. Check the micrometer calibration with the
2. Apply a coat of sealant to the outside surface micrometer standard. The micrometer
of the salvage sleeve. Hit the driver with a must read 5 inches when measuring the
hammer to push the sleeve into the bore. standard. Loosen the socket head cap-
When the sleeve hits the bottom of the bore, it screw to move the micrometer to adjust it
will make a different sound. to the standard.
3. Cut the top of the sleeve with a file so that it
b. Adjust the micrometer to the correct
will be flat with the top surface of the cylinder
value. See Table 1. Put the cutting tool in
block.
the micrometer set-block. Hold the cutting
4. Measure the depth of the counterbore. Use the tip of the tool against the hardened pad of
Part Nos. ST-1295 and ST-1065 to cut the the set-block, Fig. 1-23. Loosen the set
Cylinder Block
Table 1: Lower Bore Sleeve and Boring Data

Repair Sleeve Boring Diameter
Part Number Inch [mm]
3375306 6.250/6.245 [158.75/158.78]
3375307 6.300/6.301 [161.57/161.62]
195778 6.361/6.363 [161.57/161.62]
Fig. 1-22 (V10184). Install The O-Ring.
Fig. 1-24 (V10186). lnstall The Cutting Tool.
Fig. 1-23 (V10182). Adjust The Cutting Tool.

X 2
screw in the cutting tool to let the adjust
able pin come against the micrometer
spindle. Tighten the setscrew.
3. lnstall the cutting tool in the tool holder. Make
sure the cutting tool is all the way in the tool
holder, Fig. 1-24. Tighten the setscrews to
hold the cutting tool. Fig. 1-25 (V1018B). Adjust The Collar On The Depth Gauge Rod.
4. Adjust the collar on the depth gauge rod to the
proper depth. Align the bottom of the collar cutting tool touches the collar on the gauge
with the line on the gauge rod, (1) Fig. 1-25. rod.
Tighten the setscrew (2) in the collar.
b. Slide the depth set collar (4) on the drive
5. Install the gauge rod to the base plate of the shaft to the top of the boring tool. This
boring tool, (1), Fig. 1-26. controls the depth that the boring tool will
a. Loosen the drive engagement knob (2). cut in the bore. Tighten the setscrew in the
Push the driveshaft (3) down until the collar.
1-11
14. Put the drill on the drive shaft, Fig. 1-27. Cut
the bore until the depth set collar on the drive
shaft is against the top of the boring tool. The
feed mechanism will disengage when it
reaches the depth for which it was set.
Fig. 1-26 (V10189). Part No. ST-1287 Boring Tool.
Note: The gauge rod is not marked for the 195778

Repair Sleeve. This sleeve is approximately 0.100
inch [2.54 mm] shorter in length than the 3375306
and 3375307 sleeves. Make sure you adjust the
gauge rod correctly when the 195778 repair sleeve
is used. Fig. 1-27 (V50155). The Drill Onto The Boring Tool.
6. Remove the rod from the boring tool. 15. Loosen the knob and pull the cutting tool all
7. Pull on the knob and raise the cutting tool all the way up. Tighten the knob to hold the tool
the way up. up.
8. Make sure the counterbore and the top of the 16. Remove the boring tool.
cylinder block are clean and have no rough
Caution: Whan you remove Via tool, be careful. Do
not let the cutting tool hit the cylinder block.
9. lnstall the boring tool in the cylinder block.
Make sure the centering ring is engaged with 17. lnspect and measure the bore. Clean the bore
the and remove any rough
cloth.
10. lnstall the base plate to the cylinder block
with capscrews and spacers. Tighten the
capscrews to 50 ft.-lb. [68 N»m] torque.
1. Clean the bore and the outside diameter of the
11. Push down on the knob and slowly lower the sleeve with a sealant primer. Apply a narrow
cutting tool until it touches the lower bore. strip of bushing sealant to the outside
Raise the cutting tool 1 inch [25.4 mm] above diameter of the sleeve. Make sure the sealant
the lower bore. is all the way round the outside diameter.
12. Tighten the knob. This engages the feed
2. Push the sleeve through the upper bore. When
mechanism. Turn the drive shaft with your
the sleeve is installed in the lower bore, the
hand to make sure it rotates freely.
end with the chamfer will be closest to the top
13. Install the drive adapter in a heavy duty 1/2 or of the cylinder block.
3/4 inch electric drill.
3. lnstall the sleeve on to the sleeve driver. Put
Caution: Do not i i an electric drill that Is rated at the upper locater on the handle of the sleeve
10 The drill driver. Install the upper locator in the counter-
bore.
-12
Cylinder Block
4. Hit the handle lightly with a soft hammer to

start the sleeve into the lower bore. Then hit
the handle with a soft hammer which will push
the sleeve into the bore. When the sleeve is in
position in the bore, the sleeve driver will
rotate freely.
5. Remove the sleeve driver.
6. Remove any sealant on the inside diameter of
the sleeve.
Cut the Chamfer for the Repair Sleeve

Use the Part No. ST-1318 Chamfer Tool to cut a
chamfer for the repair sleeve after the sleeve is
installed.
Fig. 1-28 (V10195). The Cutting Tool Installed In The Cutter
1. lnstall the cutting tool in the cutter plate. The Plate.
tool must be put so that the lower edge of the
tool is below the pilot diameter of the cutter
plate, Fig. 1-28. Tighten the clamping screws.
2. Install the guide plate (1, Fig. 1-29) on the
main shaft.
3. Use a flat washer and nut to install the cutter
(3) on the main shaft. Tighten the nut.
4. lnstall the chamfer tool in the cylinder block.
5. Hold the T-handle of the tool with your hand
and loosen the capscrew in the adjusting col
lar. Lower the cutter plate until the cutting
tool touches the upper part of the repair
sleeve.
6. Push down on the T-handle and turn it
clockwise to cut the chamfer. Cut the chamfer
so that it has a smooth surface from the Fig. 1-29 (V10196). The Part No. ST-1318 Chamfer Tool.
cylinder block to the repair sleeve.
7. lf the cylinder block has more than one repair 10. Repeat Step 9 to cut the chamfers for the re
sleeve, tighten the capscrew in the adjusting maining sleeves.
collar after cutting the chamfer. This will set
the depth to cut the remaining chamfers. Turn The Water Passages
the capscrew in the top collar into the notch in
the lower collar until there is a 1/4 inch [6.4 Inspection
mm] gap between the collars. 1. Check all of the water passages to make sure
8. lnstall the chamfer tool into the next bore so they are clean and open.
that you can cut the chamfer in the repair
2. Check the water holes in the top of the
sleeve.
cylinder block for corrosion that would not
9. Turn the setscrew in the collar counterclock allow the cylinder head gasket to seal. A sleeve
wise while turning the T-handle clockwise un can be put in the water hole if the corrosion is
til the upper and lower collars touch. This will not more than 1/16 inch [1.49 mm] from the
be the depth set in Step 7. edge of the hole.
1-13
3. Corrosion must not be nearer than 1/32 inch

[0.79 mm] to the counterbore for the cylinder
liner. A maximum of 0.010 inch [0.25 mm] of
material can be removed from the surface of
the cylinder block.
Repair
The top surface of the cylinder block around the
water holes must not have any scratches, cracks
or corrosion deeper than 0.003 inch [0.08 mm].
There must not be any defect which extends more
than 3/32 inch [2.38 mm] from the edge of the
water hole.
To repair the water holes, use the following tools

from the Part No. ST-1010 Water Hole Counterbor- Fig. 1-30. Install The Locating Pin.
ing Tool Kit.
ST-1010-1 Bushing Plate
ST-1010-3 Stop Collar
ST-1010-8 Drive Adapter
ST-1010-9 Bushing Driver
ST-1010-10 Locating Pin
ST-1010-11 Counterbore Cutter
ST-1010-1 5 Capscrew Spacer
ST-1010-1 9 Allen Wrench
ST-1010-21 Gauge Block
1. lnstall the bushing plate to the cylinder block.

Use a cylinder head capscrew and the
capscrew spacer to fasten the plate to the
cylinder block. Use your fingers to tighten the
capscrew.
2. Put the locating pin into the 9/16 inch [14.30
mm] bushing in the plate- and into the Fig. 1-31. Adjust The Depth Of The Cutter.
waterhoie to be repaired, Fig. 1-30.
Make sure the locating pin and bushing plate d. Put the gauge block on top of the bushing
are in position. Tighten the capscrew to 50 plate. Hold the curve of the gauge block
ft.-lb. [68 N»m] torque. against the counterbore cutter.
4. Remove the locating pin. e. Slide the stop collar down against the
gauge block, Fig. 1-31. Tighten the
5. Adjust the depth of the counterbore cutter: setscrew in the stop collar.
a. Loosen the setscrew in the stop collar f. Remove the gauge block.
with the alien wrench.
6. Install the drive adapter in an electric drill.
b. Put the counterbore cutter into the
bushing plate until the cutter is against 7. Engage the drill adapter into the counterbore
the cylinder block. cutter, Fig. 1-32.
c. Slide the stop collar up on the counterbore 8. Start the drill. Apply minimum downward
cutter. force while cutting the hole.
1-14
Cylinder Block
Fig. 1-32. Cut The Water Hole. 1. Base Plate 10. Nut — special
2. Reamer Guide Bar 11. Chip Remover
9. Remove the counterbore cutter and bushing 3. Capscrew (standard 12. Loctite Retaining
5/8-18 x 3) Compound
plate. 4. Flatwasher 13. Loctite Primer
10. To install the Part No. 191079 Water Passage (standard 5/8 l.D.) (Grade T)
5. Locator 14. (2) Spacers
Sleeve: 6. Reamer — special (standard 4 inches
a. Make sure the hole is clean and all metal 7. Tap — special long)
particles are removed. 8. Flex Drive Adapter 15. (10) Threaded
9. Stop Collar lnserts
b. Slide the sleeve onto the end of the
bushing driver. Fig. 1-33 (N 101 122). 3376028 Repair Kit.
c. Apply a sealant to the sleeve. 2. Put the locating pin (5) through the bushing in
d. Align the sleeve with the water hole. Hit the bushing holder and into the hole to be
the bushing driver with a hammer to install repaired. Tighten the capscrew (3) that holds
the sleeve into the water hole. After the the bushing holder to the base plate.
sleeve is installed, part of it will extend
3. Remove the locating pin and put the special
above the surface of the cylinder block.
reamer (6) into the housing.
11. Cut the sleeve so that it is even with the top
4. lnstall the universal drive (8) in a 1/2 or 5/8
surface of the cylinder block. Use a flat, wide
inch heavy duty electric drill. Put the drive on
mill file to cut the sleeve.
the reamer. Cut the hole until the reamer
Salvage of the Cylinder Head reaches the bottom of the hole.
Capscrew Holes 5. Remove the reamer from the hole. Remove the
chips from the hole with the special chip
remover, Fig. 1-34.
lf the holes (for the cylinder head capscrews) in
the cylinder block are damaged, install special 6. Put the reamer into the hole again to make
thread inserts to repair them. Use the Part No. sure the reamer has reached the botom of the
3376028 Capscrew Thread Salvage Tool Kit to hole. Remove the reamer.
repair the holes. 7. To set the cutting depth for the special tap,
put the tap in the bushing. Install the stop col
Repair
lar on the tap. Put a thread insert on top of the
1. Assemble the bushing holder assembly (2, Fig. pilot bushing. Move the stop collar until it is
1-33) to the base plate (1 ). lnstall the base plate to against the thread insert, Fig. 1-35. Tighten
the cylinder block with capscrews and spacers. the setscrew in the stop collar.
1-15
13. lnstall the thread insert on the capscrew.

Make sure the counterbore end of the insert is
against the special nut. Use your fingers to
tighten the insert against the special nut on
the capscrew.
14. Clean the outside threads of the insert with
the primer for the sealant. Let the primer dry.
15. Apply a light coat of sealant to the outside
threads of the insert. lnstall the insert into the
cylinder block until the end of the insert is
even with the surface of the cylinder block,
Fig. 1-36.
Fig. 1-34 (N101123). Remove The Chips From The Hole.
Fig. 1-36 (N101125). Install The Thread Insert.
16. Hold the cylinder head capscrew so it will not

turn. Loosen the special nut one quarter of a
Fig. 1-35 (N101124). Adjust The Stop Collar. turn. Remove the capscrew from the insert.
Note: Make sure you use the correct thread insert. 17. Use a file to cut the insert so it will be even
The thread insert for the Big Cam II engine is 1 with the surface of the cylinder block.
inch [25.4 mm] longer than the other inserts.
Refinishing of the Top Surface
3. Use the electric drill with the universal drive to of the Cylinder Block
cut the threads. Stop cutting the threads when
the stop collar on the tap is 1/4 to 1/8 inch A maximum of 0.010 inch [0.25 mm] material can
from the pilot bushing. be cut from the top surface of the cylinder block
to repair the surface.
9. Remove the tap and remove the chips from the
1. Use either a milling machine or a large
hole with the special chip remover.
grinder. Use the main bearing pads to align
10. Install the tap in the hole. Use a tap handle or the cylinder block on the machine.
wrench to cut the remaining thread depth.
2. Remove the dowels from the top surface of
11. Remove the tap. Make sure all metal particles the cylinder block. Cut 0.001 to 0.003 inch
are removed from the hole. [0.03 to 0.08 mm] material from the surface on
12. Install the special nut on a cylinder head each cut.
capscrew. 3. Check the distance from the certerline of the
Cylinder Block
main bearings to the top surface of the Table 2: Height of the Cylinder Block from
cylinder block, Fig. 1-37. See Table 2 for the Main Bearing Centerline (1, Fig. 1-37)
dimensions. Do not measure the height from New Dimensions
the surface of the main bearing pads. The pad Minimum Maximum Worn Limit
surfaces are not on the centerline of the main
19.003 19.007 18.994
bearing bore. [482.68] [482.78] [482.45]
Table 3: Height of the Cylinder Block from

the ST-1 177-39 Centering Ring (2, Fig. 1-37)
New Dimensions
Minimum Maximum Worn Limit
16.628 16.632 16.619
[422.35] [422.45] [422.12]
5. Cut the counterbore for the cylinder liner so

that the amount of protrusion for the cylinder
liner will be correct.
Main Bearing Caps
Inspection
The width of the main bearing cap (3, Fig. 1-37)
must be at least as wide to 0.004 in. [0.10 mm]
Fig. 1-37 (N10181). Measure The Height Of The Cylinder Block
At These Locations. wider than the main bearing support (4, Fig. 1-37)
area of the cylinder block. Before you tighten the
a. To find this dimension, put the cylinder capscrews for the main bearing cap, make sure
block, with the top surface down onto a the cap is in contact with the cylinder block.
fiat inspection plate. Measure from the Failure to correctly position the cap in the
centerline of the main bearing bore to the cylinder block will cause distortion of the cylinder
fiat plate. You can buy a tool to measure block when the capscrews are tightened.
the dimension. For more information Replacement
about the tool, write to: Hartmann's, lnc.,
The replacement caps for the main bearings have
P.O. Box 2154, 1330 North 1st Street,
0.015 inch [0.38 mm] additional material that must
Abilene, Texas 79604.
be removed to bring the main bearing bore to the
b. Another method to measure the height is to correct size. All the other dimensions of the
install the Part No. ST-1 177-39 Centering replacement caps except the number seven cap
Ring into the main bearing bore. Let the are correct. The number seven replacement cap
centering ring extend approximately half must be machined for dowel holes. lt must also be
way from the bore. Measure the distance machined to the correct thickness for the
from the centering ring to the top surface crankshaft thrust bearings.
of the cylinder block. See Table 3 to find
the correct dimension for this method. Main Bearing Bore
c. The complete length of the top surface of Inspection
the cylinder block must be parallel to the 1. Assemble the main bearing caps in the cor
centerline of the main bearing bore within rect location in the cylinder block. Tighten the
0.002 in. [0.05 mm]. The top surface must capscrews to the torque given in Table 4.
not change from a true plane more than 2. Measure the main bearing bores with a dial
0.004 in. [0.10 mm] total indicator reading. bore gauge. Check the inside diameter of
4. After cutting the top surface of the cylinder each bore at three different points. The bores
block, the surface must be within 125 R.M.S. must be within the following limits:
1-17
1-18 NT/NTA 855 C.I.D. Engine Shop Manual
Table 4: Torque Values for Main Bearing

Capscrews (See Page 1-38 for Exceptions)
Minimum Maximum
Ft*. [N-mJ Ft.-lb. [N»m]
Step 1. Tighten to 140 [190] 150 [203]
Step 2. Tighten to 300 [407]
Step 3. Loosen completely
Step 4. Tighten to 140 [190] 150 [203]
Step 5. Tighten to 300 [407] 310 [420]
Minimum 4.7485 inch [120.612 mm]

Maximum 4.7505 inch [120.663 mm}
3. Check the alignment of the bores. Use these
tools from the Part No. ST-1177 Main Bearing
Bore Tool set. Fig. 1-38. Push The Checking Ring Through The Bore.
ST-1 177-13 Checking Ring
ST-1 177-16 Bore Bar f. lnsert a feeler gauge, 0.003 inch [0.08 mm]
ST-1 177-39 Centering Ring thick and 1/2 inch [12.7 mm] wide,
between the bore and checking ring.
a. Remove the No. 2 and No. 6 main bearing Evaluate the bores as follows:
caps. Make sure the caps and cylinder
block surfaces are not damaged. (1) The gauge will not enter the bore at
any point. The bar rotates easily. The
b. Replace the caps with the Part No. bore is acceptable.
ST-1 177-39 Centering Rings. Hit the
centering rings with a plastic hammer to (2) The gauge enters the bore on one side
position them in the bores. but not on the opposite side. The bar
rotates easily. The bore is not in align
c. lnstall, over the centering rings, the main ment but is acceptable if the bar
bearing caps that were removed. Tighten rotates easily.
the capscrews to the torque given in Table 4.
(3) The gauge enters the bore and is loose
Note: lf you have to use replacement caps in step in the bore. The bore is oversize. The
c, tighten the capscrews to 10 ft.-lbs. [14 N»m]. bore is not acceptable.
d. Apply lubrication to the bores of the (4) The gauge enters the front side of the
centering rings and to the Part No. bore but not on the rear side. The bore
ST-1177-16 Bore Bar. lnsert the bar is tapered. The bore is not acceptable.
through the centering rings while slowly
rotating the bar. The bar must turn easily. Repair
Slide one end of the bar out of a centering To cut the bores to the correct size, use the follow
ring. Slide the Part No. ST-1 177-39 Check ing tools from the Part No. ST-1177 Main Bearing
ing Ring on to the bar. lnsert the bar into Bore tool.
the centering ring.
ST-1 177-2 Cutting Tool
e. Apply lubrication to the outside diameter ST-1 177-4 Cutting Tool
of the checking ring. Use the pressure of ST-1 177-8 Cutter Holder
your fingers to push the checking ring ST-1 177-1 3 Checking Ring
through the bores, Fig. 1-38. As you push ST-1177-16 Bore Bar
the ring through the bores, rotate the bar. ST-1 177-17 Bore Feed Assembly
lf the checking ring will not pass through ST-1 177-18 Bore Bar Bridge
the bores, check the bores for rough ST-1 177-21 Bridge Boaring
edges. ST-1 177-22 Bar Bearing
1-18
Cylinder Block
2. Cutting Tool 17. Bore Feed Assembly 31. Drive Adapter 43. Micrometer
4. Cutting Tool 18. Bore Bar Bridge 32. Capscrew 44. Micrometer Base
8. Cutter Holder 21. Bearing Bridge 33. Torsion Bar 45. Micrometer Bracket
9. Checking 22. Bearing Bar 34. Bracket 46. Micrometer Shaft
13. Checking Ring 27. Swivel Joint 36. Centering Ring 49. Cutter Pin
14. Checking Ring 28. Cutter Holder 39. Centering Ring 51. Allen Wrench
16. Bore Bar 29. Capscrew 41. Centering Ring 52. Allen Wrench
Fig. 1-39 (ST-1177). Exploded View Of The ST-1177 Boring Tool.
ST-1 177-27 Swivel Joint Put the Part No. ST-1 177-39 Centering Ring on
ST-1 177-28 Cutter Holder the shaft. lnstall the micrometer ln the
ST-1 177-31 Drive Adapter bracket.
ST-1 177-33 Torsion Bar Adjust the micrometer to the value that is
ST-1 177-49 Cutter Key marked on the centering ring.
ST-1 177-34 Torsion Bar Bracket Push the micrometer through the bracket until
ST-1 177-39 Centering Ring the spindle is against the centering ring. Make
ST-1 177-51 Allen Wrench sure the micrometer setting remains at the
ST-1 177-52 Allen Wrench value set ln Step 4. Tighten the screw that
ST-1 177-51 11 Micrometer holds the micrometer In the bracket. Make
sure the micrometer spindle turns easily after
To Cut the Bore* for the Main Bearings: tightening the screw.
1. Assemble and adjust the Part No. ST-1177- 6. Remove the centering ring and put the Part No.
5111 Micrometer and the Part No. ST-1 177-28 ST-1 177-28 Cutter Holder on the base shaft.
Cutter Holder. Put the base shaft (46, Fig. 7 Align the hole for the cutting tool in the holder
1-39) through the bore of the micrometer with the hole ln the base shaft. There are lines
bracket (45, Fig. 1-39). Tighten the base shaft marked on the holder and the shaft to help you
into the micrometer base (44, Fig. 1-39). align the holes. Tighten the screws ln the
2. Tighten the screw In the micrometer bracket cutter holder. Make sure the gaps are equal
until the bracket fits tightly on the base shaft. between the two halves of the cutter holder
Make sure the hole for the micrometer In the after the screws are tightened.
bracket aligns with the hole for the cutting 8. lnstall the cutting tool in the tool Holder. The
tool In the shaft. cutting tool must be short enough that It will
1-19
not have any protrusion into the bore of the tool Cutting the Boras
holder.
1. Install the Part No. ST-1 177-16 Boring Bar and
9. Put the Part No. ST-1 177-49 Cutter Key Part No. ST-1177-39 Centering Rings in the
through the holes in the Toolholder and shaft. cylinder block. Follow the instructions given
Push the cutting tool, with a minimum of in Step 3 of "Inspect the Main Bearing Bore".
force, against the micrometer spindle. To pre
2. Install the Part No. ST-1 177-17 Bore Feed
vent damage to the tools, make sure you ad
Assembly in one end of the boring bar.
just the cutting tool and micrometer carefully.
Tighten the socket head screw in the bar to re
Tighten the retaining screw for the cutting
tain the assembly.
tool, Fig. 1-40.
3. Install the Part No. ST-1 177-33 Torsion Bar,
with the threaded end first, through the feed
assembly. Install the threaded end of the tor
sion bar into the ST-1 177-34 Torsion Bracket.
4. Fasten the torsion bracket to the end of the
cylinder block with a capscrew and washer,
Fig. 1-41.
Fig. 1-40. Adjust The Cutting Tool.
Note: Do not adjust the cutting tool to cut all the

material from the bore by cutting the bore only
one time. This will cause the cutting tool to break.
Adjust the tool to cut the bore to a diameter less
than 4.7485 inches [120.612 mm]. Adjust the tool
to cut a larger diameter each time until the bore Fig. 1-41. Install The Torsion Bracket To The Cylinder Block.
measures 4.7485 inches [120.612 to 120.663 mm].
5. Pull on the plastic knob of the feed assembly
10. Check the setting of the cutting tool. Turn the until the pin is free of the slot. Turn the knob
micrometer counter clockwise to move the one-fourth of a complete turn. Pull the feed
spindle from the cutting tool. Turn the assembly all of the way back to the knob.
micrometer clockwise to move the spindle to Tighten the set screw against the torsion bar
the cutting tool. When the spindle touches the to hold the feed assembly in position.
tool, check the reading on the micrometer.
Note: The later model of ST-1 177-17 does not have
Note: Damage to the tool will result if you tighten a plastic knob. It has an engagement lever on the
the spindle against the tool or move the spindle side of the assembly. Turn the lever to "open" to
across the tool. adjust the assembly. Turn the lever to "close" to
engage the mechanism.
11. Turn the micrometer counter clockwise and
move the spindle away from the tool. Remove 6. lnstall the square head set bolt in the second
the tool holder from the base shaft. threaded hole in the torsion bracket. Tighten
1-20
f
Cylinder Block
the bolt against the cylinder block to hold the

bracket in position.
7. lnstall the Part No. ST-1 177-31 Adapter into
the other end of the boring bar. Make sure the
1/2 inch square drive at the adapter is pointing
out from the bar. Tighten the setscrew in the
bar, Fig. 1-42.
8. lnstall the Part No. ST-1 177-27 Swivel Joint in
a 1/2 inch electric drill. These instructions are
for a drill with right hand rotation.
Caution: Do not use an electric drill that Is rated at
less than 10 amperes. The drill must not rotate
faster than 450 rpm.
9. lnstall the tool holder on the boring bar, next Fig. 1-43. Install The Tool Holder Onto The Boring Bar.
to the bore to be cut, Fig. 1-43. When the bore
is being cut, the boring bar will move toward
the feed assembly. Make sure the cutting
edge of the cutting tool is turned in the direc
tion the drill rotates.
Fig. 1-44. Cut The Bore For The Main Bearing.
c. Pull the bar back until it stops against the

feed assembly.
d. Engage the mechanism at the feed
Fig. 1-42. Install The Drive Adapter Into The Boring Bar. assembly.
e. Repeat Steps 9 and 10.
10. Put the swivel joint into the square drive, Fig. 12. Clean the cylinder block. Check the alignment
1-44. Engage the mechanism of the feed of the bore with the checking ring. Measure
assembly. Cut the bore. Make sure the boring the bores with a dial bore gauge. The bores
bar ls lubricated when you cut the bore. must measure within the following limits:
11. To cut the next bore: Minimum 4.7485 inch [120.612 mm]
Maximum 4.7505 inch [120.663 mm]
a. Remove the tool holder from the boring
bar. To Use the Bridge for The Boring Bar
b. Disengage the mechanism at the feed The bridges give more support to the boring bar.
assembly. They also make up for distortion in the cylinder
1-21
NT/NTA 855 C.I.D. Engine Shop
block. lf the centering rings are placed equally

apart, it is not necessary to use the bridges.
For example: The centering rings are placed in
No. 2 and 6 bore and No. 1, 3, 4, 5 and 7 bores are
to be cut.
1. Install the Part No. ST-1 177-21 Bridge Bearing
on the boring bar. Use your fingers to tighten
the capscrews so that you can adjust the bear
ing later.
2. Slide the bearing to the part of the boring bar
that needs support. lf the bearing is close to
the bore to be cut, make sure there is space
for the tool holder.
3. Install the Part No. ST-1 177-18 Bridge on the
Fig. 1-45. Drill The Dowel Hole In The Rear Main Bearing Cap.
bearing bar. Fasten the bridge to the cylinder
block with capscrews and washers.
4. Tighten the socket head screws for the bear
ing. Make sure the boring bar will turn freely
after tightening the screws.
5. Tighten the screws for the bearing bore and
the bridge.
6. Make sure the boring bar will turn freely.
Cut the Bore for The Rear Cap (No. 7)

1. Drill the dowel holes for the No. 7 cap:
a. Put a transfer dye on the cylinder block so
that the position of the dowel holes will
show on the cap.
Note: The dowels must be removed from the Fig. 1-46. lnstall The Depth Set Collar.
cylinder block before the cap is installed.
b. lnstall the cap on the cylinder block. 3. Remove the electric drill and square drive
adapter from the end of the boring bar.
c. Remove the cap. Use a center punch to put
a mark for the location of the dowel holes. 4. Remove the feed assembly, torsion bar and
Drill the dowel holes in the cap with a bracket.
15/64 inch drill, Fig. 1-45. 5. Put the Part No. 3375053 Thrust Bearing Sur
face Cutter on the boring bar. lnstall the depth
d. lnstall the cap on the cylinder block.
set collar on the opposite side of the surface
e. Use a reamer to cut the holes in the cap to to be cut, Fig. 1-46.
the next largest size.
6. Install the T-handle drive assembly in the end
f. Remove the cap. Install the dowels in the of the boring bar. Tighten the setscrew in the
cylinder block. Install the cap to the bar, Fig. 1-47.
cylinder block.
7. Install the cutter holder. Adjust the cutting
2. Repeat Steps 9, 10 and 12 for cutting the tool so it will cut the total surface for the
bores. thrust bearing, Fig. 1-48. The tool must be
Cylinder Block
installed in the holder so that it cuts when the

shaft is turned clockwise.
8. Set the depth collar so that the cutting tool

will make the lightest contact possible with
the surface to be cut. Tighten the setscrews
for the collar, Fig. 1-49.
9. Turn the boring bar two times in a clockwise

direction. Check the pattern and the depth of
the cut.
10. To adjust the cutting depth of the tool:
a. Loosen the thumbscrew on the depth set

collar, Fig. 1-50.
b. Rotate the collar clockwise to increase

the depth. Each line on the collar in
dicates 0.001 inch [0.03 mm].
c. Tighten the thumbscrew.
Fig. 1-48. Install The Cutter Holder.
Fig. 1-50. Adjust The Cutting Depth Of The Tool.
Note: The tool must be rotated slowly while cut

ting in order to prevent the surface from becoming
rough.
11. To cut the opposite side of the thrust bearing

surface, follow Steps 4 through 9. The finished
thickness (thrust bearing thickness) of the
rear cap (No. 7) is:
Minimum 2.496 [63.39 mm]
Fig. 1-49. Tighten The Setscrew For The Depth Set Collar Maximum 2.500 [63.50 mm]
1-23
The Cylinder Liners Table 5: Crankshaft Journal Diameters

Inspection Journal Minimum Maximum Worn Limit
lnch [mm] lnch [mm] Inch [mm]
1. Check for cracks in the cylinder liner. Check
Connecting 3.1235 3.125 3.122
carefully under the flange at the bottom of the Rod [79.337] [79.375] [79.298]
liner and above the grooves for the O-rings.
Main 4.4985 4.500 4.4975
2. The liners can be checked for cracks by using Bearing [114.262] [114.30] [114.237]
the magnetic method or by using dye.
Grind the crankshaft journals if they are out-of-
3. Discard a liner that has corrosion or damage
round more than 0.002 inch [0.05 mm]. Follow the
that is deeper than 1/16 inch [1.59 mm]. Also
instructions given in the Crankshaft lnspection
discard a liner that has damage under the
And Reconditioning Manual, Bulletin No.
flange that can not be removed with emery
3379092-00.
cloth.
4. Measure the bore of the liner with a bore Clean the Holes in the Crankshaft
gauge. Discard the liner if the bore is larger 1. Remove the pipe plugs. Use a nylon bristle
than 5.505 inch [139.83 mm] brush and solvent which dries quickly to clean
the oil holes. Flush the oil holes with solvent
Cleaning The Cylinder I and dry with compressed air.
1. Clean the liners with warm and soap. 2. Lubricate the threads of the pipe plugs with
Use a bristle brush. clean SAE20W or 30W lubricating oil. lnstall
2. Clean the soap from the liners with steam. the plugs and tighten to 60 to 95 in.-lbs. [6.8 to
10.9 N»m].
3. Use compressed air to dry the liners.
4. Put a thick coat of clean engine oil on the bore The Crankshaft Journals and Thrust Flange
of the liner and wait five to ten minutes. 1. Carefully inspect the crankshaft journals and
5. Use clean paper towels to remove the oil from the thrust flange at the No. 7 main bearing
the bore. Clean each liner bore until you can journal. lf the surfaces have damage or
not see any black or gray marks on the paper. scratches, grind the crankshaft. lf you grind
the crankshaft, you will have to install over
6. Apply a light coat of clean engine oil to the
size main and connecting rod bearings or,
liners. Put the liners in a clean, dry location for
oversize thrust rings.
storage.
Crankshaft
1. The crankshaft gear must be removed if it is n

damaged or worn.
Note: lf the crankshaft gear is in good condition,
do not remove the gear.
2. Use the following tools from the Part No.
3375840 Gear Puller Kit to remove the gear:
3375834 Gear Puller Assembly
3375839 Jaw
lnspection
Check the crankshaft for wear, damage and
cracks. Measure the journals of the crankshaft Fig. 1-51 (V50138). Marks To Show The Size Of The Main And
with a micrometer. See Table 5. Connecting Rod Journals.
Cylinder Block
5. Use a piece of tubing and a hammer to push

the gear onto the crankshaft. Do not damage
\
the gear.
■
Bearings
The bearing shells for the main bearings and the
connecting rod have two halves. One half has the
oil holes for lubrication. Thrust rings are used at
the rear main bearing.
Inspection
1. Measure the shells with a micrometer that has
a ball point, Fig. 1-53. Discard the shells that
F,.010'H,.020k are worn more than 0.001 inch [0.025 mm], or
Fig. 1-52. Marks To Show The Size Of The Thrust Surfaces. have scratches or other damage. See Table 6
for the thickness of the standard shell.
2. Put a mark on the crankshaft when you grind
it. This will show the correct size for the main
and connecting rod bearings. lnclude on the
identification both the thrust ring size and the
location of the ring. See Fig. 1-51 and Fig. 1-52.
3. Put a mark for the undersize main and con

necting rod journal on the front
counterweight. Put a mark for the oversize
thrust bearing on the rear counterweight. Fig.
1-52 shows how to mark the counterweight.
Example of an identification mark, Fig. 1-52.
F-.010 indicates Front 0.010 inch [0.25 mm]
R-.020 indicates Rear 0.020 inch [0.51 mm]
Assemble the Crankshaft Gear Fig. 1-53 (N10127). Measure The Bearing Shell.
Check the Parts Catalog for the correct gear part
number. Table 6: Bearing Shell Thickness — Inch [mm]
1. lnstall the key in the crankshaft. Bearing New Dimension
Journal Minimum Maximum Worn Limit
2. Heat the gear in an oven at 400 °F [205 °C] for Main 0.1230 0.1238 0.1215
at least one hour. Bearing [3.124] [3.145] [3.086]
Connecting 0.0724 0.0729 0.0710
Note: Be careful when you heat the crankshaft Rod* [1.839] [1.852] [1.803]
gear. Make sure the heat is even in the oven. Do Connecting 0.0942 0.947 0.093
not let the gear overheat. Overheating will change Rod** [2.393] [2.405] [2.393]
the hardness of the gear. 'Connecting Rod with bolts and nuts.
3. The timing mark on the gear must be toward * 'Connecting Rod with capscrews.
you as you install the gear.
Note: Bearing shells are available for crankshafts
4. Align the keyway of the gear with the key in which are 0.010, 0.020, 0.030 or 0.040 inch under
the crankshaft. size.
1-25
The main and connecting rod bearings must The Rubber Element Vibration Damper
have oil clearance between the shell and the
Cleaning
crankshaft, see Table 7. The clearance must
not change more than 0.002 inch [0.05] from Clean the damper with detergent. Do not use a
one bearing to the next bearing. strong detergent.
Table 7: Bean-ng Clearance — Inch [mm] 1. Check the metal parts of the damper for
Bearing New Dimension cracks or other damage. Check the rubber ele
Journal Minimum Maximum Wom Limit ment for cracks or other damage.
Main 0.0015 0.0050 0.0070
Bearing [0.038] [0.127] [0.178] 2. Check the index lines (3, Fig. 1-54) on the
Connecting 0.0015 0.0045 0.0070 damper hub (1) and the inertia member (2). lf
Rod [0.038] [0.114] [0.178] the lines are more than 1/16 inch [1.59 mm]
out of alignment, discard the damper.
Note: Never remove any metal from the bearing

shells to change the oil clearance. After opera
tion, a bearing shell that is fitted correctly will be
gray. Light areas on the shell indicate that metal
is touching metal without enough oil clearance.
Dark areas on the shell indicate that the
clearance is too large.
Crankshaft Thrust Bearings

Inspection
Check the thrust rings for wear by measuring the
end movement of the crankshaft (crankshaft end
clearance). With a new crankshaft and thrust
bearings, the end clearance must be 0.007 to
0.017 inch [0.18 to 0.43 mm].
Fig. 1-54 (N10146). Alignment Marks On The Vibration Damper.
Replacement 3. Check the inertia member and the hub for

lf the clearance exceeds the usable limit of 0.022 alignment. The flat face of the member and
inch [0.56 mm], install oversize thrust bearings. the mounting face of the hub must be aligned
Measure the thrust bearing in several locations to within 0.025 inch [0.63 mm].
make sure the upper and lower halves of the 4. The outside diameter of the inertia member
thrust bearings are the same thickness. Put a must have a common center within 0.030 inch
mark on the rear counterweight of the crankshaft [0.76 mm] with the pilot bore of the hub.
to show the thickness of the thrust bearing.
The Viscous Vibration Damper
The Vibration Damper Cleaning
All Cummins engines must use vibration Clean the damper with a solvent cleaner.
dampers. Two types of dampers are used: the rub
ber element vibration damper or the viscous vibra
tion damper. Clean the damper before inspection.
You cannot repair a vibration damper. lf a damper 1. Apply a spray of Spotcheck Developer, Type
is defective, discard it and install a new one. SKD-NF, or equivalent on the damper. Put the
-26
Cylinder Block
damper in an oven heated to 200 °F [93°CJ. Let 4. Use a micrometer to measure the thickness at
the damper reach the temperature inside the each of the four areas. Measure approxi
oven, and then remove it. mately 0.125 inch [3.18 mm] from the outside
diameter of the damper, Fig. 1-56.
2. lnspect the damper for oil leaks. Discard the
damper if any leaks are seen. 5 Replace the damper if the difference in the
measurements between any two of the four
3. Remove the paint from four areas on eacn areas is more than 0.010 inch [0.25 mm].
side of the damper, Fig. 1-55. Use these areas
to take measurements of the thickness of the The Mounting Flange for
damper. the Vibration Damper
Caution: Do not use coarse emery cloth or a sharp Inspection

tool to remove the paint. Use cleaning solvent and 1. Check the threads in the capscrew holes.
240 grit emery cloth. 2. The outside diameter of the pilot flange must
have a common center within 0.004 inch [0.10
mm] with the inside diameter of the pilot bore,
Fig. 1-57. The movement of the flange face
measured at a radius of 2.75 inch [69.8 mm]
must not be more than 0.003 inch [0.08 mm].
Take the measurements after the vibration
damper is installed on the engine. When you
measure the flange, keep the crankshaft at
the far end of the end movement.
Fig. 1-55 (N101116). Remove Paint From The Damper.
Fig. 1-57 (N114156). Check The Movement Of The Mounting

Flange.
Replacement
Replace the flange if the movement is more than
0.003 inch [69.8 mm].
The Connecting Rod

Inspection
1. Use the magnetic method (Magnaglo) to find
Fig. 1-56 (N101117). Measure The Thickness Of The Damper. cracks in the connecting rods, caps, capscrews
\-2n
or bolts. Discard the part if cracks are found. 4. Measure the inside diameter of the piston pin
Make sure you keep the connecting rod and bushing. Use a dial bore gauge. The inside
the cap together. diameter must measure between 2.0010 to
Note: Some joints in the forging will show as 2.0015 inch [50.825 to 50.838 mm].
cracks. Make sure to check the rod for the location 5. If the crankshaft bore or bushing is not cor
of these joints. These lines are not an indication of rect, the connecting rod must be machined to
cracks. Do not discard parts with these marks. the correct size.
2. Assemble the cap to the rod and tighten the
6. Discard all connecting rods that have cuts,
capscrews or nuts to the correct torque in the
scratches or other damage that is deeper than
correct sequence. Fig. 1-58 shows the correct
1/32 inch [0.80 mm] on the l-beam.
Calibrating the ST-561 Checking Fixture

Use the Part No. ST-561 checking fixture and
ST-563 locating mandrel to check the connecting
rod alignment.
1. Use a new connecting rod that measures
12.000 inches [304.80 mm] between the cen
ters of the cranksiiaft bore and the piston pin
bore to calibrate the fixture.
2. Select the correct piston pin mandrel from the
locating mandrel and install it in the piston
pin bore.
3. Install the arbor in the crankshaft bore. Ex
pand the arbor. Make sure the pin on the arbor
is down and locked in position in the center of
Fig. 1-58 (N114222). Tightening Sequence For The Connecting the connecting rod.
Rod.
4. Put the connecting rod in the fixture. Move the
Table 8: Connecting Rod Torque Specifications dial holder so that the contact points of the in
dicators are touching the mandrel in the
piston pin bore. Tighten the bracket to hold
Ft.-lb. [N»m] FL-lb. [N»m]
the indicators. Set the indicator dials at zero.
Step 1. Tighten to 70 [ 95] 75 [102]
Step 2. Tighten to 140 [190] 150 [203] 5. Remove the connecting rod from the fixture.
Step 3. Loosen compic>tely Turn the rod horizontally 180 degrees and put
Step 4. Tighten to 25 [ 34] 30 [ 41] the rod in the fixture.
Step 5. Tighten to 70 [ 95] 75 [102]
Step 6. Tighten to 140 [190] 150 [203] 6. If the dial indicators show any change from
the first reading, adjust the dials to half of the
3. Measure the crankshaft bore with a dial bore indicated change. Then, in either position that
gauge. the connecting rod is put in the fixture, the
a. The connecting rods with bolts and nuts dials will show the same reading, but in op
must have a crankshaft bore with a diam posite directions on the dials. At this point the
eter between 3.2722 to 3.2732 inch [83.114 fixture is calibrated.
to 83.139 mm].
Check the Alignment of the Connecting Rod
b. The connecting rods with capscrews must
have a crankshaft bore with a diameter 1. lnstall the mandrel and arbor in the connect
between 3.3157 to 3.3167 inch [84.219 to ing rod to be checked. Follow steps 2 and 3 for
84.244 mm]. calibrating the fixture.
1-28
Cylinder Block
Fig. 1-59 (V40138). Check The Alignment Of The Bores. Fig. 1-60 (V40139). Measure The Amount Of Twist In The
Connecting Rod.
2. Put the connecting rod in the fixture, Fig. 1-59. 2. Discard any bolts and nuts that have damaged
Take readings for the length (compared to the threads.
length of the connecting rod used to calibrate
the fixture) and for the alignment of the bores 3. Measure the pilot bore in the bolt holes. lf the
(the difference in the readings from one in pilot bore in the rod is larger than 0.6249 inch
dicator to the other). [15.872 mm] discard the rod. lf the pilot bore in
the cap is larger than 0.6252 inch [15.880 mm]
a. The length must not be longer than the discard the cap.
master rod used to calibrate the fixture
and not more than 0.002 inch [0.05 mm] 4. Check the radius on the bolt pad. The bolt pad
shorter. must have a fillet radius of 0.045 to 0.055 inch
[1.14 to 1.40 mm]. See Fig. 1-61. A maximum of
b. The bend (alignment) must not be more 0.0625 inch [1.587 mm] material can be cut
than 0.010 inch [0.25 mm] without the from the pad to repair the radius. Remove any
bushing installed or 0.004 inch [0.10 mm] sharp edges from the pad.
with the bushing installed. -
3. Measure the twist of the connecting rod with a
feeler gauge. Put the feeler gauge between
the mandrel and the dial indicator holding
plate, Fig. 1-60. When the connecting rod does
not have a piston pin bushing, the twist must
not be more than 0.020 inch [0.51 mm]. When
the bushing is installed and machined to the
correct size, the twist must not be more than
0.010 inch [0.25 mm].
The Connecting Rod Bolts and Bolt Holes

The connecting rod bolt or capscrew can be
distorted when it has been tightened to an ex
cessive torque.
1. Check the smallest diameter of the bolt or 1. Bolt head fillet radius
capscrew. If the diameter is less than shown
in Table 1-1, discard the bolt or capscrew. Fig. 1-61 (N40114A). The Fillet Radius On The Bolt Pad.
1-29
a. Cut the inside diameter of the bore for

rods with bolts and nuts to measure 3.2722
Repair the crankshaft bore of the connecting rod if:
to 3.2732 inches [83.114 to 83.139 mm].
1. For rods with bolts and nuts, the bore is larger
than 3.2732 inch [83.139 mm]; for rods with b. Cut the inside diameter of the bore for
capscrews, 3.3167 inch [84.244 mm]. rods with capscrews to measure 3.3157 to
3.3167 inches [84.219 to 83.139 mm].
2. The face of the connecting rod or cap is
damaged. 5. Put the connecting rod in the ST-561 fixture
and check the alignment.
To
6. lnstall a piston pin bushing with a thick wall in
1. Remove the bushing for the piston pin. Use the piston pin bore. A bushing with a thick
the ST-1242 bushing driver to remove the wall must be used so that you can cut the
bushing. lnstall the cap on the connecting rod bushing bore off center. Cut the bushing bore
and tighten the capscrews or nuts to the so that the length of the connecting rod will be
torque listed in Table 8. 11.998 to 12.000 inches [304.75 to 304.80 mm].
2. Use the ST-561 checking fixture to measure
the length of the rod. Discard the rod if the
length is 11.991 inches [304.57 mm] or less. Use the ST-1242 Bushing Driver to remove the
Note: A maximum of 0.009 inch [0.23 mm] can be piston pin bushing, Fig. 1-62.
removed from the rod and cap. Equal amounts of
material must be removed from the rod and the
cap. The length of the rod must be 12.000 inches
[304.80 mm] before you can remove a maximum of
0.009 inch [0.23 mm] from the rod and cap. If the
maximum of 0.009 inch [0.23 mm] had to be
removed, the rod must measure 11.991 inches
[304.57 mm] in length after machining.
a. The alignment of the bolt or capscrew
bores in the rod and cap must not change.
Hold the rod and cap in a clamp that holds
the rod in alignment when cutting material
from the surfaces. 1. Mandrel 5. Sleeve
b. Use lapping compound to polish the sur 2. Cup 6. Pin
3. Block 7. Bushing
faces that were machined. Apply a blue 4. Sleeve 8. Rod
compound to the surfaces and check them
against a flat plate. The area outside the Fig. 1-62 (N10158). The ST-1242 Bushing Driver.
centerline of the bolt bores (The area
farthest from the crankshaft bore) must To install the bushing, use the bushing driver.
show 100 percent contact. The remaining 1. Put the bushing (7, Fig. 1-62) on the mandrel
area must show a minimum of 75 percent (1). Put the sleeve (4) and then the cup (2) on
contact. the mandrel. Fasten the cup on the mandrel
3. lnstall the cap on the rod and tighten the with the locking pin (6).
capscrews or nuts to the torque listed in Table 8. 2. Put the connecting rod on the block (3) and
4. Cut the crankshaft bore with the 33751 15 Bor hold it in a horizontal position.
ing Machine or an equivalent boring machine
3. lnsert the mandrel and components as listed
that has a precision fixture to keep the piston
in Step 1 into the bore of the connecting rod.
pin bore and crankshaft bore in alignment.
The surface of the bore must be smooth 4. Align the sleeve (4) with the middle of the
within 75 micro-inches. boss on the connecting rod.
Cylinder Block
Note: Make sure the oil holes are in alignment.

5. Use an arbor press to push the bushing into
the bore until the sleeve (4) is in contact with
the connecting rod.
6. Check the alignment of the oil holes. Make
sure an 1/8 inch [3.17 mm] diameter rod can
move freely through the connecting rod and
bushing.
Cut the Bore in the Piston Pin Bushing

1. Fill the oil holes with soap to prevent metal
particles from entering the holes.
2. lnstall the connecting rod in the boring
machine. Fig. 1-63 (V40135). Check The Gap Of The Piston Ring.
Note: To put the connecting rod in the correct
position to cut the bore in the bushing, use only
the two horizontal blades of the lower mandrel on Table 9: Piston Ring Gap In
the machine. New Cylinder Liner — Inch [mm]
Piston Ring
3. The instructions for the boring machine are in Part Number Minimum Maximum
cluded with the mahchine.
147670 (Top Ring) 0.023 0.033
4. Cut the bushing to 2.0010 to 2.0015 inches [0.58] [0.84]
[50.825 to 50.838 mm] inside diameter. 218025 (Top Ring)* 0.017 0.027
[0.43] [0.68]
Remove the rod from the boring machine and 3012331 (Top Ring)** 0.017 0.027
check the bore with a dial bore gauge. [0.43] [0.68]
132280 (lntermediate Ring)*** 0.019 0.029
5. Remove all sharp edges. [0.48] [0.74]
6. Remove any metal particles and the soap from 214730 (lntermediate Ring) 0.019 0.029
the oil holes. Wash the bores and holes with [0.48] [0.74]
216383 (lntermediate Ring)* 0.020 0.030
mineral spirits and dry with compressed air. [0.51] [0.76]
7. Use the ST-561 Checking Fixture to check all 3012332 (lntermediate Ring) 0.019 0.029
[0.48] [0.74]
the dimensions. 218732 (Oil Ring) 0.010 0.025
Note: All connecting rods used in an engine must [0.25] [0.64]
be the same part number. Never use a cap from a *NTC 475 Only
different part number connecting rod. "Big Cam ll Only
***NTE Engine Only
Piston Rings
Inspection 3. Never use a rile or abrasive material to cut
Check new piston rings in the cylinder liner in chrome rings. Never use chrome rings inside a
which they are to be installed. Make sure the ends chrome cylinder liner.
of the ring have the correct gap. 4. Check the parts catalog to make sure you
1. Put each ring in the cylinder liner. Use the top have the correct piston and piston rings.
part of the piston to position the ring correctly
Pistons
in the liner.
Inspection
2. Measure the ring gap with a feeler gauge, Fig.
1-63. The ring gap must be within the limit 1. Use the ST-560 Ring Groove Gauge to check
given In Table 9. the top and second grooves for the rings.
1-31
l tr
a Pin bore area
b Area below ring groove
c. Piston skirl
Fig. 1-64 (N10142). Check For Wear In The Ring Groove. Fig. 1-65 (N20171). Check Points For The Outside Diameter Of
The Piston.
Make sure the ring grooves are clean. The
widest part (shoulder) of the tool must not measured at 68 °F. Add 0.0005 inch [0.013 mm]
come in contact with the piston, Fig. 1-64. If to the diameter per 10 "F, up to 90 °F [32 °C].
the shoulder touches the piston, the ring 5. Use a micrometer to check the outside
groove is worn too deep and the piston must diameter of the piston pin. Discard the piston
be discarded. pin if it is more than 0.001 inch [0.03 mm] out-
2. If you do not have the ST-560 Gauge, you can of-round. The outside diameter must be
check the ring groove by using a section of a 1.99875 to 1.9990 inches [50.768 to 50.774 mm].
new ring and a feeler gauge. 6. Do not increase the size of the inside diameter
a. Hold the ring in the groove and install a of the piston pin bore or, use an oversize
0.006 inch [0.15 mm] feeler gauge. piston pin.
b. If the feeler gauge enters the groove easily Assemble the Piston to
there is too much wear. Discard the the Connecting Rod
piston.
1. Always use the same part number pistons for
3. Measure the outside diameter of the piston each cylinder in the engine.
with a micrometer. Take the measurements at
right angles to the piston pin bore. Take the 2. Install a snap ring in the groove of the piston
measurement when the piston temperature is pin bore.
70° to90°F [21 Mo 32 •CJ.
3. Heat the piston for 15 minutes in boiling water
a. Measure the area A, Fig. 1-65, for pistons or in an oven set at 210 °F [98.9 °C]. lnstall the
that are barrel-ground. piston pin in the piston and connecting pin
bores before the piston pin cools to 70 "F
b. Measure the area B, 1.0 inch [25.4 mm] [21 "CJ. The piston pin cannot be installed
below the ring groove, and area C, 1.0 inch when the temperature of the piston is 70 °F
[25.4 mm] above the bottom of the piston [21 °C] or less. Install a snap ring in the groove
for pistons that are straight or tapered. of the piston pin bore opposite to the one in
c. Discard pistons that measure less than step Z
5.483 inch [39.27 mm] diameter. Caution: Merer use a hammer to Install tha piston
4. Check the piston pin bore when the pin. This can causa distortion In tha piston and a
temperature of the piston is at 68 °F. The in piston seizure In tha cylinder liner. Make sure the
side diameter of the bore must be 1.9985 to edges of the snap ring are In the groove of the
1.9990 inches [50.762 to 50.775 mm] when piston pin bore.
2
Cylinder Block
The Rear Cover Note: Failure to use the correct pipe plug will
cause the oil pressure for the engine to be incor
Inspection
rect. See the parts catalog for the engine that you
Remove the oil seal from the rear cover. Check the are working with to find the correct combination
rear cover for damage to the oil seal bore. Check of camshaft, camshaft plug and camshaft support.
the threads in the capscrew holes.
5. lnstall the pipe plug in the camshaft. Tighten
the pipe plug to 5 to 10 ft.-lbs. [7 to 14 N»m]
Replacement
torque.
Replace the rear cover if it is damaged. Install a
6. Put the camshaft gear in an oven heated to
thread insert if the threads are damaged.
400 °F [205 °C]. Heat the gear for one hour.
The Camshaft 7. lnstall the key in the camshaft. Remove the
gear from the oven and use a press to push
Inspection the gear on the camshaft.
Use a micrometer to measure the journals.
8. Use a feeler gauge to check the clearance be
Discard the camshaft if the journals measure less
tween the camshaft flange and the gear. The
than:
clearance must not be more than 0.0015 inch
1.996 inches [50.70 mm] — 2 inch camshaft [0.038 mm].
2.495 inches [63.37 mm] — 2-1/2 inch camshaft
9. Turbocharged and aftercooled engines re
quire a retaining ring for the camshaft gear.
Replacement
Put the retaining ring in an oven heated to
Replace the camshaft if it has scratches, cracks 450 °F [232 °C]. Heat the ring for one hour.
or other damage. Use a magnetic inspection Remove the ring from the oven and use a
method to check for cracks. press to push the ring on the camshaft until
Note: Cummins Engine Co., lnc. does not recom the ring is against the gear. lf a retaining ring
mend grinding the camshaft lobes. is used, make sure you have the correct cam
shaft support and pipe plug.
The Thrust Bearing Note: Always check the engine timing when a new
Replace the thrust bearing if it is damaged, worn camshaft or camshaft gear is installed.
or distorted. Replace the thrust bearing if it is
worn thinner than 0.083 inch [2.11 mm].
The Camshaft Support
The Camshaft Gear Discard the support if it is cracked or damaged or,
Remove the gear if it is cracked, damaged or if the inside diameter is worn larger than 1.757
worn. inch [44.63 mm].
1. Use a press to push the camshaft from the

gear. The Gear Cover
2. Put the camshaft in a press. Put V-blocks
under the gear. Make sure the V-blocks sup Disassembly
port the hub area of the gear. Remove and discard the oil seals.
3. Use the press to push the camshaft from the
gear. Remove the key from the camshaft. The Front OH Seal
Caution: Do not use a heating torch to remove the When the gear cover is mounted to the engine,
gear. If you use a heating torch, a new gear must follow these instructions to remove the oil seal.
be Installed. 1. Use three capscrews already removed from
4. Remove the pipe plug from the end of the cam the vibration damper to fasten the Part No.
shaft. Clean the oil passages. ST-1259 Oil Seal Puller to the crankshaft.
1-33
2. Lubricate the threads of the Part No. 2. Push the Part No. 68226-1 bushing (2) on the
ST-1259-6 screws. Put these screws in the trunnion. Make sure the chamfer on the
tool. Turn them until the threads of the screw bushing is toward the gear cover.
engage the metal casing of the seal.
The I
3. Remove the Part No. ST-1259-6 screws. lnstall (except for NTA l
a capscrew in the center of the tool. Turn the
screw until the seal is pulled from the gear 1. Measure the inside diameter of the bushing
cover. for the accessory drive. lf the inside diameter
is larger than 1.571 inches [39.90 mm].
4. lnspect the area around the seal for damage. Replace the bushing.
Make sure all metal particles are removed.
2. Measure the outside diameter of the ac
Inspection cessory drive shaft. If the shaft measures less
than 1.5665 inches [39.79 mm], an undersize
1. Check the outside diameter of the trunnion for bushing can be installed in the gear cover. The
wear. bushing and shaft must have 0.003 inch [0.08
2. Check the cover for cracks or other damage. mm] minimum clearance between them. See
Table 10 for bushing sizes.
Repair 3. Use the ST-598 Mandrel to install the bushing
Replace any worn or damaged gear cover. in the gear cover. Make sure the oil holes are
in alignment. A 0.156 inch [3.96 mm] diameter
rod must be able to move freely through the oil
holes.
lf the outside diameter of the gear cover trunnion
is worn, install a new bushing.
1. Cut the trunnion (1, Fig. 1-66) to measure 4.747 Table 10: Accessory Drive Bushing — inch [mm]
to 4.750 inches [120.57 to 120.65 mm] outside Part No. Minimum Maximum Worn Limit
diameter. 132770 1 .565 1.569 1.571
[39.75] [39.85] [39.90]
132771 1.555 1.559 1.561
[39.50] [39.60] [39.65]
132772 1.545 1.549 1.551
[39.23] [39.34] [39.40]
The Bushing for the Accessory Drive NTA Engine

1. Measure the inside diameter of the bushing
for the accessory drive. lf the inside diameter
is larger than 1.7585 inches [44.666 mm],
replace the bushing.
2. Use the ST-1 1 71 Mandrel to install the bushing
in the gear cover. See the parts catalog for the
correct part number of the bushing. Make sure
1. Gear Case Trunion
2. Bushing the oil holes are in alignment. A 0.156 inch
[3.96 mm] diameter rod must be able to move
Fig. 1-65 (N10145). The Gear Cover And Trunnion Bushing. freely through the oil holes.
1-34
Cylinder Block
Table 1-1: Cylinder Block Specifications — inch [mm] (Reference Fig. 1-0)
2-1/2 lnch Cam Engines
Specifications not listed are the
2 lnch Cam Engines same as 2 Inch Cam Engines
Ref. worn »■
new— New Worn New New
No. Measurement Limit Minimum Maximum Limit Minimum Maximum
1. Camshaft Bushing 2.0015 1.999 2.0005 2.5023 2.4983 2.4998
lnside Diameter [50.838] [50.774] [50.813] [63.558] [63.457] [63.495]
Camshaft Bushing Bore 2.1305 2.1285 2.1295 2.6265 2.6245 2.6255
lnside Diameter [54.115] [54.064] [54.089] [66.721] [66.662] [66.688]
2. Cylinder Liner Counterbore 6.5615 6.5635
lnside Diameter [166.662] [166.713]
Depth 0.412 0.350 0.352
[10.46] [8.89] [8.94]
3. Liner to Block Clearance 0.002 0.006
Lower Bore [0.05] [0.15]
4. Lower Liner Bore 6.124 6.126
Inside Diameter [155.55] [155.60]
5. Main Bearing Bore 4.7505 4.7485 4.750
lnside Diameter [120.663] [120.612] [120.650]
Block (Ref. Fig. 1-37)
Height from Main 18.994 19.003 19.007
Bearing Centerline [482.45] [482.68] [482.78]
Height from lnstalled 16.619 16.628 16.632
Alignment Bar [422.12] [422.35] [422.45]
Cylinder Liner 5.505 5.4995 5.501
lnside Diameter [139.83] [139.687] [139.73]
Note: New cylinder liners dimensions at 60° to 70 °F [16° to 21 °C]
may be 0.0002 to 0.0006 lnch [0.005 to 0.0015 mm] smaller than
indicated due to lubrite coating.
Protrusion 0.003 0.006
(lnstalled) [0.08] [0.15]
6. Crankshaft
Connecting Rod Journal 3.122 3.1235 3.125
Outside Diameter [79.30] [79.337] [79.38]
Main Bearing Journal 4.4975 4.4985 4.500
Thrust Bearing Surface 3.006 3.001 3.003
to Rear Counterweight [76.35] [76.23] [76.28]
Main and Rod Journals 0.002
Out-of-round T.l.R.* [0.05] *T.l.R. — Total lndicated Runout
Main and Rod Journal 0.0005
Taper (Length of Journal) [0.013]
7. Main Bearings" 0.1215 0.123 0.1238 "Also available in 0.010, 0.020,
Shell Thickness [3.086] 13.12) [3.145] 0.030 and 0.040 inch undersize.
Journal Clearance 0.007 0.0015 0.005
- [0.18] [0.038] [0.13]
(Connecting rods with bolts & nuts) (Connecting Rods with capscrews)
a Rod Bearings** 0.071 0.0724 0.0729 0.093 0.0942 0.0947
Shell Thickness [1.80] [1.839] [1.852] [2.362] [2.393] [2.405]
1-35
Table 1-1: Cylinder Block Specifications — inch [mm] (Reference Fig. 1-0) (Cont'd)
2-1/2 Inch Cam Engines
Sp0ciflcations not listed are the
2 Inch Cam Engines same as 2 men Cam Engines
New New \ 52 Ml;lemwum m£ozum
No! Measurement Limit Minimum Maximum 1
9. Crankshaft Thrust Ring 0.245 0.247
157280 Std. Thickness [6.22] [6.27]
157281 0.010 O.S. 0.255 0.257
Thickness [0.25] [6.48] [6.53]
157282 0.020 O.S. 0.265 0.267
Thickness [0.51] [6.73] [6.78]
'Use Crankshaft End Clearance
10. Crankshaft End Clearance 0.022 0.007 0.017
End Clearance (lnstalled) [0.56] [0.18] [0.43]
11. Connecting Rod
Crankpin Bore 3.2722 3.2732 3.3157 3.3167
lnsido Diameter [83.114] [83.139] [84.219] [84.244]
Center to Center Length 11.998 12.000
[304.75] [30480]
Piston Pin Bushing 2.0022 2.0010 2.0015
lnside Diameter [50.856] [50.825] [50.838]
^Bend*'"8 0.010 0.010

Without Bushing [0.25] [0.25]
Bend 0.004 0.004
With Bushing [0.10] [0.10]
Twist 0.020 0.020
Twist 0.010 0.Q10
Connecting Rod Bolt 0.540 0.541 0.545
Minimum Outside Diameter [13.72] [13.74] [13.84]
Pilot 0.6242 0.6245 0.6250
Connecting Rod Capscrew 0.583 0.584 0.590
Pilot 0.637 0.638 0.643
Bolt Hole Pilot
(2 Bolt Rods)
Rod 0.6249 0.6243 0.6248
[15.872] [15.857] [15.8701
Cap 0.6252 0.6246 0.6251
[15.880] [15.865] [15.878]
Dowel and Pilot
(2 Capscrew Rod)
Dowel Diameter 0.3127
[7.943]
Rod Dowel Hole 0.3128 0.3133
[7.945] [7.958]
Cylinder Block
Table 1-1: Cylinder Block Specifications — inch [mm] (Reference Fig. 1-0) (Cont'd.)
2 Inch Cam Engines same as 2 Inch Cam Engines
Ref. Worn New New Worn New New
Dowel Protrusion 0.220 0.250
[5.59] [6.35]
Dowel Press Fit ln Cap 0.0001 0.0006
[0.003] [0.015]
12. rision
Skirt Diameter 5.483 5.487 5.488
at 70 *F [21 *CJ [139.27] [139.37] [139.40]
Piston Pin Bore lnside 2.0000 1.9985 1.9990
Diameter at 70 "F [21 X] [50.800] [50.762] [50.775]
13. Piston Pin
Outside Diameter 1.9985 1.99875 1.9990
at 70 "F [21 *C] [50.762] [50.768] [50.775]
14. Piston Ring
Gap in Ring Travel Area
of Liner
Part Number Minimum Maximum
147670 0.023 0.033
[0.58] [0.84]
218025* 0.017 0.027
[0.43] [0.68]
3012331** 0.017 0.027
[0.43] [0.68]
132880*** 0.019 0.029
[0.48] [0.74]
214730 0.019 0.029
[0.48] [0.74]
216383* 0.020 0.030
[0.51] [0.76]
3012332 0.019 0.029
[0.48] [0.74]
218732 0.010 0.025
[0.25] [0.64]
Add 0.003 inch [0.08 mm] ring gap to new maximum limit for
each 0.001 inch [0.03 mm] wear in cylinder liner wall.
*NTC-475 only
"Big Cam ll only
***NTE Engine only
15. Camshaft Journal 1.996 1.997 1.998 2.495 2.496 2.497
Outside Diameter [50.70] [50.72] [50.75] [63.37] [63.40] [63.42]
Thrust Bearing 0.083 0.093 0.098
Thickness [2.11] [2.36] [2.49]
Support Bushing 1.370 1.3725 1.3755
lnside Diameter [34.80] [34.862] [34.938]
Outboard Bearing Support 1.757 1.751 1.754
lnside Diameter [44.63] [44.48] [44.55]
16. Gear Case Cover
Accessory Drive Bushing
Part No. 132770 Std. 1.571 1.565 1.569
lnside Diameter [39.90] [39.75] [39.85]
132771 0.010 [0.25] U.S. 1.561 1.555 1.559
lnside Diameter [39.65] [39.50] [39.60]
1-37
Table 1-1: Cylinder Block Specifications - inch [mm] (Reference Fig. 1-0) (Cont'd)
Specifications not listed an the
Worn
132772 0.020 [0.51] U.S. 1.551 1.545 1.549
lnside Diameter [39.40] [39.24] [39.34]
20822 Std. (NTA Series) 1.7585 1.7525 1.7565
Inside Diameter [44.666] [44.513] [44.615]
Torque Specifications — ft.-lbs. [N»m]

Pipe Plug Size Minimum Maximum
1/8 15 [ 20] 20 [ 27]
1/4 30 [ 41] 35 [ 47]
3/8 35 [ 47] 45 [ 61]
1/2 45 [ 61] 55 [ 75]
3/4 60 [ 81] 70 [ 95]
1-1/4 75 [102] 85 [115]
1-1/2 90 [122] 100 [136]
% Inch % Inch 1 Inch 1 Inch
Main Bearing Capscrews* Minimum Maximum Minimum Maximum
Step 1. Tighten to 80 [108.5] 90 [122] 100 [135.6] 110 [149]
Step 2. Tighten to 160 [217] 170 [2301 200 [271] 210 [285]
Step 3. Tighten to 250 [339] 260 [352] 300 [407] 310 [420]
Step 4. Loosen Completely All All All All
Step 5. Tighten to 80 [108.5] 90 [122] 100 [135.6] 110 [149]
Step 6. Tighten to 160 [217] 170 [230] 200 [271] 210 [285]
Step 7. Tighten to 250 [339] 260 [352] 300 [407] 310 [420]
Connecting Rod Nuts or Capscrews Minimum Maximum
Step t. Tighten to 70 [ 95] 75 [102]
Step 2. Tighten to 140 [190] 150 [203]
Step 3. Loosen Completely All All
Step 4. Tighten to 25 [ 34] 30 [ 41]
Step 5. Tighten to 70 [ 95] 75 [102]
Step 6. Tighten to 140 [190] 150 [203]
'During 1978, some engines were built with special main bearing caps and % inch main bearing capscrews. Check
the serial number and build date of your engine against the list below. // your engine Is one of those listed, the main
bearing capscrews must be tightened to 330 ft.-lbs. [447.4 N»m] maximum torque.
-38
Cylinder Block
Engine Date Engine Date Engine Date

Serial No. Built Serial No. Built Serial No. Built
10718349 10721117 10722677
thru 2-8-78 thru 2-16-78 thru 2-22-78
10718373 10721121 10722701
10718391 10721127 10729153
thru 2-8-78 thru 2-16-78 thru 3-16-78
10718394 10721131 10729177
10718413 10721161 10729428
thru 2-8-78 thru 2-16-78 thru 3-16-78
10718420 10721175 10729451
10718672 10721420 10752302
thru 2-8-78 thru 2-16-78 thru 6-9-78
10718674 10721424 10752331
10718737 10721426 10752414
thru 2-8-78 thru 2-17-78 thru 6-9-78
10718746 10721429 10752443
10719293 10721549 10759241
thru 2-10-78 thru 2-17-78 thru 7-11-78
10719309 10721563 10759275
10719311 10721864 10759566
thru 2-10-78 thru 2-20-78 thru 7-11-78
10719319 10721867 10759586
10719402 2-10-78 10721963
thru 2-20-78
10719405 10721972
thru 2-10-78
10719412 10722061
thru 2-20-78
10719682 10722070
thru 2-10-78
10719691
1-39/(1-40 Blank)
i
Cylinder Head
_ The cylinder head group includes the inspection,

GrOUP 2 repair and assembly of: the cylinder head, valves
and valve guides, crosshead and crosshead
guides, valve seats, injector sleeve and valve
springs.
Cylinder Head
1. Cylinder Head 6. Crosshead Guide

2. Valve 7. Injector Sleeve
3. Valve Guide 8. Valve Spring Retainer
4. Valve Seat lnsert 9. Half Collets
5. Spring 10. Cup Plugs
Fig. 2-1, (N10295). Cylinder head — exploded view.
2-1
Service Tool List Desirable (Or Equivalent) Service Tools

To repair the cylinder head and components Service Tool Tool
according to the instructions given in this group, Number Name
the following service tools or tools of equal ST-448 Valve Spring Compressor (Single)
quality are required. ST-547 Gauge Block
ST-583 Head Holding Fixture
ST-633 Crosshead Guide Mandrel
ST-876 Cleaning Brush
Service Tools (Or Equivalent) Required ST-1022 Valve Spring Compressor Stand
Service Tool Tool (Used with multiple compressor plate)
Number Name ST-1026 Valve Spring Compressor Plate
ST-257 Valve Seat lnsert Tool (Compress 8 springs In one operation)
ST-646 Valve Guide Reamer ST-1122 Staking Tool Driver
ST-662 Valve Seat lnsert Cutter Set ST-1124 Valve Seat Insert Staking Tool
ST-663 Valve Guide Arbor Set ST-1279 valve beat extractor
ST-684or
3376256 Valve Facing Machine ST-1166 Magnetic Crack Detector
ST-685 Valve Seat Grinding Machine ST-1187 Valve Guide Reamer
ST-788 Bead Cutting Tool 0.015 inch [0.38 mm] Oversize
ST-880 lnjector Sleeve Expander ST-1188 Valve Guide Reamer
ST-884 lnjector Sleeve Cutter 0.010 inch [0.25 mm] Oversize
ST-1010 Water Hole Counterboring Tool ST-1244 lnjector Sleeve Puller
ST-1012 Hydrostatic Tester ST-1247 lnjector Sleeve Puller Impact
ST-1013 Hydrostatic Tester Base Plate wrencn oocKet
ST-1134 Dowel Pin Extractor 3375155 Injector Protrusion Gauge
ST-1179 lnjector Sleeve Holding Tool 3375067 Loctite Cup Plug Sealer
3375282 Valve Guide Mandrel
lnjector Sleeve Installation Mandrel 3375182 vaive opring lesier
ST-1227
ST-1257
A or D Vacuum Tester Standard Tools — Obtain Locally
3375190 3/4' Cup Plug Driver
3375191 1 " Cup Plug Driver 0-1 Inch Micrometer
3375192 1-1/4" Cup Plug Driver Small
VernierBore
Depth
Gauge
Gauge
3375933 Valve Head Checking Tool
Cylinder Head c. Position the ST-1026 on the cylinder head

so the valve stems will be in the center of
The instructions for the cylinder head are the same
the holes in the plate.
for both 2 inch and 2-1/2 inch camshaft engines.
d. Pull down on the handle on the stand.
Disassembly Make sure the valve stems stay in the
1. Clean the cylinder head assembly with steam. center of the holes, Fig. 2-2.
Dry the cylinder head with compressed air. e. Bring the handle all the way down so the
2. Put the cylinder head in the Part No. ST-583, or locking pin will engage the hole in the
an equivalent tool, to hold the cylinder head plunger. The locking pin holds the plunger
during disassembly. against the plate that compresses the
springs.
3. Use the Part No. ST- 1022 Valve Spring Com
pressor Stand and the Part No. ST-1026 Valve f. Remove the valve spring collets. You can
Spring Compressor Plate to compress the use a magnet to help remove the collets.
valve springs.
g. Push down on the handle and disengage
a. Make sure the ST-1022 is fastened to the the locking pin from the plunger. Raise the
work bench you will be using. plunger from the cylinder head.
b. Align the center of the cylinder head with h. Remove the valve springs, valve spring
the plunger of the ST-1022 guides and valves from the cylinder head.
?-2
Cylinder Head
b. Use a screwdriver or pliers to pull the plug

from the hole.
Put the cylinder head in a tank of cleaning
solution heated to near, but not, 212 °F
[100°C] temperature. You can use the follow
ing solvents or an equivalent, Turko or
Wyandotte "G". Follow the instructions on
the solvent container.
Mix the solvent to help remove the
deposits.
b. Clean the valves, springs and retainers in
the solvent.
c. Use an acid-type cleaner to remove thick
Fig. 2-2. Compress The Valve Springs. deposits.
Warning: The use of acid Is dangerous. Always
i. The Part No. ST-448 Valve Spring Com have a tank of strong soda water to control the
pressor can be used to compress the valve acid. Wear safety glasses and gloves.
springs when the cylinder head is in
stalled on the engine. 3. Use the Part No. ST-876 Fuel Passage Clean
ing Brush to clean the fuel passages in the
Caution: Make sure the piston Is all the way up In cylinder head. Wash the passages with sol
the cylinder before you remove the valve springs vent to remove deposits.
In the cylinder head tor that cylinder. Replace the
valve springs before you move the piston so the 4. Check the oil passage (1, Fig. 2-3) and make
valves will not fall Into the cylinder. sure it is open.
4. Put each valve, as it is removed, on a stand 5. Dry the cylinder head with compressed air.
that has numbers to show the cylinders of the Polish the surface with an orbital sander, Fig.
engine. 2-4.
5. lf the engine has oil seals for the intake valve To test the fuel passage with air
guides, remove the seals. Discard the seals. a. Install discarded injectors in the cylinder
6. Engines that are turbocharged have a 1/8 inch head.
pipe plug in the cylinder head vent hole.
Remove the pipe plug. Naturally aspirated
engines do not have a plug in the vent hole.
7. Remove the pipe plugs from the fuel holes ln
the number 1 and 3 cylinder head.
8. Remove the pipe plugs from the fuel passages
in each end of the cylinder head.
Clean the Cylinder Head

1. Remove the cup plugs and the pipe plugs.
a. Use a hammer and punch to loosen the
cup plug. Hold the punch against the plug,
near the outside diameter of the plug, and
hit the punch with a hammer to cause one
side of the plug to move from its correct
location. Fig. 2-3 (N10266). The Oil Passage In The Cylinder Head.
2-3
NT/NTA 855 C.I.Di Engine Shop Manual
Fig. 2-4 (N10290). Polish The Cylinder Head. Fig. 2-5 (N10278). Cross-Section Of The ST-1179 Injector Sleeve
Holding Tool.
b. Close the fuel outlet and install an air
gauge.
c. lnstall air fittings to the fuel inlet and apply
air pressure of 80 to 100 psi [550 to 690 kPaj.
d. Close the air inlet valve and check the fuel
passage for leaks.
e. Check the air gauge. The pressure shown
on the gauge must not decrease for a
minimum of 15 seconds. Discard the
cylinder head with wear or damage.
Inspection
Air Pressure Test the Cylinder Head
1. lnstall the Part No. ST-1179 Injector Sleeve
Holding Tool, or an injector that has been
Fig. 2-6 (N10282). The Cylinder Head Installed ln The ST-102.
discarded into the injector sleeve, Fig. 2-5.
2. Tighten the sleeve holding tool to hold the in with the holes in the plate. Tighten the
jector sleeve ln position. If an injector is used screw for the clamping assembly. Make
lnstead of the sleeve holding tool, tighten the sure the drain valve in the adapter plate is
hold-down capscrews to 10 to 12 Ft.-Lbs. [14 in the closed position.
to 16 N»m] torque.
c. Use the pins that are supplied with the
3. lnstall the cylinder head in the Part No. quadrant to fasten the clamping assembly
ST-1012 Hydrostatic Tester and the Part No. to the quadrant. Fasten the longer bracket
ST-1013 Base Plate, Fig. 2-6 of the quadrant to the bottom of the
a. lnstall the plates on the cylinder head. clamping assembly.
Engage the locating pins for the plates
d. Use a hoist to lift the assembly over a tank
with the holes ln the cylinder head.
filled with water. Connect the air hose to
b. lnstall the clamping assembly over the the fitting on either the top or bottom
plates on the cylinder head. Engage the plate. Adjust the air pressure regulator to
locating pins for the clamping assembly 30 to 40 psi [207 to 276 kPa].
4
Cylinder Head
e. Lower the assembly into the water until 1. Remove the keeper bar from the magnet
approximately 1/2 inch [12.7 mm] of water poles.
is over the cylinder head.
2. Put the magnet on the area to be inspected.
f. Rotate the cylinder head and check for
3. Use the powder bulb to spray the powder on
leaks. Be sure to check the upper and
the area to be inspected. Use compressed air
lower injector sleeve area for leaks.
with low pressure to remove excess powder
* g. Lift the assembly from the tank. Remove from the area. The remainder of the powder
the cylinder head from the ST-1012 and will be in the cracks and will show as a white
ST-1013. line, Fig. 2-7.
Water Pressure Test the Cylinder Head

1. Install a pressure regulator and gauge into a
hose that connects to the water and air sup
ply. The water and air supply must have shut-
off valves.
2. lnstall the ST-1179 in the cylinder head as in
Steps 1 and 2 for Air Pressure Test.
3. lnstall the ST-1013 on the cylinder head as in
Steps 3a and 3b for Air Pressure Test.
4. Set the pressure at 35 to 85 psi [241 to 586
kPa]. For the best results, have the water
temperature at 180" to 200 °F [82° to 93 °C].
5. Connect the hose to the fitting in the plate.
Open the drain valve to remove the air from
Fig. 2-7 (N10279). Check The Cylinder Head For Cracks.
the cylinder head. Open the valve for the water
to fill the cylinder head with water.
To Repair the Cylinder Head Surface
6. Close the valves for the water and drain when
The cylinder head surface must be repaired if it
all the air has been removed from the head.
has scratches, damage or is worn so that the sur
7. Open the valve for the air pressure. face is not even. Use a milling machine or a grind
8. Check the cylinder head for leaks. Be sure the ing machine to cut the surface. Keep the surface
check the areas around the valve seats and at 125 micro-inch.
the injector sleeve for leaks or cracks. Discard 1. Use the Part No. ST-1279 Valve Seat Extractor
the cylinder head if it has leaks or cracks to remove all of the valve seats:
in the areas of the valve seats or lnjector
a. Make sure the valve seat is clean.
sleeves.
9. Close the valve for the air pressure. b. Apply a coat of grease to the tapered end
of the shaft.
10. Open the valve for the water drain to check the
water flow through the cylinder head. lf the c. Install the shaft in the puller.
water does not flow freely, remove the plugs d. Insert the puller in the valve seat. Make
and injector sleeves and clean the deposits sure the shaft is in vertical alignment to
from the water passages. the valve seat. Hold the puller with your
hand and rotate the T-handle clockwise to
Magnetic Method To Find Cracks tighten the puller against the seat.
Use the Part No. ST-1166 Magnetic Crack Detector e. Hit the slide hammer against the top nut
to find cracks in the areas around the valves and and let the slide hammer fall against the
lnjectors. puller.
2-5
f. Tighten the T-handle to cause the extrac lnspect the Valve Seats
tor ln the puller to expand under the seat. 1. To find loose valve seat inserts, carefully hit
g. Hit the slide hammer against the top nut the head with a wood or rubber hammer. lf the
until the seat is removed. insert is loose enough so that it moves,
replace the insert.
h. Remove the seat from the puller by
rotating the T-handle counterclockwise. 2. Check the seat area width (2), Fig. 2-8. If the
width is more than 0.125 inch [3.18 mm] and
i. Repeat the procedure to remove the re cannot be cut narrower, replace the insert.
maining seats. Be sure to apply grease to
the tapered end of the shaft each time you 3. Use the following tools to cut the counterbore:
repeat the procedure. ST-257 Valve Seat lnsert Tool Kit
ST-662 Valve Seat lnsert Cutter
2. Use a vernier depth gauge or micrometer to ST-663 Valve Guide Arbor
check the height of the cylinder head. Do not
remove more than 0.005 inch [0.13 mm] a. lnstall the arbor into the valve stem guide.
material with each cut. The cylinder head Put the adapter sleeve from the Tool Kit on
height must not be less than 4.340 inch to the arbor.
[110.24 mm]. b. Loosen the clamp screws for the swivel
and the gear case. Remove the gear case
assembly. Install the base and swivel on
to the arbor and adapter sleeve. Make sure
the base is flat against the cylinder head.
c. Use a capscrew to fasten the base to the
cylinder head. Do not tighten the cap-
screw.
d. Use a seat driver from the Tool Kit. The
driver must have the same diameter as the
cutter. Install the driver over the arbor and
adapter sleeve and through the swivel,
Fig. 2-9.
e. Adjust the position of the base and swivel
1. Minimum Seat Width 0.063 inch [1.59 mm] so the driver will move freely on the arbor.
2. Maximum Seat Width 0.125 inch (3.18 mm] Tighten the capscrew to hold the base to
the cylinder head. Tighten the clamp
Fig. 2-8 (N10228). Cross-Section Of The Valve Seat Insert. screw for the swivel.
Table 1: Valve Seat Insert Specifications — Inch [ntm]

Valve Seat Insert Amount of Oversize Ifissrt CountOftooFO Insert
Part No. Diameter Depth O.D. I.D. Thickness
127935 0.005 Standard 2.0075/2.0085 2.0045/2.0055 0.278/0.282
[0.13] [50.991/51.016] [50.914/50.940] [7.06/0.282]
127931 0.010 Standard 2.0125/2.0135 2.0095/2.0105 0.278/0.282
[0.25] [51.118/51.143] [51.041/51.067] [7.06/7.16]
127932 0.020 0.005 2.0225/2.0235 2.0195/2.0205 0.283/0.287
[0.50] [0.13] [51.372/51.397] [51.295/51.321] [7.19/7.29]
127933 0.030 0.010 2.0325/2.0335 2.0295/2.0305 0.288/0.292
[0.76] [0.25] [51.626/51.651] [51.549/51.575] [7.32/7.42]
127934 0.040 0.015 2.0425/2.0435 2.0395/2.0405 0.293/0.297
[1-02] [0.38] [51.880/51.905] [51.803/51.829] [7.44/7.54]
Cylinder Head
revolutions to make sure the counterbore

surface is even. lf the feed engagement
knob disengages before the knob is
against the gear case, turn the knob with
your hand to complete the cut.
4. Loosen the clamp screw for the gear case.
Remove the gear case, arbor and cutter. Be
careful and do not move the base or swivel.
5. Remove all metal particles and dirt from the
counterbore. Position the valve seat insert in
the counterbore. Make sure the chamber on
the insert is against the cylinder head.
6. lnstall the driver adapter and valve seat driver
through the swivel. Hit the valve seat driver
Fig. 2-9. Align The Tool With The Valve Seat. with a heavy hammer to install the valve seat
insert into the counterbore. Make sure the
f. Make sure the alignment is correct, then, valve seat goes to the bottom of the counter
remove the driver. Use the T-handle arbor bore. Remove the adapter, driver, base and
puller and remove the arbor. swivel from the cylinder head.
g. Apply lubricating oil to the arbor and the 7. Use the ST-1122 Staking Tool Driver and the
hole in the adapter sleeve. Put the cutter in ST-1124 Staking Tool to stake the valve seat
to position over the valve o3at. lnstall the insert in the cylinder head. If the staking tool
arbor into the valve guide. lnstall the and driver is not available, you can use a
adapter sleeve on to the arbor. punch to stake the valve seat insert. Make
h. lnstall the gear case into the swivel. sure the end of the punch is round.
Engage the bottom of the drive shaft with Caution: Be careful not to damage the cylinder
the top of the cutter. Make sure the drive head when you stake the valve seat Insert.
shaft is against the cutter. Tighten the
clamp screw to hold the gear case and Repair
drive shaft in the swivel.
1. Use the following tools to grind the valve seat
i. To set the depth of the cutter insert:
1) Rotate the feed depth knob counter ST-685 Valve Seat Grinder
clockwise four or five complete turns. ST-663 Valve Guide Arbor
2) Put the new valve seat insert insert
under the knob. 2. Check the width of the valve seat. The valve
seat must be a minimum of 0.063 inch [1.59
3) Turn the feed depth knob clockwise
mm] (1), Fig. 2-10 to a maximum of 0.125 inch
until it is against the valve seat insert.
[3.18 mm] (2).
Turn the knob coiunterclockwise until
there is 0.006 to 0.010 inch [0.15 to 0.25 3. Grind the valve seat:
mm] clearance between the knob and a. lnstall the valve guide arbor into the valve
the insert. guide. Turn the arbor to make sure it is in
j. Turn the feed engaging knob clockwise to stalled correctly.
engage the feed mechanism. Attach the b. lnstall the eccentrimeter gauge on the
chuck of a 1/2 inch electric drill to the arbor. Check the alignment of the valve
drive shank. seat with the valve guide. The valve seat
k. Start the drill and cut the counterbore until must not be out of alignment more than
the feed depth knob is against the gear 0.002 inch [0.05 mm] per 360 degrees.
case. Let the cutter turn two or three more Remove the gauge from the arbor.
2-7
c. Install the grinder wheel on to the drive unit.

Make sure the grinder wheel is the correct
size and has the correct grinding angle.
d. Install the grinder unit on to the arbor. Be
careful and do not let the grinder wheel hit
against the valve seat insert. The grinder
wheel must not be against the insert when
you start the motor of the drive unit.
e. Hold the drive unit in a vertical position
when you grind the insert. Touch the
grinder wheel against the insert by using a
minimum of force against the insert. Use
an up and down movement to grind the in 1 . Minimum Seat Width 0.063 inch [ 1 .59 mm]
2. Maximum Seat Width 0.125 inch [3.18 mm]
sert. Move the grinder 1/2 inch [13.7 mm]
in a vertical direction.
Fig. 2-10 (N10228). Cross-Section Of The Valve Seat Insert.
f. lf the area (2), Fig. 2-10, is wider than 0.125
inch [3.18 mm], use a grinder wheel that
has a 15 degree grinding angle to make
the width narrower. Do not grind into the
chamfer on the valve seat insert.
Caution: Grinder wheels are easily damaged. If
you drop a grinder wheel or hit It, check for
damage before you grind the insert
g. Remove the grinder unit from the arbor.
h. lnstall the eccentrimeter gauge on the
arbor. Check the alignment of the valve
seat insert.
4. After you grind the valve seats, clean the
cylinder head with a cleaning solvent. Make
sure that all abrasive material is removed from
the inside diameter of the valve guides. Use a Fig. 2-11 (N10212). Measure The Bore Of The Valve Guide.
1/2 inch diameter bristle brush to clean the
valve guide inside diameter. No. 3375282 Valve Guide Mandrel to install the
new valve guides.
The Valve Guides
2. lf the bore for the valve guide is damaged:
Inspection
a. Use the Part No. ST- 11 88 Reamer to cut
1. Check the inside diameter of the valve guide. the bore to measure 0.760 to 0.761 inch
Replace the guide if the bore is worn larger [19.30 to 19.33 mm] inside diameter. Make
than 0.455 inch [11.56 mm]. sure the reamer cuts the entire bore.
2. Use a bore gauge (1), Fig. 2-11 to check the Remove all sharp edges.
bore at four points spaced 90 degrees apart to b. Use the 3375282 Mandrel to install the
find if the bore is out-of-round. Check the full oversize valve guide, Part No. 3006457, in
length of the bore. to the cylinder head.
3. Check the valve guides for damage. NOTE: lf the damage to the valve guide bore is not
removed by using the ST-1188 Reamer, use the
Replacement Part No. ST-1187 Reamer to cut the bore to the
-nove the worn valve guides. Use the Part next largest size. Repeat Steps a and b to cut the
Cylinder Head
bore to measure 0.765 to 0.766 inch [19.43 to 19.46

mm], install the Part No. 3006458 valve guide. You
can ream the hole in the valve spring guides to
measure 0.768 to 0.775 inch [19.51 to 19.63 mm] so
the spring guides will fit the oversize valve guides.
3. lf you do not have the 3375282 Mandrel, use a
press to install the valve guide. Make sure the
height of the valve guide is 1.270 to 1.280 inch
[32.26 to 32.51 mm] after it is installed.
4. Use a new valve to check the inside diameter
of the guide. lnsert the valve into the guide.
The valve stem must move freely.
5. lf the valve does not move freely in the guide,
use the Part No. ST-646 Valve Guide Reamer to
ream the guide.
6. To ream the valve guide:
a. lnstall the reamer in a drill press that has a
floating tool holder.
b. Apply lubricating oil to the reamer while
the guide is being reamed.
c. Do not ream the inside diameter of the
guide larger than 0.4532 inch [11.511 mm].
Valves
Inspection
Visual lnspection
1. Clean the valves and polish them with a
crocus cloth. lf you clean the valves with glass
beads, do not let the beads hit the valve stem.
2. Check the valve head for damage. Use the Part
Fig. 2-13 (V40237). Measure The Outside Diameter Of The
No. 3375933 Valve Head Checking Tool to Valve Stem.
measure the thickness of the valve head rim
(A), Fig. 2-12. The rim must measure a 2. Valves that have two different metals can be
minimum of 0.105 inch [2.67 mm]. inspected by a magnetic method. At the point
3. Measure the outside diameter of the valve where the metals are welded, there will be a
stem, Fig. 2-13. Discard the valve if the stem is magnetic leakage. The leakage will show as a
damaged or, measures less than 0.449 inch wide pattern of magnetic particles. Magnetize
[11.44 mm]. the valves in a coil at 100 to 200 amperes,
then, inspect with residual magnaglo. A crack
4. Check the grooves in the valve stem for wear.
The valve spring collet must fit tightly in the at, or near, the weld will show as a bright line.
grooves. Discard the valve if the grooves are 3. Valves with only one type of metal must be
worn enough that the collet is loose. magnetized and inspected in two directions.
Magnetize the valves in a coil at 100 to 300
Magnetic lnspection amperes, then, inspect with residual
1. Make sure all grease and deposits are cleaned magnaglo. This will cause any defects to
from the valves. Use solvent or a cleaning show around the circumference of the valve.
machine that uses vapor to remove grease. Magnetize the valves again with a headshot at
2-9
500 to 700 amperes, then, inspect with residual face where the indicator shows the
magnaglo. This will cause any defects to show highest reading.
along the length of the valve.
d. Remove the vaive from the chuck. Turn the
4. The magnetic indications must be as follows: valve 180 degrees from the original posi
tion in the chuck. Put the valve in the
a. For area (1), Fig. 2-14 no indication longer
chuck and tighten the chuck.
than 1/2 inch [12.70 mm]. Also, no more
than 5 indications, or, indications spaced e. Repeat Steps (b) and (c). If the highest in
closer than 1/8 inch [3.18 mm]. dicator reading is the same and in the
same location of the face when the valve
b. The remaining areas (2, 3, 4 and 5) must
is positioned as in Steps (a) and (d), the
not have any magnetic indication or vis
valve is distorted. If the highest readings
ible indication.
are at different locations on the valve face
Note: "Visible" means that after you remove the in Steps (a) and (d), the chuck is not in
magnetic particle suspension, you can still see an alignment. The indicator must not show
indication while looking through a 3 power magni more than 0.001 inch [0.02 mm] difference
fying glass. around the circumference of the valve
face.
5. Remove the magnetism from the acceptable
Use the valve facing machine to grind the
valve face. Make sure the coolant will spray on
the valve head, not on the grinding wheel.
Grind the valve face to an angle exactly 30
degrees from the horizontal position of the
valve.
Check the thickness of the valve head rim,
Fig. 2-12, to be sure that the rim thickness is
not less than 0.124 inch [3.15 mm]. Do not
repair any valve with cracks or other damage
or any valve whose rim thickness is less than
0.124 inch [3.15 mm].
Make sure the valve face has the correct con
tact against the valve seat. Put marks on the
valve face as shown In Fig. 2-15. lnstall the
Fig. 2-14 (N10269). Areas Of Magnetic lndication.
Repair
Use the 3376256 or ST-684 Valve Facing Machine
to grind the fabe of the valve.
1. Check the setting on the facing machine by
using a new vaive and an indicator gauge.
a. Put the valve in the chuck of the machine.
Tighten the chuck on the guide area of the
valve stem.
b. Position the tip of the indicator against
the valve face.
c. Turn the valve. Put a mark on the valve Fig. 2-15 (N20217). Put
0
Cylinder Head
valve in the valve guide. Hold the valve against

the valve seat and rotate the valve at least 10
degrees. The correct contact against the seat
will cause the marks on the valve face to be
broken. lf the marks are not broken, check the
adjustment of the facing machine and the
condition of the grinding wheel.
5. Valves and valve seats that are correctly
machined do not require the use of lapping
compound to make an air-tight seal. lf the
Valve Seating Test shows leakage, you can
use a small amount of lapping compound on
the valve and seat to make an air-tight seal.
6. The correct conditions of the valve and valve
seat are: Fig. 2-16 (V10214). Test The Valve Spring.
a. No marks or scratches on the valve face or
valve seat. Table 2: Valve Spring Data — Inch [mm] lb. [N]
b. No marks or scratches ln the valve guide. Approximate Working Force To Compress
Part No. Free Length Length Minimum Maximum
c. The angle of the valve face must be
exactly 30 degrees. 178869 2.920 1.765 155 189
[74.17] [44.83] [689] [841]
d. Valve guide to valve stem clearance must 211999 [68.20]
2.685 [43.79]
1.724 147.25
[655] 162.75
[724]
be a minimum of 0.0022 inch [0.056 mm].
Replacement Replacement
Replace any valves which have any cracks or Replace any springs which do not meet the
damage or which do not have a rim thickness of at specifications ln Table 2.
least 0.124 inch [3.15 mm].
The Crosshead Guides
The Valve Springs Inspection
Inspection 1. Use micrometers to measure the outside
diameter of the crosshead guide. The
Weak valve springs can cause wear and damage
diameter must not be worn smaller than 0.432
to the valve and valve seat. Weak springs can also
change the valve timing and cause the valve to hit inch [10.97 mm].
the top of the piston. 2. Make sure the guide ls straight. The guide
must be at a right angle to the surface of the
1. Use the Part No. 33751b2 valve spring tester to cylinder head. Replace any guide that ls not
test the valve spring, Fig. 2-16. Compress the straight.
spring to the "working length" given ln Table
2. Check the amount of force required to com To Replace Crosshead Guides
press the spring, if not within the limits given
in Table 2, discard the spring. 1. Use the ST-1134 Dowel Puller to remove the
worn crosshead guides.
2. Use spacers under the valve spring when the
2. Use the ST-633 Crosshead Guide Spacer to in
valve and valve seat have had a total of 0.030
stall the crosshead guide.
Inch [0.76 mm] material removed. Do not use
more than two, Part No. 68803-A Spacers 3. If you do not have the guide spacer, use a
under a valve spring. press to install the crosshead guide. Make
2-11
sure the height of the guide is 1.860 to 1.880 Replacement

lnch [47.24 to 47.75 mm] after It is installed.
1. Replace the crosshead if the bore is worn
4. lf the bore for the crosshead guide is larger than 0.440 inch [11.18 mm].
2. Replace the crosshead if the bore is out-of-
a. Use a 29/64 inch drill to cut the guide bore. round or, if there is damage to the threads in
Cut the oversize bore to the same depth as the crosshead.
the original bore.
b. Use a 15/32 reamer to ream the bore.
Apply lubricating oil to the reamer as the
bore is being reamed. The surface of the cylinder head around the water
c. lnstall the crosshead guide, Part No. holes must not have any scratches, cracks or cor
161527, as in Step 2. rosion deeper than 0.003 inch [0.08 mm]. There
must not be any defect which extends more than
3/32 inch [2.38 mm] from the edge of the water
hole.
Repair
1. Use a magnetic method to check the
crossheads for cracks. To repair the water holes, use the following tools
from the Part No. ST-1010 Water Hole Counter-
2. Check the inside diameter of the bore, Fig. boring Tool Kit.
2-17. Replace the crosshead if the bore is worn ST-1010-1 Bushing Plate
larger than 0.440 inch [11.18 mm]. ST-1010-2 Adapter Screw
3. Use a bore gauge to check the bore at four ST-1010-3
points spaced 90 degress apart to find if the ST-1010-5 Counterbore Cutter
bore is out-of-round. ST-1010-8 Drive Adapter
ST-1010-1 3 Locating Pin
4. Inspect the rocker lever contact surface (1), ST-1010-19 Allen Wrench
Fig. 2-17 and the valve stem contact surface ST-1010-20 Gauge Block
(2) for wear. Check the adjusting screw and
threads in the crosshead (4) for wear or 1. Adjust the depth of the counterbore cutter.
damage. a. Put the bushing plate on a flat surface
with the side of the plate marked "Top"
away from the surface.
b. lnstall the counterbore cutter in the 5/8
inch [15.8 mm] bushing. Make sure the
cutter is against the flat surface.
c. Slide the stop collar up on the counterbore
cutter.
d. Put the gauge block on top of the bushing
plate. Hold the curve at the plate against
the cutter.
e. Slide the stop collar down against the
1. Rocker Lever Contact Area
2. Valve Stem Contact Area gauge block, Fig. 2-18. Tighten the set-
3 Crosshead Bore , screw in the stop collar.
4. Adjusting Screw Threads ■ (i)
f. Remove the cutter and gauge block from
Fig. 2-17 (N10299). Check The Crosshead For Wear. the bushing plate.
Cylinder Head
Fig. 2-18. Set The Depth Of The Cutter Fig, 2-20. Cut The Water Hole.
2. Put the bushing plate on the cylinder head 8. Engage the drill adapter with the counterbore
with the side of the plate marked "Top" away cutter, Fig. 2-20.
from the cylinder head.
9. Start the drill. Apply minimum downward
3. Fasten the bushing plate to the cylinder head.
force while cutting the hole.
lnsert the adapter screw through an injector
hole and through the bushing plate. lnstall the 10. Remove the counterbore cutter and bushing
adapter knob on the end of the adapter screw. plate from the cylinder head.
4. Insert the locating pin through the 5/8 inch
11. To install the Part No. 191078 water passage
bushing and into the water hole to be repaired.
sleeve:
Use your hand to tighten the adapter knob to
approximately 50 ft.-lbs. [68 N»m], Fig. 2-19. a. Make sure the hole is clean and all metal
5. Remove the locating pin. particles and sharp edges are removed.
6. lnstall the counterbore cutter in the bushing. b. Slide the sleeve into the end of the
bushing driver.
7. lnstall the drive adapter in an electric drill.
c. Apply a coat of sealant to the sleeve.
d. Align the sleeve with the water hole. Hit
the bushing driver with a hammer to install
the sleeve into the water hole.
e. Cut the sleeve so that it is even with the
surface at the cylinder head. Use a flat,
wide mill file to cut the sleeve. Be careful
and do not damage the surface of the
cylinder head when you cut the sleeve.
12. You can use copper tubing if the 191078
sleeve is not available. The tubing must have a
heavy wall and the outside diameter must be
0.002 to 0.005 inch [0.05 to 0.13 mm] larger
than the diameter of the hole. The length must
be 0.50 inch [12.7 mm] and the inside diameter
Fig. 2-19. Align The Bushing With The Water Hole. must be 0.437 inch [11.11 mm].
2-1?
lnstall the driver on the tool. The driver must

be against the large hexagon nut. Hit the
driver with a large hammer to push the form
Discard the injector sleeve if it leaked during the ing collar into the injector sleeve. Remove the
air or water pressure test. Check the sleeve for driver.
scratches or other damage.
Tighten the small hexagon nut to 50 ft.-lbs. [68
N»m] torque. Make sure you do not tighten the
Replacement
nut more than 60 ft.-lbs. [81 N»m] torque.
Replace any sleeve which leaks or has damage.
Turn the large nut clockwise to pull the injec
Use the following tools from the ST-1244 Injector
tor sleeve from the cylinder head. You can use
Sleeve Puller to remove the injector sleeve from
an impact wrench to turn the nut.
the cylinder head:
ST-1 244-1 Support Bridge 6. Remove the sleeve from the tool. Loosen the
3375616 Rod large and small nuts. Hit the small end of the
ST-1 244-3 Hexagon Nut (9/l6"-l2) sleeve lightly to loosen it from the tool. Turn
ST-1 244-4 Hexagon Nut (1 "-8) the sleeve 120 degrees and slide it from the
ST-1 244-5 Thrust Washer tool.
3375614 Forming Collar Make sure the bead in the bottom of the injec
ST-1244-7 Extractor Tip tor bore is smooth. Use the Part No. ST-788
ST-1 244-8 Driver Bead Cutting Tool with the Part No. ST-884-1
3375615 Collar and ST-884-6 Holder and Pilot to cut the bead
ST-1 247 Socket in the bore.
Caution: Do not use those tools to remove over-
Apply a coat of clean lubricating oil to a new

To Remove the Injector Sleeve injector sleeve O-ring. lnstall the O-ring into
1. Assemble the tools. Do not tighten the hex the groove in the bore for the sleeve, Fig. 2-22.
agon nuts. Use the ST-1227 Injector Sleeve Driver to push
2. Install the tool in to the sleeve so that the legs the sleeve into the bore. Do not hit the driver
of the bridge are against the surface of the with a hammer. Remove the driver from the
cylinder head; Fig. 2-21 sleeve.
2-21. lnstall The Tool Into The Cylinder Head. Fig. 2-22 (V40244). The O-RIng
Cylinder Head
the sleeve. Tighten the capscrews to 10 to 12

3. lnstall the ST-1179 lnjector Sleeve Holding ft.lbs. [14 to 16 N»m] torque.
Tool into the sleeve. Tighten the capscrew to
35 to 40 ft. lbs. [47 to 54 N»m] torque. 2. Remove the injector and check the pattern of
the blue compound in the sleeve. The pattern
4. lnstall the driver in the sleeve. Hit the driver
in the sleeve must be a minimum of 0.060 inch
two times with a hammer to make sure the
[1 .52 mm] wide and 0.469 inch [1 1 .91 mm] from
sleeve is against the bottom of the bore.
Remove the driver and tighten the holding tool the bottom surface of the cylinder head, Fig.
capscrew again to 35 to 40 ft.-lbs. [47 to 54 2-23. If the sleeve does not meet those specifi
cations, it must be replaced.
IM»m].
5. Use the ST-880 Injector Sleeve Expander to ex 3. Install the injector assembly into the sleeve.
pand the upper section of the sleeve to cause Tighten the capscrews to 10 to 12 ft.-lbs. [14 to
a seal between the sleeve and the cylinder 16 N»m] torque. Use the Part No. ST-547 Gauge
head. lnstall the expander into the sleeve. Use Block to measure the protrusion of the injector
an inch-pound torque wrench to turn the man tip, Fig. 2-24. The protrusion of the tip must
drel of the expander. Turn the mandrel until measure 0.060 to 0.070 inch [1.52 to 1.78 mm].
the torque wrench shows 75 in.-lbs. [8.5 N»m]
torque.
Caution: fie careful whan you expand the sleeve,
do not damage the sleeve and O ring. /
6. Remove the expander and the holding tool / * Injector
from the sleeve. ' > Sleeve
/
7. Use the ST-884 Injector Seat Cutter to cut the /
injector seat in the sleeve. Install the lnjector
in the cylinder head, tighten the capscrews to > Seating '
10 to 12 ft.-lbs. [14 to 16 N»m] torque. Then, Area '
0.060
use the ST-547 to measure the protrusion of Min. ^
the injector tip to find the amount to cut from _L
the sleeve. The protrusion of the injector tip 15/32 inch
must be 0.060 to 0.070 inch [1.52 to 1.78 mm].
Remove the injector. f Head Surface
8. Install the ST-884 Cutter and pilot in a drill Fig. 2-23 (N10298). Cross-Section Of The lnjector Sleeve.
press. Cut the seat for the lnjector. Be sure to
use enough cutting oil while cutting the seat.
The seat must have a smooth surface.
9. Apply Prussian blue compound to the inside of
the sleeve at the area of the injector seat. When
the injector is installed, the compound must
show completely around the lnjector and must
be a minimum width of 0.060 inch [1.52 mm].
10. Use the water test method to test the cylinder
head for leaks.
Protrusion of the Injector Tip

Check the injector sleeve to make sure the protru
sion of the injector tip and the seating pattern is
correct.
1. Apply a light coat of blue compound to the in
jector cup. lnstall the injector assembly Into Fig. 2-24 (N 10206). Measure The Protrusion Of The lnjector Tip.
2-15
NT/NTA 855 C.l.D. Engine Shop Manual
Table 3: Pipe Plug Torque — ft.lbs. [N»m]

Plug Size Minimum Maximum
Inch Torque Torque
1/16 3 [4] 6 [8]
1/8 5 [7] 10 [14]
3/8 35 [47] 45 [61]
1/2 60 [81] 70 [95]
3/4 65 [88] 75 [102]
1 135 [182] 145 [197]
Table 4: Cylinder Head Expansion Plug Driver

Driver
Part No Plug Size — Inch
3375190 3/4
3375191 1 Fig. 2-25 (N102109). Cross-Section Of Cup I
3375192 1-1/4 Cylinder Head.
Assembly and Testing 6. Install the lower guides for the valve springs
over the valve guides.
Caution: Make sun you use the correct valve
1. Install the pipe plugs, fuel inlet and fuel drain spring and valve spring guide. See the Parts Cata
fittings into the fuel passages. Make sure the log for the correct part numbers.
fittings and plugs are installed in the same
location as their original location. Apply 7. Valve guide seals for the intake valves are not
teflon tape or liquid lead compound to the installed on new engines. You can install valve
threads. Tighten the pipe plugs to the torque guide seals, but, do not install a seal instead
valve given in Table 3. of replacing the valve guide.
2. Apply a coat of 3375068 Expansion Plug 8. lnstall the valve spring, spring seat and, if
Sealant to the outside diameter of the expan required, spring spacer. lnstall the upper valve
sion plug. Apply a coat of the sealant to the spring guide. Compress the valve springs and
inside diameter at the water hole. install the valve spring collets. Always use
new valve spring collets.
3. Use the correct expansion plug driver listed in
Table 4 to install the expansion plug. 9. Cylinder heads that have two valve springs for
each exhaust valve require:
Note: If you do not have expansion plug drivers
you can use a mandrel of the correct size to install a. A heavy-duty spring guide at the top of the
the plug. lnstall the plug so it will be even with to springs.
0.090 inch [2.29 mm] below the chamfer, Fig. 2-25. b. Two spring wear plates at the bottom of
Do not push the plug to the bottom of the counter the springs.
bore.
c. See the Parts Catalog for the correct part
4. Make sure the vent hole is open in the cylinder numbers.
head for naturally aspirated engines. The vent
hole is located above the air intake port on top
The Valve Seating Test
of the cylinder head. Cylinder heads for turbo-
charged engines do not have vent holes. Use the ST-1257 Valve Vacuum Tester to check the
seal between the valve and the valve seat.
5. Apply clean lubricating oil to the valve stem.
lnstall the valves into the valve guides. Put the Caution: Never vacuum test a cylinder head with
cylinder head on a wood surface to prevent the Injectors installed. Installing the injectors can
damage to the surface of the cylinder head. cause the valves to be out of alignment and will
Cylinder Head
6. Check the time for the gauge to indicate a

decrease in vacuum.
a. Start timing when the gauge indicates
"18".
b. Stop timing when the gauge indicates "8".
The total amount of time must not be less
than 10 seconds.
7. lf the total time for the vacuum to decrease

from "18" to "8" is less than 10 seconds:
a. Make sure the valves and valve seats are
clean.
b. Lightly hit the valve stem with a soft
Fig. 2-26 (N10297). Vacuum Test The Valves. hammer.
c. Check the connections on the vacuum
show leakage during the vacuum test When the tester for leaks. Start the pump and hold
cylinder head Is Installed to the cylinder block the cup against a smooth surface. The
Installing the Injectors will not cause the valves to gauge must not show a decrease in
be out ot alignment. vacuum, a decrease indicates a loose or
1. Make sure the valve and valve seats ar clean leaking connection.
and dry. d. Check for leaks between the valve seat
2. Put the vacuum cup over the valve, Fig. 2-26. insert and counterbore. Apply a coat of
The O-ring in the cup must make a seal on the grease to the outside diameter of the
cylinder head around the valve. insert to make a grease seal between the
insert and counterbore. Vacuum test and
3. Turn the shutoff valve to the open position.
inspect the grease seal. A break in the
Hold down on the push button to operate the
seal indicates a leak between the insert
vacuum pump.
and counterbore. Stake the valve seat
4. Operate the vacuum pump until the vacuum insert and vacuum test for leaks.
gauge indicates between 18 to 25 inch-hg [457
to 635 mm hg]. e. Grind the valve face and/or the valve seat
insert.
5. Turn the shutoff valve to the closed position.
Release the push button to stop the vacuum 8. Always clean the cylinder head after any
pump. grinding or cutting operation.
2-17
Table 2-1: Specifications — Inch [mm] (Reference Fig. 2-1)

Rel. Worn New New
No. Measurement Limit Minimum Maximum
1. Cylinder Haad
Height 4.340 4.370 4.380
[110.24] [111.00] [111.25]
Outside 0.449 0.450 0.451

[11.41] [11.43] [11.48J
Angle 30 degree 30 degree
Valve Guide
lnside Diameter 0.455 0.4525 0.4532
[11.56] [11.494] [11.511]
1.270 1.280
132.26] [32.51]
Outside 2.0025 2.0035

[50.864] [50.889]
Cylinder Head
Inside Diameter 1.9995 2.0005
[50.787] [50.813]
0.278 0.282
[7.06] [7.16]
Run Out in 360 0.002
[0.05]
Refaced Seat Width 0.063 0.125
[1.59] {3.18]
Valve Spring**
Assembled Height 2.250
[57.15]
Croeahead Guide
[10.97] [11.BO] [11.011]
Assembled Height 1.860 1.880
[47.24] [47.75]
0.440 0.434 0.436
[11.18] [11.02] [11.07]
Tip Protrusion 0.060 0.070

[1.52] [1.78]
*See Ref. No. 8 for oversize valve it inserts.

"See Ref. No. 9 for valve spring
Cylinder Head
Table 2-1: Specifications — inch [mm] (Reference Fig. 2-1) (Cont'd.)

Ref. Valve Seat lnsert Oversize Oversize lnsert Cylinder Head lnsert
No. Part No. Diameter Depth O.D. l.D. Thickness
8. 127935 0.005 Std. 2.0075/2.0085 2.0045/2.0055 0.278/0.282
[0.13] [50.991/51.016] [50.914/50.940] [7.06/7.16]
127931 0.010 Std. 2.0125/2.0135 2.0095/2.0105 0.278/0.282
[0.25] [51.118/51.143] [51.041/51.067] [7.06/7.16]
127932 0.020 0.005 2.0225/2.0235 2.0195/2.0205 0.283/0.287
[0.50] [0.13] [51.372/51.397] [51.295/51.321] [7.19/7.29]
127933 0.030 0.010 2.0325/2.0335 2.0295/2.0305 0.288/0.292
[0.76] [0.25] [51.626/51.651] [51.549/51.575] [7.32/7.42]
127934 0.040 0.015 2.0425/2.0435 2.0395/2.0405 0.293/0.297
[1.02] [0.38] [51.880/51.905] [51.803/51.829] [7.44/7.54]
Be sure to measure the Insert before machining the head or Installing the Insert.
Required Load for Length
Valve Approximate Wire Lb. [N] Lb. [N] Lb. [N]
Ref. Spring Free Length No. Diameter Length Worn New New
No. Part No. Inch [mm] Colls Inch [mm] Inch [mm] Limit Minimum Maximum
9. 178869 2.920 9.5 0.177 1.765 150 155 189
[74.17] [4.50] [44.83] [667] [689] [841]
211999 2.685 9 0.177 1.724 143 147.25 162.75
[68.20] [4.50] [43.79] [636] [655] [724]
Cylinder Head Pip>e Plug Torque — Ft.-Lbai. [N»m]
Ref.
No. Plug Size Minimum Maximum
10. 1/16 lnch 3 [4] 6 [8]
1/8 lnch 5 [7] 10 [14]
3/8 lnch 35 [47] 45 [61]
1/2 lnch 60 [81] 70 [95]
3/4 lnch 65 [88] 75 [102]
1 lnch 135 [182] 145 [197]
2-19/(2-20 Blank)
Rocker Levers
_ _ This section includes the inspection, repair and

GrOlip 3 assembly of: rocker levers, rocker lever shafts,
rocker lever covers, rocker lever housings and
crankcase breather.
Rocker Levers
1. Bushing 5. lnjector Lever 9. Shaft Plug O-Ring

2. Shaft 6. Exhaust Lever 10. Rocker Lever Housing
3. Adjusting Screw 7. lnjector Lever Socket 11. Shaft Setscrew
4. lntake Lever 8. Housing and Shaft Plug 12. Adjusting Screw Locknut
Fig. 3-1, (N10329). Rocker Lever Shaft And Housing.

Service Tool List

Service Tool Tool
Number Name
ST-257 Valve Seat lnsert Tool
ST-691 Mandrel and Block
ST-863 Mandrel
ST-1053 Driver
ST-1182 Alignment Tool (80 degree tilt engine)
Standard Tools — Obtain Locally

Small Bore Gauge
Micrometers
Radius Gauge(1 (1/4
to 2lnch
inch)[6.35 mm])
Fig. 3-2 (N10318-A). The Breather Vent Hole.
Rocker Levers and Housing 3. lf the housing has a breather vent hole (1,Fig.
3-2), make sure it is free of dirt or other
deposits.
1. Mark each lever for the position it is in as
4. Check rocker lever shaft bore of housing in
removed. Remove the adjusting screws and
side diameter. The dimensions must be 1.1238
nuts from all the levers.
to 1.1246 inch [28.545 to 28.565 mm]. lf the
2. Remove the setscrew or the spray nozzle and shaft bore does not meet these dimensions,
jam nut which holds the shaft in the housing discard the housing. See the Parts Catalog for
(80 degree tilt engine). the correct part number.
3. Use a flat or drift punch to push the shaft Rocker Levers

through the housing. Be careful and do not
damage the bore in the housing. Cleaning
4. Remove the O-rings from the solid plugs and Clean the levers thoroughly and dry with com
discard them. The solid plugs can be removed pressed air.
from the shaft by putting the plug in a vise and
then moving the shaft. Discard the plugs. Inspection
1. Use magnetic inspection to check the sur
Cleaning face. Use coil magnetization with amperage at
300 to 500 with residual Magnaglo. See Fig.
Clean the bore ln the shaft with a bottle brush. 3-3 for most likely areas of damage. Demagne
tize after checking.
Inspection
2. Use a 1/4 inch radius gauge to check the bail
1. Visually inspect all the capscrew holes for end of rocker lever adjusting screw, Fig. 3-4.
damaged threads. lnspect all the levers, hous Replace the screw if the ball end is out of
ings and covers for damage. round or flat at the bottom. Check the thread
condition on all screws and in the levers.
2. lnspect the opening of the shaft bore for sharp
Check carefully for threaded distortion at the
edges or other change. The opening of the
assembly position of the locknut. Screws
bore should have a slight radius. Use 240 grit
must move freely through the levers.
aluminum oxide paper over a split rod, which
is rotating in an electric drill to remove sharp 3. inspect the sockets of the injector rocker lever
edges. for damage. Apply a bluing compound with
Rocker Levers
0.500 inch [12.70 mm] diameter gauge ball or a

new injector link. The blue pattern must coat
at least 80 percent of the socket.
4. Check the rocker lever bushings for damage.
Check the rocker lever bushing inside
diameter with inside micrometers or a small
bore gauge. lt must not exceed 1.1286 inches
[28.664 mm], Fig. 3-5.
Repair
1. Replace sockets with unacceptable blue pat
terns. Drill a small hole in the lever above the
socket and push the worn socket out. Stake
the plug in the hole and replace the socket.
Fig. 3-3 (V40305). Areas To Check For Cracks. 2. Replace the bushings whose inside diameter
were more than 1.1286 inches [28.664 mm].
Use the ST-691 Mandrel and Block to remove
the bushing. See the Parts Catalog for the cur
rent replacement bushing part numbers.
3. lnstall the new bushing with the mandrel and
an arbor press. Fig. 3-6.
a. On injector and exhaust valve levers, in
stall the bushings so that the oil holes to
the crosshead nose or the injector link and
adjusting screw are open for oil flow.
b. On intake valve levers with the oil hole to
the end with the crosshead nose, install
the bushing so that the hole is closed.
Also the bushing "slot hole" must be in
line with the oil hole to the adjusting
Fig. 3-4 (N20305). Check The Ball End Of The Adjusting Screw. screw. Do not cut a bore in steel bushings.
Fig. 3-5 (V40306). Measure The lnside Diameter Of The Rocker

Lever Bushing. Fig. 3-6 (N20306). Install The Bushing lnto The Rocker Lever.
3-3
b. lnstall the intake (4), injector (5), and

exhaust (6).
1. Check the surfaces of intake and exhaust
rocker levers which are in contact with the 4. Push the shaft until 1/2 inch extends from the
crosshead. Replace them if they are worn or housing. lnstall a lightly oiled O-ring in the
damaged. groove in the shaft assembly.
2. Check the rocker lever shaft for wear or 5. Push the shaft until other end extends from
damage. lf the shaft has ridges due to the the housing and install the second O-ring.
action of rocker lever on the shaft, replace the
shaft. See Table 3-1 (2) for shaft dimensions. 6. Align the shaft and the housing locking hole
Clean the shaft bore and dry thoroughly. by squeezing two rocker levers together to
rotate the shaft. Secure the shaft with
setscrew or oil spray nozzle. Check the levers
Assembly
for free movement.
Note: Solid plugs can be used in any rocker lever
housing and must be used in all aluminum hous Note: The 80 degree tilt engines use oil spray
ings. The use of solid plugs to replace cup plug nozzles instead of setscrews in the rocker lever
seals requires no changes to the shaft or housing. housings. The nozzles direct an oil spray to the
ends of the rocker levers as shown in Fig. 3-8.
1. Install the new plugs in the shaft until plug
reaches bottom. Use the arbor press to push Follow these instructions to install the nozzles.
in both plugs at the same time.
1. lnstall the jam nut onto the nozzle.
2. lnstall the adjusting screws and locknuts in
the rocker levers. 2. Install the nozzle and jam nut into the hous
ing. Tighten the nozzle until it stops. Then
3. Start the shaft into the housing and install the loosen the nozzle so that the spray holes are
levers as the shaft is pushed through. See Fig. aligned with the ends of the rocker levers (the
3-7 for correct position of levers. Make sure ends opposite the adjusting screws).
that you install the shaft correctly. The set-
screw hole must be to the top and the seven 3. lnstall the Part No. ST-1182 Spray Nozzle
oil holes must be toward the flat side of the Locator so that the tube part of the tool is on
housing. the breather vent plug and the blade of the
tool is in the slot in the spray nozzle, Fig. 3-8.
a. lnstall the exhaust (1), injector (-2), and
intake (3) levers. 4. Tighten the jam nut.
9 9 9
3-7 (N10326). The Rocker Lever Assembly. Fig. 3-8. Use The ST-1182 To Adjust The Spray Nozzles.
Rocker Levers
Crankcase Breather Rocker Housing Cover

Disassembly There are two types of rocker lever housing
covers: plain and breather type.
Remove the cover, screens and baffle or element
from breather body. Discard the paper element.
Inspection
Cleaning Remove all the gasket material from the sealing
edge of cover. lnspect the cover for damage.
Clean the vent tube, screens and baffle foam, or
lnspect the cover for cracks around all capscrew
the mesh element in an approved cleaning sol
holes and breather port area.
vent. Clean the breather housing.
Replacement
Replacement
1. Replace any unacceptable gaskets.
1. Replace the paper or foam element.
2. Replace the cover if it is damaged.
2. Replace the gasket.
Note: Current engines which use a rocker lever Assembly
cover that has a baffle plate do not have a baffle
lf a breather cover is used, press in the breather
or screens in the crankcase breather body. neck. lnstall the new or reconditioned breather
body. Make sure the breather is pressed in
Assembly
straight. After the installation of breather body or
Assemble the baffle, screens or element and a breather neck, check carefully for cracks around
new gasket in the body. lnstall the cover. the press fit area.
Table 3-1: Specifications — inch [mm] (Reference Fig. 3-1)

2 Inch Cam Engines 2-1/2 Inch Cam Englnes
1. Bushings 1.1286 1.1245 1.1275 1.1286 1.1245 1.1275
lnside Diameter [28.664] [28.562] [28.639] [28.664] [28.562] [28.639]
2. Shaft 1.122 1.123 1.124 1.122 1.123 1.124

3-5/(3-6 Blank)
{
Cam Followers
This section includes the inspection, repair and

Group 4 assembly of: cam follower, mechanical variable
timing (MVT) mechanism, and push rods.
Cam Followers
Cam Followers
2 " Cam
Although the cam followers and push rods are of

different size, both assemblies are disassembled,
Big Cam inspected and assembled in like manner. Refer to
Fig. 4-1, (N10420). Cam followers comparison. Table 4-1 for dimensions.
Push Rods
2 " Cam
Big Cam
Fig. 4-2, (N10421). Push Rods comparison.
4-1
1. Shaft 5. Valve Cam

2. Bushing 6. Housing
3. Injector Cam Roller 7. Shaft Plug
4. Valve Cam Roller &
Service Tool List

To repair the cam follower assembly and the MVT
mechanism according to the inspections given in 1. Remove the gaskets from the housing.
this section, the following service tools or tools of
equal quality are required. 2. Remove the lockscrews that hold th
the housing, Fig. 4-4.
Service Tools (Or Equivalent) Required 3. Remove the cup plugs from the ends of the
Service Tool Tool housing. Use a punch with a sharp point to
Number Name make a hole in the center of the plugs. Hit one
ST- 195 Plug Gauge edge of the plug to loosen it. Use pliers to
ST-249 Mandrel and Block
ST-970 Plug Driving Mandrel
ST-1053 Plug Driving Mandrel
3376021 Actuator Retainer Adjustment Tool
3376022 Solenoid Valve Seat lnstallation Tool
3376023 Solenoid Stem lnstallation Removal Tool
3376024 Sleeve and Guide lnstallation Tool
3376025 Sleeve and Guide Removal Tool
3376026 Lever Bushing Block/Mandrel Set
3376027 Cam Follower Shaft Positioning Tool
3376028 Variable Timing Fixture
3376185 Male and Female Positioning Gauge
3376186 Expansion Plug Driver
3376209 Bracket and Studs (Variable Timing)

Small Bore Gauge
Micrometer (0 to 1 lnch)
Micrometers (1 to 2 inch)
Snap Ring Pliers
Feeler Gauge Fig. 4-4 (N10401). Remove The Lockscrew From The Shaft.
4-2
Cam Followers
remove the plug. lnstall a mandrel in a press. 3. Check the bushing in the cam follower lever
Push the mandrel against the shafts in the for scratches or other damage. Use inside
housing to move the plug out of the hole in the micrometers to measure the inside diameter
opposite end of the housing. of the bushing, Fig. 4-6. The bushing mu.it
measure 0.7501 to 0.7511 inch [19.053 to
4. Remove the cam follower levers from the
19.078 mm]. Replace the bushing if it
housing.
measures more than 0.752 inch [19.10 mm].
5. Put a mark on the cam follower levers to iden
4. Use a magnetic inspection method to check
tify their location in the housing as they are
the levers for cracks. Apply coil magnetization
removed.
to the lever. Use 300 to 500 amperes with
residual magnaglo. Fig. 4-7 shows the areas of
Cleaning
the lever to check carefully for cracks.
1. Put the cam follower shafts in a container of
5. Check the cup plug holes in the housing for
mineral spirits. Use compressed air to dry the
damage or sharp edges. Use 240 grit
shafts.
aluminum oxide paper to remove any sharp
2. Clean the other parts with a cleaning solvent
and dry with compressed air.
Caution: Make sure the oil passages in the levers
are clean.
Inspection
1. Use micrometers to measure the outside
diameter of the shaft, Fig. 4-5. The shaft must
measure 0.7485 to 0.7490 inch [18.012 to 19.02
mm]. Replace the shaft if it is damaged or the
outside diameter measures less than 0.748
inch [19.00 mm].
Note: On the part of the shaft for the lockscrew,
make sure that the grooves are clean.
2. lnspect the cam follower housing for cracks or
other damage. Discard if damaged or worn. Fig. 4-6 (N10402). Measure The Cam Follower Bushing.
Fig. 4-5 (N10411). Measure The Cam Follower Shaft. Fig. 4-7 (N10410). Check These Areas For Cracks.
4-3
edges. Put the aluminum paper in a rod that 7. Remove the roll pins (5, Fig. 4-8), Roller pins
has a slot in the end to hold the paper. lnstall (4) and rollers (6) from the cam levers (2).
the rod in an electric drill. Start the drill and
push the paper through the hole. Make a 8. Inspect the rollers. Use a small bore gauge to
chamfer on the edge of the hole and remove measure the inside diameter of the rollers,
any sharp edges. Fig. 4-10. Check the rollers to be sure they are
not out-of-round. See Table 1 for the dimen
6. Check the lnsert in the cam follower lever (3, sions of the rollers. Use micrometers to
Fig. 4-8) for wear or damage. Use a new push measure the outside diameter at the roller,
rod ball or a 0.625 inch [15.88 mm] checking Fig. 4-11. The outside diameter of the roller
ball to check the insert. Apply a prussian blue must have a common center within 0.002 inch
compound to the ball. Put the ball into the in [0.05 mm].
sert in the lever and rotate the ball 180
degrees, Fig. 4-9. Replace the insert if it is 9. Use micrometers to measure the outside
damaged or has less than 80 percent contact diameter of the roller pins, Fig. 4-12. See Table
with the ball. 1 for dimensions of the roller pins.
Fig. 4-8 (N10412). Cam Follower — Exploded View. Fig. 4-10 (N10414). Measure The I.O. Of The Cam Roller.
Fig. 4-9 (N10413). Using A Push Rod To Check The Insert. Fig. 4-11 (N10415). Measure The O.D. Of The Cam Roller.
-4
Cam Followers
Table 4-1: Cam Follower Dimensions — Inch [mm]

2 Inch Cam Engines 2-1/2 Inch Cam Engines
Worn Maw
now Maw Worn MaMH
PlfW nfw
Measurement Limit Minimum Maximum Limit Minimum
Shaft 0.748 0.7485 0.749 0.748 0.7485 0.749
Bushing 0.752 0.7501 0.7511 0.752 0.7501 0.7511
lnside Diameter [19.10] [19.053] [19.078] [19.10] [19.053] [19.078]
Injector Cam Roller
lnside Diameter 0.505 0.503 0.504 0.705 0.703 0.704
[12.83] [12.78] [12.80] [17.91] [17.86] [17.88]
Outside Diameter 1.2485 1.2490 1.251 1.2485 1.2495 1.2505
[31.71] [31.72] [31.77] [31.71] [31.73] [31.76]
Valve Cam Rollers
lnside Diameter 0.503 0.5005 0.5015 0.503 0.5005 0.5015
[12.78] [12.713] [12.738] [12.78] [12.773] [12.708]
[31.71] [31.72] [31.75] [31.71] [31.73] [31.76]
Roller Pin Diameter
Valve 0.497 0.4995 0.500 0.497 0.4997 0.500
[12.62] [12.687] [12.70] [12.62] [12.692] [12.70]
lnjector 0.497 0.4995 0.500 0.697 0.6997 0.7000
[12.62] [12.687] [12.70] [17.70] [17.772] [17.780]
Diameter of the Bore
for the Roller Pin
Valve 0.4990 0.4997 0.4990 0.4995
[12.674] [12.692] [12.674] [12.687]
lnjector 0.4990 0.4997 0.6992 0.6997
[12.674] [12.692] [17.759] [17.772]
10. Measure the roller pin bore ln the cam 2. Use compressed air to clean the oil passages.
follower lever. See Table 1 for dimensions. 3. Use the ST-249 to Install a new bushing in the
11. If the rollers are damaged, be sure to Inspect
the camshaft for damage. Replace any part
that is damaged or worn beyond the limits in
Table 1.
Replacement
1. Replace the cam followers if they have any
damage or cracks.
2. Replace the cam followers if they are worn
beyond the limit.
Repair
1. Remove the bushing in the cam follower If the
Inside diameter of the bushing is more than
0.752 inch [19.10 mm]. Use the ST-249 Lever
Bushing Block and Mandrel to remove the
bushing, Fig. 4-13.
Fig. 4-13 (N10403). Remove The Bushing From The Cam

Follower.
lever. Make sure the oil hole in the bushing is

aligned with the oil hole in the lever.
4. Cut a chamfer on each end of the bushing.
Use a drill press at a slow speed and a
chamfer tool that cuts a 60 degree angle
chamfer.
5. Put soap into the oil hole in the bushing. This
will prevent metal particles from entering the
oil hole.
6. Cut the bore in the bushing to measure 0.7501
to 0.7511 inch [19.053 to 19.078 mmj.
7. Use the ST-195 Plug Gauge to check the bore.
8. Use compressed air to remove the soap from
Fig. 4-15 (N10407). Assemble The Levers And Shafts Into The
the oil holes. Wash the lever in cleaning sol Housing.
vent and dry with compressed air.
9. lf the socket insert in the lever was removed, Note: Make sure the push rod sockets in the levers
use a press to install the new insert. Make and the dowel holes in the housing are to the top
sure the insert is installed tightly. when the assembly is mounted on the engine.
Caution: If a new socket Insert Is Installed In the 3. lnstall a temporary screw ln the shaft. This
lever, a new push rod must also be used. will prevent breakage of the lockscrew when
the plug is installed in the housing.
Assembly 4. Apply a light coat of sealant to the hole
1. Hold a 0.006 lnch [0.15 mm] feeler gauge be in each end of the housing. Use the ST-1053
tween the lever and roller. lnstall the roller pin Expansion Plug Driver to install the cup plug.
through the lever and roller, Fig. 4-14. Install Install the plug so it is at least even with the
the roll pins into the lever and roller pin. edge of the hole or not more than 0.010 inch
[0.25 mm] below the edge of the hole, Fig. 4-16.
2. Assemble the levers and shafts in the hous
ing, Fig. 4-15. Make sure the lever for the lnjec 5. Remove the temporary screws and lnstall the
tor is in the center position in each assembly. lockscrews in the shafts.
5
Cam Followers
the air pressure in the vehicle air system exceeds

80 psi [Kpa], the air pressure raises the plunger.
This causes the injection timing to advance. The
air pressure will hold the plunger in the raised
position (advanced injection timing) until the
engine reaches 25 percent of rated power. When
the engine reaches approximately 25 percent of
rated power, the electrical pressure switch
causes the solenoid valve to close. With the valve
closed the air supply to the actuator is shut off.
The air pressure against the plunger becomes
less than 80 psi [5t51 Kpa] and the spring moves
the plunger down to retard the injection timing.
From 25 percent of rated power to full power the
engine runs with retarded injection timing.
Fig. 4-16 (N10409). Install The Cup Plugs Some design changes have been added to the
NTC engine with MVT. The cam follower housings
Mechanical Variable Timing (MVT) are joined together by a spline coupling between
the housings. The three housings must be in
Operating Principles stalled as an assembly. One gasket is used for all
Mechanical Variable Timing (MVT) is used to con three housings instead of a seperate gasket for
trol the emissions produced by the engine. To each housing. A special camshaft is used with
control the emissions, the MVT changes the fuel MVT. Adjustments to injection timing are made by
injection timing according to the load put on the an adjustment sleeve in the actuator instead of
engine. This is done by changing the position of adding or removing cam follower housing gaskets.
the injector cam follower levers on the camshaft. Warning: Do not try to adjust the MVT for con
The MVT actuator is an air operated cylinder that tinuous operation with the injection timing ad
controls the movement of the injector cam vanced. This will not increase the power of the
follower levers. The shaft in the actuator has a engine, but will Increase the emissions of the
rack of teeth that joins with a gear on the cam engine. Operating the engine continuously with
follower shaft. The raising and lowering of the advanced injection timing at above 25 percent of
plunger in the actuator causes the shaft and gear the rated RPM of the engine will cause high stress
to rotate the cam follower shaft. Eccentric and damage to the engine.
cylinders are mounted to the cam follower shaft.
The levers are mounted to the eccentric. The ec Disassembly
centrics and levers are held to the cam follower Center Housing
shaft by setscrews. Rotating the cam follower
shafts causes the levers to change position of the 1. Remove the housing to the left of the center
camshaft and changes the injection timing. cam follower housing.
Air flow to and from the actuator is controlled by a 2. Remove the spline coupling and seal.
solenoid valve mounted to the actuator. An elec
3. Remove the housing and seal to the right of
trical switch that senses a change in fuel
the center housing.
pressure, or engine load, opens or closes the
solenoid valve. The air for the actuator is supplied 4. Disassemble the actuator.
through a line from the dry air storage tanks of the
a. Remove the cap from the actuator.
vehicle. When the engine is started, and the air
system of the vehicle is less than 80 psi [551 Kpa], b. Remove the locknut and washers for the
the spring in the actuator holds the plunger in the spring retainer. Use the 3376021 Actuator
down position. When the plunger is in the down Adjustment Tool to hold the retainer while
position, the injection timing is retarded. When removing the locknut, put a mark on the
4-7
1. Gasket 14. Actuator Housing 27. Actuator Gear

2. Actuator Cap 15. Pipe Plug 28. Cam Follower Housing (Center)
3. Copper Washer 16. Solenoid Seat 29. Coupling
4. Nut 17. Actuator Shaft Guide 30. Cam Follower Housing (Front)
5. Copper Washer 18. O-Ring 31. Roller
6. Capscrew 19. Seal 32. Roller Pin
7. Spacer 20. Actuator Shaft 33. Roll Pin
8. Actuator Spring Retainer 21. Cup Plug 34. Bushing
9. Actuator Spring 22. Expansion Plug 35. Cam Follower Lever (Valve)
10. Actuator Plunger 23. Cam Follower Shaft 36. Eccentric
11. O-Ring 24. Cam Follower Housing (Rear) 37. Cam Follower Lever (lnjector)
12. Plunger Seal 25. Seal 38. Bushing
13. Sleeve 26. Roll Pin 39. Setscrew
Fig. 4-17. Exploded View Of Cam Follower Housing And Actuator (MVT).
Cam Followers
retainer and actuator housing to make 4. Remove the shaft and levers from the housing.
sure the retainer does not move.
5. Remove the eccentrics from the cam follower
c. Measure the distance from the top of the levers.
spring retainer to the top of the actuator
housing. This will help to find the correct Cleaning
injection timing when you assemble the
1. Put the cam follower shafts and actuator shaft
actuator. lf the retainer turned more than
in a container of mineral spirits. Use com
one-fourth of a turn when you removed the
pressed air to dry the shafts.
locknut, use the ST-593 lnjection Timing
Fixture to time the engine. 2. Clean the other parts with a cleaning solvent
and dry with compressed air. Make sure the oil
d. Remove the capscrew from the actuator
passages in the levers are clean.
shaft. Before you remove the capscrew, hit
the capscrew lightly with the handle of a Caution: Do not clean the solenoid coll.
hammer to make sure the plunger is down.
Inspection
e. Remove the spring retainer and spacer.
1. Use micrometers to measure the outside
f. Remove the actuator housing and shaft
diameter of the shaft. See Table 2 for dimen
from the cam follower housing.
sions. Check the shaft and the teeth at the end
g. Remove the plunger and shaft from the of the shaft for wear or damage.
actuator housing.
2. Check the cam follower housings for cracks or
h. Remove the air filter and adapter from the other damage. Discard damaged or worn
solenoid valve. Discard the O-ring. parts.
i. Remove the jam nut. Remove the solenoid 3. Check the bushing in the cam follower levers
valve. for scratches or other damage. Use inside
micrometers to measure the inside diameter
j. Remove the solenoid stem and spring
of the bushings, Fig. 4-18. Replace the
from the housing. Use the 3376023 Sole
bushings if they are not within the limits given
noid Stem lnstallation and Removal Tool
in Table 2.
to remove the stem. Remove and discard
the sealing ring. 4. Use a magnetic inspection method to check
the levers for cracks. Apply coil magnetization
5. Remove the expansion plug from the cam
to the levers. Use 300 to 500 amperes with
follower housing.
6. Remove the setscrews from the injector cam
follower eccentric.
7. Remove the shaft, levers and gear from the
housing. Put a mark on the levers to identify
their location in the housing as they are
removed.
8. Remove the eccentric from the injector cam
follower lever.
End Housings
1. Remove the expansion plugs from the housings.
2. Remove the setscrews from the injector cam
follower levers.
3. Put a mark on the levers to identify the loca
tion of the levers in the housings. Fig. 4-18 (N10402). Measure The Cam Follower Bushing.
4-9
residual magnaglo. Fig. 4-19 shows the areas to the ball. Put the ball into the insert and
of the lever to check carefully for cracks. rotate the ball 180 degrees, Fig. 4-20. Replace
the insert that is damaged or has less than 80
5. Check the cup plug holes in the housing for
percent contact with the ball.
damage or sharp edges. Use 240 grit
aluminum oxide paper to remove sharp edges. 7. Check the roller pins for wear or damage. Use
Put the aluminum paper in a rod that has a micrometers to measure the outside diameter
slot in the end to hold the paper. lnstall the rod of the pins. Replace the pin if it is damaged or
in an electric drill. Start the drill and push the worn beyond the limits in Table 2.
paper through the hole. Make a chamfer on
8. Check the rollers for wear or damage.
the edge of the hole and remove any sharp
Measure the inside diameter and the outside
edges.
diameter. Replace the roller if it is damaged or
6. Check the insert in the levers for wear or worn beyond the limits in Table 2. If the roller
damage. Use a new push rod ball or a 0.625
inch [15.88 mm] checking ball to check the in
sert. Apply a coat of prussian blue compound Table 2: MVT Cam Follower
Dimensions — Inch [mm]
Worn New New
Measurement Limit Mintmuni Maximum
Cam Follower Shaft 0.748 0.7485 0.7490
Outside Diameter [19.001 [19.01] [19.02]
Bustling
vaive 0.752 0.7501 0.7511

[19.10] [19.05] [19.07]
Injector 1.3765 1.3775
[34.96] [34 981

[17.91] [17.861 [17.881
Outside Diameter 1 .2485 1.2495 1.2505
[31.71] [31.73] [31.76]
Fig. 4-19 (N10410). Check These Areas For Cracks. Valve Cam Roller
[12.78] [12.71] [12.731
[31.71] [31.73] [31.761
Roller Pin
Outside Diameter
Valve 0.497 0.4997 0.5000
[12.62] [12.692] [12.70]
lnjector 0.697 0.6997 0.7000
[17.70] [17.772] [17.78]
Diameter Of The Bore
For The Roller Pin
Valve 0.4990 0.4995
[12.67] [12.68]
lnjector 0.6992 0.6997
[17.76] [17.77]
Eccentric 1.3743 1.3748
Fig. 4-20 (N10413). Using A Push Rod To Check The Insert. Outside Diameter [34.90] [34.92]
4-10
Cam Followers
is damaged be sure to check the camshaft for 4. Cut a chamfer on each end of the bushing.
damage. Use a drill press operating at slow speed with
a chamfer tool that cuts a 60 degree angle
9. Measure the inside diameter of the roller pin
chamfer.
bore in the lever. Discard the lever if the roller
pin bore is worn beyond the limits in Table 2. 5. Put soap into the oil hole in the bushing. This
10. Check the cylinder of the actuator housing for will prevent metal particles from entering the
damage. lf the cylinder sleeve is damaged, oil hole.
remove the sleeve from the housing. Use the 6. Cut the bore in the bushing. See Table 2 to find
Part No. 3376025 Sleeve and Guide Removal the correct dimension for the bushings.
Tool and a press to push the sleeve and shaft
guide from the housing. 7. Use compressed air to remove the soap from
the oil holes. Wash the levers in cleaning sol
11. Check the actuator shaft for wear or damage. vent and dry with compressed air.
Check the teeth on the shaft for wear or
damage. Check the threads in the end of the 8. lf the socket insert was removed from the
shaft for damage. Replace the shaft if it is lever, use a press to install a new socket in
damaged. sert. Make sure the insert is installed tightly.
Caution: If a new socket insert Is installed in the
Repair cam follower lever, a new push rod must also be
Cam Follower Lever used.
1. lf the bushing in the cam follower lever is Assembly
beyond the limit in Table 2, Remove the
bushing. Use the ST-249 Lever Bushing Block The End Cam Follower Housings
and Mandrel to remove the bushing, Fig. 4-21. 1. Hold a 0.006 inch [0.15 mm] feeler gauge be
Use the 3376026 to remove the bushing in the tween the lever and roller. lnstall the roller pin
injector cam follower lever. through the lever and roller, Fig. 4-22. Remove
2. Use compressed air to clean the oil passages. the feeler gauge. Fasten the roller pin with a
roll pin.
3. Use the ST-249 to install a new bushing in the
lever. Make sure the oil hole in the bushing is 2. Apply a light coat of sealant to the cup plug
aligned with the oil hole in the lever. Use the hole in the housing. Use the ST-1053 Expan
3376026 to install the bushing in the injector sion Plug Driver to install the cup plug. lnstall
cam follower lever. the cup plug in the housing so it is even with
Fig. 4-21 (N10403). Remove The Bushing From The Cam Follower. Fig. 4-22 (N10406). Install The Roller And Roller Pin.
4-11
the edge of the hole and not more than 0.010 Positioning Tool to adjust the shaft to the cor
inch [0.25 mm] below the edge of the hole. rect dimension, Fig. 4-24.
Note: The front and rear cam follower housings 8. Tighten the setscrews in the eccentrics to 45
are the same and require only one cup plug per to 55 ft.-lbs. [61 to 75 N»m] torque, Fig. 4-25.
housing. The end of the housing the plug is
9. Make sure the follower levers move freely on
installed into will determine if the housing is a
the shaft.
front or rear housing. The center housing does not
have a cup plug.
3. Use the 3376186 Expansion Plug Driver to
install an expansion plug into each end of the
cam follower shaft. Push the plug into the
shaft until the edge of the plug is even with
the end. of the shaft.
4. lnstall the eccentric into the bore of the injec
tor cam follower lever. lnstall the setscrew
into the eccentric to hold the eccentric in
position in the lever, Fig. 4-23. Make sure the
setscrew does not extend into the shaft bore
of the eccentric.
5. Put the valve follower levers and injector
follower levers in their correct location in the
cam follower housing.
6. lnstall the shafts for the end housings. Slide
the shaft through the bores in both the hous
ing and levers so that the spline end of the
shaft extends from the housing. Make sure the
flat part of the shaft aligns with the setscrews
in the eccentric.
7. Put the shaft so that the spline extends 0.915
to 0.935 inch [23.24 to 23.76 mm] from the
housing. Use the Part No. 3376185 Shaft
Fig. 4-25. Tighten The Setscrew For The Eccentric.
The Center Cam Follower Housing

1. lnstall a roll pin into each end of the housing.
2. Use the 3376186 Driver to install an expansion
plug into each end of the shaft. Push the plug
into the shaft until the edge of the plug is even
Fig. 4-23. Install The Setscrew For The Eccentric. with the end of the shaft.
4-12
Cam Followers
3. lnstall the eccentric into the bore of the injec

tor cam follower lever. lnstall the setscrew
into the eccentric to hold the eccentric in
position in the lever. Make sure the setscrew
does not extend into the shaft bore of the
eccentric.
4. Put the valve follower levers and injector
follower levers in their correct location in the
cam follower housing.
5. Put the actuator gear in the housing, with the
teeth of the gear next to the housing. Make
sure the part of the gear that has a wide tooth
is toward the bottom of the housing, Fig. 4-26.
L 6. lnstall the shaft in the housing. Slide the shaft
Fig. 4-26. Position The Actuator Gear Into The Housing. through the bores in the housing, levers and
gear, Fig. 4-27. At the end of the shaft, the
wide tooth of the spline must align with the
wide groove in the bore in the gear. Make sure
the flat part of the shaft aligns with the
setscrews in the eccentrics.
7. Position the shaft so that the end opposite the
actuator gear is at a depth of 0.996 to 1.000
inch [25.30 to 25.40 mm] from the end of the
housing. Use the 3376185 Tool to adjust the
shaft to the correct dimension, Fig. 4-28.
8. Tighten the setscrews in the eccentrics to 45
to 55 ft.-lbs. [61 to 75 N»m] torque.
9. Make sure the follower levers move freely on
the shaft.
Fig. 4-27. Install The Shaft Into The Housing. 10. lf the actuator sleeve and shaft guide were
removed from the actuator housing, install a
new sleeve and shaft guide. Use the 3376024
Sleeve and Shaft Guide lnstallation Tool and
an arbor press to install the sleeve. With the
mounting surface of the housing up, put the
housing on the press. With the machine part
of the outside diameter of the sleeve up, push
the sleeve into the housing, Fig. 4-29.
11. lnstall a new O-ring onto the shaft guide. With
the O-ring up, push the shaft guide into the
housing, Fig. 4-30. Use the 3376024 tool to
install the shaft guide.
12. lnstall a new rectangular sealing ring to the
actuator plunger. lnstall the plunger in the
actuator housing, Fig. 4-31.
Fig. 4-28. Use The 3376185 Tool To Adjust The Shaft. 13. lnstall the actuator spring in the housing.
4-13
Fig. 4-29. Install The Sleeve Into The Housing. Fig. 4-32. Install The Spring Retainer.
Fig. 4-30. Install The Shaft Guide. Fig. 4-33. Install The Sealing Ring Into The Shaft Guide
Counterbore.
14. With the notched end of the retainer up, install

the spring retainer in the housing, Fig. 4-32.
Note: You will need to press down against the
spring to start the threads of the retainer into the
housing.
15. Use the 3376021 Retainer Adjusting Tool to in
stall the retainer into the housing. Turn the re
tainer until the top edge of the retainer is one
inch [25.4 mm] above the top of the housing.
Do not remove the mark you put on the re
tainer when you disassembled the housing.
16. lnstall the rectangular sealing ring into the
shaft guide counterbore, Fig. 4-33. Make sure
the lip on the sealing ring is toward the
Fig. 4-31. Install The Plunger Into The Housing. plunger.
4-14
Cam Followers
Fig. 4-34. Install The Actuator Shaft. Fig. 4-37. Install The Plunger And Spring Assembly.
Fig. 4-35. Install The Spacer And Retainer Capscrew. Fig. 4-38. Tighten The Plunger And Spring Assembly.
17. lnstall a new O-ring into the groove in the

inside diameter of the plunger. Lubricate the
O-ring with engine lubricating oil.
18. lnstall the actuator shaft. Push the shaft
threaded end first, through the sealing ring
and shaft guide and into the plunger bore, Fig.
4-34. Make sure the shaft goes all the way into
the plunger bore.
19. lnstall the spacer and retaining capscrew
through the spring retainer, Fig. 4-35. lnstall
the capscrew into the actuator shaft, but do
not tighten to the torque value.
20. lnstall a new sealing ring in the solenoid valve
bore, Fig. 4-36. Lubricate the sealing ring with
Fig. 4-36. Install The Sealing Ring. clean engine lubricating oil.
4-15
orifice, do not install the orifice into the stem. ln

stall the Part No. 3028355 MVT Kit. Follow the in
structions given in steps 23, 25, 26 and 29.
22. lnstall the solenoid end plate, solenoid body
and dataplate onto the solenoid stem, Fig.
4-39. Fasten the solenoid to the stem with the
jam nut. Make sure the electrical connections
are toward the top of the actuator. Tighten the
jam nut to 30 to 45 in.-lbs. [3.4 to 5.1 N»m]
torque.
23. lnstall the Part No. 3008706 Screen and the
Part No. 174299 Clip from the MVT Kit into the
solenoid adapter, Fig. 4-40.
24. Install the adapter and a new O-ring on the
Fig. 4-39. Install The Solenoid Body. solenoid stem. Tighten the adapter to 20 to 25
in.-lbs. [2.2 to 3.0 N»m] torque.
21. lnstall the plunger and spring into the plunger 25. lnstall the Part No. 1 77283 Orifice and Part No.
bore of the solenoid stem. lnstall this 173086 Gasket from the MVT Kit into the Part
assembly into the solenoid valve bore, Fig. No. 3028353 Elbow, also from the MVT Kit,
4-37. Use the Part No. 3376023 lnstallation Fig. 4-40. Tighten the orifice to 10 in.-lbs. [0.1 1
Tool to tighten the stem to 10 to 15 ft.-lbs. [14 N»m] torque.
to 20 N»m] torque, Fig. 4-38.
26. lnstall the Part No. 3028353 Elbow into the so
Note: If the solenoid stem was equipped with an lenoid adapter, Fig. 4.40. Tighten the elbow to
• Remove 0.010 inch orifice from
213714 Filter
Fig. 4-40. Part No. 3028355 MVT Kit (Solenoid Valve)
4-16
Cam Followers
27. lnstall the air filter into the adapter and

tighten to 20 to 25 in.-lbs. [2.2 to 3.0 N»m]
torque.
28. lnstall the actuator to the cam follower
housing.
a. Rotate the cam follower shaft clockwise
as far as possible. Use the 3376027 Cam
Follower Shaft Positioning Tool to rotate
the shaft.
b. Lubricate the O-ring on the actuator shaft
guide with clean engine lubricating oil.
c. lnstall the actuator shaft through the shaft
guide bore in the housing until the O-ring
Fig. 4-41. Fasten The Actuator To The Cam Follower Housing. is in position in the bore.
Note: lf the actuator shaft does not engage with
25 in.-lbs. [2.8 N»m] torque. The elbow must
the gear, use the 3376027 to rotate the cam
point straight down after it is installed. lf the
follower shaft until the teeth engage.
elbow has been tightened to the correct torque
value and does not point down, remove the d. Use four capscrews and lockwashers to
elbow. Apply teflon tape onto the threads of fasten the actuator to the cam follower
the elbow. lnstall the elbow and tighten to the housing. Tighten the capscrews to 15 to 19
correct torque value. Make sure that the tape ft.-lbs. [20 to 26 N»m] torque. The solenoid
does not cover or enter the orifice. must be in the position shown in Fig. 4-42.
• 3028354 Vent Tube
• Drill 0.3390 inch ("R" drill) hole through cap.

Tap 1/8 x 27 NPT 0.400 to 0.500 deep.
Fig. 4-42. Part No. 3028355 MVT Kit (Actuator Cap)

4-17
NT/NTA 855 C.I.D.
Note: install the capscrew with the cross-drilled pression release is actuated, the collar permits
head into the hole farthest from the gasket sur the push rod to be raised which opens the exhaust
face of the cam follower housing. valve. On engines without a compression release,
the exhaust push rod does not have a collar. The
e. Tighten the actuator shaft retaining
intake and exhaust pushrods are identical.
capscrew to 40 to 45 ft.-lbs. [54 to 61 N»m]
torque.
29. lnstall the Part No. 175836 Check Valve, the
1. Clean the push rods with mineral spirits or
Part No. 3028354 Vent Tube and the Part No.
cleaning solvent.
3015521 Steel Balls (2) from the MVT Kit into
the actuator cap. 2. Use a radius gauge to check the ball end of
the push rods, Fig. 4-43. The radius of the ball
a. Drill a hole through the center of the actu
end must be 0.619 to 0.625 inch [15.12 to 15.88
ator cap as shown in Fig. 4-42. Use a 0.339
mm]. Replace the push rod if the ball is
in. diameter ("R" drill) drill bit to drill the
damaged or less than 0.619 inch
hole. Tap the hole with a 1/8 x 27 NPT tap.
[15.72 mm].
Tap the hole to a depth of 0.400 to 0.500
inch [10.2 to 12.7 mm] as measured from
the top of the cap.
b. Enlarge the 1/8 inch diameter lockwire
holes that are in the top of the cap to a di
ameter of 0.1850 inch. Use a No. 13 drill bit
to enlarge the holes. Drill from each side
of the cap to a minimum depth of 0.1875
inch [4.76 mm] for each hole, Fig. 4-42.
c. Clean the cap to remove the metal parti
cles and oil.
d. lnstall one Part No. 3015521 Steel Ball into
the enlarged hole on each side of the actu
ator cap, Fig. 4-42.
e. Install the Part No. 175836 Check Valve in
to the actuator cap, Fig. 4-42. Tighten the
Fig. 4-43 (N20309). Check The Ball End Of The Push
check valve to 10 in.-ibs. [1.1 N»m] torque.
The outlet on the check valve must position
so that the vent tube will not be against
any part of the engine.
f. Install the Part No. 3028354 vent tube onto
the check valve, Fig. 4-42.
g. lnstall the copper washer, jam nut, second
copper washer and actuator cap onto the
spring retainer. Do not tighten.
Push Rods
Each cylinder of the engine requires an intake, ex
haust and injector pushrod. The injector push rod
is the largest of the three and fits into the middle
socket of the cam follower assembly. When the
engine has compression release, the exhaust
push rod is equipped with a collar. When the com Fig. 4-44 (N20310). Check The Socket End Of The Push
4-18
Cam Followers
3. Use the ball end of a new rocker lever

adjusting screw to check the socket of the
push rods, Fig. 4-44. A 0.500 inch [12.70 mm]
diameter checking ball can be used to check
the socket. Apply a coat of prussian blue com
pound to the checking ball or adjusting screw.
Put the ball or screw into the push rod socket
and rotate the ball or screw 180 degrees.
Replace the push rod if the socket is damaged
or has less than 80 percent contact with the ball.
4. Check that the push rod is not out-of-round.
Replace the push rod if it is out-of-round more
than 0.035 inch [0.89 mm].
5. Never use push rods with worn balls in cam
followers with new sockets.
Table 3: Push Rod Length — Inch [mm]

2 lnch Cam 2-1/2 Inch Cam
Injector 18.290(464.57] 17.775(451.49]
18.320(465.32] 17.805(452.25]
Valve 18.360(466.34]
18.390 (467.11] 17.880(454.15]
17.910(454.91]
4-19/(4-20 Blan
Fuel System
The PT fuel system is used exclusively on Cummins

GrOlip 5 Diesels. lt was developed by Cummins Engine
Company. The identifying letters "PT" are an
abbreviation for pump functions of supplying fuel
pressure at the proper time "pressure-time."
Fuel System
PT Fuel Pumps
Three models of PT fuel pumps are used: The PT
(type G), PT (type R) and PT (type G) AFC. The
PT (type G) indicates that fuel pressure regulation
is a part of the governor function. The PT (type R)
refers to fuel pressure regulation as a function of
a regulator assembly. The PT (type G) AFC fuel
pump indicates that the air fuel control is an
integral part of the fuel pump.
1. Repair of PT (type G and H) pumps and calibra
tion instructions is described in Bulletin No.
3379084 or revisions.
2. Bulletin No. 3379101 covers calibration and
rebuilding of the PT (type R) pumps as used
on Cummins engines.
3. Bulletin No. 3379068 covers calibration speci
fications of the PT (type G) pumps as used on
Cummins engines.
4. For Air Fuel Control, aneroid adjustment and
calibration refer to fuel pump Calibration
manuals.
5. The CPL (Control Parts List) Manual, Bulletin
No. 3379133, is a listing of basic engine parts
and timing specifications which are neces
sary to produce a given engine performance.
By reference to CPL numbers stamped on
engine nameplate, this list may be used to
identify parts within an engine. These parts
then determine whether a fuel pump calibra
tion is suitable for that engine.
5-1/(5-2 Blank)
lnjectors
This group covers injectors, tubing and connections

Group 6 which carry fuel to and from injectors.
Injectors
Injectors and Connections

PT injectors and connections are described, with
all repair and calibration information covered, in
Bulletin No. 3379071 or reprints thereof.
Manuals on all Cummins products may be pur
chased through a Cummins Distributor.
6-1/(6-2 Blank)
_j
Lubricating System
This section includes the disassembly, inspec-

QrOUP 7 tion, repair and assembly of the: oil pump,
pressure regulator, oil cooler, filter, oil pan and
dipstick.
Lubricating System
1. Bushing 5. Main Drive Gear 9. Driven Gear

2. Shaft 6. Pressure Regulator 10. ldler Gear
3. Tube 7. Dowel 11. Gasket
4. "O" Ring 8. Body 12. Cover
Fig. 7-0. Lubricating Oil Pump — Exploded View.

7-1
Service Tool List 2. Remove the idler gear from the idler shaft.
■j Remove the driven gear from the drive shaft
and gear. Use the Part No. 3375082 Gear Puller
Service Tools (Or Equivalent) Required to remove the part no. 143190 drive gear. Use
Service Tool Tool the Part No. 3375083 Gear Puller to remove the
Number Name part no. 125988 drive gear.
ST-994 Bushing Mandrel
ST-1157 Spacer Mandrel Note: Some double lubricating oil pumps have a
ST-1158 Bushing Mandrel scavenger pump body that must be removed after
337601 1 DFC Pressure Valve Fixture the drive shaft is pushed through the driven gear.
3375206 Boring Tool After removing the scavenger pump body, repeat
step 2.
Desirable (Or Equivalent) Service Tools 3. If the oil pump has a tube for piston cooling
ST-1134 Dowel Pin Extractor and the tube is damaged, push the tube from
ST-1160 Hose Assembly Tool Kit the inside part of the pump body to remove it.
ST-1218 Mandrel (O-ring)
ST-1223 Mandrel (O-ring) 4. Push the idler shaft from the pump body.
3375082 Gear Puller 5. Remove the cap, spring and plunger for the
3375083 Gear Puller
Tube Bundle Tester pressure regulator or pressure by-pass valve.
3375253
3375049 Oil Filter Wrench Make sure the plunger can move freely in the
3375301 Tube Cutter bore.
6. lf the mounting head for the oil filter has a by
pass valve, remove the valve.
The Lubricating Oil Pump
The same general methods are used to disassem
ble, inspect and assemble the lubricating oil
pumps for the NH and NT engines. 1. Check the idler shaft for damage.
2. Check the dowel pins in the pump body for
Put a mark on the parts such as the pressure
damage. Use the Part No. ST-1134 Dowel
regulator plunger, idler shaft, drive shaft and mark
Puller to remove damaged dowel pins.
the capscrew length, size and location, as they
are removed during disassembly. This will help 3. Check the drive shaft for damage. Check all of
you to correctly assemble the oil pump. the gears for worn or broken teeth.
Note: Full Flow Cooling (FFC) engines have a 4. Check the pump body for cracks or other
high pressure by-pass valve in the oil pump in damage. Make sure the threads are not
stead of a pressure regulator. The pressure damaged or distorted. Check the gasket sur
regulator for the FFC engine is located in the oil face for scratches, wear or damage.
cooler support. Use the same method to remove 5. lnspect the bushings in the pump body, cover
and install the high pressure by-pass valve in the and idler gear.
oil pump as you would use when the pressure
regulator is located in the oil pump. Check the
parts catalog to find the correct part number of
the spring for the by-pass valve and the pressure 1. Replace all parts that are damaged or worn
regulator. beyond the limits in Table 1.
Disassembly Repair
1. Follow these instructions to replace the
1. Refer to Fig. 7-0. Remove the capscrews and
lockwashers that hold the cover to the pump bushings.
body. Remove the cover. Hit the cover lightly a. Use the Part No. ST-1 158 Bushing Mandrel
with a rubber hammer to help remove the to push the worn or damaged bushing
cover from the dowels in the body. from the body, cover or gear.
Lubricating System
b. Use the ST-1158 to push new bushings 4) lnstall the boring tool into the guide
into the body, cover or gear. The bushings bushing. The tool bit must go through
must be even with or 0.020 inch [0.51 mm] the slot in the guide bushing. Do not
below the surface of the body, cover or gear. hit the tool bit against the bushing.
c. Use the Part No. 3375206 Lubricating Oil 5) Adjust the travel of the boring bar so
Pump Boring Tool to cut the bore in the the tool bit will go through the guide
bushings in the pump body. bushing but does not touch the bush
ing in the pump body.
1) Install the guide bushing into the gear
pocket, Fig. 7-1. Tighten the capscrew 6) Fasten the boring tool to the pump
against the side of the gear pocket to body with capscrews, Fig. 7-2. Rotate
hold the guide bushing in position. the shaft to make sure it will turn
freely.
Fig. 7-1. Install The Guide Bushing lnto The Gear Pocket.
Fig. 7-2. lnstall The Boring Tool.
2) lnstall the dial indicator into the set 7) Move the feed control lever to the "on"
ting block. Put the setting block on the position. This will prevent the drive
setting standard with the indicator tip shaft from moving down. Put the pump
on the diameter size of the bore to be and boring tool in a vertical position.
cut. See Table 1 for the correct size Make sure the boring tool can cut com
bore. Adjust the dial indicator. pletely through the bushing.
3) Install the tool bit into the boring bar. 8) Install the drive adapter into a heavy
Do not completely tighten the set- duty 3/8 inch electric drill. Engage the
screw. lnstall the tool bit adjusting adapter with the drive shaft of the bor
knob into the boring bar. Hold the set ing tool.
ting block and indicator against the
9) Start the drill and cut the bore in the
boring bar so the indicator tip will be
bushings. Make sure you cut the bore
over the tool bit. Turn the adjusting
in both bushings. Do not push down on
knob clockwise to push the tool bit
the drill. The feed mechanism in the
against the indicator tip. Adjust the
boring tool will move the boring bar.
tool bit until the indicator has the
same reading as when adjusted on the 10) Stop the drill. Move the feed control
setting standard. After the tool bit is lever to the "off" position. Pull up on
correctly adjusted, tighten the set- the drive shaft to remove the tool bit
screw and remove the adjusting knob. from the bore.
7-3
1 1) Remove the boring tool from the pump 13) Remove the cover from the body.
body. Make sure the tool bit moves
through the slot in the guide bushing. 14) Remove the guide bushing. Clean all
metal particles from the body and
Do not hit the tool bit against the
cover.
guide bushing.
12) Remove the guide bushing. Clean the 15) Measure the inside diameter of the
metal particles from the pump body. bushing.
13) Measure the bore in the bushings. Table 1: Oil (Except DFC*)
d. Cut the bore in the bushings that are in the — Inch [mm]
cover.
1) Repeat Steps 1) through 3) for the
Single Oil
bushings in the body.
Bushing 0.6185 0.6165 0.6175
2) Install the pump cover to the body. lnside Diameter [15.710] [15.659] [15.684]
ldler and Drive 0.6145 0.615 0.6155
3) Put the pump on a work bench with the Shaft Outside Dia. [15.608] [15.62] [15.6341
cover down.
Single Oil Pump (Scavenge)
4) Install the boring tool to the pump Bushing 0.6185 0.6165 0.6175
body. Use the long capscrews and lnside Diameter [15.710] [15.659] [15.684]
nuts to fasten the tool to the body. ldler and Drive 0.6145 0.615 0.6155
Shaft Outside Dia. [15.608] [15.62] [15.634]
5) Install the boring bar through the
guide bushing. Do not damage the tool Single Oil Pump (Double Capacity)
bit. Bushing 0.879 0.8767 0.8777
lnside Diameter [22.33] [22.268] [22.293]
6) With the feed control lever in the "off" ldler- and Drive 0.874 0.8745 0.875
position, move the drive shaft down Shaft Outside Dia. [22.17] [22.212] [22.22]
until the tool bit touches the bushing
Double Oil Pump
in the cover.
Bushing 0.6185 0.6165 0.6175
7) Hold a new bushing and a 1/16 inch lnside Diameter [15.710] [15.659] [15.684]
[1.59 mm] feeler gauge against the ldler and Drive 0.6145 0.615 0.6155
drive shaft, at the top of the boring tool Shaft Outside Dia. [15.608] [15.62] [15.634]
body. Move the stop collar down Double Oil I
against the feeler gauge. Tighten the Bushing 0.841 0.840 0.8405
set screw in the stop collar. Move the lnside Diameter [21.36] [21.34] [21.349]
feed lever to the "on" position and ldler and Drive 0.838 0.8375 0.838
remove the feeler gauge and bushing. Shaft Outside Dia. [21.26] [21.272] [21.29]
8) Start the drill and cut the bore in the 'See Page 7-9 for DFC Specifications.
bushing.
9) Stop the drill when the stop collar on Assemble the Oil Pump
the drive shaft is against the body of 1. Apply a coat of lubricating oil to the large out
the boring tool. side diameter of the idler shaft. lnstall the
10) Move the feed control lever to the "off" large outside diameter of the shaft, from the
position. gear pocket side of the body, into the bore in
the pump body. Use the Part No. ST-1157 Gear
11) Pull the drive shaft up to remove the
and Spacer Mandrel and an arbor press to
tool bit from the bushing. Move the
push the shaft into the bore. See Table 2 to
lever to the "on" position.
find the correct amount of protrusion the idler
12) Remove the boring tool from the pump shaft must have after it is installed in the
body. Do not damage the tool bit. pump body.
Lubricating System
Table 2: Oil Pump Specifications (Except DFC*) — inch [mm]

Minimum Maximum
Single Oil Pump
Drive Shaft Protrusion © 0.855 0.875
[21.72] [22.22]
ldler Shaft Protrusion © 0.720 0.740
[18.29] [18.80]
Drive Shaft End ® 0.002 0.005
Movement [0.05] [0.13]
Single Oil Pump (Double Capacity)
[26.29] [26.80]
[24.26] [25.02]
Movement [0.05] [0.20]
Minimum Maximum
Double Oil Pump
[1.02] [1.52]
[66.04] [66.55]
ldler Shaft Protrusion® 2.680 2.690
(When Part No. is followed by [68.07] [68.33]
the letter "L")
Movement [0.10] [0.18]
Minimum Maximum
Single Scavenger and Double Scavenger Pump
Drive Shaft Protrusion ® 0.580 0.610
[14.73] [15.49]
7
Drive Shaft Protrusion ® 0.050 0.070
From Adapter [127] [1.78]
ldler Shaft Protrusion ® (Even with front
surface of the pump) w.W
Dowel Pin Protrusion © 0.990 1.010 I
From Adapter [25.15] [25.65] T7ii ■ ■
Drive Shaft End Movement
1
Single 0.004 0.010
[0.10] [0.25] [
Double 0.004 0.007
[0.10] [0.18]
See Page 7-10 for DFC Specifications.

7-5
2. Apply a coat of lubricating oil to the inside cooling oil and the tube was removed, install a
diameter of the driven gear. lnstall the gear on new tube into the body. Push the end of the
to the drive shaft. Use the ST-1157 and an arbor tube which is not beveled into the pump body.
press to push the gear onto the shaft. See Table Make sure the tube has 2.970 to 3.000 inch
2 to find the correct amount of protrusion the [75.44 to 76.20 mm] protrusion from the body.
shaft must have after the gear is installed.
6. lf the dowels were removed from the body,
3. lnstall the drive shaft, from the gear pocket install new dowels.
side of the pump body, into the bore in the
7. Apply clean lubricating oil to the gears,
pump body. Apply a coat of lubricating oil to
bushings and shafts.
the inside diameter of the drive gear. Put the
gear on the shaft on the side of the body op 8. lnstall the pressure regulator or pressure by
posite to the gear pockets, use an arbor press pass valve into the pump body. Tighten the cap-
to push the gear onto the shaft. There must screw to 30 to 35 ft.-lbs. [40 to 47 N»m] torque.
not be more than 0.012 inch [0.30 mm]
clearance between the gear and the body. 9. lnstall the cover and a new gasket to the pump
body. Hit the cover lightly with a rubber ham
4. Apply lubricating oil to the inside diameter of mer to push the cover onto the dowels. Install
the idler gear. lnstall the idler gear onto the the capscrews and lockwashers so that the
idler shaft. cover is held to the body. Tighten the cap-
Note: For double lubricating oil pumps, install a screws to 30 to 35 ft.-lbs. [40 to 47 N»m]
new gasket and the scavenger pump body to the torque. Turn the gears to make sure they move
oil pump body. Apply lubricating oil to the inside freely in the pump.
diameter of the driven gear for the scavenge 10. If the pipe plugs were removed, apply a seal
pump. Use an arbor press to push the gear onto ing compound or teflon tape to the threads.
the drive shaft. There must be 0.002 to 0.004 inch lnstall and tighten the plugs to the following
[0.05 to 0.10 mm] clearance from the bottom of the torque values.
gear pocket to the gear. Repeat Step 4 to install
1/2 inch pipe plug 30 to 40 ft.-lbs. [40 to 54 N»m]
the idler gear.
3/8 inch pipe plug 20 to 30 ft.-lbs. [27 to 40 N»m]
5. lf the oil pump requires a tube for the piston 3/4 inch pipe plug 45 to 55 ft.-lbs. 161 to 74 N»m]
Fig. 7-3. Demand Flow and Cooling (DFC) Oil Flow Schematic.
7-6
Lubricating System
1. Body 7. Drive Shaft Key 13. Driven Gear

2. Gasket 8. Dowel Pin 14. Bushing
3. Spacer 9. ldler Shaft 15. Gasket
4. Drive Gear 10. Drive Shaft 16. Oil Pump Cover
5. Bushing 11. Gear Bushing 17. Cover Plate Gasket
6. High Pressure Limit Valve 12. ldler Gear 18. Cover Plate
19. Main Rifle Pressure Regulator
Fig. 7-4. Demand Flow and Cooling (DFC) Oil Pump — Exploded View
7-7
Demand Flow and Cooling

The Demand Flow and Cooling (DFC) lubricating
system adjusts the oil flow and oil cooling as
needed by the engine, instead of operating con
tinuously at maximum capacity. The DFC system
has a lower pressure in main oil passage (main oil
rifle), 35 to 45 psi [241 to 310 kPa], less oil flow
from the pump, 40 GPM [151.4 LPM], and controls
the amount of oil that is cooled before it enters
the engine oil passages.
The flow is controlled through two independent
circuits. One circuit is a lower flow capacity oil
pump that has an internal pressure control mech
anism and external feedback signal hose. The
second circuit contains a temperature-controlled Fig. 7-6. Measure The Outside Diameter Of The Idler Shaft.
bypass in the oil cooler assembly, Fig. 7-3. In
structions for the disassembly, inspection and
assembly of the oil cooler assembly are found
later in this section.
Disassemble and Inspect the Oil Pump

1. Follow the same general instructions given to
disassemble the other oil pumps.
2. Check the drive shaft and idler shaft for
damage or wear, Fig. 7-5 and 7-6. Replace the
shaft if the outside diameter does not mea
sure 0.8745 to 0.8750 inch [22.21 to 22.22 mm]
or if it is damaged.
3. Inspect the bushings in the pump body, cover
and idler gear, Fig. 7-7. Replace the bushings
if they are damaged or the inside diameter Fig. 7-7. Measure The Inside Diameter Of The Bushings.
Fig. 7-5. Measure The Outside Diameter Of The Drive Shaft. Fig. 7-8. Check The Movement Of The Plunger In The Bore.
7-8
Lubricating System
does not measure 0.8765 to 0.8775 inch [22.26

to 22.29 mm].
4. lnspect the gears for worn or broken teeth.
Replace the gears that are worn or damaged.
5. Check the pump body and cover for cracks or
other damage. Make sure the surfaces for tho
gaskets are flat and smooth. Replace the
parts that are damaged.
6. Remove the pressure regulator retainer,
spring and plunger. Make sure the plunger can
move freely in the bore, Fig. 7-8.
7. Check the disc for the high pressure limit
valve for damage. Push on the disc to check
the spring for damage. Do not use a tool that Fig. 7-9. Position The Locating Plate.
has a sharp point to push on the disc. Remove
the retainer plug, disc and washer to replace
the spring if it is weak, damaged or broken.
8. Follow the instructions given earlier in Step
11a, b and c to install and bore the new
bushings in the pump body and cover. See
Table 3 to find the correct dimensions of the
bushing and shaft.
Table 3: DFC OH Pump Specifications — Inch [mm]

Worn New New
Limit Minimum Maximum
Bushing 0.8785 0.8765 0.8775
lnside Diameter [22.31] [22.26] [22.29]
ldler and Drive 0.8740 0.8745 0.8750
Fig. 7-10. Position The Assembly Into The Locating Plate.
Assemble the Oil Pump

Except for its unique parts the DFC oil pump re
quires the same procedure, tools and torque
values for assembly as the other oil pumps. See
Table 4 to find the correct amount of protrusion
the idler and drive shafts must have after
assembly. Special instructions for assembly of
the DFC oil pumps are as follows:
1. lnstall the high pressure limit valve into the
pump body.
a. Use the Part No. 3376011 pressure valve
fixture to install the pressure valve.
b. Use capscrews and lockwashers to install
the locating plate to the pump body. Do
not tighten the capscrews at this time. Fig. 7-11. lnstall The Assembly.
7-9
c. Install the large diameter end of the f. Remove the mandrel and locating plate
mandrel into the locating plate to put the from the pump body.
plate in the correct position on the body,
Fig. 7-9. Tighten the capscrews and then NTE Lubricating Oil Pump
remove the mandrel. (European Big Cam Engine)
d. Make sure the prongs of the disc are down Use the same procedures to disassemble, inspect
and the lip of the seat is up when you and assemble the NTE oil pump as are used for
install the bypass spring, washer, disc the other NH/NT oil pumps. The difference be
into the locating plate, Fig. 7-10. tween the NTE oil pump and the other pumps is
e. Install the small diameter end of the the type and location of the oil pressure regulator
mandrel into the locating plate. Push on and the amount of protrusion of the idler and drive
the mandrel with an arbor press until the shaft.
large end of the mandrel is against the The pressure regulator is a checkball valve and is
locating plate, Fig. 7-11. located in the front part of the pump body. It is
operated by oil pressure from the pump and oil
Table 4: DFC Shaft Protrusion — Inch [mm] pressure from the main oil passage (oil rifle) of
the engine. Fig. 7-12 (A) shows the position of the
ldler Shaft 0.705 0.735 regulator when the engine is first started and the
[17.9] [18.6] oil temperature If less than its normal operating
temperature. Fig. 7-12 (B) shows the position of
Drive Shaft
the regulator when the oil temperature is at nor
from Pump Body 1.990 2.010 mal operating temperature.
[50.5] [51.0]
from Pump Drive Gear 0.050 0.070 The regulator keeps the oil pressure in the engine
[1.27] [1.79] at a minimum of 10 psi [69 kPa] when the engine is
Fig. 7-12. NTE Oil Pump Pressure Regulator.
10
Lubricating System
at idle RPM and 40 to 45 psi [275 to 310 kPa] at'

rated RPM. See Table 5 to find the corect size of
the bushings and amount of shaft protrusion.
Table 5: NTE Oil Pump Specifications — lnch [mm]

Worn . New New
Limit Minimum Maximum
Bushing 0.8785 0.8765 0.8775
lnside Diameter [22.31] [22.26] [22.28]
Idler and Drive 0.8740 0.8745 0.8750
Idler Shaft 0.955 0.985
Protrusion [24.25] [25.02]
Drive Shaft 2.305 2.325
Protrusion [58.54] [59.05]
Fig. 7-13 (V40727). Inspect The Paper Element.
Lubricating Oil Filters
Full-Flow Oil Filter (Center-Bolt) 3. lnspect all parts for wear, damage or distor
tion. Discard the parts that are damaged, worn
Disassembly or distorted.
1. Remove the drain plug from the filter shell to
drain the oil. Clean the dirt from around the Replacement
filter head and shell before you remove the 1. Replace the element with a new element.
shell.
2. Replace all the parts that were discarded with
2. Remove the center-bolt from the shell. new parts.
Remove the shell, element and seal ring from
the filter head. Keep the element for inspec Assembly
tion and discard the seal ring.
1. If the bypass valve was removed, install the
3. Remove the retaining ring from the center-bolt. new valve into the filter head.
4. Remove the filter support, rubber seal, washer 2. Install a new copper washer onto the center-
and filter spring from the filter shell. Remove bolt.
the center-bolt and copper washer.
3. lnstall the center-bolt into the filter shell. Slide
5. Check the bypass valve in the filter head to the spring, washer, a new rubber seal and the
make sure the valve works freely. If the valve filter support onto the center-bolt. lnstall the
does not work freely, remove and replace the retaining ring onto the center-bolt.
valve.
4. lnstall a new element into the filter shell.
Cleaning 5. lnstall a new seal ring to the filter head.
Clean the filter shell and parts with cleaning 6. install the filter assembly to the filter head. ln
solvent and dry with compressed air. stall the drain plug into the filter shell.
lnspection Note: Use the parts catalog to find the correct part
numbers.
1. Use a knife to cut the element. Remove the
element from the center spool. Full Flow Oil Filter (Spin-On)
2. lnspect the element for metal particles and
Disassembly
dirt, Fig. 7-13. lf metal particles are found in the
element, be sure to inspect all bearings in the 1. Use the Part No. 3375049 Oil Filter Wrench to
engine. Discard the element after inspection. remove the oil filter.
7-11
2. Remove the capscrew and lockwasher that 2. The tee-handle of the hold-down assembly or
fastens the spin-on adapter to the filter head. the stand-pipe in the filter shell will have an
Remove the spin-on adapter and discard the orifice. The orifice controls the oil flow
O-ring. through the filter. Make sure the orifice is
Cleaning
Clean the spin-on adapter with cleaning solvent
and dry with compressed air. Check the hold-down assembly, filter shell and
cover for <
1. Use the Part No. 3375301 Tube Cutter to

remove the element from the filter cartridge. 1. Install a new element into the filter shell.
2. lnspect the element for metal particles and 2. Install the hold-down assembly onto the
dirt. If metal particles are found in the ele stand-pipe. Tighten the assembly.
ment, be sure to inspect all bearings in the
3. Install the cover and O-ring on the filter shell.
engine. Discard the element after inspection.
4. Install the clamp ring to the cover and filter
3. lnspect the spin-on adapter for damage.
shell. Tighten the capscrews until the lugs on
the clamp ring come together.
Assembly
1. Apply a coat of lubriplate to a new adapter Lubricating Oil Lines
O-ring. lnstall the spin-on adapter and O-ring
Hose Size and Specifictions
to the filter head. Tighten the capscrews for
the adapter to 25 to 35 ft.-lbs. [34 to 47 N»m] 1. For oil supply and drain Iines less than 10 ft. [3
torque. m] in length, use a flexible hose size No. 6
(5/16 in. [7.9 mm] inside diameter).
2. Apply a coat of lubricating oil to a new sealing
ring and to the threads of a new filter 2. For oil supply and drain lines more than 10 ft.
cartridge. [3 m] in length, use hose size No. 8 (13/32 in.
[10.3 mm] inside diameter).
3. Install the sealing ring and filter to the spin-on
adapter. To tighten the filter, follow the in 3. The fittings used in the oil bypass circuit must
structions on the filter cartridge. not be less than 1/4 in. pipe size.
4. The oil return line to the oil pan must be below
Bypass Oil Filter the oil level in the oil pan.
Full-flow oil filters must always be used with 5. The oil supply line must be connected to the
bypass filters. Never use a bypass filter instead of oil circuit between the oil pump and full-flow
a full-flow oil filter. filter.
6. Make sure the hose for the oil and fuel lines
meet these specifications:
1. Remove the capscrews for the clamp ring.
Remove the cover and O-ring. a. The inside liner is made of rubber or teflon
and has fabric and wire support.
2. Remove the element hold-down assembly
the element from the filter shell. b. The outside of the hose has fabric or wire
support.
c. The hose cannot be damaged by oil or
fuel.
Use cleaning solvent to clean the hold-down
assembly and filter shell. Dry with com 7. The hose with the inside liner must have the
pressed air. ability to let oil flow at -40°F to 300 °F [ -40°
7-12
Lubricating System
to 149°C]. Do not use hoses that have the SAE has reached the bottom and is not pushing
specifications of 100R1 and 100R5. into the inside of the socket.
8. A hose with a teflon liner must have the ability 6. Put the socket and hose assembly in a vise.
to let oil flow at up to 450 °F [232 °C]. The hose Make sure the socket is clamped in the vise.
must have a stainless steel wire support for Apply lubrication to the nipple and the inside
the liner. Permanent fittings are to be used. of the hose, Fig. 7-15.
9. Make sure the clamps used to hold the hose in 7. Use the Part No. ST-1 160 Lube Hose Assembly
position will not damage the hose. Tool to install the nipple into the hose and
socket assembly, Fig. 7-16. The ST-1 160 in
To Assemble New Hoses cludes hose mandrels for the hose sizes 4, 5,
6, 8, 10, 12 and 16.
Replace the hose and fittings after either 100,000
to 200,000 miles [160,900 to 321,000 km] or 3200 to 8. After assembly, check the inside of the fit
6400 hours of engine operation. tings and the hose. Make sure the hose is not
damaged. Any damage to the hose liner can
Follow these instructions to make hose from bulk stop the oil flow.
material.
1. Use a hacksaw to cut the hose to the correct
length. Make the cut square or straight within
5 degrees.
2. Do not compress the hose while cutting. This
can cause a restriction inside the hose.
3. Put the socket in a vise. Check all fittings to
make sure they fit correctly.
4. Hold the hose so that it enters straight into
the socket, Fig. 7-14. This will prevent a bad
connection in the socket. Turn the hose coun
terclockwise while you push the hose into the
socket.
5. Turn the hose until it comes in contact with
the bottom of the socket. Make sure the hose Fig. 7-15 (N10738). Lubricate The Nipple.
Fig. 7-14 (N10737). Install The Hose Into The Socket. Fig. 7-16 (N10739). Assemble The Hose Nipple And Socket
7-13
The Lubricating Oil Pan 1) lncrease the diameter of the hole to

1-11/64 inch [29.77 mmj.
To select the correct oil pan, you must know the
type of equipment the engine is to be used in. lf 2) Use a 1-1/4 inch X 12 tap to cut the
the engine is used in an automotive vehicle, the threads in the hole. Use diesel fuel as
oil pan must be designed for engine operation up a lubricant as you cut the threads.
to 10 degrees tilt or angularity. lf used in construc
3) lnstall the new drain plug and copper
tion equipment, the oil pan must be designed for
washer. Tighten the plug to 60 to 70
operation up to 30 degrees tilt or angularity.
ft.-lbs. [81 to 95 N»m] torque.
Use Table 7-5, in the back of this section, to find
b. To use the Part No. 120349 Drain Plug with
the specifications of the oil pan.
1-3/8 inch X 12 thread size.
Inspection 1) Increase the diameter of the hole to
1-19/64 inch [32.94 mm].
1. Check the oil pan for cracks. Use the dye
method to find cracks. 2) Use a 1-3/8 inch X 12 tap to cut the
threads in the hole. Use diesel fuel as
a. Apply dye to the area of inspection. Let
a lubricant as you cut the threads.
the dye dry for 15 minutes. Do not use
compressed air. 3) Install the new drain plug and copper
washer. Tighten the plug to 60 to 70
b. Apply the developer to the dye and check
ft-lbs. [81 to 95 N»m] torque.
for indications of cracks.
2. Check the aluminum oil pans for damage to The Lubricating Oil Dipstick
the thread inserts.
The dipstick has marks that show the level of the
oil in the oil pan.
Repair
lf the level of the oil is too high, this can cause
1. To replace damaged thread inserts:
foam in the oil and a loss of power. lf the oil level
a. Measure the diameter of the hole. Use the is too low, this can cause a loss of oil pressure
correct tool from the Part No. 3375021 and damage to the engine.
Thread lnsert Kit to remove the damaged
thread insert. Clean and inspect the hole. lf the dipstick is missing, install a new dipstick.
Use the same tool to install a new insert. If the Part No. of the dipstick is not known, use a
b. Use different taps to start and to finish the dipstick that does not have marks on it. Make the
threads in new or oversize holes for thread correct marks on the dipstick.
inserts. Use diesel fuel as a lubricant 1. The engine must be mounted in the chassis
when you cut the thread in aluminum. and in the correct operating position.
c. After the new insert is installed, bend the
2. Find the oil pan Part No. Refer to Table 7-5 to
bottom of the insert toward the center
find the capacity of the oil pan.
then toward the side of the hole. This will
cause the tip of the insert to break. 3. Drain all of the oil from the oil pan.
Remove the tip.
4. Put enough oil into the oil pan to equal the low
2. Weld any small cracks in the oil pan. Do not capacity shown in Table 7-5. Make sure the oil
weld machined surfaces. Make sure that you has enough time to drain from the engine into
clean all of the oil from the oil pan before the pan.
welding.
5. Install the dipstick into the dipstick tube until
3. Repair the damaged threads for the oil drain the dipstick makes contact with the bottom of
plug. lnstall an oversize drain plug in the oil pan. the pan. Measure the amount of protrusion
a. To use the Part No. 62117 Drain Plug with from the tube to the bottom of the dipstick
1-1/4 inch X 12 thread size. cap. Remove the dipstick. Cut the same
7-14
Lubricating System
amount from the end of the dipstick that was position which allows approximately half of the
measured from the tube to the cap. oil flow through the cooler. When the oil
temperature is more than 230 °F [110°C], the valve
6. lnstall the dipstick all of the way into the tube. is in the open position which allows the full flow
Remove the dipstick and make a mark where of the oil through the cooler.
the oil level shows on the dipstick. The mark
must be 0.010 inch [0.3 mm] deep. Mark the
letter "L" above the first mark. Do not use a
Secondary Flow
chisel to make the mark. Cut the dipstick so it
has at least 1/2 inch [12.7 mm] of length below
the mark.
7. Add enough oil to the oil pan to equal the high
capacity shown in Table 7-5. lnstall the
dipstick into the tube. Remove the dipstick
and make a mark where the oil level shows on
the dipstick. Mark the letter "H" above this
mark.
The Lubricating Oil Cooler

The FFC (Full Flow and Cooling) engine has the
oil pressure regulator in the front support for the
oil cooler, Fig. 7-17. The regulator controls the oil
pressure before the oil flows through the oil filter.
Use the same procedure to remove and install the
regulator in the oil cooler that you used to remove
and install the regulator in the oil pump.
Fig. 7-18. The DFC Oil Bypass Valve.
The oil cooler for the NTE (European Big Cam)

engine has a thermostat that controls the oil flow
through the cooler, Fig. 7-19. When the engine and
the oil is cold (oil temperature less than 215°F
[96.1 °C], the thermostat is in the closed position
and the oil flow bypasses the oil cooler. As the oil
becomes hotter (more than 215°F [96.1 °C], the
thermostat begins to open to allow a small
amount of oil flow through the cooler. When the
oil temperature reaches 235"F [112.7°C], the ther
mostat is fully open and allows the full flow of oil
Fig. 7-17. The FFC Oil Pressure Regulator. through the cooler.
The oil cooler for the DFC (Demand Flow and Disassembly (FCC and Big Cam)
Cooling) system has a bypass valve that controls
1. Remove the cooler support (8, Fig. 7-20) and
the oil flow through the cooler, Fig. 7-18. The
cover (3) from the housing (1).
temperature of the oil causes the bypass valve to
open and close. When the oil temperature is less 2. Remove and discard the gaskets (2 and 10)
than 230°F [110°C], the valve is in the closed and retainers (4).
7-15
Fig. 7-19. The NTE Oil Flow Through The Oil Cooler.
Lubricating System
Fig. 7-20. FFC and Big Cam Oil Cooler
3. Remove and discard the O-ring (7). Be careful 2. Flush the tubes with a solution of alkaline.
and do not damage the element (6) when you After cleaning, flush several times with hot
remove the O-ring. water.
4. Remove oil and dirt from the housing. Flush 3. Put the element into a container of solution.
the oil passages with mineral spirits in the The solution is to be:
reverse direction of the oil flow. 1 part muriatic acid
5. Remove the element from the housing. Hit the 9 parts water
edge of the housing against a block of wood 1 lb. [0.5 kg] oxalic acid and 0.01 gal.
to remove the element from the housing. [0.038 L] of pyridene added to each
6. Remove and discard the O-ring (5). 5 gal. [18.9 L] of muriatic acid.
4. Remove the element when there are no foam
Cleaning or bubbles in the solution. The foam and bub
Cleaning the Element bles normally stop in 30 to 60 seconds.
5. Put the element into a container that has a 5
1. Put the element into a container of carbon
percent solution of sodium carbonate. Re
tetrachloride or trichlorethylene. Keep the ele
move the element when there are no bubbles
ment in the solution for several minutes. Then,
coming from the solution.
flush the solution around and through the
tubes in the element. 6. Flush the element with clean, warm water.
Warning: The fumes from the solution are
Cleaning the Housing
dangerous. Use the solution In open air or In a
room that has proper ventilation. Wear safety Use steam and cleaning solvent to clean the
glasses and gloves. housing.
7-17
Inspection
1. Check the cooler housing for cracks, damage
and corrosion.
2. Check the suport and cover for cracks,
damage and corrosion.
3. Check the cooler element for damage and
leaks. Use the Part No. 3375253 Tube Bundle
Tester to check for leaks. Follow these
instructions:
a. Install the end plates to each end of the
element.
b. Put the sliding plate of the fixture so that
the fixture will fit over the element and end
plates, Fig. 7-21. Fig. 7-22. The Element Installed Into The Bundle Tester.
completely covers the element. Check the

element for air leaks.
h. Remove the element and tool assembly
from the container.
i. Use the air discharge valve to release the
air pressure from the element.
j. Remove the tube bundle tester from the
element.
4. Replace all the parts that are damaged.
Repair
lf less than 5 percent of the tubes in the element
have restrictions or are damaged, the element can
Fig. 7-21. Adjust The Length Of The Fixture be repaired. If more than 5 percent of the tubes
have restrictions, or are damaged, replace the
c. Put the element into the fixture. Put the element.
fixture so that the air connection fitting Caution: Never use a cooler element from an
goes through the notch in the fixture plate. engine that had a failure. When an engine has a
Install locking clips into the bars of the fix failure, metal particles enter the oil cooler. These
ture, Fig. 7-22. particles cannot be completely removed from the
d. Connect an air supply line that has a element and can cause damage to the engine.
quick-disconnect fitting to the air connec
To repair the damaged tubes:
tion fitting.
e. Use an air pressure regulator and a three 1. lnstall a new tube into the damaged tube. The
way air discharge valve to control the air CD. of the new tube must be smaller than the
pressure. I.D. of the tube you are repairing.
f. Apply 60 psi [414 kpa] of air pressure to 2. Cut the ends of the tube so it will be the same
the element. length as the other tubes. Make sure the ends
of the tube are flared.
g. Put the element and tool assembly into a
container of water. Make sure the water 3. Solder the ends of the tube to the element. Do
-18
Lubricating System
not cause damage to the other tubes or the

element when you solder the new tubes.
4. Check the element for leaks.
Assembly (FFC and Big Cam)
1. Put the element into the housing. Put the

housing and element onto a flat workbench
with the rear of the housing up.
2. Align the index mark on the element with the
index mark on the housing, Fig. 7-23.
Fig. 7-24. Index Marks On The Element.
Fig. 7-25. Use The Mandrel To Install The O-Rlng.
Note: The O-ring must be installed in less than

one hour after the oil is applied.
4. Push the O-ring into the housing. Use the Part
Fig. 7-23. Align the Index Marks On The Element And Housing. No. ST-1218 or ST-1223 Cooler O-Ring Mandrel
to push the O-ring into the housing. Hit the
a. Some of the Part No. 208149 elements mandrel with a plastic hammer until the man
have two lndex marks. They can have an drel is against the element and housing, Fig.
"0" on the tube end plate and a notch cut 7-25.
into the inside diameter of the rim, Fig.
a. Use the ST-128 for an oil cooler that has a
7-24. Use the notch to align the element in
5.0 inch [127.0 mm] diameter element.
the housing.
b. Use the ST-1223 for an oil cooler that has a
3. Apply a coat of clean lubricating oil to a new 4.0 inch [101.6 mm] diameter element.
O-ring. Put the O-ring between the element and
the housing. Make sure that the O-ring does 5. lnstall the retaining ring. Make sure that the
not protrude over the element and housing. part number on the ring is up.
7-1°
6. lnstall the cover and a new gasket to the hous

ing. Tighten the capscrews to 30 to 35 ft. -lbs.
[41 to 47 N»m] torque.
7. Slide the housing to the edge of the
workbench until you can hold the element In
position with your hand. Make sure that the
element does not move in the housing. Put the
housing with the cover end down onto the
workbench.
8. Repeat Steps 3, 4 and 5 to install the O-ring
and retaining ring.
9. lnstall the support and a new gasket to the
housing. Tighten the capscrews to 30 to 35
Fig. 7-27. Remove The Thermostat And O-Ring.
10. Install all of the pipe plugs that were removed.
a. Tighten the 1/4 inch pipe plug to 15 to 25
ft.-lbs. [20.3 N»m] torque.
b. Tighten the 1/8 inch pipe plug to 5 to 7
ft.-lbs. [6.8 to 9.5 N»m] torque.
NTE (European) Oil Cooler

Disassembly
1. Remove the cover plate from the housing and
discard the gasket, Fig. 7-26.
Fig. 7-26. Remove The Cover Plate.
2. Remove the thermostat from the thermostat

housing. Discard the O-ring, Fig. 7-27.
3. From the opposite end of the cooler housing,
remove the plate that holds the element in the Fig. 7-29. Remove The O-Ring From The Thermostat End Of
housing, Fig. 7-28. The Housing.
Lubricating System
4. To remove the O-ring from the thermostat end

of the housing, push the element approx
imately 0.50 inch [12.4 mm] toward the filter
end of the housing. Remove and discard the
O-ring, Fig. 7-29.
5. Push the element through the housing, toward
the thermostat end of the housing. Remove
the element, Fig. 7-30.
6. Remove and discard the O-ring from the filter
end of the housing, Fig. 7-31.
7. Remove the pipe plugs from the housing.
8. Check the filter bypass valve to make sure the
valve works freely, Fig. 7-32.
1 Plug
2 Gasket
3 Valve Seat
4 Valve
5 Valve Spring
6 Washer
Fig. 7-32. Filter Bypass Valve — Exploded View.
Cleaning
1. Clean the element and housing immediately
after disassembly. This will prevent hardening
and drying of foreign material in the element
and housing.
Fig. 7-30. Remove The Element From The Housing.
2. Use mineral spirits or equivalent to clean the
housing. Flush the oil passages in the reverse
direction of the oil flow.
3. Flush the element with hot water. Make sure
the water goes around and through the tubes
of the element. Dry with compressed air.
Cuatlon: Never use a cooler element from an
engine that had a failure. When an engine has a
failure, metal particles enter the oil cooler. These
particles cannot be completely removed from the
element and can cause damage to the engine.
Inspection
1. Check the oil cooler element for damage and
leaks. To check the element for leaks:
Fig. 7-31. Remove The O-Ring From The Filter End Ot The a. Seal both ends of the element. One end
Housing. must have a fitting for an air connection.
7-21
b. lnstall an air connection to the end that

has a fitting.
c. Put the element into a container of water.
d. Apply 40 psi [276 kPa] air pressure to the
element.
e. Check for air bubbles coming from the
element.
Check the cooler housing for cracks, damage
or corrosion.
1. Replace the element if it has damage or leaks.

2. Replace the housing if it has cracks, damage Fig. 7-34. Install The O-Ring Into The End Of The
or corrosion. Housing.
Apply a coat of SAE 30 oil to the O-ring for the

thermostat. lnstall the O-ring into the groove
in the housing.
lnstall the thermostat into the housing. Push
the thermostat into the housing until it is
against the bottom of the bore, Fig. 7-33
Fig. 7-35. Install The Element Into The Housing.
5. lnstall the element into the housing from the

filter end of the housing. Make sure the drain-
cock on the element is to the filter end of the
housing, Fig. 7-35. Use your hand to push the
element into the housing.
6. lnstall the cover and a new gasket to the
cooler housing. Do not tighten the capscrews,
Fig. 7-33. Install The Thermostat. install them 2 to 3 threads deep into the
housing.
Apply a coat of to the O-ring for the 7. Apply a coat of grease to the second O-ring for
element. the element.
4. lnstall the O-ring into the groove at the ther 8. lnstall the O-ring into the groove at the filter
mostat end of the housing, Fig. 7-34. end of the housing.
Note: Make sure the groove does not have any Note: Make sure the groove does not have any
sharp edges before you install the O-ring. sharp edges before you install the O-ring.
Lubricating System
9. Tc push the element into position over the Table 7-1: Lubricating Oil Pump Specifications —
O-ring, evenly tighten four of the capscrews
Inch [mm] (Reference Fig. 7-0)
for the support.
Ref. Worn New New
10. Tighten all of the capscrews to 15 to 20 ft.-lbs. No. Measurement Limit Minimum Maximum
[20 to 27 N»m] torque, Fig. 7-36. Single Lubricating Oil Pump
11. Install the retaining plate with a retaining Bushings
Inside diameter 0.6185 0.6165 0.6175
screw, lockwasher and plain washer, Fig. 7-37. [15.710] [15.659] [15.684]
Tighten the screw to 5 to 6 ft.-lbs. [6 to 8 N»m] Idler and Drive Shaft
torque. Outside diameter 0.6145 0.615 0.6155
[15.606] [15.62] [15.634]
12. Apply a coat of Locktite 572 to the threads of Drive Gear to Body
the draincock. lnstall the draincock into the Clearance 0.012
element and tighten to 5 to 10 ft.-lbs. [6 to 13 [0.30]
N»m]. Drive Shaft
End Movement 0.002 0.005
[0.05] [0.13]
ldler shaft
Shaft Protrusion 0.720 0.740
lnside Body [18.29] [18.80]
Driven Gear/Drive Shaft
[21.72] [22.22]
Single (Double Capacity) Lub tcatlng OH Pump
Bushings
Inside Diameter 0.879 0.8767 0.8777
[22.33] [22.268] [22.293]
Idler and Drive Shaft
[22.17] [22.212] [22.22]
3. Drive Gear to Body
Clearance 0.012
[0.30]
Drive Shaft
[0.05] [0.20]
ldler Shaft
Fig. 7-36. Tighten The Capscrews For The Cover. Shaft Protrusion
Above body to Cover Face 0.955 0.985
[24.26] [25.02]
[26.29] [26.80]
Piston Cooling OH Tube
Protrusion Above Body 2.970 3.000
Mounting Face [75.44] [76.20]
Double Lubricating Oil Pump
Bushings
lnside Diameter 0.6185 0.6165 0.6175
[15.710] [15.659] [15.684]
ldler and Drive Shaft
[15.608] [15.62] [15.634]
Drive Gear to Body
Clearance 0.012
[0.30]
Drive Shaft
[0.10] [0.18]
Fig. 7-37. Install The Retaining Plate.
7-
Table 7-1: Lubricating Oil Pump Specifications — Table 7-1: Lubricating Oil Pump Specifications —
Inch [mm] (Reference Fig. 7-0) (Cont.) inch [mm] (Reference Fig. 7-0) (Cont)
Ref. New New Ref. Worn New New
No. Measurement No. Measurement Minimum Maximum
Idler Shaft Load at 2.125 inch 45 50
Shaft Protrusion Above [53.98 mm] lb. [N] [200] [222]
Back Surface of Body 2.600 2.620 Recommended Oil 50 70
[66.04] [66.55] psi [kPa] [345] [483]
Idler Shaft FFC Lubricating Oil
Suffix Letter L 2.680 2.690 Free Length 2.500
[68.07] [68.33] [63.50]
Drive Gear/Drive Shaft Load at 1.780 inch 79 91
Shaft Protrusion 0.040 0.060 [45.21 mm] lb. [N] [351] [405]
[1.02] [1.52] Oil Pressure 130
Single psi [kPa] [896]
Bushii DFC Lubricating Oil I
lnside 0.6185 0.6165 0.6175
[15.710] [15.659] [15.684] 3.310
[84]
Outside Diameter 0.6145 0.615 0.6155 Load at 1.820 lnch 21.9 25.7
[15.608] [15.62] [15.634] [46.2 mm] lb. [N] [97.4] [114]
Idler Shaft Oil Pressure 40
Protrusion Flush with front surface of pump. psi [kPa] [275.7]
Driven ' DFC Lubricating Oil
Protrusion 0.580 .0610
[14.73] [15.49] Free Length 2.224
[56.5]
Protrusion Above 1.010 Load at 1.145 inch 59.2 72.4
Coupling Face [25.15] [25.64] 129.07 mm] lb [N] [263] [322]
Coupling/Drive Shaft Oil Pressure 150
Shaft Protrusion 0.050 0.070 psi [kPa] [1034]
[1-27] [1.78]
Drive Shaft Table 7-2: Hose
[0.10] [0.25]
Turbocharger Oil No. 6
Full Flow Filter No. 16
lnside Diameter 0.841 0.840 0.8405 No. 16
[21.36] [21.34] [21.349]
Outside Diameter 0.837 0.8375 0.838 Table 7-3: Hose — Inch [mm] (Rubber-Lined)
[21.26] [21.272] [21.29] nose Inside Outside Minimum
Idler Shaft Size Diameter Diameter Bend Radius
Protrusion Flush with front surface of pump.
Driven Gear/Drive Shaft 4 3/16 [4.76] 31/64 [12.30] 2 [50.80]
Protrusion 0.580 0.610 5 1/4 [6.35] 35/64 [13.89] 2-1/4 [57.15]
[14.73] [15.49] 6 5/16 [7.94] 39/64 [15.48] 2-3/4 [69.85]
Coupling Dowels 8 13/32 [10.32] 47/64 [18.65] 4-5/8 [117.48]
Protrusion Above 0.990 1.010 10 1/2 [12.70] 53/64 [21.03] 5-1/2 [139.70]
Coupling Face [25.15] [25.65] 12 5/8 [15.87] 61/64 [24.21] 6-1/2 [165.10]
Coupling/Drive Shaft 16 7/8 [22.23] 1-13/64 [30.56] 7-3/8 [187.34]
Shaft Protrusion 0.050 0.070 20 1-1/8 [28.58] 1-31/64 [37.70] 9 [228.60]
[1.27] [1.78] 24 1-3/8 [34.93] 1-23/32 [43.66] 11 [279.40]
Drive Shaft
End Movement 0.004 0.007 Table 7-4: Hose Bends — Inch [mm] (Teflon-Lined)
[0.10] [0.25] Hose Inside Outside Minimum
FFC Filter/Cooler or Non-FFC Lubricating OH Size Diameter Diameter Bend Radius
Pump Pressure Regulator Spring
Free Length [86.36]
3.410 6 5/16 [7.94] 39/64 [15.48] 4 [101.60]
16 7/8 [22.23] 1-13/64 [30.56] 7-3/8 [187.33]
24
Lubricating System
Table 7-5: Oil Pan Capacity — U.S. Gallons [Litres] and Degrees of Angularity
Capacity Degrees of Angularity
F.P. Exhaust
Part Sump Front Pront Side Side
Number Location High Low Up Down Down Down
10451 Center 6-1/2 [25] 4 [15]
10474-2 Rear 7 [26] 5-1/2 [21] 19 21 35 35
10492-2 Rear 6-1/2 [25] 4 [15] 19 21 35 35
10668-1 Rear 8-1/2 [32] 5-1/2 [21] 16 16 16 16
10774 Rear 7 [26] 5-1/2 [21] 19 20 30 25
10777 Front 7 [26] 5-1/2 [21] 40 40 45 35
10779 Rear 8-1/2 [32] 5-1/2 [21] 16 16 16 16
10809 Full 11 [42] 3 [11]
10811 Center 7 [26] 5-1/2 [21] 32 40 37 35
10850 Rear 7 [26] 5-1/2 [21] 14 12 45 20
10850-A Rear 7 [26] 5-1/2 [21] 14 12 45 20
11055 Front 7 [26] 5-1/2 [21]
11102 Front 7 [26] 5-1/2 [21]
11150 Dry
11194 Dry
103949 Front 7 [26] 5-1/2 [21] 15 35 35 35
110626 Rear 7 [26] 5-1/2 [21] 40 25 45 19
116916 Rear 7 [26] 5-1/2 [21] 20 15 37 35
118784 Rear 7 [26] 5-1/2 [21] 14 12 45 20
119330 Center 7 [26] 5-1/2 [21] 45 45 45 45
119382 Full 7 [26] 5-1/2 [21] 42 1 19 40
119586 Front 7 [26] 5-1/2 [21]
120905 Center 7 [26] 5-1/2 [21]
121089 Front 6 [23] 4-3/4 [18] 15 30 30 30
121244 Front 6 [23] 4 [15] 36 45 45 40
121862 Center 6-1/2 [25] 4-1/2 (17] 22 24 40 40
121377 Rear 6 [23] 4 [15] 45 38 42 40
125318 Rear 6-1/2 [25] 4 [15] 28 15 38 38
126818 Rear 7 [26] 5-1/2 [21] 40 25 45 19
129434 Rear 6 [23] 4 [15] 45 38 42 40
133879 Rear 7 [26] 5-1/2 [21] 36 11 32 30
134070 Center ^ 6 [23] 4 [15] 35 33 35 35
134271 FTr.r" 7 [26] 5-1/2 [21] 10 35 40 40
134279 Rear 7 [26] 5-1/2 [21] 19 21 35 35
134283 Rear 7 [26] 5-1/2 [21] 19 20 30 25
137156 Full 7 [26] 4 [15] 45 8 42 40
139493 Front 6 [23] 4 [15] 36 45 45 40
139745 Rear 6 [23] 4 [15] 45 38 42 40
146866 Dry
148160 Rear 6 [23] 4 [15] 45 39 40 42
151079 Rear 6 [23] 4 [15]
152410 Rear 6 [23] 4-1/2 [17] 27 15 25 35
7-25
Table 7-5: Oil Pan Capacity — U.S. Gallons [Litres] and Degrees of Angularity (Cont'd.)
F.P.
Part Sump Front Front Side îde**
Number Location High Low Up Down Down
153729 Rear 7 [26] 5-1/2 [21] 19 12 25 25
154418 Full 6 [23] 4 [15] 15 15 15 15
161206 rroni 6 [23] 4 [15] 36 45 45 40
162377 Rear 7 [26] 5-1/2 [21] 45 38 42 40
164436 rroni 6 [23] 4 [15] 40 40 45 35
164776 Rear 7 [26] 5-1/2 [21] 40 25 45 19
167186 Rear 7 [26] 5-1/2 [21] 19 12 25 25
167429 Rear 7 [26] 5-1/2 [21] 40 25 45 19
169348 Front 6 [231 4 [15] 40 40 45 35
177155 Rear 6 [23] 4 [15] 45 39 40 42
181768 Rear 7 [26] 5-1/2 [21] 20 15 37 35
187756 Center 6-1/2 [25] 4 [151 24 24 32 30
189672 Full 12 [45] 3-1/2 [13]
193625 Rear 7 [26] 5-1/2 [21] 16 12 35 30
193629 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193631 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193634 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193635 Rear 7 [26] 5-1/2 [21] 16 12 35 39
1 93636 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193637 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193638 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193639 Rear 7 [26] 5-1/2 [21] 16 12 35 39
200787 Rear 7 [26] 5-1/2 [21] 16 12 35 39
201836 Rear 5 [19] 3-1/2 [13] 27 15 25 35
201837 Rear 5 [19] 3-1/2 [13] 27 15 25 35
201839 Rear 7 [21] 5-1/2 [21] 16 12 35 39
201841 Rear 5 [19] 3-1/2 [13] 27 15 25 35
201842 Rear 7 [26] 5-1/2 [21] 16 12 35 39
201843 Rear 7 [26] 5-1/2 [21] 16 12 35 39
201844 Rear 5 [19] 3-1/2 [13] 27 15 25 35
202283 rroni 7 [26] 5-1/2 [21] 10 35 40 40
202284 rroni 7 [26] 5-1/2 [21] 10 35 40 40
203561 Rear 7 [26] 5-1/2 [21] 19 12 25 25
203563 Rear 7 [26] 5-1/2 [21] 19 12 25 25
203564 Rear 7 [26] 5-1/2 [21] 19 12 25 25
203841 Front 7 [26] 5-1/2 [21] 10 35 40 40
3002151 Center 6-1/2! [25] 5-1/2 [21] 24 24 32 30
3002152 Center 7 [26] 5-1/2 [21]
3005178 Rear 7 [26] 5-1/2 [21] 19 12 25 25
3005179 Rear 7 [26] 5-1/2 [21] 19 12 25 25
3005181 Rear 7 [26] 5-1/2 [21] 19 12 25 25
3005183 Rear 7 [26] 5-1/2 [21] 19 12 25 25
7-26
Cooling System
The cooling system includes the water pump for

Group 8 the engine, the fan hub, thermostat, heat ex
change, and sea or raw water pump.
Cooling System
16
1. Pipe Plug 7. Spacer 13. Water Pump Housing 19. Capscrew 25. Spacer
2. Pulley 8. Snap Ring 14. Pipe Plug 20. Washer 26. Snap Ring
3. Wear Sleeve 9. Ball Bearing 15. Carbon Face Seal 21. ldler Pulley 27. Capscrew
4. Grease Seal 10. Shaft 16. Adjusting Screw 22. ldler Shaft 28. Grease Seal
5. Snap Ring 11. Grease Seal 17. Seat 23. Ball Bearing 29. Lockwasher
6. Ball Bearing 12. Pipe Plug 18. lmpeller 24. "0" Ring 30. Spacer
31. Nut
Fig. 8-1 (N10894). FFC And Eccentric Water Pump — Exploded View. 8-1
Service Tool List The Eccentric Water Pump
Service TooIs (Or Equivalent) Required Remove the huglock nut (14, Fig. 8-2) and the
Service Tool Tool washer (15). The huglock nut and washer are
Number Name
not used on the water pump with the short
ST-657 Bearing Mandrel shaft. Use the Part No. 3375265 Puller to
ST-658 Bearing Mandrel
ST-709 remove the pulley (1) from the shaft (7).
ST-1114 Bearing Separator Remove the large retaining ring (2).
ST-1154 Seal Mandrel
ST-1159 Wear Sleeve Driver Use the 3375265 Puller to remove the impeller
ST-1161 Seal Mandrel (13) from the shaft, Fig. 8-3. lf the pump has a
ST-1191 Seal Driver plastic (phenolic) impeller, the impeller does
3375110 lmpeller Support Plate not have holes for a puller. Use the Part No.
(Phenolic impellers only)
3375180 Oil Seal Pilot 3375110 Support Plate between the impeller
3375257 Pulley/lmpeller Puller and water pump housing. Use a press to push
3375265 Pulley/lmpeller Puller the shaft from the impeller, Fig. 8-4.
3375318 Bearing Mandrel
3375326 Bearing Separator Support the water pump housing on the pulley
3375448 Seal and Seat Mandrel side of the housing. Use a press to push the
3376081 Bearing Mandrel shaft and bearing assembly from the housing.
Apply the pressure to the impeller end of the
Standard Tools shaft.
Arbor Press Grease Gun
Bearing Packer Feeler Gauge Set Remove the cup seat (12, Fig. 8-2), face seal
0-1, 1-2, 2-3 Micrometers Telescoping Gauges (11), grease fittings (10), and relief fittings (8).
Snap Ring Pliers (Large and Small)
5/16-18, 3/8-16, 6/16-14 Taps Use the Part No. ST-1114 Bearing Disassembly
Fixture to support the bearing and spacer. Push
1. Water Pump Pulley 5. Retaining Ring 9. Water Pump Housing 13. lmpeller
2. Retaining Ring 6. Ball Bearing 10. Grease Fitting 14. Huglock Nut
3. Ball Bearing 7. Shaft 11. Face Seal 15. Washer
4. Spacer 8. Relief Fitting 12. Cup Seat
Fig. 8-2 (N10845). Eccentric Water Pump With Short Shaft And Eccentric Water Pump With Long Shaft.
8-2
Cooling System
Fig. 8-6 (N10849). Remove The Retaining Ring.
the shaft from the bearing and spacer, Fig. 8-5.

6. Remove the small retaining ring that holds the
inner bearing in position, Fig. 8-6.
7. Use the ST-1114 to support the bearing. Push
the shaft from the bearing.
Cleaning
1. Clean all parts with cleaning solvent. Dry with
compressed air.
Inspection
1. lnspect the bearings. Check for damage or
wear to the races of the bearings. lf the bear
Fig. 8-4 (N10847). Using A Press To Remove The Impeller. ings are damaged or worn, be sure to check
the shafts and bore in the housing for damage
and wear. Discard the bearings.
2. lnspect the bearing spacer for wear or damage.
3. Check the water pump impeller for cracks or
corrosion.
4. Measure the bore of the impeller and the out
side diameter of the impeller and of the shaft.
The press-fit between the shaft and the im
peller bore must be a minimum of 0.001 inch
[0.03 mm]. Refer to Table 8-1, in the back of
this section, to find the correct dimensions of
the parts.
5. Check the shaft for wear and damage.
6. Check the grooves in the pulley for wear and
Fig. 8-5 (N10848). Push The Shaft From The Bearing. damage.
8-3
Note: A new belt, when pushed down into the

groove, must protrude 1/16 to 1/8 lnch [0.06 to 0.13
mm] above the outside diameter of the pulley. The
belt must not touch the bottom of the groove.
7. Check the water pump housing for wear and
damage. Make sure the weep hole in the hous
ing is open. Measure the bore in the housing,
Fig. 8-7. Discard the housing if the bore is
larger than 2.4494 inch [62.215 mm].
Fig. 8-8 (N 10851). Push The Shaft Into The Bearing.
Caution: To prevent damage to the bearing, make

sure the inner race of the bearing is not over
loaded from contact with the spacer.
4. Apply a thin coat of Loctite 601 to the outer

race of the bearings, Fig. 8-9. To support the
waterpump housing, put the impeller side of
the housing on a mandrel. Use the ST-658
Mandrel to push the shaft and bearing
assembly into the housing.
Fig. 8-7 (N10850). Measure The Bore In The Housing.
Replacement
Replace any parts which are damaged or worn
beyond the specifications in Table 8-1.
Assembly
1. Apply a coat of clean lubricating oil to the out
side diameter of the shaft. Support the new in
ner bearing with a Part No. ST-658 Mandrel.
Use a press to push the shaft into the bearing,
Fig. 8-8. Push the shaft into the bearing until
the bearing is against the larger diameter
(shoulder) of the shaft.
2. lnstall the small retaining ring on the shaft.
Make sure the ring is against the bearing. In
stall the bearing spacer onto the shaft. The Fig. 8-9 (N10852). Apply Loctite Onto The Bearings.
side of the spacer must be against the side of
the bearing. Caution: Do not support the housing on the thin
section of the Impeller cavity.
3. Support the new outer bearing with the
ST-658. Push the shaft into the bearing until 5. lnstall the larger retaining ring into the water
the bearing is against the spacer. Make sure pump housing. The flat side of the ring must
the bearings turn freely. be against the bearing.
8-4
Cooling System
6. Turn the water pump housing and support the

drive side of the housing. Apply a coat of Part
No. 3375066 Loctite to the outside diameter of
the brass part of the seal, Fig. 8-10. Push the
new seal into the housing until the seal is
against the bottom of the bore. Use the Part
No. 3375448 Mandrel to push the seal into the
housing.
7. Use the 3375448 and push the new cup seat
onto the shaft. The 3375448 will put the cup
seat into the correct position against the seal,
Fig. 8-11.
8. Apply one drop of Loctite 290 to the cup seat.
Put the drop of Loctite between the shaft and
Fig. 8-10 (N10853). Apply Sealant Onto The Seat. the cup seat, Fig. 8-12.
Caution: Do not apply more than one drop of the
Loctite. More than one drop will cause the seal
and seat to become fastened together.
9. Apply a thin coat of Loctite 601 to the inside
diameter of the impeller. Support the water
pump on the pulley end of the shaft. Push the
impeller onto the shaft. The minimum clear
ance between the vanes of the cast iron im
peller and the water pump housing must be
0.020 inch [0.51 mm]. The maximum clearance
must not be more than 0.040 inch [1.02 mm],
Fig. 8-13.
Fig. 8-11 (N 10854). Install The Seat Onto The Shaft.
Fig. 8-13 (N10855). Measure The Clearance For The Impeller.
Note: The minimum clearance for a plastic

(Phenolic) impeller is 0.030 inch [0.76 mm]. The
maximum clearance must not be more than 0.050
Fig. 8-12 (UW102). Apply Loctlte Between The Shaft And The Seat. inch [1.27 mm].
8-5
(18, Fig. 8-15). Push the shaft from the bearing. A new belt, when pushed down into the
groove, must protrude 1/16 to 1/8 inch [0.06 to 0.13
10. Remove the pipe plug (2, Fig. 8-15) from the
idler pulley (4).
11. Remove the retaining ring (3, Fig. 8-15) from
5. Measure the bore in the drive and idler pulley.
the shaft (8).
Measure the outside diameter (pulley end) of
12. Use the 3375326 to support the idler pulley. the water pump shaft Measure the outside di
Push the shaft and bracket assembly (8, Fig. ameter (pulley end) of the idler shaft. The
8-15) from the pulley, Fig. 8-19. press-fit between the shaft diameters and
pulley bores must be a minimum of 0.001 inch
13. Remove the oil seal (7, Fig 8-15) and retaining
[0.03 mm].
ring (6) from the pulley. Use the flat end of a
punch to push the bearing (5) from the pulley, Check the wear sleeve (23, Fig. 8-15) for wear
Fig. 8-20. Discard the oil seal and bearing. or damage. To remove the sleeve, use a chisel
to cut a groove in the sleeve, Fig. 8-21. Be
careful and do not damage the pulley. Use a
Fig. 8-20 (N10863). Remove The Bearing From The Pulley.
Fig. 8-21 (N10864). Cut The

Clean all of the parts with cleaning solvent. Dry
with compressed air.
1. Check the impeller for cracks or corrosion.

2. Measure the bore of the impeller and the out
side diameter of the impeller end of the shaft.
The press-fit between the shaft and the im
peller bore must be a minimum of 0.001 inch
[0.03 mm]. Refer to Table 8-2, in the back of
this section, to find the correct dimensions of
the parts.
4. Check the grooves in the pulleys for wear and
damage. Fig. 8-22 (N10865). Push The
8-8
Cooling System
3. lnstall the retaining ring (6, Fig. 8-15) with the

flat side of the retaining ring against the bear
ing. lnstall a new seal (7) so that the flat side
of the seal is even with the hub of the pulley as
shown in Fig. 8-24. Use the Part No. ST-1159
Seal Driver to install the seal.
4. Push the pulley and bearing assembly onto
the shaft (8, Fig. 8-15). lnstall the retaining
ring (3).
5. Put grease into the pulley cavity until the
cavity is one-half to two-thirds full. lnstall the
pipe plug.
Assemble the Water Pump

Fig. 8-23 (N10866). Measure The Bore ln The Housing. 1. Apply a thin coat of clean lubricating oil to the
shaft (19, Fig. 8-15). Use the Part No. ST-658
punch to push the sleeve from the pulley, Fig. Bearing Mandrel to support the smaller bear
8-22. ing (18). Push the impeller end of the shaft
7. Check the water pump housing for cracks, into the bearing until the bearing is against
damage or corrosion. Make sure the "weep" the larger diameter (shoulder) of the shaft as
hole in the housing is open. Measure the bore shown in Fig. 8-25.
in the housing, Fig. 8-23. Refer to Table 8-2 to 2. Use the Part No. 3375318 Bearing Mandrel to
find the correct dimensions. support the outer bearing (20). Push the pulley
Assembly
Assemble the Idler Pulley and Bracket
1. Apply grease to the bearings. Make sure the
grease meets the specifications of MlL-
G-3545.
2. Use the Part No. ST-567 Bearing Mandrel to
push the bearing (5, Fig. 8-15) into the pulley (4).
Fig. 8-24 (N10867). The Seal Installed Into The Pulley. Fig. 8-25 (N10868). lnstall The Shaft Into The Bearing.
8-9
end of the shaft through the bearing until the

bearing is against the larger diameter of the
shaft.
3. Use the Part No. ST-1154 Seal Mandrel to push
the small seal (12, Fig. 8-15) into the water
pump housing (9). The seal must be even with
to 0.015 inch [0.38 mm] below the edge of the
bore, Fig. 8-26.
Fig. 8-28 (N 10871 ). Install The Shaft Assembly Into The Housing.
5. lnstall the grease fitting. Make sure the grease

fitting is clean. Install grease, through the fit
ting, into the housing until you can see the
grease in the opposite pipe plug hole. You
must use grease that meets the specifications
of MIL-G-3545. Do not use grease that has
sodium or soda soap thickeners.
Fig. 8-26 (N10869). Install The Seal Into The Housing.
4. Apply a thin coat of Loctlte 601 to the outside

diameter of the bearings, Fig. 8-27. Install the
shaft and bearing assembly into the housing.
Use the 3375318 to push the shaft and bearing
into the housing, Fig. 8-28. Install the larger
retaining ring (4, Fig. 8-15).
Fig. 8-27 (N10870). Apply Loctlte Onto The Bearings.

Cooling System
6. Support the water pump housing at the im

peller side of the housing. lnstall the larger
grease seal. Use the Part No. ST-1161 Seal
Driver to install the seal, Fig. 8-29.
7. lnstall the idler pulley and bracket assembly
to the water pump housing.
8. Support the water pump assembly at the im
peller end of the shaft. Push the drive pulley
(24, Fig. 8-15) onto the shaft until the pulley is
against the bearing.
9. Support drive side of the housing. Apply a
coat of Part No. 3375066 Locktite to the out
side diameter of the brass part of the seal, Fig.
8-30. Use the Part No. 3375448 Mandrel to
push the seal into the housing, Fig. 8-31. Fig. 8-32 (UW102). Apply Loctite Between The Shaft And The
Cup Seat.
Fig. 8-30 (N10853). Apply Loctlte Onto The Seal.

Fig. 8-33 (N10874). Measure The Clearance For The lmpeller.
10. Install a new cup seat (14, Fig. 8-15) onto the
shaft. Use the 3375448 to push the cup seat
onto the shaft.
Put the Loctite between the shaft and the cup
seat as shown in Fig. 8-32.
Caution: Do not apply more than one drop of the
Loctlta 290. More than one drop will cause the
seal and cup seat to become fastened together.
12. Support the water pump on the pulley end of
the shaft. Push the impeller onto the shaft.
The minimum clearance between the vanes of
the impeller and the housing must not be less
Fig. 8-31 (N10873). Install The Seal Into The Housing. than 0.020 Inch [0.51 mm]. The maximum
8-11
clearance must not be more than 0.040 inch

[1.02 mm], Fig. 8-33.
The minimum clearance for a
(Phenolic) impeller must not be less than 0.030
inch [0.76 mm]. The maximum clearance must not
be more than 0.050 inch [1.27 mm].
13. Apply clean lubricating oil to a new O-ring (11,
Fig. 8-15). lnstall the O-ring into the groove in
the water pump housing (9). Install the hous
ing (9) to the inlet housing (16). Do not
damage the O-ring.
The FFC Water Pump
Fig. 8-35 (UW104). Remove The

1. Remove the nut (19, Fig. 8-34) and the ad
justing screw (16). Remove the idler pulley
assembly. (phenolic) impeller that does not have puller
2. Remove the drive pulley (2) and the impeller
(18) from the shaft (10). Use the Part No. a. Remove the larger retaining ring that
3375265 Puller to remove the pulley and im holds the bearing assembly and shaft in
peller, Fig. 8-35. To remove the plastic the housing.
1. Pipe Plug 7. Spacer 13. Water Pump Housing 19. Nut 25. Ball Bearing
2. Pulley 8. Retaining Ring 14. Pipe Plug 20. Spacer 26. ldler Shaft
3. Wear Sleeve 9. Ball Bearing 15. Face Seal 21. Grease Seal 27. Idler Pulley
4. Grease Seal 10. Shaft 16. Adjusting Screw 22. Retaining Ring 28. Washer
5. Retaining Ring 11. Grease Seal 17. Cup Seat 23. Spacer 29. Capscrew
6. Ball Bearing 12. Pipe Plug 18. lmpeller 24. O-Rlng
Fig. 8-34 (N10875). (FFC) Water Pump — Exploded View
9-12
Cooling System
b. Push on the shaft, from the impeller end, 7. Use the Part No. ST-1114 Bearing
to remove the impeller. Disassembly Fixture to support the outer
bearing (6, Fig. 8-34) and spacer (7). Push the
3. Remove the grease seal (4, Fig. 8-34) from the
shaft from the bearing and spacer, Fig. 8-38.
housing (13). Use a pry bar to remove the seal,
Fig. 8-36. Do not damage the bore. 8. Remove the retaining ring (8, Fig. 8-34). Use
the ST-1114 to support the bearing (9). Push
4. Remove the larger retaining ring (5, Fig. 8-34) the shaft from the bearing.
that holds the bearing and shaft in the housing.
9. Hold the spacer of the idler pulley assembly
5. Support the pulley side of the housing. Push with a vise. The jaws of the vise must have
on the impeller end of the shaft to remove the copper plates to prevent damage to the
bearings and shaft from the housing. spacer. Lightly hit the shaft with a plastic
6. Remove the cupseat (17, Fig. 8-34). Use a drift hammer to push the shaft from the spacer,
to push the grease seal (11) and face seal (15) Fig. 8-39.
from the housing as shown in Fig. 8-37. Dis 10. Remove the oil seal (21, Fig. 8-34) from the
card the cupseat and seals.
Fig. 8-38 (N10879). Remove The Shaft From The Bearing.

Fig. 8-36 (N10877). Remove The Seal From The Housing.
Fig. 8-39 (N10880). Remove The Pulley And Shaft From The
Fig. 8-37 (N10878). Remove The Seal From The Housing. Spacer.
8-13
pulley. Use the round end of a pry bar to

remove the seal. Do not damage the bore for
the seal.
11. Remove the retaining ring (22).
12. Remove and discard the O-ring (24).
13. Remove the bearing assembly from the pulley.
a. Remove the plug (29) from the pulley.
b. Hold the pulley in a vise.
c. Put the flat end of a punch through the
plug hole. Lightly hit the punch with a
plastic hammer to push the bearing
assembly from the pulley, Fig. 8-40.
14. Use a press and a mandrel to push the shaft
(26, Fig. 8-34) from the bearing (25).
Cleaning
Clean the parts with cleaning solvent. Dry with
compressed air.
lnspection
1. Check the bearings for wear and damage. lf Fig. 8-40 (N10881). Remove The Bearing Assembly From The
the bearing races are damaged, be sure to Pulley.
check the outside diameter of the shafts and
the bearing bores for damage. Discard the
bearings after inspection.
2. Check the impeller for cracks, corrosion or
damage.
3. Measure the bore in the impeller. Measure the
outside diameter of the shaft at the impeller
end of the shaft. There must be at least 0.001
inch [0.03 mm] press-fit between the impeller
bore and outside diameter of the shaft.
4. Check the wear sleeve of the drive pulley for
wear or damage. Remove the wear sleeve if it
is worn or damaged.
a. Use a chisel as shown in Fig. 8-41 to cut a
groove into the wear sleeve.
b. Use a chisel to push the sleeve from the Fig. 8-41 (N 10882). Cut The Wear Sleeve.
pulley, Fig. 8-42.
above the outside diameter of the pulley. The belt
c. Use the Part No. ST-1159 Wear Sleeve must not touch the bottom of the groove.
Driver to install the new wear sleeve.
6. Check the shafts to make sure they are
5. Check the pulley grooves for wear or damage. straight and are not damaged.
Note: A new belt, pushed down into the groove, 7. Measure the bore in the drive pulley and idler
must protrude 1/16 to 1/18 inch [0.06 to 0.13 mm] pulley. Measure the outside diameters, at the
Cooling System
pulley end, of the water pump and idler shafts.

There must be at least 0.001 inch [0.03 mm]
press fit between the pulley bores and outside
diameter of the shafts.
Check the water pump housing for damage.
Measure the housing bore, Fig. 8-43. Discard
the housing if the bearing bore is larger than
2.4494 inches [62.215 mm]. Make sure the
weep hole in the housing is open.
Fig. 8-44 (N10855). Install The Bearing Onto The Shaft.
Fig. 8-42 (N10883). Remove The Wear Sleeve From The Pulley. 2. Apply a light coat of Loctite 601 to outside
diameter of the bearing. Use a press to push
the bearing and shaft into the pulley until the
bearing is against the buttom of the bore.
3. Install the retaining ring with the flat side next
to the bearing.
4. lnstall a clean grease fitting into the plug hole
in the pulley. lnstall grease, through the fit
ting, into the pulley until you can see the
grease through the bearing. Remove the fit
ting and install the plug.
5. lnstall a new grease seal, with the lip of the
seal toward the pulley, into the pulley bore.
6. Apply a light coat of clean lubricating oil to a
new O-ring. lnstall the O-ring into the groove
on the shaft.
Fig. 8-43 (N10884). Measure The Bore ln The Housing. 7. lnstall the spacer on the shaft. Push the
spacer over the O-ring until the spacer is
Assembly against the bearing, Fig. 8-45.
1. Apply a thin coat of clean lubricating oil to the 8. lnstall the idler pulley assembly to the water
outside diameters of the idler shaft. lnstall a pump housing.
new bearing onto the shaft. Use the Part No. 9. Support the impeller side of the water pump
ST-658 Mandrel to support the bearing, Fig. 8-44. housing. Put the rear grease seal (11, Fig.
8-'
Fig. 8-45 (N10886). Install The Spacer Onto The Idler Shaft.
Fig. 8-47 (N10888). Install The Bearing Onto The Shaft.
port the new inner bearing (9). Push the pulley

end of the shaft through the bearing until the
bearing is against the larger diameter (shoul
der) of the shaft.
11. Install the smaller retaining ring (8) onto the
shaft.
12. Use the ST-658 to support the new outer bear
ing (6, Fig. 8-34). lnstall the bearing spacer (7)
onto the shaft. Push the shaft and spacer
through the bearing until the bearing ls
against the spacer, Fig. 8-47. Make sure the
bearings turn freely.
Caution: To prevent damage to the bearing, make
sure the Inner race of the bearing is not over
loaded from contact with the spacer.
Fig. 8-46 (N10887). lnstall The Seal Into The Housing.
13. Apply a thin coat of Loctite 601 to the outside
8-34) onto the Part No. ST-1191 Seal Driver. diameter of the bearings. Install the Part No.
Make sure the lip of the seal is toward the 3375180 Oil Seal Pilot to the impeller end of
driver. Push the seal into the bore of the hous the shaft, Fig. 8-48. lnstall the bearing and
ing until the seal is at the bottom of the bore, shaft assembly into the bore of the housing.
Fig. 8-46. Use the ST-658 to push the bearing and shaft
into the housing. Remove the 3375180 pilot.
10. Apply a light coat of clean lubricating oil to
the shaft (10, Fig. 8-34). Use the ST-658 to sup- 14. Install the larger retaining ring, with the flat
16
Cooling System
Fig. 8-48 (N10889). Install The Pilot For The Oil Seal Onto The Fig. 8-49 (N10890). Install The Seal Into The Housing.
Shaft.
side toward the bearing, into the groove in the

housing.
15. lnstall a clean grease fitting into the housing.
lnstall grease into the housing, through the fit
ting, until you can see the grease through the
outer bearing (6, Fig. 8-34). You must use
grease that meets the specifications of MlL-
G-3545. Do not use grease that has thickeners
of sodium or soda soap.
Caution: Do not Install too much grease. This can
cause damage to the bearings.
16. lnstall the front grease seal (4, Fig. 8-34) into
the water pump housing. The lip of the seal
must be toward the bearing. The seal must be
installed so it is even with the top edge of the
bore. Use the Part No. ST-1191 Seal Driver to
install the seal, Fig. 8-49.
17. Turn the water pump housing over and sup
port the drive side of the housing. Apply a coat
of Part No. 3375066 Loctite to the brass part of
the seal outside diameter, Fig. 8-50. Use the
Part No. 3375448 Mandrel to install the new
seal into the housing.
18. lnstall the new cup seat (17, Fig. 8-34). Use the
3375448 to install the cupseat, Fig. 8-51.
Put the drop of Loctite between the shaft and
cup seat, Fig. 8-52.
Caution: Do not apply more than one drop of Loc
tite. More than one drop will cause the seal and
cup seat to become fastened together. Fig. 8-51 (N10891). lnstall The Cup Seat.
8-17
22. Apply a light coat of Loctite 601 to the bore in

the impeller. Support the pulley end of the
shaft. Push the impeller onto the shaft. The
clearance between the vanes of the cast iron
impeller and the housing must be 0.020 to
0.040 in [0.51 mm to 1.02 mm]. The clearance
for the phenolic impeller must be 0.030 to
0.050 inch [0.76 mm to 1.27 mm].
The Fan
Check the fan blades to make sure they are not
bent, cracked or have any other damage. Replace
the fan if it has any damage.
Fig. 8-52 (UW102). Apply Loctlte I The Shaft And The Warning: Do not try to make any repairs to the fan.
Cup Seat
Use steam to clean the fan. Dry with compressed
20. Remove the grease fitting from the housing. air.
Install the pipe plugs in the housing.
21 . Apply a light coat of Loctite 601 to the bore in
The Fan Hub
the drive pulley. Push the water pump shaft in
to the bore until the pulley is against the Fan Hub with "Step-bore"
larger diameter (shoulder) of the shaft. (without bearing spacer)
1. Capscrew 5. Cotter Pin 9. Pulley Hub 13. Seal

2. Lockwasher 6. Slotted Nut 10. Pipe Plug 14.
3. Spacer 7. Washer 11. Roller Bearing 15. Nut
4. Gakset 8. Roller Bearing 12. Shaft
Fig. 843 (N10895). Fan Hub Assembly — Exploded View
18
Cooling System
Disassembly below the edge. Make sure the top of the seal
is toward the bearing.
1. Remove the pipe plugs, fan spacer (3, Fig.
8-53) and gaskets (4). 3. Apply a coat of clean lubricating oil to the in
2. Remove the cotter pin (5), locknut (6) and side diameter of the seal. Slide the shaft (12)
washer (7) from the shaft (12). through the seal and bearing.
3. Support the fan hub (9) with smaller end of the 4. Lubricate the front bearing (8) with grease. In
shaft up. Push the shaft from the hub. stall the bearing into the outer race. lnstall the
washer (7) and locknut (6) to the shaft.
4. Push the bearings (8 and 11) and oil seal (13)
from the shaft. 5. Slowly rotate the fan hub while you tighten the
locknut. Tighten the locknut until you can feel
5. Remove the bearing races from the shaft. light fricition against the fan hub.
Cleaning Note: The hub must be rotated while the nut is be
ing tightened to make sure the bearing is in the
Use cleaning solvent to clean the parts. Dry with correct position.
compressed air.
6. Loosen the locknut only enough to install the
Inspection cotter pin. Do not bend the cotter pin at this
time. lf a "huglock" nut is used, loosen the nut
1. Check the shaft for damage or wear.
approximately 30 degrees.
2. Check the fan hub and fan spacer for cracks.
7. Check the end movement (end clearance of
3. Check the pulley grooves in the fan hub for the fan hub. The clearance must be from 0.003
wear or damage. to 0.010 inch [0.08 to 0.25 mm]. lf the end
movement is more than 0.010 inch [0.25 mm],
remove the cotter pin. Tighten the locknut to
groove, must protrude 1/16 to 1 18 inch [0.06 to 0.13
the next position that will let the cotter pin go
through the locknut and shaft. lf the end
movement is less than 0.003 inch [0.08 mm],
support the fan hub. Loosen the locknut one
Replacement
turn. Use an arbor press to push against the
Replace the shaft if it is damaged or worn. locknut end of the shaft. The force against the
Replace the fan hub or fan spacer if cracked or shaft must not be more than the force re
damaged. quired to push a bearing onto a shaft. Repeat
steps 5 and 6. Check the end movement of the
Assembly hub. Bend the cotter pin so it will stay in
position.
Note: Apply grease to the bearings, before in
stallation, when they are installed into a fan hub 8. lnstall a clean grease fitting into the fan hub.
that does not use a grease seal with a lip. Install grease through the fitting until the fan
hub cavity is 60 to 70 percent full. Use grease
1. lnstall the outer races for the bearings (8 and that meets the specifications of MlL-G-3545.
11, Fig. 8-53) into the fan hub (9). Push the Do not use grease that has sodium or soda
outer race, with the cupped side up, into the soap thickeners.
hub until the race is against the smaller
diameter of the bore. 9. Remove the grease fitting. lnstaH the pipe
plugs. Tighten the pipe plugs to 5 to 7 ft.-lbs.
2. Lubricate the rear bearing (11) with grease. ln
stall the bearing into the outer race. Push the
seal (13) into the bore. The seal must be in 10. Apply 0.2 to 0.3 oz. [6 to 9 g] of grease to the
stalled so it is even with the edge of the pulley outer bearing (8, Fig. 8-53]. lnstall a new
bore or, not more than 0.020 inch [0.51 mm] gasket (4) and the fan spacer (3).
8-19
Fan Hub with "Through-bore" Inspection

(with bearing spacer) 1. Check the shaft for damage or wear. Replace
the shaft if it is damaged or worn.
Disassembly
2. Check the fan hub and fan spacer for damage.
1. Remove the grease fitting (6, Fig. 8-54) and
relief fitting (7) from the fan hub (8). 3. Check the pulley grooves in the fan hub for
wear or damage.
2. Remove the fan spacer (1) and locknut (2).
3. Remove the fan hub from the shaft (12). groove, must protrude 1/16 to 1/8 inch [0.06 to 0.13
4. Remove the front bearing (3) and spacers (4 mm] above the outside diameter of the pulley. The
and 5). belt must not touch the bottom of the groove.
5. Remove the grease seal (11) and the rear bear
ing (10).
Replace the fan hub or fan spacer if cracked or
6. To remove the outer races for the bearings (3
damaged.
and 10), hold a flat punch against the back
side of the race. Hit the punch with a hammer
until the race is loosened from the bore.
Remove the races. Remove the retaining ring 1. Install the new retaining ring (9, Fig. 8-54) into
(9) from the bore. the groove in the fan hub bore.
2. Install the outer race of the bearing (10) into
the fan bracket end of the fan hub. Push the
Clean the parts with cleaning solvent. Dry with race into the bore until the race is against the
compressed air. retaining ring.
Cooling System
3. lnstall the bearing spacer (4) into the fan hub. The Thermostat and Housing
lnstall the spacer from the fan spacer end of
Never operate the engine without the thermostat.
the hub. Make sure the holes in the spacer are
The thermostat helps control the temperature of
in alignment with the grease holes in the hub.
the combustion chamber in the engine.
4. lnstall the outer race of the bearing (3) into the
fan spacer end of the fan hub. Push the race Disassembly
into the bore until the race is against the bear 1. Remove the connection for the water outlet (7,
ing spacer. Do not damage the retaining ring Fig. 8-55) and the gasket (6).
when you push the race against the spacer.
2. Remove the front water manifold (1) and
5. Lubricate the rear bearing (10) with grease. In gasket (2).
stall the bearing into the outer race. Push the
seal (11) into the bore. The seal must be in 3. Remove the thermostat (3) and seal (4) from
stalled so it is even with the edge of the bore the housing (5).
or, not more than 0.020 inch [0.51 mm] below
the edge. Make sure the lip of the seal is
toward the bearing.
6. Apply a coat of clean lubricating oil to the in
side diameter of the seal. Slide the shaft (12)
through the seal and bearing.
7. Install the inner spacer (5) into the fan spacer
end of the fan hub. Slide the spacer over the
shaft and into the outer spacer (4).
8. Lubricate the front bearing (3) with grease. ln
stall the bearing into the outer race.
9. lnstall the washer and locknut (2) to the shaft.
Tighten the locknut to 145 to 155 ft.-lbs. [196 to
210 N»m] torque. Rotate the fan hub while
tightening the locknut.
Fig. 8-55 (N10814). The Thermostat Housing And Seal.
10. Check the end movement (end clearance) of
the fan hub. The fan hub must rotate freely Inspection
and the end clearance must not be less than 1. Check the connection, manifold and housing
0.003 inch [0.08 mm] or more than 0.016 inch for corrosion, cracks or other damage.
[0.41 mm].
2. Check the operation of the thermostat.
a. lf the end clearance is not correct, check a. Check the body of the thermostat to find
the width of the bearings (3 and 10). The at what temperature the thermostat is in
bearing width can be from 0.710 to 0.714 the open position.
inch [18 to 18.1 mm]. lf the bearing width is
more than 0.714 inch [18 mm], remove b. Put the thermostat and a thermometer into
material from the end of the bearing a container of water. Use a device to hold
spacer (4) to adjust the end clearance. the thermostat and thermometer so that
Remove material from the end of the they will not touch the container.
spacer that does not have grease holes. c. Heat the water. The thermostat must
begin to open when the temperature of the
11. Fill the fan hub with grease until it is 60 to 70 water is at the same temperature marked
percent full. on the body of the thermostat.
12. Install the pipe plugs. Tighten to 5 to 7 ft.-lbs. d. Continue to heat the water until the
[7 to 10 N»m] torque. temperature is 15° to 20 °F [8.3° to 11.1 °C]
8-21
more than the value marked on the ther 3. lnstall the front water manifold (1) and a
mostat. At this temperature, the thermostat gasket (2) to the thermostat housing.
must be fully opened. The thermostat is
4. lnstall the water outlet connection (7) and a
fully opened when there is at least a 0.375
new gasket (6) to the thermostat housing.
in. [9.5 mm] space between the seal sleeve
and the brass part of the thermostat.
The Raw Water or Sea Water Pump
Disassembly
Replace the thermostat if it does not operate in 1. Remove the pump drive gear or pulley. Use the
the correct temperature range. Part No. 3375257 Puller to remove the gear or
pulley. Remove the key (10, Fig. 8-56) from the
shaft (9).
1. lnstall the new seal (4, Fig. 8-55) into the ther
2. Remove the retaining ring (13). If the pump is
mostat housing (5). Use the Part No. ST-1225
driven by a belt, you must remove the rubber
Seal Mandrel to install the seal. Make sure the
seal (14) before you can remove the retaining
part number or metal side of the seal is
ring.
against the mandrel when you install the seal.
3. Remove the cover (1) and gasket (2).
Note: Make sure the seal is correctly installed. If
the rubber plug (3) and the impeller (4).
the seal is not correctly installed, engine coolant
can leak past the seal when the thermostat is in Note: lf the pump is to be installed in the original
the closed position. This can cause the engine position. Take notice of the direction of the im
temperature to be colder than normal. peller blades. This will help you to correctly
assemble the pump.
2. lnstall the thermostat into the housing. Slide
the sleeve of the thermostat through the seal. 4. Push the shaft (9) from the pump housing (7).
1. Cover 5. Cam 9. Shaft 13. Snap Ring

2. Gasket 6. Wear 10. Key 14. Rubber Seal
3. Plug 7. Housing 11. Oil Seal 15. Seal Assembly
4. Impeller 8. Slinger 12. Bearing
"56 ( N 10806). Raw (Sea) Water Pump — Exploded View.

Cooling System
Remove the slinger (8).

5. Remove the cam (5) and wear plate (6).
6. Remove the seal assembly (15).
Cleaning
Clean all parts with cleaning solvent. Dry with
compressed air.
Inspection
1. Check the impeller for scratches, cracks or
other damage.
2. Check the surfaces of the cam and wear plate.
The surfaces must be smooth.
Fig. 8-58 (N20806). Install The Shaft lnto The Housing.
4. Check the housing for cracks or other 4. Hold the rubber slinger (8) in the correct posi
damage. tion in the housing. lnstall the shaft into the
housing and through the slinger as shown in
Replacement Fig. 8-58.
Replace any damaged parts. 5. Push the bearing and shaft assembly into the
bore in the housing. Make sure you push
Assembly against the outer race of the bearing.
1. Apply lubricant to the shaft (9, Fig. 8-56). Push 6. Install the retaining ring (13, Fig. 8-56).
the bearing (12), with the part number up, onto
7. lnstall the seal gasket, seat, carbon seal,
the shaft. Push the bearing until it is against
O-ring, ferrule, washer and marcel washer
the larger diameter (shoulder) of the shaft.
(The Seal Assembly, 15, Fig. 8-56) onto the
2. Install the key (10) into the shaft. shaft and then into the housing bore.
3. Push the oil seal (11) into the drive side of the 8. Push the new oil seal into the housing bore.
housing as shown in Fig. 8-57. The lip of the seal must be toward the impeller.
Fig. frdO (N20608). Install The Drive Gear Onto The Shaft. Fig. &62 (N20810). The Impeller Installed For Left Hand Rotation.
9. Install the cam (5) and wear plate (6) as shown

in Fig. 8-59.
10. Use an ovei. to heat the drive gear to 200 "F
[93 °C]. Support the impeller end of the shaft.
Push the drive gear onto the shaft, Fig. 8-60.
11. Apply glycerine or soap to the edges of the im
peller blades. Install the impeller. lnstall the
rubber plug (3, Fig. 8-56).
Note: The direction of the water flow through the
pump is controlled by the direction of the impeller
blades. Make sure the impeller is installed cor
rectly. Fig. 8-61 and Fig. 8-62 shows the direction
of the water flow through the pump.
12. Install a new gasket (2, Fig. 8-56) and the cover
Fig. &61 (N20810). The Impeller Installed For Right Hand Rotation. (D-
Cooling System
Table 8-1: Specifications — Inch [mm] Eccentric and FFC Water Pump
Ref. Dimension New New Worn
No. Locations Minimum Maximum Limit
Housing Bearing Bores 2.4408 2.4414 2.4494
[61.996] [62.012] [62.215]
Housing Bore 1.5000 1.5200

Carbon Face Seal [38.100] [38.608]
1. Shaft Diameter 0.6262 0.6267

lmpeller End [15.905] [15.918]

Seat Location [15.905] [15.918]

Inner Bearing [25.001] [25.011]

Outer Bearing [25.001] [25.011]

Pulley End [17.000] [17.008]
6. Impeller Bore 0.624 0.625

[15.85] [15.88]
lmpeller Vane to Body

Clearance
(Cast lron) 0.020 0.040
[0.51] [1.02]
(Phenolic) 0.030 0.050
[0.76] [1.27]
Pulley Bore Diameter 0.6663 0.6673
[16.924] [16.949]
Minimum Press-Fit
Shaft and lmpeller 0.001
[0.03]
Shaft and Pulley 0.001
[0.03]
8-25
Table 8-1: Specifications — Inch [mm] Eccentric and FFC Water Pump (Cont'd.)
Ret. New New
Maximum Limit
Housing Bora 2.8345 2.8351 2.8431
Outer Bearing [71.996] [72.012] [7Z215]
2.0471 2.0477 2.0557
Inner Bearing [51.996] [52.0121 [52.215]
Housing Bora 1.435 1.436

Housing Bora ' 2.9985 3.0015

Outer Seal [76.162] [76.238]
1.374 1.376
Inner Seal [34.90] [34.95]

lmpeltor End [15.905] [15.918]
z Shaft Diameter 0.6262 0.6267

Seat Location [15.905] [15.918]
3. 0.872 0.878
Inner Seal [22.15] [22.30]
4 Shaft Diameter 0.9842 0.9846

lnner Bearing Surface [24.999] [25.009]

Outer Bearing Surface [29.997] [30.008]
6. 1.1810 1.1814
P^ley^nd"1*' [29.997] [30.008]
7. impeller Bora 0.624 0.625

[15.85] [15.881
Impeller Vane to Body 0.020 0.040

Clearance [0.51] [1.02]
Pulley Bora 1.1787 1.1798

[29.939] [29.967]
Wear Sleeve O.D. 2.2540 2.2560

Outer Seal Surface [57.252] [57.302]
Shaft and 0.001

[0.03]
Shaft and 0.001
[0.03]
^-26
Drive Units 9-1
The drive unit takes power from the crankshaft,

GrOUP 9 through the camshaft gear, to actuate the fuel
pump, air compressor and other assemblies.
Drive Units
1. Gasket 4. Thrust Washer 7. Bushing 10. Coupling

2. Oil Sllnger 5. Shaft 8. Thrust Washer 11. Locknut
3. Drive Gear 6. Housing 9. Clamping Washer
Fig. 0-1 (N10910). Fuel Pump Drive - Exploded View.

Service Tool Tool General Information
Number Name
ST-1249 Puller OH Seals
Standard Tools Required The surface of the seal must be free of damage.
Arbor Press Feeler Gauge Set Before installing a new seal, always check the
Grease Gun 0-1, 1-2, 2-3 Micrometers surface of the hub sleeve for wear and replace the
Bearing Packer Telescoping Gauges sleeve if necessary.
9-1
The Bores In The Housing (11) from the shaft. lnstall the capscrew (12)
into the shaft after you have removed the
The bearings or bushings must not turn in the
housing retaining bore. lf the old bearing has
turned and ruined the housing, the housing must 2. Install the Part No. ST-1249 Coupling Puller
be discarded. The bore of the housing must be onto the coupling (10). Remove the coupling.
clean before you press the bearing in position. 3. Remove the washer (14).
Caution: LDL (Laydown Lip) TFE oil seals must be 4. Remove the thrust washers (6 and 9).
clean and dry when they are installed. Do not ap
ply lubricating oil to the seal or shaft 5. Remove the shaft and gear assembly (13 and
5) from the housing (7).
Thrust Washers 6. Remove the gear (5) from the shaft (13). Put
the housing side of the gear onto a support
On accessory drive units the grooved side of the
and use a press to push the shaft from the
washer is installed away from housing. The steel
gear. Remove the pulley key or pin from the
backing against the cast iron housing will keep
shaft before you push the shaft from the gear.
the thrust washers from turning. lncorrect in
stallation of these washers will result in ex
cessive wear and increased end play, which
causes early failure of the accessory drive Clean all the parts in an approved cleaning sol
assembly. vent and dry with compressed air.
Inspection
1. Check the bushing in the drive housing. If the
bushing is worn larger than 1.321 remove and
discard the bushing.
2. Check the shaft for wear distortion or damage.
The outside diameter of shaft must not be
worn less than 1.310 inch [33.27 mm].
Replace the thrust washers if they are worn or
1. Install the dowel or key into the shaft (13, Fig.

9-2).
2. Install the gear (5) onto the shaft. Use a |
to push the gear onto the shaft. Push the |
onto the shaft until the gear is against the
1. Nut 8. Bushing shoulder on the shaft.
2. Washer 9. Thrust
3. Seal 10. Coupling 3. Apply a coat of lubricating oil to the thrust
4. Dowels 11. Washer washer (6) and the bushing (8) in the housing.
5. Gear 12. Capscrews
6. Thrust Washer 13. Shaft 4. Install the gear and shaft assembly through
7. Housing 14. Washer the thrust washer and into the bushing in the
housing. The grooved side of the thrust
Fig. 9-2 (N10911). Cross Section Of The Accessory Drive. washer must be away from the housing.
5. Turn the assembly over so that the gear on the
Disassembly shaft is down. Make sure that the thrust
1. Remove the capscrew (12, Fig. 9-2) and washer washer (6) remains in position.
Drive Unit*
6. Apply a coat of lubricating oil to the rear remove all units from housing (14), separate
thrust washer (9). Install the thrust washer. drive gear (2) and support assembly from
The grooved side of the thrust washer must be reservoir (21); then remove drain plug,
away from the housing. dipstick, vent plug and elbow.
7. Install the clamping washer (14). 3. Remove the shaft locknut (22) and washer (23)
from the drive shaft (31). Use the ST-1249
8. lnstall the coupling (10). Use a press to push
Puller to remove the coupling (24). Lift the key
the coupling onto the shaft. Do not damage
out (30). Remove the spacer (25) and governor
the threads on the shaft.
drive gear (26).
9. Install the washer (11) and capscrew (12). 4. Press the small end of the shaft to remove the
Tighten the capscrew to 30 to 35 ft.-lbs. [41 to shaft from the support (3) and the large end of
47 N»m] torque. the shaft to remove the drive gear (2). Remove
Note: Check end clearance with unit assembled. keys (32) from the shaft keyway and snap ring
lt must be as listed ln Table 9-1. The dowel pin (27) from the support. Invert support and press
shaft can be used to replace the 121940 and out rear bearing (28) and oil seal (29).
199969 Accessory Drive Shafts.
Inspection
Hydraulic Governor Drive 1. Check bearing for worn race or rough action,
Disassembly gears for chipped or broken teeth or uneven
wear and governor shaft housing oil holes to
1. Remove the governor drive assembly, snap make certain they are open.
ring (11, Fig. 9-3), ball key and collar (13).
2. Inspect support and reservoir for cracks,
2. Press the shaft (12) opposite gear end to breaks or rough mating surfaces.
1. Sllnger 9. Gear 17. Studs 25. Spacer

2. Drive Gear 10. Gasket 18. Coupling 26. Drive Gear
3. Support 11. Snap Ring 19. Snap Ring 27. Snap Ring
4. Capscrew 12. Shaft 20. Snap Ring 28. Bearing
5. Lockwashers 13. Collar 21. Reservoir 29. Oil Seal
6. Qasket 14. Housing 22. Locknut 30. Key
7. Pipe Plug 15. Nuts 23. Flatwasher 31. Shaft
8. Gasket 16. Lockwashers 24. Coupling Gear 32. Keys
Fig. 9-3 (N10912). Fuel Pump, Hydraulic Governor Drive (Woodward Governor).
NT7NTA 855 C.I.D. Engine Shop Manual
Replacement drive housing so flatwasher rests on

bronze bushing.
Replace all damaged parts.
c. lnvert assembly and install ball key, col
Assembly lared washer (13) and snap ring (11). Press
1. Lubricate outside of oil seal (29, Fig. 9-3) and on end of cylinder until flatwasher is
press into support from large end. Open end against bronze bushing.
of seal must be down. Lubricate rear bearing d. Press gear into position allowing end
(28) and press into support. lnsert snap ring clearance of 0.003 to 0.006 inch [0.08 to
(27), flat side down. 0.15 mm].
2. Lubricate shaft (31) and place key (32) in 8. Place gaskets (8) and install drive gear and
shaft. Press shaft into flat side of gear (2) until housing assembly to serial number side of
shoulder seats on gear face. reservoir. Large oil hole in housing must be at
3. Press small end of shaft assembly into large top. lnstall slinger (1) over gear end of shaft.
end of support. Press governor drive gear (26)
onto shaft until it bottoms on bearing. Drive Pulleys
4. Insert key (30) and press on coupling (24). Inspection

Shoulder of coupling goes against gear 1. Check for cracks and ships in hub, web and
unless a spacer (25) is used. lnstall flatwasher groove areas.
(23) and shaft locknut (22).
2. Check for wear in grooves and oil seal sleeve.
5. Position reservoir (21) in vise with governor
drive studs (17) up. lnstall dipstick, vent plug, 3. On two-piece pulleys, check for stripped or
weatherhead fitting and drain plug. distorted threads on sheave and in capscrew
holes.
6. On governors with 2:1 gear ratio:
a. Install shaft (12) in housing (14) with splined 4. Clean in an approved cleaning solvent and dry
end up. Drop collar (13) into housing. with moisture free compressed air.
b. Lubricate ball key and insert in drive shaft: Replacement

install snap ring (11). Line up ball key with
collar (13). lnvert assembly and press on Replace all parts that are damaged.
gear (9). Allow end clearance of 0.003 to
0.006 inch [0.08 to 0.15 mm]. Repair
7. On governor with 3:1 gear ratio: lf wear on sleeve is visible:

a. Press governor two-piece drive shaft (12) 1. Remove worn oil sleeve by splitting with
into washer flush with bottom side. Note chisel. Do not damage pulley hub.
relief in washer to start shaft.
2. Press new sleeve onto pulley hub with man
b. Press shaft assembly into cylinder until drel, until it is flush to 0.015 inch [0.38 mm]
shoulder on shaft is flush with end of below face of hub. Consult latest Parts Cata
cylinder. Slide this assembly into governor log for correct pulley/sleeve combination.
9-4
Drive Units
Table 9-1: Drive Unit Specifications — lnch [mm]

Ref. Worn New New
Shaft
(Bushing Location) [33.27J [33.312] [33.32]
Bushing
[33.55] [33.43] [33.50]
Outside Diameter 1.449 1.450
[36.80] [36.83]
Out-of-Round 0.002
[0.05]
Press-Fit Between 0.002 0.0045
Housing and Bushing [0.05] [0-11]
(
Accessory Drive
End Clearance NH/NT 0.002 0.012 g>
[0.05] [0.26]
End Clearance NTA 0.004 0.024
[0.10] [0.61]
Hydraulic Governor Drive
End Clearance 0.003 0.006
[0.08] [0.15]
9-5/(9-6 Blank)
r
Air Intake System
The air intake section includes intake manifolds,

Group 10 connections and aftercoolers. The information
about cold starting and air cleaners is found in
the Operation and Maintenance Manuals. The in
formation about the turbochargers is found in the
Turbocharger Component Shop Manual.
Air Intake System
The Intake Manifold and Connection
Cleaning
Clean the intake manifold and the connection
with steam.
Inspection
Check for cracks, distortions and damaged
threads.
Repair
Threads which are damaged can be repaired by in
stalling Heli-coils.
The Afftercooler
Disassembly 1. Housing 7. Cover

2. Intake Manifold Gasket 8. Gasket
1. Remove the water inlet and water outlet con 3. Gasket 9. Water Outlet
nections. Discard the gaskets. 4. Element 10. Capscrews
5. O-rings 11. Water Inlet
2. Remove the element cover and the element 6. Cover Gasket 12. Plugs
from the housing. Discard the gaskets.
Fig. 10-1 (N10898). Aftercooler — Exploded View.
3. Remove and discard the O-rings from the
element. Assembly
1. Put the aftercooler housing (1, Fig. 10-1) on a
Cleaning
workbench. Hold the housing so that it will be
1. Clean the element cover and housing with in the same position as it is on the engine.
steam. 2. Put the gasket (3) on the housing. Apply clean
2. Use a solvent that will not damage copper to lubricating oil to the new O-rings. lnstall the
clean the element. Dry with compressed air. O-rings onto the water inlet and outlet fittings
Note: The aftercooler elements generally are of the element (4). Fit the element into the
taken to a qualified radiator repair shop to be housing.
cleaned, tested and repaired. 3. Install the water inlet connection (11) and new
10-1
gasket onto the inlet fitting of the element. Do

not damage the O-rings. Use your fingers to
tighten the capscrews that hold the connec
tion to the I
lnstall the gasket (6) into the mounting flange
of the element. Make sure the capscrew holes
in the gaskets, element and housing are in
alignment. lnstall the cover (7) but do not
tighten the capscrews to the correct torque at
this time.
lnstall the water outlet connection (9) and new
gasket to the cover. lnstall the capscrews and
copper washers. Use your fingers to tighten
the capscrews.
the O-rings are in the correct
Tighten the capscrews that fasten the cover

(7) to the element (4) and housing (1). Do not 7. Capscrew
tighten the capscrews to the correct torque 8. Inlet Connection Gasket
9. Inlet Connection
t this i 10. Housing
11. Cross-Bolts
7. Tighten the capscrews that fasten the water 12. Hardened Washer
inlet connection (11) to the housing. Tighten
the capscrews to 27 to 32 ft.-lbs. [37 to 43 Fig. 10-2 (N10899). Cross-Bolt Aftercooler — Exploded
N»m] torque.
8. Tighten the capscrews that fasten the cover to clearance. The clearance must not be less than
the housing, to 25 ft.-lbs. [34 N»m] torque. 0.003 inch [0.07 mm] or more than 0.013 inch
Tighten the center capscrews first. Then, [0.33 mm].
tighten the capscrews, moving from one side
of the cover to the other side. Work from the Caution: Make sure the O-rings are in the correct
center toward each end of the cover.
9. Tighten the capscrews for the water outlet 3. Align the holes in the housing and element for
connection (9) to 15 to 20 ft.-lbs. [21 to 27 the cross-bolts. lnstall the cross-bolts (1 1) and
N»m] torque. hardened washers. Tighten the cross-bolts in
the center of the housing first, then tighten
Assembly (Cross-bolt Design Aftercooler) the cross-bolts at each end. Tighten the cross-
1. Put the aftercooler housing (10, Fig. 10-2) on a bolts to 15 ft.-lbs. [21 N»m] torque. Starting at
workbench. Hold the housing so that it will be the center, tighten the cross-bolts again to 25
in the same position as it is on the engine. ft.-lbs. [35 N»m] torque.
2. Apply clean lubricating oil to the new O-rings 4. lnstall the water inlet connection (9) and new
(2). lnstall the O-rings to the inlet and outlet gasket (8) onto the inlet fitting of the element.
fittings of the element (1). lnstall the element Do not damage the O-rings. Use your fingers
into the housing. to tighten the capscrews.
Note: The element has a precision fit in the hous 5. lnstall a new gasket (3) and the aftercooler
ing. Move the element carefully as you install it cover (4) to the housing. Make sure the holes
into the housing. Check the clearance between in the gasket are aligned with the cover and
the element and housing. Hold the element housing. Use your fingers to tighten the
against one side of the housing to check the (7).
10-2
Air Intake System
6. Install the water outlet connection (7) and new

gasket (5). lnstall the copper washers and
capscrews. Use your fingers to tighten the
capscrews.
7. Tighten the capscrews that fasten the water
inlet connection (9) to 27 to 32 ft.-lbs. [37 to 43
N»m] torque.
8. Tighten the capscrews, that fasten the cover
to the housing, to 25 ft.-lbs. [34 N»m] torque.
Tighten the center capscrews first. Tighten
the capscrews, moving from one side of the
cover to the other side. Work from the center
toward each end of the cover.
9. Tighten the capscrews, that fasten the water
outlet connection (6), to 15 to 20 ft.-lbs. [21 to
27 N»m] torque.
10-3/(10-4 Blank)
r
1
Exhaust System
The exhaust system group includes the exhaust

Group 1 1 manifolds.
Exhaust System
Exhaust Manifolds
Dry Type
Inspection
Inspect the exhaust manifold for cracks and
distortions.
When ordering replacement parts, order same
part as presently used.
Wet Type
Inspection
1. The exhaust manifold is a combination water
header and water-cooled exhaust manifold.
Clean as outlined in Group 0, Disassembly
and Cleaning. Water test at 30 to 80 psi [207 to
552 kPa]
2. Remove the inspection plate from the exhaust
manifold. lnspect for cracks and distortions.
Replace the manifold if it is damaged.
3. Install the inspection plate and gasket to the
exhaust manifold.
Caution: Do not run the engine without coolant in
a water-cooled exhaust manifold.
11-1/(11-2 Blank)
r
4
Air Equipment
The air equipment group consists of Cummins air

GrOlip 1 2 compressors, check valve, vacuum pump and pip
ing; it also includes the air-actuated cranking
motors, which are sometimes used on Cummins
engines.
Air Equipment
Air Compressor
Cummins air compressors are used on all models

of Cummins Engines and are covered from a ser
vicing standpoint in Bulletin No. 3379056.
Optional Units, such as Bendix-Westinghouse,
Wagner and others are covered by publications
available from the manufacturer or authorized ser
vice station.
Vacuum Pump
Cummins vacuum pump is an adaptation of the
compact Cummins air compressor and is covered
in Bulletin No. 3379056.
Air Cranking Motor

Air cranking motor servicing is covered by the
manufacturer or authorized service station.
12-1/(12-2 Blank)
0
Electrical Equipment
The principal function of the Electrical System on

GrOUP 1 3 Cummins Diesel Engines is that of cranking or
starting and operating electrical accessories as
required by the unit being powered.
Electrical Equipment
Wiring Diagram
A complete collection of wiring diagrams, as

applied to all Cummins Engines, is contained in
Bulletin No. 3379099. The diagrams are all in the
single manual because the same diagram may ap
ply to more than one engine model or series. This
bulletin may be obtained from a local Cummins
Distributor.
Electrical Components
Complete instructions for testing, repairing and
adjusting alternators, generators, voltage regu
lators, cranking motors, batteries, electric cables
and connections are available from the local elec
trical equipment service distributor.
lf this service is not available, further specific in
formation can be obtained as follows:
Delco-Remy Equipment
Electrical Equipment Operation and Maintenance
Handbook DR-324-1 or -2, -3, -4 and Test Specifica
tions DR-324-S-1 may be purchased from the near
est United Motor Service Station, or the Service
Department, Delco-Remy Division, General Motors
Corp., Anderson, Indiana.
Leece-Neville Equipment
Operation and adjustment information may be ob
tained from the nearest Leece-Neville distributor
or the Service Department of the Leece-Neville
Co., 5109 Hamilton Avenue, Cleveland 14, Ohio.
13-1/(13-2 Blank)
1
Engine Assembly and Testing
The engine assembly section includes the

GrOUP ■4 assembly of all the units and subassemblies to
the cylinder block. This section also includes
assembly specifications, adjustments, engine
testing and storage.
1. Main Bearings
2. Connecting Rod
Bearings
3. Crankshaft and G
4. Cylinder Liner
5. Connecting Rod/Piston
Assembly
6. Camshaft Gear
7. Camshaft
8. Camshaft Bushings
9. Gear Cover
10. Water Pump/ldler
Assembly
11. Fan Hub Assembly
12. Water lnlet 17. Lube Oil Cooler/Filter 23. Cylinder Head and 30. Lubricating Oil Pump
Connections 18. Rocker Levers/Shaft Gasket 31. Cam Follower/Push
13. Exhaust Manifolds 19. Water By-Pass Tube 24. Cranking Motor/Spacer Tubes
14. Fan Hub Mounting 20. Thermostat Housing 25. lntake Manifold 32. Fuel Pump
Bracket/Support 21. Water Manifold 26. Main Bearing Cap 33. Oil Pan and Gasket
15. Cylinder Liner Assembly 27. Cylinder Block 34. Thermostat
Packing Rings 22. Rocker Lever Housing 28. Rear Cover Assembly
16. Cylinder Liner Shim Cover/Cap 29^ Flywheel and Housing
Fig. 14-0 (N114235). Engine — Exploded View
14-1
Service Tool List Service Tools (Or Equivalent) Required

To assemble and make adjustment to the engine, Service Tool Tool
according to the instructions given in this section, N
the following service tools or tools of equal qual ST-1 184 Cylinder Liner Hold-Down Tool
ST-1190 Fuel Consumption Measuring Device
ity are required.
ST-1229 Liner Driver
ST-1232 Drill and Reaming Fixture
ST-1258 Engine Lifting Fixture
service 1001s jur tquivaienij nequireu ST-1259 Seal Mandrel (Teflon Seal)
ST-1263 Seal Pilot (Teflon Seal) (Rear)
Service Tool Tool ST-1 273 Pressure Gauge (in. hg.)
Number Name ST-1 274 Belt Gauge
ST-163 Engine Support Stand ST-1 325 Dial Gauge Attachment
3376326 Pulley Assembly Tool 3375013 Block Mounting Plate
ST-547 Gauge Block 3375044 Torque Wrench Kit (0-150 in.-lbs.)
ST-593 3375045 Torque Wrench Kit (0-175 ft.-lbs.)
or Timing Fixture 3375046 Torque Wrench Kit (0-350 ft.-lbs.)
3375522 3375047 Torque Wrench Kit (50-400 ft.-lbs.)
ST-669 Torque Wrench Adapter 3375049 Oil Filter Wrench (Spin-On)
ST-754 Torque Wrench Kit (0-600 ft.-lbs.) 3375066 Loctite Pipe Sealant
ST-763 Piston Ring Expander 3375096 lnj./Valve Adjust Kit with
ST-835 O-Ring Assembly Tool Jacobs Brake
ST-997 Seal and Sleeve Driver 3375150 Blow-By Checking Tool
ST-1135 Lube Oil Sampling Filter 3375151 Seal Pilot (Teflon Seal) (Front)
ST-1138 Belt Gauge 3375159 Air Compressor Wrench
ST-1 172 Seal Mandrel 3375162 Piston Ring Compressor
ST-1 173 Seal Mandrel 3375193 Engine Rebuild Stand
ST-1182 Valve Spring Spray Nozzle Locator 3375601 Connecting Rod Guide Pins
(80 degree Tilt Engine) 3375958 Nylon Lifting Sling
Fig. 14-1 (N1 14239). Install The Pipe Plugs.

Note: Apply a coat of 30W lubricating oil to the 1 /8

pipe plugs to be installed for the oil galley. Do not
Service Tool Tool use teflon tape with these plugs.
Number Name
3376021 Actuator Retainer Adjustment Tool 2. Install the pipe plugs into the cylinder block,
3376028 Variable Timing Fixture Fig. 14-1. Tighten the pipe plugs to the torque
3376029 Bracket and Studs valves listed in Table 1.
3376050 Dial lndicator and Sleeve
3801048 Cylinder Liner Sealant
Install The Crankshaft And Main Bearings
Dial lndicator (Starret No. 196A) 1. Make sure the main bearing bores are clean.
Dial lndicator Sleeve (Starret No. 196-L) Use a clean cloth to clean the bores. Make
Manometer (Mercury or Water) sure the cloth does not leave any particles
0-1 Micrometer (lint) in the bores. Make sure the capscrew
lmpact Wrench holes are clean and dry.
Engine and/or Chassis Dynamometer
Hoist (Power or Chain) 2. lnstall the upper main bearing shells, Fig.
Straight Edge 14-2.
Feeler Gauge
Engine Assembly
Install The Cylinder Block To The

Engine Stand
1. lnstall the water header adapter plate to the
cylinder block. Tighten the capscrews to 6 to 8
ft.-lbs. [8.1 to 11 N»m] torque.
2. lnstall the Part No. 3375013 Block Mounting
Plate to the Part No. 3375193 Engine Rebuild
Stand. Make sure that the top of the stand and
the plate are aligned correctly.
3. Put the cylinder block in the correct position
on the rebuild stand. lnstall the lockwashers,
spacers and capscrews to hold the cylinder Fig. 14-2 (N114242). Install The Upper Main Bearing Shells.
block to the rebuild stand. Tighten the cap-
screws to 75 ft.-lbs. [102 N»m] torque. Note: The upper main bearing shells have a
groove and oil hole to permit lubrication or the
crankshaft. The upper shells for the No's 2, 4 and
Install The Pipe Plugs
6 are the same. The groove in the shell for No. 7 is
not in the center of the shell. lnstall the No. 7 shell
Table 1: Pipe Plug Torque Value
so the wider part of the shell, from the groove, is
Torque Ft.-Lbs. [N»m] toward the flywheel end of the cylinder block.
Pipe Plug Size Minimum Maximum
Also, each shell has a groove for the dowel ring.
1/8 10 [13.5] 15 [20] lnstall the shell so the groove will be next to the
3/8 20 [27] 25 [34] counterbore in the cylinder block.
1/2 35 [47] 40 [54]
3/4 50 [68] 55 [74.5] 3. Apply a heavy coat of clean lubricating oil to
7/8* 60 [81] 70 [95] the upper shells.
•7/8-18 Straight Plug
4. lnstall the main bearing dowel rings, Fig. 14-3.
1. Apply teflon tape or an equivalent to the pipe 5. lnstall the crankshaft. Use a hoist and the Part
plugs. No. 3375958 Nylon Lifting Sling to lift the
14-3
crankshaft. Check the marks on the rear

counterweight of the crankshaft to find the
size of the thrust rings.
6. lnstall the upper thrust ring. Make sure the
grooved side of the thrust ring is against the
crankshaft flange, Fig. 14-4.
7. Apply a coat of clean lubricating oil to the
bearing surfaces of the crankshaft and to the
lower bearing shells. Align the bearing shells
with the dowel rings. Then, push on the side of
the shell opposite the dowel ring to install the
shell, Fig. 14-5.
8. lnstall the lower thrust ring onto the No. 7
main bearing cap. The grooved side of the thrust
ring must be toward the crankshaft flange. Fig. 14-5 (N1 14244). Install The Lower Bearing Shells.
9. Install the main bearing caps.

a. Put the caps into the correct location on
the cylinder block. Make sure that the
number on each cap is the same as the
number marked on the cylinder block.
b. Align the capscrew holes in the caps with
the holes in the cylinder block.
c. Install new lockplates onto the cap-
screws.
d. Lubricate the capscrew threads and the
lockplates. Use SAE 30W oil to lubricate
the capscrews. Use SAE 140W oil to lubri
cate the lockplates. Drain the excess oil
from the capscrews before you install
them into the cylinder block.
Fig. 14-3 (N11402). Install The Dowel Ring.
e. Install the capscrews and lockplates
through the caps and into the cylinder
block. Use your hand to tighten the cap-
screws two to three threads.
f. Hit the caps with a rubber mallet to push
them into the correct position. Make sure
that the dowel pins and dowel holes for the
No. 7 main bearing are correctly aligned.
Caution: When you hit the cap with the mallet,
make sure the bearing shell does not move.
10. Tighten all of the capscrews for the main bear
ing caps. Use the sequence shown in Fig. 14-6
when you tighten the capscrews. Follow these
instructions.
a. Tighten the 3/4 inch capscrews, Part No.
208346, in steps of 85 ft.-lbs. [115 N»m]
Fig. 14-4 (N11404). Install The Thrust Ring. torque until the capscrews are tightened
14-4
, «j
21 is !\29 Ii313 i1
i212
1
i£28 1
4O
• ;» 27 3Q
w
i" 3" 1. «
From face of block
Fig. 14-6. Tightening Sequence For The Main Bearing Fig. 14-7 (N1 14245). Measure The End Clearance Of The
Capscrews. Crankshaft.
to 250 to 260 ft.-lbs. [339 to 352.5 N»m] c. Follow the instructions in Step 10 to
torque. See page 18-5 for exceptions. tighten the capscrews.
b. Tighten the 1 inch capscrews, Part No. d. Check the end clearance.
105953, in steps of 100 ft.-lbs. [135.6 N»m]
torque until the capscrews are tightened to 14. Make sure the end clearance for a used
300 to 310 ft. lbs. [407 to 420 N»m] torque. crankshaft is not more than the worn limit of
0.022 inch [0.56 mm]. lf the clearance is more
c. Loosen all of the capscrews 3 to 5 threads. than 0.022 inch [0.56 mm], you must repair the
d. Repeat Step a. or b. crankshaft and use oversize thrust rings as
11. Check the crankshaft to make sure it rotates described in Section 1.
freely. Use your hands to rotate the crankshaft. 15. Bend the tang of the lockplates against the
12. Check the end clearance of the crankshaft. head of the capscrews.
The end clearance must be between 0.007
inch [0.18 mm] and 0.018 inch [0.45 mm] for Install the Cylinder Liners
new crankshafts and thrust rings. 1. Check the bore for the cylinder liner.
a. lnstall a dial indicator gauge to the rear
a. The bore must not have any sharp edges
face of the cylinder block. Put the contact
that would cut or damage the cylinder
tip of the gauge against the end of the
liner O-rings.
crankshaft.
b. Push the crankshaft toward the front of b. The counterbore in the cylinder block and
the cylinder block. the cylinder liner flange must be clean and
free from oil. Use a hydrocarbon solvent to
c. Adjust the indicator to read "0" (zero). clean oil from the parts. You can use a sol
d. Push the crankshaft toward the rear of the vent such as Naptha, Methyl Ethyl Ketone
cylinder block, Fig. 14-7. Read the (MEK) or Trichlorethane 1,1,1 (Methyl
indicator to find the amount of end Chloroform).
clearance.
Caution: Naptha and Methyl Ethyl Ketone (MEK)
13. If the end clearance is less than 0.007 inch are flammable materials and must be used with
[0.18 mm]: care. Do not use starting fluid as a cleaning agent.
a. Loosen the capscrews one turn. 2. Install new O-rings and a crevice seal onto the
b. Push the^crankshaft toward the front and cylinder liner. lnstall the crevice seal into the
then toward the rear of the cylinder block. top groove. The chamfer on the crevice seal
14-5
must be toward the bottom of the cylinder

liner. lnstall the black O-ring into the center
groove. lnstall the red O-ring into the bottom
groove. Apply a light coat of clean lubricating
oil to the crevice seal and O-rings just before
you install the cylinder liner into the cylinder
block. Make sure that the oil does not touch
the counterbore or the cylinder liner flange.
Caution: Do not lubricate the O-rings until you are
ready to install the cylinder liner. The O-rings will
increase in size when they are in contact with
lubricating oil for an extended period of time. If
the cylinder liners are not to be installed within 15
minutes after lubricating the O-rings, use vege
table oil to lubricate the O-rings.
Fig. 14-9 (N1 14106). Use A Quick Push To Put The Liner Into
3. Apply a bead of Cummins Sealant, Part No. The Bore.
3801048, onto the counterbore or the cylinder
liner flange as shown in Fig. 14-8. The diam
eter of the bead must be at least 3/64 inch and
not more than 1/16 inch. The liner must be in
stalled within five minutes after the sealant
has been applied.
Apply 3/64 lo 1/16 inch RTV is extruded out to

diameter RTV bead form seal Only enough
to liner flange RTV to cover the counterbore
or cylinder block ledge should be applied.
counterbore Excess amounts of RTV must be
avoided
Fig. 14-10 (N1 14240). Install The Liner.
5. Use the Part No. ST-1229 Liner Driver and a

mallet to push the flange of the cylinder liner
against the counterbore ledge, Fig. 14-10.
6. Check the protrusion of the cylinder liner.
Fig. 14-8. Apply The Sealant To These Locations.
a. lnstall the Part No. ST-1184 Cylinder Liner
Note: Do not use an excessive amount of sealant. Hold-down Tool. Make sure the tool is
Excessive sealant can cause problems in the spaced evenly around the cylinder liner so
cooling system. that the tool will apply equal amounts of
pressure. Make sure the tool does not
4. Put the cylinder liner into the bore in the damage the bead of the cylinder liner.
cylinder block. Make sure the O-rings and
b. Tighten the capscrews to 50 ft. lbs. [68
crevice seal do not move from the grooves on
N»m] torque.
the cylinder liner. lnstall the cylinder liner into
the bore with a quick push as shown in Fig. c. Use the Part No. ST-547 Gauge Block to
14-9. check the protrusion of the cylinder liner,
Engine Assembly end Testing
the ring has a mark or the word "Top." lnstall

the ring so that this side is toward the top of
the piston. lnstall the oil control ring first. Use
the Part No. ST-763 Piston Ring Expander to
install the rings, Fig. 14-13.
Fig. 14-11 (V514150). Check The Protrusion Of The Liner
Fig. 14-13 (N1 14246). Install The Piston Rings.
Caution: Do not damage the rings when you In

stall them onto the piston. Expand the ring just
enough to allow It to fit over the piston.
2. Make sure the ring gap of each ring is not in
alignment with the piston pin or with any other
ring, Fig. 14-14. lnstall the two-piece oil con
trol ring so that the gap of the expander is 180
degrees from the gap of the ring.
Fig. 14-12. Measure The Bore Of The Liner. 3. lnstall the upper bearing shell into the con-
Fig. 14-11. The amount of protrusion must No. 1 (Top) Ring Gap No. 4 (Bottom) Ring Gap
be from 0.003 inch [0.08 mm] to 0.006 inch
[0.15 mm].
7. Check the inside diameter of the bore in the
cylinder liner for an out-of-round condition. Fol
low the instructions given on pages 1-5 and 1-6.
Use a dial bore gauge to measure the bore, Fig.
14-12. Measure the bore at several points with
in the range of the piston travel. The bore must
not be out-of-round more than 0.003 inch [0.08
mm] in the top 1 inch [25.4 mm] of the piston
travel area, and not more than 0.002 inch [0.05
mm] in the crevice seal and O-ring area.
No. 3 Ring Gap -—"""^ No. 2 Ring Gap
Install The Pistons And Connecting Rods
1. lnstall the rings onto the piston. One side of Fig. 14-14. Alignment Of The Piston Rings.
14-7
necting rod. The tang of the bearing shell apply a coat of oil to the piston and rings.
must be into the slot in the connecting rod, Remove the piston and ring assembly from
Fig. 14-15. Make sure the oil hole in the shell is the container. Use the Part No. 3375162 Ring
aligned with the oil hole in the connecting rod. Compressor to compress the rings. Make sure
that the piston rings are correctly located in
4. Follow the instructions in Step 3 to install the
the grooves in the piston.
lower bearing shell into the connecting rod cap.
The connecting rod caps do not have oil holes. 8. Install the piston and rod assembly into the
cylinder block.
5. Install the Part No. 3375601 Nylon Guide
Screws into the connecting rod, Fig. 14-16. a. Rotate the crankshaft so that the journal
for the connecting rod being installed is at
6. Apply a coat of clean 30W lubricating oil to the
bearing shells in the connecting rod and cap. bottom dead center.
b. Use the ring compressor to hold the piston
7. Put the piston and ring assembly into a con
and rod assemblly.
tainer of clean 30W lubricating oil in order to
c. Push the piston through the ring compres
sor and into the cylinder liner, Fig. 14-17.
Do not use a metal device to push against
the piston. Make sure the tang of the con
necting rod Is toward the camshaft side of
the cylinder block.
d. Push the piston until the top ring is into
the cylinder liner. The piston must move
freely from the ring compressor and into
the cylinder liner. lf the piston does not
move freely, remove the piston and check
for broken or damaged rings.
e. Use the nylon guide screws to pull the
connecting rode into position against the
crankshaft, Fig. 14-18.
Note: Guide the connecting rod onto the crank
Fig. 14-15 (N1 14248). Install The Upper Bearing Shell Into The shaft as you push the piston into the cylinder liner
Connecting Rod.
in order to prevent damage to the crankshaft.
Fig. 14-16 (N1 14249). Install The Guide Screws lnto The
Connecting Rod. Fig. 14-17. Install The Piston And Connecting Rod Assembly.
14-8
Fig. 14-18. Position The Connecting Rod Against The Crank Fig. 14-19. Measure The Side Clearance.
shaft Journal.
Make sure the bearing shells are the correct
9. Install the connecting rod cap. size. Check for dirt or damage.
a. Remove the nylon guide screws.
Install the Camshaft
b. lnstall the connecting rod cap so that the 1. lnstall the cup plug into the camshaft bore at
tang side of the cap is against the tang the rear face of the cylinder block. lf the bore
side of the rod. Make sure that you install measures 2.6245 to 2.6255 in. [66.662 to 66.688
the correct cap for the connecting rod. mm], use the Part No. 3375153 Cup Plug Driver
c. Apply a coat of clean 30W lubricating oil to install the plug. lf the bore measures 2.6865
to the threads of the capscrews or bolts. lf to 2.6875 in. [68.237 to 68.262 mm], use the
the connecting rod has bolts, apply a coat Part No. 3375708 Cup Plug Driver.
of HOW Lubricant to the washers. 2. Apply a coat of lubriplate to both sides of the
d. Tighten the capscrews or bolts evenly to thrust ring. lnstall the thrust ring onto the
push the cap onto the connecting rod. camshaft. Make sure that the oil grooves on
Table 2 gives the correct torque values and the thrust ring are toward the camshaft gear,
the correct sequence to follow. Fig. 14-20.
Table 2: Connecting Rod Torque Specifications

Minimum Maximum
Step No. ft.lbs. [N»m] ft.lbs. [N»m]
1. Tighten To 70 [95] 75 [102]
2. Tighten To 140 [190] 150 [203]
3. Loosen Completely
4. Tighten To 25 [34] 30 [41]
5. Tighten To 70 [95] 75 [102]
6. Tighten To 140 [190] 150 [203]
10. Check the side-to-side (side clearance) move

ment of the connecting rod, Fig. 14-19. The
connecting rod must move freely. The side
clearance must be between 0.0045 inch [0.114
mm] and 0.013 inch [0.33 mm]. If the connect
ing rod does not move freely, remove the cap. Fig. 14-20 (N1 14253). Install The Thrust Ring Onto The Camshaft.
14-9
3. Apply a coat of lubriplate to the camshaft jour

nals and camshaft bushings. Rotate the cam
shaft slowly as you push it through the bush
ings. Do not damage the camshaft or bushings.
Install the Part No. 3375268 Camshaft lnstalla
tion Pilots onto the 2Vz inch camshaft before
you install the camshaft, Fig. 14-21.
4. Align the "O" mark on the camshaft gear with
the "O" mark on the crankshaft gear, Fig.
14-22.
5. Check the amount of backlash between the
camshaft gear and crankshaft gear.
a. lnstall a dial indicator gauge onto the front
face of the cylinder block. Position the tip
Fig. 14-23. Check The Gear Backlash.
of the gauge against a tooth of the cam

shaft gear, Fig. 14-23.
b. Rotate the camshaft gear as far as it will
freely move. Make sure that the crankshaft
gear does not move. Turn the dial of the
gauge to zero.
c. Rotate the camshaft gear in the opposite
direction. The reading on the gauge shows
the amount of backlash between the
gears.
d. The normal amount of backlash between a
new camshaft gear and a new crankshaft
gear is 0.004 to 0.016 inch [0.10 to 0.40
Fig. 14-21 (N1 14254). Install The Pilots Onto The 2V4 Inch mm]. The backlash must measure at least
Camshaft. 0.002 inch [0.05 mm].
e. The backlash between gears that have
been used must measure no more than
0.020 inch [9.51 mm].
Install The Cylinder Heads

1. Make sure that the surfaces for the gaskets
are clean.
2. lnstall the new gasket onto the dowel pins in
the cylinder block. Make sure the side of the
gasket with the word "Top" is up, Fig. 14-24.
Note: Two types of head gaskets can be used.
One type has red silicone sealing beads. This gas
ket does not require any additional parts. The
other type does not have the red silicone sealing
Fig. 14-22. Align The Timing Marks On The Camshaft Gear And beads and you must install water grommets into
Crankshaft Gear. the gasket.
3. lnstall two guide studs into the cylinder block.

Use the guide pins to help you to install the
cylinder head in the correct position on the cyl
inder block. lnstall T-handies into the cylinder
head. Put the cylinder head over the guide pins
and into position on the cylinder block. Use the
T-handles to lift the cylinder head, Fig. 14-25.
4. Lubricate the cylinder head capscrews with
preservative oil. Drain the excess preservative
oil from the capscrews before you install them.
Note: The cylinder head capscrews for the turbo-
charged engine must have the letters "NT" on the
head of the capscrew.
5. lnstall the washers and capscrews. Tighten
the capscrews in the sequence shown in Fig.
14-26. Tighten the capscrews to the torque
values given in Table 3.
Table 3: Cylinder Head Capscrew Torque Value

Minimum Maximum
Step No. ft.-lbs. [N»m] ft.-lbs. [N»m]
1. Tighten To 20 [27] 25 [34]
2. Tighten To 80 [108] 100 [136]
3. Tighten To 265 [359] 305 [413.5]
Install The Fuel Crossover

1. lnstall new O-rings into the counterbores in
the cylinder heads.
2. lnstall the fuel crossover connections over the
O-rings and onto the cylinder loads.
Fig. 14-26 (N11427). The Tightening Sequence For The Cylinder Fig. 14-27 (N1 14258). Tighten The Screws For The Fuel
Head Capscrews. Crossover.
14-1 1
3. lnstall the screws. Tighten the screws to 34 to

38 in.-lbs. [3.8 to 4.3 N»m] torque, Fig. 14-27.
Install The Fuel Fittings And Tubing

1. Apply teflon tape or an equivalent to the fittings.
2. lnstall the fuel inlet and drain fittings into the
cylinder heads. lnstall the fittings into the
same locations as when they were removed.
3. Tighten the 1/8 inch angle fittings to 150
in.-lbs. [16.9 N»m] torque. lf the fitting is not in
alignment with the fuel tubing, turn the fitting
in the tightening direction to align the fitting. Do
not turn the fitting in the loosening direction.
4. lnstall the fuel tubing into the fitting. Tighten the
tubing nuts to the torque value given in Table 4. Fig. 14-28 (N1 14259). Install The "Print-O-Seal" Cam Follower
Gasket.
Table 4: Tubing Nut Torque Value
Nut Size In.-lbs. [N»m] In.lba. [N»m]

1/4 inch 120 [13.5] 145 [16.4]
5/16 inch 180 [20.3] 200 [22.6]
1/2 inch 275 [31] 335 [37.8]
Install The Cam Followers And Push Rods

1. lnstall the cam follower gaskets to the cylin
der block. Use new gaskets with the same
thickness as the gaskets that were removed.
2. The Big Cam engine must have at least one
"print-o-seal" gasket with a silicone sealing
bead for each cam follower housing. lnstall
the "print-o-seal" gasket so that it is against
the cylinder block and the sealing bead is Fig. 14-29 (N1 14236). Sequence For The
toward the cam follower housing, Fig. 14-28. Follower Housing.
Note: Make sure that the total gasket thickness 140W lubricating oil. Install the ball end of the
for the Small Cam engine is at least 0.014 inch push rod into the socket of the cam follower.
[0.36 mm] and not more than 0.125 inch [3.2 mm]. The outside diameter of the injector push rod
The total gasket thickness for the Big Cam engine is larger than the outside diameter of the valve
must be between 0.014 inch [0.36 mm] and 0.080 push rod. The push rods for the intake and ex
inch [2.0 mm]. haust valves are the same. lnstall the injector
push rod into the middle cam follower.
3. lnstall the cam follower assembly. Hit the
housing with a plastic hammer to push the Note: The outside diameter of the injector push
housing onto the dowel pins. rod will be either 0.750 inch [19.05 mm] or 0.656
inch [16.67 mm]. The outside diameter of the valve
4. Install the capscrews and lockwashers. push rod is 0.625 inch [15.88 mm]. (0.656 in. [16.66
Tighten the capscrews to 15 ft.-lbs. [20 N»m] mm] for the Big Cam NTC-400 only) The valve push
torque. Then, tighten the capscrews to 30 to rod is 0.007 inch [1.78 mm] longer than the injector
35 ft.-lbs. [41 to 47 N»m] torque. Follow the se push rod. See Table 5 to find the difference in
quence in Fig. 14-29 to tighten the capscrews. length between the push rods for the Big Cam en
Lubricate the ball end of the push rods with gine and the push rods for the Small Cam engine.
3. Make sure that the rectangular seals are in the

Table 5: Push Rod Length — Inch [mm]
correct position.
2 Inch Camshaft 2 V* inch Camshaft
Push Rod Minimum Maximum Minimum Maximum 4. lnstall the guide pins into three of the cap-
lnjector 18.290 18.320 17.775 17.805 screw holes in the cylinder block. lnstall the
[464.56] [465.32] [451.48] [452.24] guide pins so that they will align with the top
Valve [466.34]
18.360 [467.11]
18.390 [454.15]
17.880 [454.91]
17.910 right hand capscrew hole of each housing.
5. Install the cam follower housing gasket onto
the dowels and guide pins.
To Install the MVT Cam Follower
Note: The MVT has only one gasket and only one
The three housings of the MVT cam followers gasket thickness.
must be installed to the engine as an assembly.
6. Apply a coat of clean 30W lubricating oil to
1. Assemble the front and rear housing assem the lobes of the camshaft.
blies to the center housing assembly.
7. lnstall the cam follower assembly onto the
Note: When the instructions refer to the front guide pins and dowel pins, Fig. 14-30.
housing or the front of the housing, that is the
housing or the end of the housing nearest the
front face of the cylinder block when the
assembly is installed to the engine.
a. lnstall the spline coupling onto the shaft
in the front of the center housing.
b. lnstall a new O-ring (rectangular seal) into
each end of the center housing.
c. Align the splines on the shafts in the front
and rear housing with the splines on the
shaft in the center housing. Use the Part
No. 3376027 Cam Follower Shaft Posi
tioner to turn the shaft so that you can
align the splines.
d. lnstall the shaft of the front housing into
the spline coupling. Align the dowel in the
center housing with the slot in the front
housing. Push the shaft into the coupling
until the housing is against the rec Caution: The cam follower assembly Is heavv. Use
tangular seal. another person to help lift the assembly.
e. Install the shaft of the rear housing lnto 8. Remove the 3376028 and the 3376029 from the
the actuator gear in the center housing. assembly.
Align the dowel in the center housing with
9. Hit the housings with a plastic hammer to
the slot in the rear housing. Push the shaft
push them onto the dowel pins.
into the gear until the housing is against
the rectangular seal. 10. Remove the guide pins.
2. lnstall the Part Nos. 3376028 Variable Timing 11. lnstall the capscrews and lockwashers.
Fixture and 3379029 Bracket to the Cam fol Tighten the capscrews for the center housing
lower Assembly. The 3376028 holds the hous first. Tighten the capscrews in the same se
ings in alignment. The 3376029 holds the cam quence used for the small cam and Big Cam
follower levers in an upward position to pre engines. Tighten the capscrews to 15 ft.-lbs.
vent damage to the camshaft and rollers when [20 N»m] torque. Then, tighten the capscrews
the assembly is installed to the engine. to 30 to 35 ft.-lbs. [41 to 47 N»m] torque.
14-1?
Injection Timing
For Small Cam and Big Cam Engines
Use the cylinders No. 1 , 3 and 5 to check the injec
tion timing of the Small Cam and Big Cam
Engines. Use the Part No. 3375522 Injection Tim
ing Tool to check the timing. The timing tool is
ued to check the timing of all Cummins engines
and can be used with the rocker levers installed
on the engine.
Follow these instructions to check the timing.
1. lnstall the support bracket for the push rod
adapter (5, Fig. 14-31) into the slot nearest the
clamp handle (4).
2. lnstall the piston plunger rod (1, Fig. 14-31) in Fig. 14-32 (V31435). Injection Timing Procedure Diagram.
to the injector sleeve of the No. 1 cylinder. To
fasten the timing tool to the cylinder head, in push rod. Tighten the clamp handle. Loosen
stall the adapter screws through the mounting the support bracket (5). Slide the bracket
foot (2) and into the holes for the injector hold- down until the adapter (6) engages the push
down plate. Use the tightening rod (3) to rod. Then, compress the tension spring for the
tighten the adapter screws. adapter approximately 0.50 inch [12.7 mm].
Tighten the support bracket. Make sure the
3. Loosen the clamp handle (4, Fig. 14-31) and
support bracket is aligned with the vertical
align the push rod adapter (6) with the injector
line on the clamp handle bracket.
4. Rotate the crankshaft in the direction of
engine rotation to the Top Dead Center (TDC)
position of the compression stroke for the No.
1 cylinder, (1) Fig. 14-32. Loosen the thumb
screw for the piston travel gauge. Move the
gauge so that the stem of the gauge is in the
center of the piston plunger rod. Lower the
gauge against the piston plunger rod until the
stem is fully compressed, then raise the
gauge approximately 0.025 inch. Tighten the
thumbscrew to hold the gauge in position.
Rotate the crankshaft 2 or 3 degrees clock
wise and counterclockwise to make sure the
piston is at TDC. Loosen the setscrew for the
gauge dial and turn the dial so that the In
dicator is at zero. Tighten the setscrew.
Note: Each gauge for the Timing Tool has a total
travel of 1.0 inch. One revolution of the indicator
needle equals 0.100 inch travel of the indicator
stem. When the stem of the gauge is compressed,
the indicator turns clockwise and the revolution
counter turns counterclockwise. Be sure to note
the reading on the revolution coiunter at TDC.
This will help you find 0.2032 inch Before Top
Fig. 14-31. The Part No. 3375522 Injection Timing Tool. Dead Center (BTDC).
14-14
5. Rotate the crankshaft in the direction of Table 6: Injection Timing Codes and
engine rotation to 90 degrees After Top Dead Push Rod Travel
Center (ATDC), (2) Fig. 14-32. Loosen the
Push Rod Travel (2) Advanced
thumbscrew for the push rod travel gauge. Timing (1) (lnches) Timing
Move the gauge so that the stem of the gauge Code Fast Slow MVT Only
is in the center of the push rod adapter. Lower A - 0.0395 -0.0435
the gauge against the adapter until the stem C -0.0315 - 0.0355
is fully compressed. Then raise the gauge ap D -0.034 -0.038
proximately 0.025 inch. Tighten the thumb E - 0.028 -0.030
Z -0.024 - 0.028
screw to hold the gauge in position. Loosen AA -0.030 -0.032
the setscrew for the gauge dial. Turn the dial AC - 0.027 -0.029
so that the indicator is at zero. Tighten the AF - 0.044 -0.046
setscrew. AH -0.034 -0.036
AK -0.040 -0.042
6. Rotate the crankshaft in the opposite direc AN - 0.045 -0.047
AQ -0.041 -0.043
tion of engine rotation, until you reach TDC. AS -0.035 - 0.037
a. Always rotate the crankshaft slowly. AU - 0.048 -0.050
AV -0.049 -0.051
b. Watch the piston travel indicator as you AW - 0.059 -0.061
AX -0.054 -0.056
rotate the crankshaft. AY - 0.039 -0.041
AZ -0.058 -0.060
c. Continue to rotate the crankshaft past BA - 0.027 -0.029
TDC until the indicator shows 0.225 inch BC -0.023 - 0.025
(two and one-fourth revolutions of the in BH - 0.051 -0.053
BM -0.052 -0.054
dicator needle past TDC, (3) Fig. 14-32). BS -0.071 -0.073
This step is necessary to take up the gear BT -0.080 -0.082
lash in the engine. BU -0.064 -0.066
BV -0.061 -0.063
7. Rotate the crankshaft in the direction of BW -0.066 -0.068
engine rotation until the piston travel gauge is BY -0.069 -0.071
CB (3) -0.104 -0.106 -0.065 ±0.005
at 0.2032 inch BTDC (4) Fig. 14-32. CC (3) -0.114 -0.116 -0.062 + 0.005
CD -0.073 -0.075
Note: The engine must be on the compression CE - 0.025 - 0.027
stroke. When the crankshaft is rotated to TDC on CF -0.037 -0.039
the compression stroke, the indicators on both CH - 0.051 - 0.053
gauges will move in the same direction. lf they do CM (3) -0.099 -0.101 -0.060 ±0.005
CN (3) -0.104 -0.106 -0.065 ±0.005
not, rotate the crankshaft one complete revolu CO -0.0625 - 0.0645
tion and repeat Step 5. CP (3) -0.119 -0.121 -0.060 ±0.005
CR (3) -0.109 -0.111 -0.067 ±0.005
8. Read the push rod travel gauge. The push rod (1) Check the engine dataplate to find the Timing Code.
travel must be within the limits given in Table 6. (2) Measure the push rod travel when the piston is at
0.2032 inch Before Top Dead Center.
Note: Never change the cam follower gaskets to (3) Timing Code for Mechanical Variable Timing (MVT).
correct the injection timing until you check the
following: 9. Follow Steps 4 through 8 to check the lnjec
a. That the Timing Tool is correctly installed. tion Timing of cylinders No. 3 and 5.
b. That the gauges are correctly adjusted. 10. lf the reading on the push rod travel gauge is
not within the limits given in Table 6, increase
c. That the crankshaft has been rotated in or decrease the thickness of the cam follower
the correct direction. gaskets to correct the injection timing.
d. That the capscrews for the cam follower a. lncrease the thickness of the gaskets to
housings are tightened to 30 to 35 ft.-lbs. Advance the injection timing of Right Hand
[41 to 47 N»m] torque. rotation engines.
14-15
NT/NTA 855 C.I.O. Engine Shop Manual
b. Decrease the thickness of the gaskets to a. Loosen the spring retainer locknut.
Retard the injection timing of Right Hand b. Rotate the spring retainer to adjust the in
rotation engines. jection timing. Use the Part No. 3376021
Retainer Adjusting Tool to rotate the
c. lncrease the thickness of the gaskets to
spring retainer, Fig. 14-33. Rotate the re
Retard the injection timing of Left Hand
rotation engines. tainer counterclockwise to advance the
timing. Rotate the retainer clockwise to
d. Decrease the thickness of the gaskets to
Advance the injection timing of Left Hand
rotation engines.
Table 7: Cam Follower Gasket Specifications
11. See Table 7 to find the thickness of the cam Change In
follower gaskets and the amount of change in Gasket Thickness Push Rod Travel
the push rod travel for each gasket. Part No. Inch [mm] ■■■■ill
incn run I1
immj 1 iibiHm mIIii™
Application
Note: Do not increase the total gasket thickness 0.006 to 0.008 0.0015 to 0.002 Big Cam
to more than 0.125 inch [3.2 mm] for the Small [0.15 to 0.20] [0.04 to 0.05]
Cam engine or more than 0.080 inch [2.0 mm] for 0.014 to 0.020 0.0035 to 0.005 Big Cam
the Big Cam engine. The Small Cam and Big Cam [0.36 to 0.51] [0.09 to 0.13]
engines must have at least 0.014 inch [0.3 mm] 3020003 0.020 to 0.024 0.005 to 0.006 Big Cam
[0.51 to 0.61] [0.13 to 0.15]
total gasket thickness.
3020004 0.027 to 0.033 0.007 to 0.008 Big Cam
12. lf you cannot correct the injection timing by [0.69 to 0.84] [0.18 to 0.20]
increasing or decreasing the thickness of the 0.006 to 0.008 0.0015 to 0.002 Small Cam
gaskets, install an offset camshaft key. See [0.15 to 0.20] [0.04 to 0.05]
Table 8 to find the correct key. Follow the in 0.014 to 0.020 0.035 to 0.005 Small Cam
structions in Group 1 to remove and install a [0.36 to 0.51] [0.09 to 0.13]
camshaft key. 3011272 0.020 to 0.024 0.005 to 0.006 Small Cam
[0.51 to 0.61] [0.13 to 0.15]
The MVT Injection Timing 120819 0.027 to 0.033 0.007 to 0.008 Small Cam
[0.69 to 0.84] [0.18 to 0.20]
1. The MVT system must be completely retarded 3011273 0.037 to 0.041 0.009 to 0.010 Small Cam
when you check the timing. [0.94 to 1.04] [0.23 to 0.25]
a. Remove the actuator cap and check the 'Must not be used alone.
actuator plunger to make sure it is all of
the way down in the housing.
b. If the plunger is not in the down position, Table 8: Timing Key Information
rotate the crankshaft two complete revolu Equivalent
tions. This will cause the plunger to move Gasket
down in the housing. Stack
V* Inch 1 Inch Thickness
2. lnstall the Part No. 3375522 lnjection Timing Key Key Offset Timing Change
Part No, Part
art No.
Nc Inch [mm] Change Inch [mm]
Tool into the injector sleeve of the No. 3
cylinder. Follow the instructions given for the 3021601 69550 None None
3021595 200722 0.0060 [0.15] Retard 0.012 [0.30]
Small Cam and Big Cam engines to install the 3021593 200712 0.0075 [0.19] Retard 0.015 [0.38]
Timing Tool. 3021592 200707 0.0115 [0.29] Retard 0.023 [0.58]
3. Check the retard injection timing. Follow the 3021594 200713 0.0185 [0.47] Retard 0.037 [0.94]
3021596 200723 0.0255 [0.65] Retard 0.051 [1.30]
instructions given for the Small Cam and Big 3021598 208746 0.0310 [0.79] Retard 0.062 [1.57]
Cam engines to check the timing. 3021597 202600 0.0390 [0.99] Retard 0.078 [1.98]
3021600 3012307 0.0510 [1.30] Retard 0.102 [2.59]
4. The push rod travel must be within the limits 3021599 3012328 0.0115 [0.29] Advance 0.023 [0.58]
given in Table 6. 3022352* 0.0185 [0.47] Advance
5. Follow these instructions to adjust the injec 3022353* 0.0310 [0.79] Advance
tion timing: 'For Mechanical Variable Timing (MVT) Engines)
14-16
c. Apply air pressure to move the actuator

plunger to the advance position, Fig.
14-34. The actuator plunger must move
freely to the advance position.
d. Check the advance timing. See Table 6 to
find the correct specification for the ad
vance timing.
e. Remove the air supply line and the electric
current after you check the advance timing.
7. lnstall the 3375522 Timing Tool into the injec
tor sleeve of the next cylinder to be checked.
Follow the engine firing order. See Table 9 to
find the engine firing order.
Fig. 14-33. Use The 3376021 Adjusting Tool To Rotate The

Spring Retainer. Table 9: Engine Firing Order
Cylinder Number 1 - 5 - 3 - 6 - 2 - 4
8. Check the retard injection timing. Follow the

instructions given to check the timing for the
No. 3 cylinder.
9. lnstall the actuator cap. Tighten the cap to 25
to 30 ft.-lbs. [34 to 40 N»m] torque.
Note: The difference in timing from one cylinder
to another can be ±0.004 inch. The MVT engine
uses a one-piece cam follower gasket. You cannot
change the thickness of the gasket to adjust the
timing for each cylinder.
Install the Accessory Drive Assembly

Fig. 14-34. Apply Air Pressure To The Actuator Housing. 1. Rotate the crankshaft in the direction of
engine rotation until the No. 1 cylinder is at
retard the timing. One complete turn of the
Top Dead Center of the compression stroke.
retainer will change the push rod travel ap
proximately 0.004 inch [0.10 mm]. 2. Rotate the crankshaft in the direction of
c. Hold the spring retainer in position and engine rotation to 90 degrees after Top Dead
tighten the locknut to 30 to 35 ft.-lbs. [40 to Center.
47 N»m] torque. 3. Install the accessory drive assembly. Make
6. Check the advance timing of the No. 3 sure that the timing marks on the accessory
cylinder. drive gear align with the timing marks on the
camshaft, Fig. 14-35.
a. lnstall an air supply line into the air inlet of
the actuator housing. The air supply must Note: The timing marks on the accessory drive
have more than 80 psi [551 Kpa] air gear and camshaft gear must be aligned so that
pressure. the valve and injector adjustment marks on the
accessory drive pulley will be correctly aligned.
b. Apply 12 volts of DC current to the MVT
solenoid. You can use a battery charger to 4. Tighten the capscrews to 40 to 45 ft.-lbs. [54 to
supply the electric current. 61 n»m] torque.
14-17
shaft gear is 0.004 to 0.016 inch [0.10 to

0.40 mm]. The backlash must be at least
0.002 inch [0.05 mm].
Install the Lubricating Oil Pump

1. lnstall a new gasket onto the mounting flange
of the oil pump.
2. Position the pump into the mounting hole in
the cylinder block. Make sure that the gear
teeth of the pump align with the camshaft
gear teeth.
3. Install the capscrews and lockwashers to
fasten the pump to the cylinder block. Tighten
the capscrews to 35 to 45 ft.-lbs. [47 to 61
Fig. 14-35 (N 114262). Align The Timing Marks. N»m] torque.
4. Check the backlash of the pump gear, Fig.
14-37. Use the same procedure that you used
to check the backlash of the accessory drive
gear.
Fig. 14-36 (N1 14263). Check The Gear Backlash.
5. Check the accessory drive gear to camshaft

gear backlash.
a. lnstall a dial indicator gauge onto the
cylinder block. Position the gauge so that Fig. 14-37 (N114264). Check The Of The Pump Gear.
the stem is against a tooth on the ac
cessory drive gear, Fig. 14-36. 5. Install the power steering pump to the oil
pump, if the engine is so equipped.
b. Rotate the accessory drive gear as far as it
will freely move. Turn the dial of the gauge 6. lnstall the oil filter assembly to the oil pump, if
to zero. the engine is so equipped. Make sure that you
install a new O-ring and filter element. Tighten
c. Rotate the accessory drive gear in the op the center bolt to 25 to 35 ft.-lbs. [34 to 47
posite direction. The reading and the N»m] torque.
gauge shows the amount of backlash be
tween the gears. Install the Gear Case Cover
d. The normal amount of backlash between a 1. Put the new gear cover gasket onto the gear
new accessory drive gear and a new cam- case cover. Use Lubriplate or an equivalent to
1-18
6. lnstall a new oil seal into the gear cover. Use

the Part No. ST-1259 Mandrel and the Part No.
3375151 Pilot to install the seal, Fig. 14-39.
Use the Part No. ST-1 172 Mandrel to install the
seal when the end of the crankshaft is tapered.
7. lnstall a new accessory drive oil seal into the
gear cover. Use the Part No. ST-1 173 Mandrel
to install the seal, Fig. 14-40.
Caution: Do not use any lubricants when you In
stall LDL (lay down lip) TFE oil seals. The lip of
the seal and the outside diameter of the shaft
must be clean and dry.
8. lnstall the support bearing or thrust plate into
the gear cover. Make sure that the clearance
Fig. 14-38 (N114265). Check The Concentricity Of The Oil Seal between the support bearing or the thrust
Bore. plate and the end of the camshaft is correct.
hold the gasket on the gear case cover. See
the parts catalog to find the correct gasket
part number.
2. Install the gear cover onto the dowel pins.
Tighten the capscrews to 45 to 55 ft.-lbs. [61 to
74 N»m] torque.
3. Cut off the ends of the gear cover gasket so
that the gasket is even with the mounting
flange for the oil pan.
4. Check the alignment of the oil pan mounting
flange of the gear cover with the oil pan mount
ing flange of the cylinder block. The gear
cover flange must be even with the cylinder
block flange within ±0.004 inch [0.10 mm].
5. The oil seal bore in the gear cover must have a Fig. 14-39 (N1 14266). Install The Oil Seal.
common center with the crankshaft. Use a dial
indicator gauge to check the concentricity, Fig.
14-38. The total indicator reading must not
exceed 0.010 inch [0.25 mm]. lf the reading ex
ceeds 0.010 inch [0.25 mm], do the following:
a. Remove the gear cover.
b. Remove the gasket from the gear cover.
c. Make sure that the gear cover and cylinder
block are clean. Make sure that the dowel
pins in the cylinder block are not damaged.
d. lnstall a new gasket to the gear cover.
e. lnstall the gear cover to the cylinder block.
Make sure that the gear cover is correctly
installed on the dowel pins.
f. Check the concentricity. Fig. 14-40 (N1 14267). Install The Oil Seal For The Accessory Drive.
14-19
Fig. 14-41 (N11440). The Camshaft Thrust Plate. Fig. 14-43 (N1 14268). Measure The Clearance For The Bearing
Support.
Fig. 14-43. Use this measurement to find

the thickness of the spacers needed to
provide the correct clearance.
d. Use a micrometer to measure the thick
ness of the spacers. Add or remove the
spacers as needed to make the clearance
correct.
e. lnstall a new O-ring and the spacers to the
support bearing or thrust plate. Install the
bearing or plate into the gear cover.
Tighten the capscrews to 15 to 20 ft.-lbs.
Install the Accessory Drive Pulley

Fig. 14-42 (N1 14187). The Camshaft Bearing Support. 1. Install the tapered end of the pin into the ac
cessory drive shaft, Fig. 14-44.
Note: Some engines use a support bearing in the Note: The pipe plug in the gear cover can be
gear cover and some use a thrust plate, Fig. 14-41 removed so that you can see the timing marks on
and Fig. 14-42. The support bearing clearance the gears. Make sure that the timing marks are
must be 0.008 to 0.013 inch [0.20 to 0.33 mm]. The aligned, Fig. 14-45. lf the pipe plug has been
thrust plate clearance must be 0.001 to 0.005 inch removed, install the plug. Tighten the pipe plug to
[0.03 to 0.13 mm]. 35 to 45 ft.-lbs. [47 to 61 N»m] torque.
a. Remove the O-ring and spacers from the 2. Apply a coat of lubriplate or an equivalent to
support bearing or thrust plate. the drive shaft.
b. Put the support bearing or thrust plate into 3. Align the keyway of the pulley with the roll pin
the bore in the gear cover. Hold the bear in the shaft. Push the pulley over the roll pin
ing or plate so that it will be against the and onto the shaft. Use your hands to start the
end of the camshaft. pulley onto the shaft.
c. Use a feeler gauge to measure the space 4. Install the Part No. 3376326 Pulley Assembly
between the mounting flange of the sup Tool to the drive shaft. Use the 3376326 to ln
port bearing or thrust plate and gear cover, stall the pulley onto the shaft, Fig. 14-46.
14-20
Engine Assembly end Testing
5. Remove the ST-386.

6. lnstall the rubber keyway seal into the pulley
keyway. Make sure that one leg of the seal is
toward the drive shaft.
7. lnstall the flat washer and pulley retaining
nut.
a. Tighten the flanged retaining nut to 300 to
310 ft.-lbs. [407 to 420 N»m] torque.
b. Tighten the retaining nut that does not
have a flange to 90 to 110 ft.-lbs. [122 to
149 N»m] torque.
Note: The flanged retaining nut can be used to
rotate the crankshaft.
Fig. 14-44 (N 114269). Install The Pin Into The Accessory Drive
Shaft. Install the Air Compressor
The coupling driven single cylinder air com
pressor must be timed to the engine firing order.
Follow these instructions to install and time the
single cylinder air compressor.
1. Rotate the engine crankshaft until the "A"
valve set mark on the accessory drive pulley is
aligned with the pointer on the gear cover.
2. Hold the air compressor so that you are look
ing at the coupling end of its crankshaft.
Rotate the air compressor crankshaft until the
keyway or timing mark is positioned half-way
between 9 o'clock and 10 o'clock.
3. lnstall the splined coupling to the air com
pressor crankshaft.
Fig. 14-45 (N114143). The Timing Marks For The Accessory Drive. 4. lnstall the air compressor and a new gasket to
the accessory drive. Tighten the capscrews to
40 to 45 ft.-lbs. [54 to 61 N»m] torque.
5. lnstall the support bracket to the air com
pressor and the cylinder block. Tighten the
capscrews to 30 to 35 ft.-lbs. [40.6 to 47 N»m]
torque.
Install the Vibration Damper

The Vibration Damper Mounting Flange
(Tapered End Crankshaft)
Make sure that the mounting flange fits correctly
onto the crankshaft.
1. Apply an even coat of blue compound (Prus
sian Blue) to the tapered end of the crankshaft.
Fig. 14-46 (N1 14270). Install The Accessory Drive. 2. Put the flange onto the crankshaft.
14-21
3. Rotate the flange approximately 1/8 of a turn. 3. Install the retainer and -capscrew to hold the
Remove the flange. flange onto the crankshaft. Tighten the Part
No. 140410 capscrew to 180 to 200 ft.-lbs. [244
4. Check the pattern of blue compound on the in
to 271 N»m] torque. Tighten the Part No.
side diameter of the flange. The pattern must
196653 capscrew to 250 to 270 ft.-lbs. [339 to
show, at the larger diameter of the crankshaft,
366 N»m] torque.
the flange has 100 percent contact with the
crankshaft. The 100 percent contact must ex 4. lnstall the vibration damper to the mounting
tend at least 1/2 inch [12.7 mm] toward the flange. Install the capscrews with new lock-
end of the crankshaft. The remainder of the plates. Bend the ends of the lockplates
flange must have at least 70 percent contact against the head of the capscrews. Tighten
with the crankshaft. the capscrews to 55 to 60 ft.-lbs. [74.5 to 81
5. Clean the blue compound from the flange and N»m] torque.
the crankshaft. 5. Measure the movement of the circumference
6. Use Magnaglo inspection to check the flange and the face of the vibration damper.
for cracks. a. Install the dial indicator gauge to the gear
7. lf the flange does not fit onto the crankshaft cover as shown in Fig. 14-47. Position the
correctly: tip of the indicator on point "A". Rotate
the crankshaft. The total indicator reading
a. Make sure that the inside diameter of the must not exceed 0.003 inch [0.08 mm] per
flange and the outside diameter of the 1.0 inch [25.4 mm] of vibration damper
crankshaft are free of damage or rough diameter.
surfaces.
b. Measure the movement of the face of the
b. Apply a coat of Grade A (280 grit) lapping
vibration damper. Put the tip of the indi
compound to the inside diameter of the
cator on point "B" (Fig. 14-47). Rotate the
flange. crankshaft. The crankshaft must be at the
c. Put the flange onto the crankshaft. Rotate front or rear of the thrust clearance when
the flange one-half turn in each direction you measure the movement. The total indi
until the flange fits onto the crankshaft cator reading must not exceed 0.0025 inch
correctly. [0.064 mm] per 1.0 inch [25.4 mm] of the
d. Clean the lapping compound from the radius (as measured from the center of the
flange and the crankshaft. vibration damper).
Caution: Make sure that none of the lapping com
pound gets onto the crankshaft seal or Into the
engine.
e. Follow Steps 1 through 5 to make sure that
the flange fits correctly onto the crankshaft.
Install the Mounting Flange and Vibration Damper

1. Apply lubricant to the area of the crankshaft
on which the flange will be installed. Use SAE
30 preservative oil.
Caution: Make sure that the lubricant does not
touch the crankshaft seal. Do not apply lubricant
when you Install any of the cast Iron flanges, Part
No. 115562, 115563, 175183 or 175185.
2. lnstall the mounting flange onto the crank
shaft. Use your hands to push the flange onto Fig. 14-47 (N114140). Measure The Movement On The Circum
the crankshaft. ference And The Face Of The Vibration Damper.
22
Install the Vibration Damper and Pulley

(Straight End Crankshaft)
1. lnstall the front engine support, if the engine
has one. Tighten the capscrews to 55 ft.-lbs.
[75 N»m] torque.
Caution: Make sure that the mounting surfaces of
the vibration damper and pulley are clean and dry.
Do not apply any lubricant.
2. lnstall two guide pins into the end of the
crankshaft.
3. lnstall the pulley and vibration damper onto
the guide pins.
4. Apply a coat of clean SAE 30 lubricating oil to
the threads of the capscrews and face of the Fig. 14-48 (N1 14191). Install The Water Pump Support
washers.
5. Install the capscrews and washers to hold the
pulley and vibration damper onto the crank
shaft. Tighten the capscrews to the torque
valves given in Table 10.
Table 10: Vibration Damper Capscrew

Torque Values
Capscrew SAE Grade Minimum Maximum
Size Number ft.-lbs. [N»m] ft.-lbs. [N»m]
1/2 inch 8 115 [156] 125 [170]
5/8 inch 8 180 [244] 200 [271]
5/8 lnch 5 150 [203] 170 [231]
6. Measure the movement on the circumference

and the face of the vibration damper. Follow
Fig. 14-49 (N1 14144). Install The Fan Bracket.
the procedure given to install the Mounting
Flange and Vibration Damper, Steps 5a and 5b.
Install the Water Pump

The Eccentric Water Pump f
1. Install the water pump support and a new
gasket to the cylinder block, Fig. 14-48.
Tighten the capscrews to 30 ft.-lbs. [41 N»m]
torque.
<Q II V ) \
2. lnstall the water pump into the support. lnstall XI—
the fan bracket (Fig. 14-49] or clamp ring if the
engine does not have a fan bracket. lnstall the
iockwashers and capscrews. Tighten the cap- i —4k§| l°jr— 4
screws to 3 to 5 ft.-lbs. [4 to 6.8 N»m] torque.
Turn the body of the pump clockwise so that
3— 1^4- 6
the water pump pulley moves toward the ac
cessory drive pulley. Fig. 14-50. The Tightening Sequence For The Fan Bracket.
14-23
3. Install the belt onto the water pump pulley and belts. Tighten the belts so that they have
accessory drive pulley. Tighten the belt so 100 to 110 lbs. tension. Use the Part No.
that it has 90 to 110 lb. [400 to 489 N] belt ten ST- 1274 Belt Tension Gauge to check the
sion. Put a large screwdriver into the slots in belt tension, Fig. 14-53.
the pump body and turn the body counter
c. Tighten the locknut for the idler pulley
clockwise to tighten the belt. Use the Part No.
shaft to 45 to 55 ft.-lbs. [61 to 74 N»m] torque.
ST-1138 Belt Tension Gauge to check the belt
tension. d. Check the belt tension again after you have
tightened the locknut. The belt tension must
4. Tighten the capscrews for the fan bracket or
be 120 to 140 lbs. [534 to 623 N]. If the ten
clamp ring. Follow the tightening sequence
sion is not correct, loosen the locknuts and
shown in Fig. 14-50. Tighten the capscrews to
repeat steps a, b and c.
12 to 15 ft.-lbs. [16 to 20 N»m] torque.
4. Install the fan hub bracket to the water pump
The Water Pump with Idler Pulley housing. Tighten the capscrews to 70 to 80
1. lnstall the water pump and idler assembly and
a new gasket to the cylinder block, Fig. 14-51.
Fig. 14-52. The Tightening Sequence For The Water Pump With
Idler Pulley.
Fig. 14-51 (N114271). Install The Water Pump And Idler Pulley.
2. Tighten the capscrews in the sequence shown

in Fig. 14-52.
a. Tighten the capscrews to 10 ft.-lbs. [14
N»m] torque.
b. Tighten the capscrews to 20 ft.-lbs. [27
N»m] torque.
c. Tighten the capscrews to 30 to 35 ft.-ibs.
3. lnstall the belts onto the water pump, water
pump idler and accessory drive pulleys.
a. Tighten the locknut for the idler pulley
shaft to 5 to 6 ft.-lbs. [6.7 to 8 N»m] torque.
b. Turn the adjusting screw to tighten the Fig. 14-53 (N114272). Adjust The Belt Tension.
Install the Rear Cover and Oil Seal 7. lnstall the seal assembly tool onto the
crankshaft. Put the largest inside diameter
1. Make sure that the oil seal area on the
crankshaft is clean and dry. Use a crocus part of the tool toward the cylinder block.
cloth to polish the crankshaft. Use a clean Note: "LDL TFE" (Lay-down Lip, Teflon) oil seals
cloth to clean the crankshaft. for service replacement have an assembly tool
2. lnstall the rear cover and a new gasket to the which protects the seal lip during shipment and
installation.
cylinder block. Tighten the capscrews only
enough to hold the rear cover in position. Caution: The "LDL TFE" oil seal must be Installed
3. Install the Part No. ST-997 Oil Seal Driver onto with the lip of the seal and the crankshaft clean
the crankshaft and into the bore of the rear and dry. Do not use any kind of lubricant.
cover. Use the ST-997 to align the rear cover 8. Push the oil seal from the assembly tool onto
with the crankshaft. The ST-997-6 Buttons the crankshaft. Remove the assembly tool.
must be removed from the ST-997 Driver.
9. lnstall the oil seal into the rear cover. lnstall
4. Check the alignment of the rear cover with a the ST-997-6 Buttons into the ST-997 Seal
dial indicator gauge, Fig. 14-54. Driver. Use the seal driver to push the oil seal
into the rear cover, Fig. 14-55.
Fig. 14-54 <N1 14273). Check The Alignment Of The Rear Cover.
a. The rear cover must be on a common Fig. 14-55 (N1 14274). Install The Oil Seal.
center with the crankshaft within 0.010 Install the Flywheel Housing
inch [0.25 mm] total indicator reading.
The Dry Flywheel Housing
b. The rear cover must be square to the
centerline of the crankshaft within 0.010 1. Make sure that the mounting surface of the
inch [0.25 mm] total indicator reading. flywheel housing is clean and free from
damage.
c. The rear cover must be within 0.004 inch
[0.10 mm] of being flat with the oil pan 2. lnstall a new camshaft bore gasket onto the
flange of the cylinder block. flywheel housing. Use gasket cement to in
stall the gasket to the housing. The cement
d. Tighten the capscrews to 30 to 35 ft.-lbs. must be completely dry before you install the
[40.6 to 47 N»m] torque. flywheel housing.
5. Remove the ST-997 from the crankshaft. Note: The 2Vt inch cam (Big Cam) engines use a
6. Cut off the excess gasket material so that the cup plug seal in the rear camshaft bore. These
gasket is even with and not more than 0.010 engines do not require a camshaft bore gasket in
inch [0.25 mm] above the oil pan flange. the flywheel housing.
14-2
3. Remove the dowels when you install a new fly 5. Check the circumference of the bore. The total
wheel housing. Remove the dowels if they are indicator reading must not exceed the limits
damaged or the outside diameter of the dowels given in Table 11.
measure less than 0.5005 inch [12.71 mm].
6. After the readings are within the limits,
4. Install two studs into the cylinder block to tighten the capscrews in the sequence given
support the flywheel housing. in Fig. 14-57 to 140 to 160 ft.-lbs. [190 to 217
N»m] torque.
5. lnstall the flywheel housing. Tighten the
capscrews to 10 to 20 ft.-lbs. [13.5 to 27 N»m]
torque.
6. Remove the studs. Install and tighten the re
maining capscrews.
Check the Location of the Bore

1. Install the Part No. ST-1325 Dial Gauge Attach
ment to the crankshaft. Install the Part No.
3376050 Dial Gauge to the attachment, Fig.
14-56.
Fig. 14-57. Tightening Sequence For The Flywheel Housing

Capscrews.
Check the Alignment of the Housing Face

1. lnstall the dial gauge attachment and dial
gauge as shown in Fig. 14-58.
2. Push the crankshaft toward the front of the en
gine to remove the crankshaft end clearance.
Fig. 14-56 (N1 14275). Check The Location Of The Bore.
2. Use chalk to mark the housing at the positions

of 12, 3, 6 and 9 o'clock.
3. Rotate the crankshaft to check the housing
bore at 3 o'clock and 9 o'clock. lf the total indi
cator reading exceeds the limits given in Table
11, move the housing in a horizontal direction
one-half of the distance of the total indicator
reading. Use a pry bar to move the housing.
4. Rotate the crankshaft to check the housing
bore at 12 o'clock and 6 o'clock. Follow the
procedure given in Step 3, but move the hous
ing in a vertical direction until the reading is Fig. 14-58 (N1 14276). Check The Alignment Of The Housing
within the limits. Face.
4-26
Table 11: Flywheel Housing Specifications — lnch [mm]

SAE No. Bore Diameter (For Reference Only) Bore Location Tolerance Face Alignment Tolerance
00 31 .000 to 31 .010 [787.40 to 787.65 mm] 0.012 [0.30 mm] TlR 0.012 [0.30 mm] TlR
0 25.500 to 25.520 [647.70 to 647.95 mm] 0.010 [0.25 mm] TlR 0.010 [0.25 mm] TIR
1/2 23 000 to 23.008 [584.00 to 584.20 mm] 0.010 [0.25 mm] TlR 0.010 [0.25 mm] TlR
1 20 125 to 20.130 [534.27 to 534.40 mm] 0.008 [0.20 mm] TlR 0.008 [0.20 mm] TlR
2 17 625 to 17.630 [447.68 to 447.80 mm] 0.008 [0.20 mm] TIR 0.008 [0.20 mm] TlR
4 14.250 to 14.255 [361.95 to 362.08 mm] 0.006 [0.15 mm] TlR 0.006 [0.15 mm] TlR
3. Rotate the crankshaft and check the align the flywheel housing. Tighten the Nylok cap-
ment of the face of the flywheel housing. screws to 2 to 3 ft.-lbs. [2.7 to 4 N»m] torque.
Make sure that the crankshaft is pushed
6. Check the alignment of the seal carrier. Align
toward the front of the engine as you check the seal carrier so that it is on a common
the alignment. center with the crankshaft within 0.008 inch
4. The total indicator reading must not exceed [0.20 mm] total indicator reading.
the limits given in Table 11. 7. Tighten the capscrews to 8 to 9 ft.-lbs. [10.8 to
12.2 N»m] torque.
The Dowel Pins
Caution: Never operate the engine without clutch
1. lf the dowel pins were removed from the oil in the housing. Operating without clutch oil wil
cylinder block, use a drill and reaming fixture damage the clutch seal and clutch.
to ream the dowel holes to the next oversize.
Install the Flywheel
2. lnstall the dowel pins. The dowels must be
even with or 0.010 inch [0.25 mm] below the Note: When you install a new flywheel, remove the
surface of the housing that is closest to the dowels.
flywheel. 1. lnstall two guide studs that have 5/8-18
threads and are 6 inches [152 mm] long into
The Flywheel Housing with Wet Clutch Seal the crankshaft flange.
lf the engine is to be tested with a dynamometer, 2. lnstall the flywheel onto the studs. Align the
do not install the wet clutch seal until after the dowel holes in the flywheel and crankshaft.
engine is tested. Any usage without clutch oil will
3. lnstall and tighten the capscrews.
destory the clutch seal.
a. Lubricate the threads of the capscrews
1. lnstall the housing and a new O-ring onto the ' and the face of the hardened washers with
cylinder block. 30W oil.
2. Check the location of the bore and the align b. Use the sequence shown in Fig. 14-59 and
ment of the face. Use the same procedure to tighten the capscrews until the flywheel is
check the location and alignment as for the flat against the crankshaft flange.
dry flywheel housing.
c. Remove the guide studs and install the re
3. Use the same procedure to install oversize maining two capscrews.
dowel pins as for the dry housing.
d. Tighten the capscrews that use the
4. Install a new seal into the seal carrier. The lip hardened flatwashers to 200 to 220 ft.-lbs.
of the seal must be toward the flywheel. Use [271 to 298 N»m] torque.
the parts catalog to find the correct seal part
e. Tighten the capscrews that have safety
number. wire holes in the head of the capscrew to
5. Install the seal carrier and new gasket onto 190 to 200 ft.-lbs. [258 to 271 N»m] torque.
14-27
Fig. 14-59 (N11451). Tightening Sequence For The Flywheel Fig. 14-61 (N114139). Check The Alignment Of The Face.
Capscrews.
b. Rotate the crankshaft and read the indicator.
The total indicator reading must not ex
ceed 0.0005 inch [0.013 mm] per 1 inch
[25.4 mm] of flywheel diameter.
Install the Oil Pan

Note: The oil pan used for the 80 degree tilt engine
has machined bosses for the oil gauge and filter
bracket, the alternator bracket and lifting eyes. ln
stall those parts when you install the oil pan.
1. lnstall two guide studs into the oil pan flange
of the cylinder block.
2. Put the oil pan and new gasket over the guide
studs. Use your hand to install the capscrews
with washers and lockwashers.
Fig. 14-60 (N1 14138). Check The Location Of The Bearing Bore.
4. Check the location of the pilot bearing bore.
a. Install the ST-1325 attachment and
3376050 gauge onto the flywheel housing.
Put the trip of the indicator in the position
shown in Fig. 14-60.
b. The total indicator reading must not ex
ceed 0.005 inch [0.13 mm] in one complete
revolution of the flywheel.
5. Check the alignment of the clutch face of the
flywheel. The crankshaft end movement will
change the indicator reading. Make sure that
the crankshaft is moved all of the way toward
the front of the engine.
a. Move the indicator so that it is positioned Fig. 14-62. Install Two Capscrews Into The Buttress End Of The
Oil Pan.
as shown in Fig. 14-61.
4-28
Install the Oil Suction Tube

1. Apply clean lubricating oil to the tube nuts
and tube sleeves. Assemble the tube sleeve
and nuts onto the oil stuction tube. lnstall the
a a a a o -b~ 4-4- s—a a as oil pump adapter and oil pan flange onto the
J7 tube nuts but do not tighten.
lnstall the oil pan flange and a new gasket
onto the oil pan. Do not tighten the capscrews.
o o o o 0 0- a a q fl y 3. Push the tube and sleeve assembly into the oil

pump adapter until it is against the bottom in
the adapter. Use your hand to tighten the nut.
Then tighten the nut an additional 1 to 1-1/4
turn, Fig. 14-64.
Fig. 14-63. Install The Capscrews Into The Oil Pan. Use your hand to tighten the -tube nut on the
oil pan suction flange. Tighten the capscrews
3. Use the following sequence to tighten the that hold the suction flange to the oil pan to 30
capscrews. This will prevent damage to the oil to 35 ft.-lbs. [41 to 47 N»m] torque. Tighten the
pan or flywheel housing. tube nut until it is against the stop on the suc
tion flange.
a. lnstall and tighten the middle capscrew in
each of the two buttresses on the flywheel
housing, Fig. 14-62.
b. Tighten two capscrews on each side of the
oil pan flange. Tighten the capscrews that
are located halfway between the front and
the rear of the oil pan, Fig. 14-63.
c. Remove the capscrews that were installed

In Step 3a. This is necessary to provide the
clearance to perform the following step.
d. Tighten the capscrews to hold the rear
corners of the oil pan to the cylinder block.
e. Remove the guide studs and install the
capscrews.
f. Tighten the capscrews that hold the oil

pan to the cylinder block and front cover. Fig. 14-64 (N1 14277). Install The Oil Suction Tube.
Tighten the capscrews to 35 to 40 ft.-lbs.
Install the Fuel Pump
g. Tighten the capscrews that hold the oil
1. Install the buffer or spline to the coupling of
pan buttress to the flywheel housing but
the air compressor or accessory drive.
tress. Tighten the capscrews to 70 to 80
ft.-lbs. [95 to 108 N»m] torque. 2. Install the fuel pump and new gasket to the air
compressor or accessory drive. Tighten the
h. Tighten the capscrews that hold the oil
capscrews to 30 to 35 ft.-lbs. [41 to 47 N»m]
pan to the rear cover plate. Tighten the
torque, Fig. 14-65.
capscrews to 15 to 20 ft.-lbs. [20 to 27
N»m) torque. 3. Install the fuel line to the solenoid valve.
14-29
Install the Thermostat Housing

and Water Manifold
1. Install new O-rings onto the water manifold
coupling pipes. lnstall the coupling pipes into
the water manifold sections.
2. Apply grease to the sealing rings for the water
manifold and thermostat housing. lnstall the
sealing rings into the counterbores in the
cylinder heads.
3. Position the water manifold assembly onto
the cylinder heads. lnstall and tighten the cap-
screws to 30 to 35 ft.-lbs. [41 to 47 N»m] torque.
4. Install the front section of the thermostat
housing and a new gasket. Make sure that the
Fig. 14-65 (N1 14278). Install The Fuel Pump. thermostat has been correctly installed into
the housing according to the instructions
Install the Injectors given in Group 8. Tighten the capscrews to 30
1. lnstall new O-rlngs onto the injectors. to 35 ft.-lbs. [41 to 47 N»m] torque. lnstall the
water bypass tube.
2. Apply a light coat of clean lubricating oil to
the injector body and O-rings. Install and Adjust the Crossheads
3. lnstall the injector into the cylinder head. 1. Lubricate the end of the valve stems and the
Align the screen on the fuel inlet hole so that entire crosshead guide with clean oil.
it is toward the exhaust side of the cylinder
2. Install the crossheads onto the crosshead
head.
guides. The adjusting screw must be toward
a. Use the Part No. 3376000 lnjector Puller to the water manifold.
install the PT (type D) injectors. lnstall the
3. Loosen the adjusting screw locknut. Loosen
tool onto the injector and use a quick hand
push to push the injector into the bore. the adjusting screw one full turn.
b. Use the Part No. 3375161 Injector Puller to Note: Engines equipped with Jacobs Brake use
special crossheads for the exhaust valves. See
install the top stop injectors. Use the
Group 20.
same procedure as for the PT (type D)
injectors. 4. Hold the crosshead down against the valve
stem that is nearest to the push rod. Use light
4. Install the hold-down plate, with the counter-
pressure to hold the cross head. Turn the ad
bore up, onto the injector.
justing screw in until it touches the valve
5. lnstall the plunger link into the injector. stem, Fig. 14-66.
Tighten the capscrews for the hold-down plate
in increments of 4 ft. -lbs. [5 N»m] torque until 5. Hold the crosshead adjusting screw in posi
they are tightened to 10 to 12 ft.-lbs. [14 to 16 tion and tighten the locknut. Tighten the lock-
N»m] torque. Tighten the nylok capscrews to nut to 25 to 30 ft.-lbs. [34 to 41 N»m] torque.
12 to 14 ft. lbs. [16 to 19 N»m] torque. Note: When the Part No. ST-669 Torque Wrench
6. Check the injector plungers for free move Adapter is used, tighten the locknut to 22 to 26
ment after you tighten the hold-down plate. lf
the plunger does not move freely, loosen the 6. Check the clearance between the crosshead
capscrews then tighten to the correct torque. and valve spring retainer, (1 and 2) Fig. 14-67.
Check the injector plungers for the top-stop Use a wire gauge to check the clearance. The
injectors. The lnjector plunger must rotate clearance must be a minimum of 0.025 inch
freely. [0.64 mm].
4-30
Fig. 14-66 (N1 14279). Adjust The Crosshead. Fig. 14-68. The Correct Position For The Adjusting Screw.
3. Hold the levers in position and install the

housing onto the guide pins and cylinder
head. Put the ball end of the adjusting screws
into the sockets of the push rods. Remove the
guide pins.
4. lnstall the fan bracket brace, if the engine is
so equipped, and the engine lifting brackets.
Use the longest capscrews to install the fan
bracket brace and the lifting brackets.
Note: Check the alignment of the oil spray nozzles
for the 80 degree tilt engines. Use the ST-1182
spray nozzle locator to check the alignment.
5. Tighten the capscrews in the sequence shown
in Fig. 14-69 to 55 to 65 ft.-lbs. [75 to 89 N»m]
torque.
Fig. 14-67. Check These Areas For Clearance.
Install the Rocker Lever Housing

1. Put new rocker lever gaskets onto the cylinder
heads. Install two guide pins into each
cylinder head. The guide pins must be long
enough to protrude above the top surface of
the housing.
2. Loosen the locknuts for the adjusting screws.
Loosen the adjusting screws so that there is a
maximum of 1.250 inch [31.8 mm] from the top
surface of the lever and the ball end of the ad
justing screw, Fig. 14-68.
Caution: If the adjusting screw protrudes beyond
the maximum shown In Fig. 14-68, the push rods
can be damaged when you tighten the capscrews Fig. 14-69 (N11463). The Tightening Sequence For The Rocker
for the housing. Lever Housing Capscrews.
14-31
Install the Fan Hub and Pulley e. When identical belts are installed on a
pulley, the protrusion of the belts must not
1. Tighten the capscrews for the fan bracket
vary more than 1/16 inch [1.59 mm].
brace to 70 to 80 ft.-lbs. [95 to 108 N»m] torque.
f. Make sure that the belts do not touch or
2. lnstall the fan hub assembly onto the fan hub
hit against any part of the engine.
bracket.
2. To adjust the belts.
a. Install the fan hub adjusting screw.
a. Use the Part No. ST-1 274 Belt Tension
b. lf capscrews fasten the assembly to the Gauge to check the tension of belts that
bracket, tighten the capscrews to 3 to 5 are from 3/8 to 1/2 inch [9.53 to 12.70 mm]
ft.-lbs. [4 to 7 N»m] torque. wide. Use the ST-1 138 gauge to check
c. If a Marsden nut is used to fasten the belts that are from 11/16 to 7/8 inch [17.46
assembly to the bracket, tighten the nut to to 22.23 mm] wide. Use the ST-1 293 gauge
45 to 55 ft.-lbs. [61 to 74 N»m] torque. to check the "Poly-V" belts.
3. Loosen the adjusting screw so that the fan b. Tighten the 3/8 to 1/2 inch [9.53 to 12.70
hub is in its lowest position. mm] wide belts until a reading of 120 to
140 lbs. is indicated on the gauge. Tighten
4. lnstall new belts onto the fan hub pulley and the 11/16 to 7/8 inch [17.46 to 22.23 mm]
accessory drive pulley. wide belts until a reading of 90 to 110 lbs.
5. Tighten the fan hub adjusting screw until the is indicated on the gauge. Tighten the
belts have 90 to 1 10 lbs. [400 to 489 N] tension. "Poly-V" belt until a reading of 140 to 160
Use the ST-1 138 gauge to check the belt tension. lbs. is indicated on the gauge.
6. Tighten the capscrews or Marsden nut to the c. After the engine has been running for at
correct torque value. least 1 hour, stop the engine and check
the belt tension. If the tension is less than
a. Tighten the capscrews to 70 to 80 ft.-lbs.
the value given in Step b, adjust the belt to
the correct value.
b. Tighten the Marsden nut to 400 to 450
ft.-lbs. [542 to 610 N»m] torque. Install the Engine Brake
7. Loosen the fan hub adjusting screw 1/2 turn. Install the engine brake or Jacobs Brake if the
engine is so equipped. Follow the instructions
Belt Installation and Tension given in Group 20.
1. To install the belts. Adjust the Valves and Injectors
a. When two or more identical belts are used The valves and injectors must always be in the cor
on the same pulley, all of the belts must be rect adjustment for the engine to operate efficiently.
replaced at the same time.
The adjustment value for the injectors is determined
b. Make sure the distance between the by which type of rocker lever housings are used
pulley centers is as short as possible on the engine. See Table 14 to find the correct
when you install the belts. Do not roll the value for the aluminum and the cast iron rocker
belts over the pulley. Do not use a tool to housings.
pry the belts onto the pulley.
Note: When you adjust the valves and injectors for
c. The pulleys must not be out of alignment a left hand rotation engine, make sure that you
more than 1/16 inch [1.59 mm] for each 12 use the correct sequence shown in Table 12.
inches [30.5 cm] of distance between the
pulley centers. The Dial Indicator Method to Adjust the Injectors
d. The belts must not touch the bottom of the Caution: Do not use this method to adjust the top-
pulley grooves. The belts must not pro stop Injectors.
trude more than 3/32 inch [2.38 mm] above 1. Rotate the crankshaft in the direction of en
the outside diameter of the pulley. gine rotation. Align the "A" or "1-6 VS" mark
14-32
Fig. 14-70 (OM1050L). Align The Timing Marks With Pointer On The Gear Cover.
1-6 TC
A Of C or
1-6 vsN 3-4 VS
o X
0 J
B or
2-5 VS
Fig. 14-71 (N 114230). The Timing Marks On The Accessory Fig. 14-72 (OM1051 L). Check The Travel Of The Injector Plunger.
Drive Pulley.
valves are closed, the rocker levers for cyl
on the accessory arive pulley with the pointer inder number 5 will be loose. lf they are not,
on the gear cover, Fig. 14-70 and Fig. 14-71. rotate the crankshaft 360 degrees and align
2. When the "A" or "1-6 VS" mark is aligned with the marks on the pulley with the pointer.
the pointer, the intake and exhaust valves for Note: The instructions using cylinder No. 3 to
cylinder number 5 must be in the closed posi begin the injector adjustments are for illustration
tion. The injector plunger for cylinder number purposes. You can begin the adjustments with
3 must be at the top of its travel. When the any of the cylinders as shown in Table 12.
14-33
Table 12: Injector and Valve Set Position

Right Hand Rotation Engine
Bar In Pulley Set Cylinder
Direction Position Injector Valve
Start A or 1-6 VS 3 5
Adv. To B or 2-5 VS 6 3
Adv. To C or 3-4 VS 2 6
Adv. To A or 1-6 VS 4 2
Adv. To B or 2-5 VS 1 4
Adv. To C or 3-4 VS 5 1
Left Hand Rotation Engine 1
Bar in Pulley Set Cylinder
Direction position injector vaive Si
1-6 VS 2 4 ft 1
Start
Adv. To MVS 6 2 4t-^
Adv. To 2-5 VS 3 6 Fig. 14-73 (OM1052L). Actuate The Rocker Lever.
Adv. To 1-6 VS 5 3
Adv. To 3-4 VS 1 5 Definition of "Hot"
Adv. To 2-5 VS 4 1
The oil sump (oil pan) temperature must be a
minimum of 190 °F [88 "C] and the water (coolant)
temperature a minimum of 185 °F [85 °C]. The
Table 13: Engine Firing Order "Hot" values are given for when the engine is be
Right Hand: 1-5-3-6-2-4 Left Hand: 1-4-2-6-3-5 ing tested on a dynomometer. At these times the
adjustments must be made quickly.
Table 14: Adjustment Limits 3. Use the Part No. 3375842 lnjector Adjustment
Using Dial Indicator Method — Inch [mm] Kit to check the travel of the injector plunger.
OH Injector Plunger Valve Clearance Install the dial indicator and support so that
Temp. Travel Intake Exhaust the extension for the dial indicator is against
the injector plunger, Fig. 14-72. Make sure that
Aluminum Rocker Housing the extension is correctly installed into the in
Cold 0.170 ± 0.001 0.011 0.023 dicator stem and that it does not touch the
[4.32 ± 0.03] [0.28] [0.58]
0.011 rocker lever.
Hot 0.170 ± 0.001 0.023
[4.32 ± 0.03] [0.28] [0.58] 4. Actuate the rocker lever to push the injector
Cast Iron Rockor Housing plunger to the bottom of its travel. Use the
Cold 0.175 ± 0.001 0.013 0.025 ST-1193 Rocker Lever Actuator from the
[4.45 ± 0.03] [0.33] [0.64] 3375842 Adjustment Kit to actuate the rocker
Hot 0.170 ± 0.001 0.011 0.023 lever, Fig. 14-73. Let the plunger rise to the top
[4.32 ± 0.03] [0.28] [0.58] of its travel. Actuate the lever again and set
NTE-8SS (European Big Cam Only) the indicator at zero as you hold the plunger at
0235 0.011 0.023 the bottom of its travel.
[5.72] [0.28] [0.58]
NT-8SS (Australian Big Cam Only) 5. Tighten the rocker lever adjusting screw until
0.228 0.011 0.023 the injector plunger has the correct travel as
[5.79] [0.28] [0.58] shown in Table 14.
6. Hold the adjusting screw in position and
Note: Always check the engine dataplate for the tighten the locknut to 40 to 45 ft.-lbs. [54 to 61
injector and valve adjustment values. N»m] torque. Actuate the rocker lever two or
three times to make sure that the adjustment
Definition of "Cold" is correct. When you use the ST-669 Adapter
The engine must be at any stabilized water to tighten the locknut, tighten the locknut to
oerature of 140 °F [60 °C] or below. 30 to 35 ft.-lbs. [41 to 47 N»m] torque.
Adjust the Valves 2. Loosen the iocknut for the rocker lever ad
justing screw. Tighten the adjusting screw until
After you adjust the injector, the valves must be ad
all of the clearance is removed from between
justed for the cylinder shown in Table 12 before you
the rocker lever and injector link. Then tighter
rotate the crankshaft to the next adjustment mark.
the adjusting screw one additional turn.
1. Make sure that the locknuts for the adjusting 3. Loosen adjusting screw until the spring washer
screws are loose. is against the stop of the injector, Fig. 14-75.
2. Put a feeler gauge between the rocker lever
and the contact surface of the crosshead, Fig.
14-74. See Table 14 to find the correct thick
ness of the feeler gauge.
6
Fig. 14-74 (OM1055L). Adjust The Valves.

3. Tighten the adjusting screw until the rocker
lever touches the feeler gauge. Hold the ad
justing screw in position and tighten the lock-
nut to 40 to 45 ft.-lbs. [54 to 61 N»m] torque.
Fig. 14-75. Top-Stop lnjector — The Washer Against The Stop.
When you use the ST-669 Adapter, tighten the
locknut to 35 to 40 ft.-lbs. [47 to 54 N • m] torque.
4. Repeat the procedure to adjust all of the re
maining valves.
To Adjust the Top-Stop Injectors
Note: To adjust the injectors for engines with
MVT, the MVT actuator must be in the fully retarded
position.
Caution: The top-stop injector plunger travel can
only be adjusted when the Injectors are removed
from the engine. Use the Part No. 3379160 Ad
justing Tool to adjust the plunger travel.
engine rotation and align the "VS" mark on
the accessory drive pulley with the pointer on
the gear cover. Fig. 14-76. Tighten The Adjusting Screw.
14-35
Valve Adjustment
4. Tighten the adjusting screw to 5 to 6 in.-lbs.
[0.56 to 0.68 N»m] torque. Use the Part No. When using the Torque Method, the valves and in
3375232 Torque Wrench to tighten the screw, jector are adjusted on the same cylinder before
Fig. 14-76. If you do not have a torque wrench, rotating the crankshaft for the next cylinder. See
tighten the screw until there is light pressure Table 16 to find the correct valve clearance.
against the injector link. The link must be free Tighten the locknuts to 40 to 45 ft.-lbs. [54 to 61
enough that you can rotate it with your hand. N»m] torque.
Table 16: Valve Clearance
tighten the locknut to 40 to 45 ft.-lbs. [54 to 61 (Torque Method) — Inch [mm]
N »m] torque. When you use the ST-669 Adapter
Intake Valves Exhaust Valves
tighten the locknut to 30 to 35 ft.-lbs. [41 to 47 Cold Set Hot Set Cold Set Hot Set
N»m] torque.
0.014 0.014 0.027 0.027
The Torque Method to Adjust the Injectors [0.36] [0.36] [0.69] [0.69]
1. Rotate the crankshaft in the direction of Cast Iron Rocker Housing
engine rotation. Align the mark on the pulley 0.016 0.014 0.029 0.027
with the pointer on the gear cover. Check both [0.41] [0.36] [0.74] [0.69]
cylinders indicated on the pulley (Fig. 14-71)
to see which valve rocker levers are loose. Ad Install the Rocker Housing Covers
just the injector of the cylinder in which the
1. Install the rocker housing covers and new
rocker levers are loose.
gaskets onto the rocker housing.
2. Loosen the adjusting screw locknut. Tighten
a. Tighten the capscrews for the aluminum
the adjusting screw until the injector plunger
cover to 12 to 17 ft-lbs. [16 to 23 N»m] torque.
is at the bottom of its travel. Tighten the ad
justing screw an additional 15 degrees to b. Tighten the capscrews for the steel cover
remove all of the oil from the injector cup. to 10 to 15 ft.-lbs. [14 to 21 N»m] torque.
Loosen the adjusting screw one full turn. c Tighten the capscrews for the aluminum
3. Use a torque wrench that is calibrated in inch- cover that uses gaskets made of cork and
lbs, to adjust the injectors. The torque wrench rubber to 75 to 95 in.-lbs. [8.5 to 10 N»m]
must have a screwdriver adapter. Tighten the torque.
adjusting screw to the correct torque value
Note: Refer to the parts catalog to find the correct
shown in Table 15. Loosen the adjusting screw
gasket to use.
and adjust it to the torque value two or three
times to make sure that it is correctly adjusted.
Install the Intake Manifold or Aftercooler
1. Put new manifold gaskets onto the intake
Table 15: Injector Adjustmcint (Torque Method) ports of the cylinder heads. Use a small
Cold Set Hot Set amount of Lubriplate to hold the gasket
Cast Iron Rocker Housing against the cylinder head.
48 inch-lb. 72 inch-lb. 2. Follow these instructions to install the intake
[5.4 N»m] [8.1 N»m] manifold.
a. Install a capscrew and washer assembly
72 inch-lb. 72 inch-lb.
[8.1 N»m] [8.1 N»m] into the bottom capscrew hole of each in
take port on the cylinder head. Tighten the
capscrews 3 to 5 turns.
tighten the locknut to 40 to 45 ft.-lbs. [54 to 61 b. lnstall the manifold with slots onto the
N»m] torque. When you use the ST-669 capscrews and washers. Make sure that
Adapter, tighten the locknut to 30 to 35 ft.-lbs. the washers are not between the cylinder
[41 to 47 N»m] torque. head and manifold.
-36
c. Install the remaining capscrews and gine as when it was removed. Tighten the cap-
washers into the manifold and cylinder screws to 25 to 30 ft.-lbs. [34 to 40.6 N»m] torque.
heads. Tighten the capscrews to 20 to 25 2. Install the filter head on to the bracket.
ft.-lbs. [27 to 34 N»m] torque. Tighten the capscrews to 15 to 20 ft.-lbs. [20 to
3. Follow these instructions to install the after- 27 N»m] torque.
cooler. 3. Apply a light coat of lubricating oil to a new
a. lnstall a guide pin Into a capscrew hole in cartridge seal and to the gasket of a new car
the intake port of each cylinder head. tridge. lnstall the seal and cartridge onto the
b. lnstall the aftercooler onto the guide pins. filter head. Use your hand to tighten the car
tridge. Tighten the cartridge until the gasket is
c. Install the capscrews and washers. Remove against the filter head and then tighten the
the guide pins and install the remaining cap- cartridge an additional one-half turn.
screws and washers. Tighten the capscrews
to 20 to 25 ft.-lbs. [27 to 34 N»m] torque. 4. Install the fuel line from the fuel pump to the
filter head. lnstall the line to the connection
4. lnstall the air inlet connection and a new gasket that is marked "OUT".
onto the intake manifold. Tighten the cap-
screws to 20 to 25 ft.-lbs. [27 to 34 N»m] torque. The Filter Element
5. lnstall the front and the rear water crossover 1. lnstall the mounting bracket and filter head to
tubes to the aftercooler. Make sure that the the engine. lnstall the bracket to the same lo
hoses for the water crossover tubes are not cation on the engine as when it was removed.
damaged. Tighten the hose clamps to 35 to 45 2. Check the connections in the filter head for
in.-lbs. [4 to 5 N»m] torque. leaks. Make sure that the connections are tight
ened to 30 to 40 ft.-lbs. [41 to 54 N»m] torque.
Install the Aneroid Control
3. lnstall a new gasket to the filter head. lnstall a
1. lnstall the aneroid control and bracket new element into the filter shell. lnstall the
assembly, if the engine is so equipped, to the element and shell assembly onto the filter
fuel pump side of the engine. Tighten the cap- head. Tighten the center bolt to 20 to 25 ft.-lbs.
screws to 25 to 30 ft.-lbs. [34 to 40.6 N»m] torque. [27 to 34 N»m] torque.
2. Install the fuel pressure line, from the bottom 4. lnstall the fuel line from the fuel pump to the
of the fuel pump, to the connection on the filter head. lnstall the line to the connection
aneroid that is marked "lN". lnstall the fuel that is marked "OUT".
return line from the fuel inlet connection on
the aneroid that is marked "OUT". Remove the Engine from the Stand
3. Install the air line to the top of the aneroid and 1. lnstall the lifting fixture to the engine.
to the intake manifold. 2. Remove the capscrews that hold the engine to
4. Tighten the 1/4 inch tube nuts to 10 to 15 the stand.
ft.-lbs. [13.5 to 20 N»m] torque. Tighten the Caution: Make sure that the lifting fixture Is cor
5/16 inch tube nuts to 15 to 20 ft.-lbs. [20 to 27 rectly Installed to the engine.
N»m] torque. 3. lnstall the front and rear supports onto the
engine. Lower the engine until it is supported
Install the Fuel Filter
by the front and rear supports.
The Filter Cartridge 4. Remove the lifting fixture.
Note: All construction engines and engines that 5. Remove the engine stand support plates. ln
have a rating of above 350 horsepower must be stall the cover plates and new gaskets to the
equipped with dual fuel filters, install the filter water header.
cartridges to a dual cartridge filter head.
1. Install the mounting bracket for the filter. In Install the Exhaust Manifold
stall the bracket to the same location on the en 1. lnstall new exhaust manifold gaskets onto the
14-37
cylinder heads. The side of the gaskets marked

"OUT" must be away from the cylinder heads.
Apply a small amount of "Man-Gil No. 1865"
paste or an equivalent to the gaskets to hold
them in position on the cylinder heads.
2. Assemble the sections of the exhaust
manifold and install them onto the engine.
Install new lockplates, if the engine is so
equipped, onto the capscrews. Apply a coat of
anti-seize compound onto the threads of the
capscrews. Start all of the capscrews two to
three turns. lnstall the special capscrews for
the heat shield, if the engine is so equipped.
3. Tighten the capscrews evenly to 15 to 20
ft.-lbs. [20.3 to 27 N»m] torque. If the engine
uses bar clamps to hold the manifold, make Fig. 14-77. Install The Piston Cooling Nozzles.
sure that the clamps are parallel to the mount
ing surface of the cylinder heads when tight
ened. Tighten the capscrews again to 40 to 45
4. Bend the tabs of the lockplates until they are
against the heads of the capscrews.
Install the Piston Cooling Nozzles
1. Apply vegetable oil to new O-rings for the
piston cooling nozzles. Install the O-rings into
the groove of the nozzle. Use the Part No.
ST-835 O-ring Assembly Tool to install the
O-ring. Make sure that the O-ring is not
twisted in the groove.
Note: Do not soak the O-rings in oil.
2. Install the nozzles into the cylinder block, Fig.
Fig. 14-78. Tighten The Screw For The Piston Cooling Nozzle.
14-77. Tighten the slotted head screw to 60 to
96 in.-lbs. [7 to 11 N»m] torque. Tighten the
hex head screw to 100 to 140 in. lbs. [11 to 15.8
N»m] torque, Fig. 14-78.
Install the Oil Cooler
1. lnstall guide pins into the cylinder block to
help you to install the cooler assembly.
2. lnstall a new oil cooler support gasket over
the guide pins.
3. Install the oil cooler assembly onto the
cylinder block, Fig. 14-79.
4. lnstall the capscrews and lockwashers.
Remove the guide pins. Tighten the capscrews
to 30 to 35 ft.-lbs. [40.6 to 47.4 N»m] torque.
5. Install the support bracket, if the engine is so
equipped, onto the rear of the cooler and onto Fig. 14-79. Install The Oil Cooler Assembly.
M-38
the cylinder block. Tighten the capscrews for Install the Water Inlet Connection
the bracket to the following values: lnstall a new gasket and the water inlet connec
a. 3/8 inch capscrews — 30 to 35 ft.-lbs. [40.6 tion onto the water pump. Tighten the capscrews
to 47.4 N»m] torque. to 30 to 35 ft.-lbs. [40.6 to 47.4 N»m] torque.
b. 7/16 inch capscrews — 50 to 55 ft.-lbs. [68
to 74.5 N»m] torque. Install the Air Compressor Water Lines
c. 1/2 inch capscrews — 75 to 85 ft.-lbs. 1. lnstall the water inlet and outlet lines to the
[101.7 to 115 N»m] torque. air compressor, the cylinder block and the
water bypass connection.
6. lnstall the water transfer tube into the rear of
the cooler housing and onto the connection 2. Tighten the tube nuts to the following values:
on the rear water header cover. Tighten the a. 1/2 inch — 10 to 15 ft.-lbs. [14 to 20 N»m]
hose clamps to 35 to 45 in.-lbs. [4 to 5 N»m] torque.
torque.
b. 7/8 inch — 15 to 20 ft.-lbs. [20 to 27 N»m]
7. lnstall new O-rings onto the water transfer torque.
tube. Install the tube into the thermostat hous
ing and the oil cooler. Tighten the retaining c. 1-1/4 inch — 20 to 25 ft.-lbs. [27 to 34 N»m]
capscrew to 30 to 35 ft.-lbs. [40.6 to 47.4 N»m] torque.
torque, Fig. 14-80.
Install the Alternator or Generator
1. Follow those instructions to install the alter
nator/generator that uses the spool type of
mounting bracket.
a. lnstall the mounting bracket onto the cyl
inder block. Do not tighten the capscrews
at this time.
b. Align the alternator/generator mounting
holes with the mounting holes of the
bracket. Put the hardened washers or
spacers between the mounting lugs of the
alternator/generator and the mounting
bracket. lnstall the bolt onto the mounting
holes in the alternator/generator and the
mounting bracket. Do not tighten the bolt
at this time.
Fig. 14-80. Install The Water Transfer Tube.
c. lnstall the adjusting link onto the cylinder
8. Apply a coat of clean oil to the sealing gasket block.
of the oil filter element. lnstall the oil filter. d. lnstall the belt(s) onto the alternator/gen
a. Use the installation instructions that are erator pulley and the pulley on the engine.
printed on the spin-on filter cartridge in Check the alignment of the pulleys. The
order to install it. pulleys must be aligned within 0.062 inch
[1.57 mm] for each 12.0 inches [305 mm] of
b. lnstall the element and filter shell distance between the centers of the pul
assembly onto the filter head. Tighten the leys. Move the mounting bracket until the
center bolt to 25 to 35 ft.-lbs. [34 to 47.4 alignment is correct. Then tighten the cap-
N»m] torque. screws for the mounting bracket.
Note: Make sure that there is a minimum of 0.250 e. Adjust the belt(s) to the correct tension.
inch [6.3 mm] clearance between the filter and the Use a pry bar to push the alternator/gen
oil pan flange of the cylinder block. erator away from the cylinder block to
14-39
tighten the belt(s). Tighten the capscrews Table 17: Torque Values (To Adjusting Link)
for the adjusting link. See Table 17 to find
Torque
the correct torque value. Ft-Lb.]N»m]
f. Tighten the alternator/generator mounting 5/16 15 to 19 [20 to 26]
bolt. See Table 18 to find the correct 7/16 25 to 30 [34 to 41]
torque value. 1/2 50 to 55 [68 to 75]
2. Follow these instructions to install the alter
nator/generator that uses a two-lug type of Table 18: Torque Values (To Bracket)
mounting bracket: Torque
a. lnstall the mounting bracket onto the Ft-Lb.[N»m]
cylinder block. Do not tighten the cap- 3/8 29 to 31 [39 to 42]
screws at this time. 7/16 63 to 65 [85 to 88]
1/2 77 to 80 [104 to 108]
b. Align the mounting holes as described in
Step 1b. lnstall the mounting bolts so that
the nuts for the bolts are toward each other.
c. Follow the procedures in Steps 1c, 1d and (Pulley to Alternator or
1e to install the adjusting link, to check Nominal BoH Size Torque
■Lb.lNTn]
Ft-Lb.
the alignment and to tighten the belt(s).
1/2 50 to 60 [68 to 81]
d. Tighten the alternator/generator mounting 5/8 55 to 65 [75 to 88]
bolts. Tighten the bolt nearest to the pul 3/4 90 to 100 [122 to 126]
ley first. Then use a hammer to hit the head
of the bolt in the opposite end of the alter
nator/generator. Hit the bolt until the Note: Exceptions to the above limits
bushing that is in the mounting hole of the Peteo flamy Torque
alternator/generator is against the mount Alternators R.Lb.]N»ml
ing bracket. Tighten the bolt. See Table 18 10 DN 150 70 to 80 [95 to 108]
to find the correct torque value. 25 SI
3. Follow the same instructions to install the CAV
alternator/generator that uses the fabricated
steel mounting bracket. AC 5 40 to 42 [54 to 57]
AC 7 60 to 70 [81 to 95]
4. When you install a pulley onto the alternator/ AC 90 60 to 70 [81 to 95]
generator, always use the locknut and hardened
washer that are supplied with the alternator/
1. Install the starting motor and if used, the spacer
generator. Tighten the locknut to the torque onto the mounting pad of the flywheel housing.
value given in Table 19. Make sure that the starting motor drive gear will
engage with the flywheel ring gear when the
Install the Breather Tube starting motor is activated.
1. lnstall the breather tube, if the engine is so Note: When the engine is equipped with a wet
equipped, onto the crankcase breather. Be clutch, use a new gasket and nylok capscrews to in
sure to install a new O-ring for the breather tube. stall the starting motor.
2. Use a tube clamp to fasten the tube to the 2. Tighten the capscrews to 150 to 170 ft.-lbs. [203
cylinder block. to 230 N»m] torque.
Install the Starting Motor Install the Oil Gauge Bracket

lf a new starting motor is to be installed, make sure lnstall the oil gauge bracket and new gasket to the
that it is the same type of starting motor that was cylinder block. Tighten the capscrews to 30 to 35
removed. ft.-lbs. [40.6 to 47.4 N»m] torque.
40
Install the Water Filter a. Align the tube with the connection in the
1. Install the bracket and filter head onto the bearing housing and the connection in the
cylinder block. lnstall the bracket and filter cylinder block.
head at the same location on the engine as b. Tighten the tube nut to 50 to 60 ft.-lbs. [68
when it was removed. Tighten the capscrews to 81 N»m] torque.
to 30 to 35 ft.-lbs. [40.6 to 47.4 N»m] torque.
c. Tighten the hose clamps to 35 to 45 in.-ibs.
2. lnstall the valves and hoses to the filter head. [4 to 5 N»m] torque.
3. Apply a light coat of oil to the sealing gasket d. If the drain tube uses a "Flex" type of tube
of a new filter cartridge. nut, tighten the nut until it is against the
4. lnstall the new filter cartridge onto the filter stop.
head. Tighten the cartridge until the sealing
e. Tighten the hose swivel nut to 50 to 60
gasket touches the filter head. Then, tighten
the cartridge an additional one-half to three-
fourth turn. Note: The centerline of the oil drain hole must be
Caution: Do not use a wrench to tighten the car within 30 degrees of vertical when the turbo
tridge. Over-tightening can damage the threads charger is installed onto the engine. lf you loosen
and the seal. the Vee clamps of the housing to align the oil
drain hole, tighten the clamp nuts to 32 to 36
Install the Turbocharger in.-ibs. [3.6 to 4.1 N»m] torque. Then, use a plastic
hammer to lightly hit around the circumference of
To Install the Single Turbocharger
the clamps. Tighten the clamp nuts again to 32 to
1. Apply a coat of anti-sieze compound to the 36 in.-ibs. [3.6 to 4.1 N»m] torque.
threads of the turbocharger mounting studs.
5. lnstall the oil supply hose to the connections
2. lnstall a new turbocharger gasket onto the ex in the top of the turbocharger and on the oil
haust manifold. The raised bead on the gasket cooler. Tighten the swivel nuts to 19 to 26
must be toward the turbocharger. ft.-lbs. [25.7 to 35 N»m] torque.
3. lnstall the turbocharger onto the exhaust 6. lnstall the air intake crossover onto the turbo
manifold. Tighten the mounting nuts to 20 to charger and the air intake manifold or the after-
25 ft.-lbs. [27 to 34 N»m] torque, Fig. 14-81. cooler, Fig. 14-82. Use a new rubber tubing
4. lnstall the oil drain tube or hose onto the con connection and new gasket. Tighten the cap-
nection in the bottom of the bearing housing. screws into the air intake manifold or after-
Fig. 14-81. Install The Turbocharger Onto The Exhaust Manifold. Fig. 14-82. Install The Air Intake Crossover.
14-41
7. lnstall the adapter (6), clamp (5) and inlet con

nection (7) onto the outlet connection (4).
Align the connection (7) with the supports (3)
and install the capscrews, washers and nuts
to fasten the connection onto the supports.
8. Align and tighten the parts in the following
sequence.
a. Tighten the clamp for the exhaust connec
tion to 70 to 80 in.-lbs. [8 to 9 N»m] torque.
b. Tighten the mounting nuts for the turbo
charger to 30 to 35 ft.-lbs. [40.6 to 47.4
N»m] torque.
c. Tighten the mounting nuts that fasten the
exhaust connection to the turbocharger to
Fig. 14-83 . Tighten The Capscrews For The Crossover. 30 to 35 ft.-lbs. [40.6 to 47.4 N»m] torque.
cooler to 20 to 25 ft.-lbs. [27 to 34 N»m] torque, d. Tighten the capscrews that fasten the sup
Fig. 14-83. Tighten the nuts for the clamps to ports to the exhaust manifold to 50 to 60
65 to 75 in.-lbs. [7.4 to 8.5 N»ml torque. ft.-lbs. [68 to 81 N»m] torque.
e. Tighten the capscrews and nuts that
To Install the Series Turbochargers
fasten the inlet connection to the supports
The High Pressure (H.P.) turbocharger installs on to 30 to 35 ft.-lbs. [40.6 to 47.4 N»m] torque.
to the exhaust manifold. The Low Pressure (LP.)
Note: The centerline of the oil drain hole must be
turbocharger installs onto the exhaust inlet con
within 30 degrees of vertical when the turbo
nection. Follow these instructions to install the
charger is installed onto the engine.
turbocharger.
Install the H.P. Turbocharger Install the L.P. Turbocharger
1. Apply a coat of anti-sieze compound onto the 1. Install the LP. Turbocharger (1, Fig. 14-84) and
threads of the mounting studs that are in the a new gasket (2) onto the exhaust connection
exhaust manifold. (7). The bead on the gasket must be toward
the turbocharger. Tighten the capscrews and
2. lnstall a new gasket (9, Fig. 14-84) for the H.P. nuts to 5 to 10 ft.-lbs. [6.8 to 13.5 N»m] torque.
Turbocharger (10) onto the exhaust manifold.
The raised bead on the gasket must be toward 2. lnstall the oil drain tube onto the turbo
the turbocharger. charger. Tighten the capscrews for the tube
flange to 5 to 10 ft.-lbs. [6.8 to 13.5 N»m] torque.
3. Install the H.P. Turbocharger (10) onto the ex
haust manifold. Tighten the nuts to 5 to 10 Note: The centerline of the oil drain hole must be
ft.-lbs. [6.8 to 13.5 N»m] torque. within 30 degrees of vertical.
4. lnstall the supports (3) onto the exhaust mani 3. Install the air connection (16), hose (14) and
fold. Tighten the nuts to 5 to 10 ft.-lbs. [6.8 to clamps (15) onto the LP. Turbocharger (10).
13.5 N»m] torque. 4. lnstall the air crossover, air inlet pipe (12) and
5. lnstall the oil drain tube onto the turbo new O-rings (11) onto the H.P. Turbocharger.
charger. Tighten the capscrews for the tube Install the retaining braces (13) onto the H.P.
flange to 5 to 10 ft.-lbs. [6.8 to 13.5 N»m] torque. Turbocharger.
6. lnstall a new gasket (8) and the exhaust outlet 5. lnstall the oil drain tubes into the hose con
connection (4) onto the turbocharger. lnstall nections on the cylinder block. Tighten the
the gasket so that the bead is toward the hose clamps to 30 to 35 in.-lbs. [3 to 4 N»m]
turbocharger. torque.
42
1. Low Pressure 5. Clamp 9. Gasket 14. Hose

Turbocharger 6. Exhaust Outlet 10. High Pressure 15. Clamp
2. Gasket Adapter Turbocharger 16. Air Connection
3. Support 7. Exhaust lnlet 11. O-Ring
4. Exhaust Outlet Connection 12. Air lnlet Pipe
Connection 8. Gasket 13. Brace
Fig. 14-84. Series Turbochargers — Exploded View
14-43
6. Align and tighten the parts. Use the following percent of the maximum engine horsepower. If
torque values. the capacity is not enough, the testing proced
a. Tighten mounting capscrews and nuts for ures must be changed to prevent damage to the
the turbocharger to 30 to 35 ft.-lbs. [40.6 to dynamometer.
47.4 N»m] torque. Caution: Make sure the dynamometer can operate
b. Tighten the capscrews for the oil drain at engine speeds. The couplings must have the
tube flange to 30 to 35 ft.-lbs. [40.6 to 47.4 centrifugal forces balanced.
N»m] torque.
c. Tighten the clamps for the air connection
1. Use the correct lifting device to put the engine
to 65 to 75 in.-lbs. [7.3 to 8.5 N»m] torque.
on the dynamometer test stand.
d. Tighten the capscrews for the retaining
braces to 15 to 20 ft.-lbs. [7.3 to 8.5 N»m] 2. Install and fasten the engine to the supports.
torque. 3. Put the dynamometer drive shaft flange onto
7. lnstall the oil supply hoses onto both of the the engine flywheel. Use the correct flywheel
turbochargers. Tighten the swivel nuts to 19 to adapter flange for the flywheel capscrew holes.
26 ft.-lbs. [25.7 to 35 N»m] torque. 4. Check for correct alignment.
8. Install the clamps to hold the oil hoses as a. lf the drive coupling is direct or flexible,
shown in Fig. 14-85. lnstall the hoses onto the put an indicator holding fixture on the face
connections In the oil cooler and filter head as of the flywheel housing. Put the pointer of
shown in Fig. 14-85. Tighten the hose nuts to 5 the indicator on the hub of the adapter
to 10 ft.-lbs. [6.89 to 13.5 N»mJ torque. flange. Rotate the engine to get a reading.
The flywheel adapter flange must be to the
center of the flywheel and the flywheel
housing within 0.002 inch [0.05 mm]. Move
the flange hub on the flywheel as needed
and tighten the capscrews. On direct
coupling dynamometers, measure from
the face of the flywheel housing to the
outer edge of the dynamometer drive
flange. When the dynamometer is turned
one revolution the reading must not ex
ceed 0.003 inch [0.08 mm].
b. lf a universal drive coupling is used, the
drive flange on the flywheel must be to the
center within 0.003 inch [0.08 mm]. The
drive flange on the dynamometer must
also be to the center within .003 inch [0.08
Fig. 14-85. Location Of Hose Clamps And Oil Connections. mm]. Measure the center of these flanges
as described in "a" above. Install the
To Test the Engine engine so that the center of the engine
The run-in period of the engine is completed dur crankshaft and the center of the dyna
ing the testing of the engine. It is necessary to mometer drive shaft are out of alignment
test the engine to find errors that can occur during by 1/4 inch [6.35 mm] to 1/2 inch [12.7
the assembly process. Testing also lets you make mm]. Fasten the flywheel to the drive flange.
final adjustments and check the performance.
Preparation for Starting
Engine Dynamometer Test Before priming the fuel and the lubricating
Check the dynamometer capacity. Make sure the systems, remove and fill all the filters with the cor
capacity is enough to permit testing at least 96 rect fluid.
Fill Cooling System

1. lnstall the drain plugs and close all draincocks.
2. Open the cooling system vents, if applied.
3. Fill the system with coolant until it flows from
the vents. Close the vents and finish filling the
system.
Note: For cold weather operation, see Service
Bulletin No. 3379009.
Preparing the Fuel System

1. Attach the fuel return tube from the flow tank
to the fuel drain connection.
2. Attach the fuel supply tube of the flow tank to
the suction connection of the fuel pump. Fig. 14-86 (OM1001L). The Priming Location For The Lubricat
ing System.
3. Connect the electrical wiring to the starting
motor if the motor is to be used for starting. lf 5. A 30 psi [207 kPa] minimum pressure must be
another method of starting is to be used, reached.
make the necessary connections. 6. Use the starter to rotate the crankshaft. Make
4. Connect the throttle linkage and all the instru sure that the fuel shut-off valve is closed to
ments on the control panel of the dynamometer. prevent starting the engine. Rotate the crank
shaft for 15 seconds. Keep the oil pressure at
5. Fill the fuel pump with fuel before starting the a minimum of 15 psi [103 kPa] while you rotate
engine for the first time. the crankshaft.
6. Check the fuel tanks. There must be a supply 7. Remove the external oil supply line. lnstall the
of a clean, good grade No. 2 diesel fuel in the pipe plug. Tighten the plug to 60 to 70 ft.-lbs.
tanks. See "Fuel Oil", Group 18, for the cor [81 to 95 N»m] torque.
rect specifications.
8. Fill the crankcase to the "H" (high) mark on
7. Connect the exhaust piping to the engine ex the dipstick with oil meeting the specifica
haust manifold or turbocharger. tions listed in Group 18. The oil which is best
8. Connect the air intake pipe to the intake mani for engine operation is also best for the run-in
fold or turbocharger. Use a standard air cleaner period. No change in the oil viscosity or type
for the engine model being tested. is needed for new or rebuilt engines.
Warning: Always clean off any lubricating oil
Preparing the Lubricating System which was spilled while priming or filling the
1. lf the engine has a turbocharger, remove the crankcase.
oil inlet hose and lubricate the bearing with 2 Caution: Stop the engine after It has run for 5
ounces [33 cc] of clean engine oil. lnstall the minutes and check the oil level. Keep the oil level
oil lnlet line. as near as possible to the "H" mark on the dip
2. Fill the crankcase to "L" (low) mark on the stick. Never operate the engine with the oil level
dipstick. below the "L" mark or above the "H" mark.
3. Remove the plug from the lubricating oil Fill the Hydraulic Governor
crossover passage as shown in Fig. 14-86. 1. Fill the oil sump of the hydraulic governor, if
Caution: Do not prime the engine lubricating the engine is so equipped, with the same type
system from the by-pass filter. of lubricating oil that is used in the engine.
4. Connect a primingrpump line from a supply of a. Fill the sump until the oil level is at the full
clean engine oil to the pipe plug hole. mark on the dipstick.
14-'
b. If the governor sump has an inspection General Test Procedures

glass instead of a dipstick, the oil level 1. Air Compressors.
must be at the centerline of the glass.
a. All Cummins-manufactured air compres
Check the Oil Flow to the Turbocharger sors are to be operated in a pumping mode
1. Remove the oil drainline from the turbo- during engine run-in.
charger. b. Cummins single-cylinder air compressors
2. Start the engine and keep the engine RPM at must pump through a 0.125 to 0.130 inch
low idle. [3.18 to 3.30 mm] diameter orifice located
down line from a 150 psi pressure relief
3. Check the oil drain from the turbocharger. The valve.
oil must drain from the turbocharger in 10 to
15 seconds. If it does not, stop the engine and c. Adjust the Cummins two-cylinder air com
correct the problem. pressors to maintain 50 to 75 psi [345 to
517 kPa] in the air tank regardless of the
Starting the Engine engine speed.
To start the engine requires clean air and fuel d. Air compressors of another manufacturer
supplied to the combustion chamber in proper can be operated in a pumping or a non-
quantities and a starting system meeting pumping mode at the option of the tester.
minimum Cummins recommendations.
e. Engine performance checks are to be
Normal Starting Procedure made with the air compressor operating in
a non-pumping mode.
if the fuel system is equipped with an overspeed
stop, push the "Reset" button before attempting 2. Blow-by Measurement.
to start the engine. a. If a water manometer is used to measure
1. Set the throttle for idle speed. blow-by, you can add or remove water to
raise or lower the height of the water column
Caution: To prevent damage to the turbocharger,
to the "0" position. Dye can be added to the
do not accelerate the engine above 1000 RPM until
water to make the column easier to read.
the reading on the oil pressure gauge Indicates
normal oil pressure at idle speed. b. Record the blow-by readings along with
the respective engine speed and load at
2. Disengage the transmission or make sure the
one-minute intervals during engine run-in.
gears are in neutral.
This will inform the tester of any unex
3. Open the manual fuel shutoff valve on the fuel pected increase or fluctuation in blow-by.
pump if the engine is so equipped. The electric
3. Engine Starting.
shutoff valve operates as the switch is turned on.
a. To start the engine, put the throttle in the
4. Press the starter button or turn the switch-key
low idle position and activate the starter.
to the "start" position.
After the engine starts, operate it at low
Caution: To prevent damage to the starting motor, idle only long enough (five to ten minutes)
do not engage the starting motor continuously for to check for proper oil pressure and in
more than 30 seconds. If the engine does not start spect for any fuel, oil, water or air leaks.
within the first 30 sedonds, wait two minutes be
Note: Do not allow the engine speed to exceed
fore attempting to restart
1000 rpm before run-in. Do not run the engine at
5. A manual override knob provided on the for idle speed for prolonged periods of time before
ward end of the electric shutoff valve allows run-in.
the valve to be opened in case of electric
4. Engine Run-in performance data.
power failure. To use the override manually,
open it by turning the knob completely clock a. Refer to the Mechanics Specification
wise. Return the knob to the run position after Handbook to find the engine performance
the repair has been completed. data. Check the engine dataplate to find
14-46
Table 20: Mechanics Specifications Handbook Step 3, 1600 rpm and 65% of rated load for five
minutes.
Engine Build Use Bulletin No.
Date Step 4, Nominal torque peak rpm* and full load
•1976 for four minutes.
3379116-O0
1977 3379138-00 Sfep 5, Rated speed and full load for four
1978 3379156-00 minutes.
1979 3379212-00
•For engines built prior to 1976 use Bulletin No. *100 rpm below torque peak rpm.
3379116-00. 2. Chassis dynomometer run-in schedule.
a. Use the engine dynomometer run-in sched
the year that the engine was built. See ule, but multiply the load values by 0.8 (to
Table 20 to find the correct Mechanics compensate for lower drive line efficiency)
Specification Handbook. for a readout on the chassis dynomometer
load scale.
5. Leakage lnspection.
3. ln-chassis run-in schedule.
a. After each run-in step has been com
pleted, carefully inspect the engine for a. Operate the engine on the torque curve at
fuel, oil, water, air, or exhaust leaks and less than rated speed for the first 50 to 100
correct as necessary. miles after rebuild (e.g. pulling a loaded
trailer at 1500 to 1800 rpm in high gear).
6. Engine is shutoff.
Note: Do not idle the engine for more than five
a. After the run-in has been completed, allow minutes at any one time during the first 100 miles
the engine to run at low idle for a minimum of operation.
of three minutes before stopping the engine.
4. Blow-by measurement.
Note: Do not stop the engine immediately after
a. lf the engine is naturally aspirated, plug
the last run-in step is completed as serious
the breather holes in the cylinder heads.
engine damage can result.
Remove the plugs after the blow-by check
has been completed.
Maintenance of Dynamometer
Note: Do not plug the cylinder head breather
Follow the manufacturer's maintenance instructions
holes in engines equipped with a wet flywheel
to get the best service from the dynamometer.
housing (labyrinth type rear seal covers). lf this is
done, an oil leak will result.
Calibration of Instruments
b. Put a plug in the crankcase breather vent.
1. Keep the scales properly calibrated. Remove the "bottle stopper" oil filler cap
2. Follow the manufacturer's recommendations and replace it with the blow-by tool con
when calibrating is necessary. taining a 0.302 inch [7.67 mm] diameter
orifice, Part No. 3375150. Connect the
3. If the instruments need adjustment, follow the blow-by tool to the blow-by gauge.
manufacturer's instructions.
Note: Do not attempt to contain the blow-by gases
NH/NT-855 Engine Run-in Test when a labyrinth type seal cover is used.
Refer to "General Test Procedures" section c. Referto the "Blow-by Measurement" section
before beginning run-in. of the "General Test Procedures" for the
actual measurement-recording procedure.
1. Engine dynomometer run-in schedule:
d. lf a sudden increase in blow-by occurs, or
Step 1, 1200 rpm and 25% of rated load until if blow-by exceeds the maximum allowable
water temperture reaches 160 °F [71 °CJ. limit listed in (e.) during any run-in step,
Step 2, 1200 rpm and 40% of rated load for two return to the previous step and run the en
minutes. gine an additional 15 minutes. When blow
14-47
by reaches an acceptable level, proceed to of the coolant must not exceed 200 "F [93 °C] or be
the next step and continue the run-in. less than 160 °F [71 °] during operation of the engine.
Note: lf blow-by does not reach an acceptable
level after repeating the previous step for 15 min
utes, discontinue the run-in and determine the The overspeed stop is used to shut off the fuel
cause of the excessive blow-by. supply when the engine speed is approximately
e. Maximum allowable blow-by during run-in: 15 percent in excess of the maximum rated en
gine speed. lf the engine is equipped with an over-
Naturally aspirated 8 inch H20 speed stop and the overspeed stop has become
Turbocharged 12 inch H20 activated, correct the cause and reset the over-
speed stop.
Checks During the Engine Run-in Test
During the engine run-in test, make the following Fuel Pressure and Fuel Rate
checks frequently: Refer to the Fuel Pump Calibration Manuals to
find the values for the fuel pressure and fuel rate
Lubricating Oil and for the adjustment procedure. Check the en
1. After the lubricating oil has reached normal gine dataplate to find the fuel rate and the year
operating temperature, the oil pessure must that the engine was built. Check the fuel pump
not change while the engine is operating at a nameplate to find the fuel pump calibration code.
given RPM and load. See Table 21 to find the See Table 22 to find the correct manual. Use the
correct oil pressure limits. Part No. ST-1 190 or 3376375 Fuel Measuring lnstru
ment to measure the rate of fuel consumption.
a. If the oil pressure is above the limit, check
for restrictions in the oil lines.
b. If the oil pressure is below the limits, check Table 21: Fuel Pump Calibration and
for restrictions in the oil supply line to the oil Instructions Manuals
pump or damaged bearings in the engine.
No. Title Year
2. Check the temperature of the oil in the oil pan.
lf the oil temperature rises above 225 °F 3379077 PT (type G) Calibration Values 1963-1969
[107 °C], stop the engine and make the 3379068 PT (type G) Calibration Values 1970-1975
3379182 PT (type G) Calibration Values 1976-1980
necessary corrections. 3379101 PT (type R) Rebuild and All
Calibration instructions
3379084 PT (type G & H) Rebuild and All
Table 21: Lubricating Oil Pros sure for Calibration Instructions
New or Rebuilt Engines
Oil Pressure At Oil Pressure At Torque Converter Governor — PT (type R) Fuel Pump
Engine Idle Speed Rated Speed
Series PSl [kPa] PSI [kPa] Refer to the PT (type R) Fuel Pump Manual,
Bulletin No. 3379101 to find the correct procedure
NH/NT and 1S „m. 50 to 70 [345 to 483]
Big Cam 15 11031 to adjust the engine governor and torque con
verter governor.
Big Cam 1 ^
NTE 10 [69] 35 to 45 [241 to 310]
Aneroid Control Adjustment
Note: Measure the oil pressure when the Refer to the Fuel Pump Manual, Bulletin No.
temperature of the oil in the oil pan is at 200 to 3379068 to find the correct procedure to adjust
225 °F [93 to 107 °C]. the aneroid control.
Paint the Engine

After the engine is started, add enough coolant to 1. Make sure all engine surfaces are clean and
completely fill the cooling system. The temperature dry before painting them.
M-48
2. Put tape over all openings that must not be running at idle, move the fuel line to the con
painted. tainer with the preservative oil. Operate the
engine five to ten minutes on the preservative
3. Put tape over all belts or remove them.
oil. Stop the engine and reconnect the fuel
4. Protect the fuel pump dataplate, engine data- lines to the supply tank.
plate and other dataplates on the engine from
4. The oil sump, fuel filters and fuel tank, must
paint.
be drained and the drain plugs installed. New
5. Exposed threads, wire terminals and hose fit oil can be added.
tings must be protected with tape. Pipe open 5. Remove the intake hose from between the air
ings, fuel pump drain, fuel manifold drain and cleaner and the intake manifolds.
oil cooler openings must have a cap installed.
6. Disconnect the electrical wiring. Turn the
6. Protect the clutch contact surface of the fly shutoff valve on the fuel pump counterclock
wheel with a rust preventing compound if the wise so that the engine will not start. Rotate
engine is not going into immediate service. the crankshaft of the engine while applying a
7. Apply a coat of primer to the outside surfaces spray of 10W oil into the intake manifold and
of the engine. the air compressor.
8. Apply enamel paint to the outside surfaces of 7. Put tape over all the intake manifold openings
the engine after the primer is dry. to keep out dirt and moisture.
8. Put tape over all the engine openings, includ
Engine Storage ing the coolant inlets, cylinder block, oil
All surfaces of an engine will rust or corrode if breather and crankcase.
they are not protected. Make sure all outside sur 9. Drain the coolant from the cooling system,
faces are painted before the engine is put in unless it is a permanent antifreeze with a rust
storage. Protect the inside of the engine during inhibitor added.
storage as described below.
10. Put the engine in a place protected from the
Temporary Storage weather where the air is dry and the tempera
ture is even.
lf an engine remains out of service for three or
four weeks (maximum six months), take steps to 11. Rotate the engine crankshaft two or three rev
prevent rust. The operations listed below are re olutions each three to four weeks.
quired to prevent damage to engines in temporary
storage. Long Term Storage
1. The engine must be started and the speed 1. When an engine is to be in storage for six
gradually increased to 1200 rpm with no load. months or more, it must be protected against
Operate the engine until the water tempera rust and corrosion.
ture is at least 160 °F [71 °C]. 2. The engine must be started and the speed
gradually increased to 1200 rpm with no load.
2. Disconnect both fuel lines at the fuel supply
Operate the engine until the water tempera
tank. Fill two portable containers, one with
ture reaches 160 "F [71 8C]. Stop the engine
diesel fuel and a second with preservative oil
and drain the old oil.
U.S. Military Specification MlL-L-644 Type P-9.
Preservative oil to this specification is Dau- 3. Fill the crankcase to the full mark on the
bert Chemical Co., Nox-Rust No. 518. Daubert dipstick with preservative oil, U.S. Military
Chemical address is 2000 Spring Road, Specification MlL-L-21260, Type P-10, Grade 2,
Chicago, Illinois. SAE 30. This specification can be obtained as
3. Start the engine with the fuel inlet line pulling Shell Brand Code 676202 or Texaco Preserva
tive Oil 30.
fuel from the can with the diesel fuel. Let the
drain line flow into the container with the 4. Disconnect both fuel lines at the fuel supply
diesel fuel. After the engine is started and is tank. Fill two portable containers, one with
14-49
diesel fuel and the second with preservative 14. Put a tag on the engine to show the following:
oil U.S. Militry Specification MlL-L-644, Type a. The engine has been prepared for storage.
P-9. Preservative oil to this specification is
Daubert Chemical Co., Nox-Rust No. 518. Dau- b. The coolant has been removed.
bert Chemical address is 2000 Spring Road, c. The crankshaft must not be rotated.
Chicago, lllinois.
d. The date the engine was prepared for
5. Start the engine with the fuel inlet line pulling storage.
fuel from the can with the diesel fuel. The in
e. The compound used for storage must be
jector drain line can flow into the container
removed before running the engine.
with the diesel fuel. After the engine is started
and is running at idle, move the fuel inlet line 15. Put the engine in a place protected from the
to the container with the preservative oil. Op weather and where the air is dry and the tem
erate the engine five to ten minutes on the perature is even.
preservative oil. Stop the engine and recon Note: After the engine has been in storage for 24
nect the fuel lines to the supply tank. months, flush it with solvent and repeat the prep
6. The fuel tank must be drained and the drain aration for storage.
plug installed. Make a cover for the filler vent 16. Keep all rust preventing compounds clean.
with tape.
Preparing an Engine from
7. Drain all the pumps, compressors, coolers,
Storage to Service
filters and the crankcase. Replace all the
plugs after draining. When an engine is removed from storage and put
into service, the operations listed below must be
8. Remove the intake and exhaust manifolds. completed. lnspections will be limited to opera
Apply the preservative oil in a spray into the tions indicated for the length of the storage time.
intake and exhaust parts of the engine. Also
apply it into the intake part of the air compres Clean the Engine
sor. lnstall the intake and exhaust manifolds.
1. Remove all dirt from the outside of the engine.
9. lnspect the coolant in the cooling system. If
2. Remove all the paper covers and tape.
the coolant contains rust, drain and flush the
system. Then fill it with a rust preventing com 3. Use solvent to remove rust preventing com
pound. Drain the system while it is hot and pound from the surfaces of the engine.
then replace the plug. Use an oil which has 4. Fill the crankcase with clean oil.
rust inhibitors that will mix with the water.
Flush the cooling system before returning it to 5. Flush the cooling system.
service.
Inspection
10. If an air starter is used, remove the exhaust
plate from the top of the starting motor. Pro 1. Engines in storage six months or less must
tect the air starter with a spray of preservative have the adjustment of the injectors, valves
oil into the exhaust part. Install the exhaust and the belts checked. Also check the oil fil
plate. Loosen the tension on the V-belt. ters, air filters, connections and the torque of
the cylinder head capscrews.
11. Make sure all outside surfaces of the engine
are painted. 2. When an engine has been in storage for six
months or more, the following inspection pro
12. Remove the valve covers and apply preserva cedure must be followed:
tive oil to the rocker levers, valve stems,
springs, guides, crossheads and push tubes. a. Flush the fuel system with fuel oil until the
lnstall the covers. fuel system is clean.
13. All engine openings must have a cover of b. Remove the plug from the oil filter head
heavy paper and tape. and run hot, light mineral oil through the
oil passages. Rotate the engine three or

four times during the flushing operation.
c. Remove all screens and make sure they
are clean before the engine is started.
Precautions
1. Too much oil in the combustion chamber can
cause a hydraulic lock. Damage to the engine
will occur if it is started before the oil is
removed.
2. When returning an engine to service from
storage, make sure all foreign matter is re
moved from the screens and strainers.
3. Apply oil under pressure to the lubricating
system before starting the engine.
4. The engine is now ready to start.
Caution: Always check with the nearest Cummins
Distributor for the correct perservatlve oil for the
engine.
Starting the Engine

After inspecting the engine and parts, make sure
all the preservative oil has been flushed away.
Start the engine as described in "Preparation for
Starting," on page 14-44.
14-51/(14-52 Blan
Mounting Adaptations
This group includes the inspection of the fly

Group 16 wheel, flywheel ring gear, removal and installation
of the flywheel ring gear.
Mounting Adaptations
The Flywheel The Flywheel Ring Gear

Inspection
The flywheel must be inspected for cracks or
other damage any time that it is removed from the lnspect the ring gear for broken or damaged teeth.
engine. Replace the ring gear if the teeth are broken or
damaged.
Inspection
Removal
1. Use the Part No. ST-1166 Magnetic Crack
Detector to inspect the flywheel for cracks. Use a heating torch to heat the ring gear. Do not
use a cutting torch. Use a blunt chisel and hit the
a. Remove the keeper bar from the magnet chisel with a hammer to push the ring gear from
poles. the flywheel.
b. Put the magnet onto the area to be
inspected. Replacement
c. Spray the powder onto the area to be in 1. Use an oven to heat the ring gear to 600 °F
spected. Use low pressure air to remove [316°C].
the excess powder. The powder will show a. If an oven is not available, use a heating
the cracks as a white line. torch. Do not use a cutting torch. Apply
the heat to the inside diameter of the ring
Warning: Never use a flywheel that has cracks in
gear. Use a 600 °F [316 °C] tempilstlck
the bolt circle (mounting) area.
crayon or an equivalent to find the temper
2. lnspect the clutch face of the flywheel. Heat ature of the ring gear. Apply the crayon to
from operation of the clutch can cause small the ring gear. When the temperature is cor
cracks or marks on the clutch face of the fly rect, the chalk mark left by the crayon will
wheel. You can use a machine to remove the become a liquid. Do not overheat the ring
cracks or marks. gear, this will change the hardness of the
metal.
Warning: Do not machine the flywheel unless the
equipment In the shop can keep the factory stan 2. After the ring gear has been heated to the cor
dards for flywheel dimensions and static balance. rect temperature, quickly install it onto the fly
The clutch face of the flywheel must not be ma wheel.
chined to less than 0.625 Inch [15.87 mm] thick. Warning: Always wear protective gloves when
Do not machine the flywheel within a 4.0 inch
handling parts that have been heated.
[101.6 mm] radius of the center of the flywheel.
The static balance of the flywheel must be 2 Inch
ounces [1440 g mm] or less.
16-1/(16-2 Blank)
Wear Limits, Specifications and Torque
Worn limits as stated in this manual indicate that

GrOUP 1 8 the part may be reused if it is at the worn limit.
Discard only if it exceeds the worn limit. All
engine models are the same unless otherwise
stated. Limits are given in U.S. and metric
measurements. All metric units are enclosed in
brackets [ J.
Group 1: Cylinder Block Specifications — inch [mm]

No. . Measurement Limit Minimum Maximum Limit Minimum Maximum
1. Camshaft Bushing 2.0015 1 .999 2.0005 2.5023 2.4983 2.4998
lnside Diameter [50.838] [50.774] [50.813] [63.558] [63.457] [63.495]
Camshaft Bushing Bore 2.1305 2.1285 2.1295 2.6265 2.6245 2.6255
lnside Diameter [54.115] [54.064] [54.089] [66.721] [66.662] [66.688]
2. Cylinder Liner Counterhore 6.5615 6.5635
Depth 0.412 0.350 0.352
[10.46] [8.89] [8.94]
3. Liner to Block Clearance 0.002 0.006
Lower Bore [0.05] [0.15]
4. Lower Liner Bore 6.124 6.126
5. Main Bearing Bore 4.7505 4.7485 4.750
lnside Diameter [120.663] [120.612] [120.650]
Block (Ref. Fig. 1-37)
Height from Main 18.994 19.003 19.007
Bearing Centerline [482.45] [482.68] [482.78]
Height from lnstalled 16.619 16.628 16.632
Alignment Bar [422.12] [422.35] [422.45]
Cylinder Liner 5.505 5.4995 5.501
lnside Diameter [139.83] [139.687] [139.73]
Note: New cylinder liners dimensions at 60° to 70°F [16° to 21 "C]
may be 0.0002 to 0.0006 inch [0.005 to 0. 0015 mm] smaller than
indicated due to lubrite coating.
(lnstalled) [0.08] [0.15]
Crankshaft
Connecting Rod Journal 3.122 3.1235 3.125
18-1
Group 1: Cylinder Block Specifications — inch [mm] (Cont'd.)

Specifications not listed an the
Rof- Wom New New til
worn Mm.f
mew new
Main Bearing Journal 4.4975 4.4985 4.500
Thrust Bearing Surface 3.006 3.001 3.003
to Rear Counterweight [76.35] [76.23] [76.28]
Main and Rod Journals 0.002
Out-of-round T.l.R.* [0.05] 'T.l.R. — Total lndicated Runout
Main and Rod Journal 0.0005
Taper (Length of Journal) [0.013]
7. Main Bearings'* 0.1215 0.123 0.1238 "Also available in 0.010, 0.020,
Shell Thickness [3.086] [312] [3.145] 0.030 and 0.040 inch undersize.
[0.18] [0.038] [0.13]
8. Rod Bearings" 0.071 0.0724 0.0729 0.093 0.0942 0.0947
Shell Thickness [1.80] [1.839] [1.852] [2.362] [2.393] [2.405]
9. Crankshaft Thrust Ring • 0.245 0:247
157280 Std. Thickness [6.221 [6.27]
157281 0.01 a O.S. • 0.255 0.257
Thickness [0:25] [6.48] [6.53]
157282. 0.020 O.S. * 0.265 0.2ST
Thickness [0.51] 16.73} [6.78]
'Use Crankshaft End Clearance
10. Crankshaft End Clearance 0.022 0.007 (X017
End Clearance (lnstalled) {0.56] [0.18] [0.43]
It. Connecting Rod
Crankpin Bore 3.2722 3.2732 313157- 3.3167
lnside Diameter [8JLT14] [83.139] [84.219] [84.244]
Center to Center Length 11.998 12000
[304.753 [304.80]
Piston Pin Bushing 2.0022 2.0010 2.0015
lnside Diameter [50.856] [50.825] [50.838]
Connecting- Rod
Bend 0.010 0.010
Bend 0.004 0.004
Twist 0.020 0.020
Without Bushing. [0.51] [0.51]
Twist 0.010 0.010
Connecting Rod Bolt 0.540 0.541 0.545
Minimum Outside Diameter [13.72] [13.74] [13.84]
Pilot 0.6242 0.6245 0.6250
18-2

2 Inch Cam Engines same as 2 Inch Cam Engines
Connecting Rod Capscrew 0.583 0.584 0.590
Pilot 0.637 0.638 0.643
Bolt Hole Pilot
(2 Bolt Rods)
Rod 0.6249 0.6243 0.6248
[15.872] [15.857] [15.870]
Cap 0.6252 0.6246 0.6251
[15.880] [15.865] [15.878]
Dowel and Pilot
(2 Capscrew Rod)
Dowel Diameter 0.3127
[7.943]
Rod Dowel Hole 0.3128 0.3133
[7.945] [7.958]
Dowel Protrusion 0.220 0.250
[5.59] [6.35]
Dowel Press Fit ln Cap 0.0001 0.0006
[0.003] [0.015]
12. Piston
Skirt Diameter 5.483 5.487 5.488
at 70 *F [21 *C] [139.27] [139.37] [139.40]
Piston Pin Bore lnside 2.0000 1.9985 1.9990
Diameter at 70 *F [21 *C] [50.800] [50.762] [50.775]
13. Piston Pin
at 70*F[21 *C] [50.762] [50.768] [50.775]
14. Piston Ring
Gap in Ring Travel Area
of Liner
Part Number Minimum Maximum
147670 0.023 0.033
[0.58] [0.84]
218025* 0.017 0.027
[0.43] [0.68]
301233V 0.017 0.027
[0.43] [0.68]
132880*" 0.019 0.029
[0.48] [0.74]
214730 0.019 0.029
[0.48] [0.74]
216383* 0.020 0.030
[0.51] [0.76]
3012332 0.019 0.029
[0.48] [0.74]
218732 0.010 0.025
[0.25] [0.64]
Add 0.003 lnch [0.08 mm] ring gap to new maximum limit for
each 0.001 inch [0.03 mm] wear in cylinder liner wall.
•NTC-475 only
**Blg Cam ll only
***NTE Engine only
18-3

15. Camshaft Journal 1.996 1.997 1.998 2.495 2.496 2.497
Thrust Bearing 0.083 0.093 0.098
Thickness [2.11] [2.36] [2.49]
Support Bushing 1.370 1.3725 1.3755
lnside Diameter [34.80] [34.862] [34.938]
Outboard Bearing Support 1.757 1.751 1.754
lnside Diameter [44.63] 144 481 [44.55]
16. Gear Case Cover
Part No. 132770 Std. 1.571 1.565 1.569

lnside Diameter [39.90] [39.75] [39.85]
132771 0.010 [0.25J U.S. 1.561 1.555 1.559
lnside Diameter [39.65] [39.50] [39.60]
132772 0.020 (0.511 U.S. 1.551 1.545 1.549
[39 401 □9.241 '39 341
20822 Std. (NTA Series) 1.7585 1.7525 1.7565
inside Diameter [44.666] [44.513] [44.6T5J
Torque Specifications — ft.-lbs. [ft»m]
i /. rip* ring w
15 £ 20} 20 [ 27]
1/4 39 I 411 35 [ 47]
3/8 36 f47T 45 [ 6?1
1/2 45 [ 61} 55 [ 75]
3/4. 60 [ 81] 70 [95]
T-1/4 75 [102] 85 [115]
1-1/2 90 [122] 100 [136]
% Inch %lnch 1 inch tlnch
18. Main Bearing Capscrews» Minimum Maximum Minimum Maximum
Step 1. Tighten to 80 [108.5] 90 [122] 100 [135.61 110 [149]
Step 2. Tighten to 160 [217] 170 [230] 200 [271] 210 [285]
Step 3. Tighten to 250 [339] 260 [3521 300 [407] 310 [420]
Step 4. Loosen Completely All All All All
Step 5. Tighten to 80 [108.5] 90 [122] 100 [135.61 110 [149]
Step 6. Tighten to 160 [2171 170 [230] 200 [271] 210 [285]
Step 7. Tighten to 250 [339] 260 [352] 300 [407] 310 [420]
19. Connecting Rod Nuts or Capsc Minimum Maximum
Step 1. Tighten to 70 [ 95] 75 [102]
Step 2. Tighten to 140 [190] 150 [203]
Step 3. Loosen Completely All All
Step 4. Tighten to 25 [ 34] 30 [ 41]
Step 5. Tighten to 70 [ 951 75 [102]
Step 6. Tighten to 140 [190] 150 [203]
'During 1978, some engines were built with special main bearing caps and % inch capscrews. Check the serial
number and build date of your engine against the list on the next page. lf your engine is one of those listed, the
main bearing capscrews must be tightened to 330 ft.-lbs. [447.4 N»m] maximum torque.
Engine Date Engine Date Engine Date Engine Date

Serial No. Built Serial No. Built Serial No. Built Serial No. Built
10718349 10719402 2-10-78 10721426 10729428
thru 2- 8-78 10719405 thru 2-17-78 thru 3-16-78
10718373 thru 2-10-78 10721429 10729451
10718391 10719412 10721549 10752302
thru 2-8-78 10719682 thru 2-17-78 thru 6-9-78
10718394 thru 2-10-78 10721563 10752331
10718413 10719691 10721864 10752414
thru 2-8-78 10721117 thru 2-20-78 thru 6-9-78
10718420 thru 2-16-78 10721867 10752443
10718672 10721121 10721963 10759241
thru 2-8-78 10721127 thru 2-20-78 thru 7-11-78
10718674 thru 2-16-78 10721972 10759275
10718737 10721131 10722061 10759566
thru 2-8-78 10721161 thru 2-20-78 thru 7-11-78
10718746 thru 2-16-78 10722070 10759586
10719293 10721175 10722677
thru 2-10-78 10721420 thru 2-22-78
10719309 thru 2-16-78 10722701
10719311 10721424 10729153
thru 2-10-78 thru 3-16-78
10719319 10729177
Group 2: Cylinder Head Specifications — inch [mm]
Ref. Worn New New
1. Cylinder Head
Height 4.340 4.370 4.380
[110.24] [111.00] [111.25]
2. Valve, Stem
[11.41] [11.43] [11.46]
Face Angle 30 degree 30 degree
3. Valve Guide
[11.56] [11.494] [11.511]
[32.26] [32.51]
4. Valve Seat Insert*
[50.864] [50.889]
Cylinder Head
lnside Diameter 1.9995 2.0005
[50.787] [50.813]
lnsert Height 0.278 0.282
[7.06] [7.16]
Run Out in 360 Degrees 0.002
[0.05]
Refaced Seat Width 0.063 0.125
[1.59] [3.18]
5. Valve Spring**
Assembled Height 2.250
[57.15]
6. Crosshead Guide
[10.97] [11.00] [11.011]
[47.24] [47.75]
Crosshead Bore 0.440 0.434 0.436
[11.18] [11.02] [11.07]
7. Injector Sleeve
Tip Protrusion 0.060 0.070
[1.52] [1.78]
'See Ref. No. 8 for oversize valve seat inserts.
"See Ref. No. 9 for valve spring data.
18-5
Group 2: Cylinder Head Specifications — inch [mm] (Cont'd.)

Ref. Valve Seat lnsert Oversize Oversize lnsert Cylinder Head lnsert
No. Part No. Diameter Depth P.P. LD. Thickness
8. 127935 0.005 Std. 2.0075/2.0085 2.0045/2.0055 0.278/0.282
[0.13] [50.991/51.016] [50.914/50.940] [7.06/7.16]
127931 0.010 Std. 2.0125/2.0135 2.0095/2.0105 0.278/0.282
[0.25] [51.118/51.143] [51.041/51.067] [7.06/7.16]
127932 0.020 0.005 2.0225/2.0235 2.0195/2.0205 0.283/0.287
[0.50] [0.13] [51.372/51.397] [51.295/51.321] [7.19/7.29]
127933 0.030 0.010 2.0325/2.0335 2.0295/2.0305 0.288/0.292
[0.76] [0.25] [51.626/51.651] [51.549/51.575] [7.32/7.42]
127934 0.040 0.015 2.0425/2.0435 2.0395/2.0405 0.293/0.297
[1.02] [0.38] [51.880/51.905] [51.803/51.829] [7.44/7.54]
Be sure to measure the insert before machining the head or installing the insert.
Required Load for Length
Valve Approximate Wire Lb. [N] Lb. [N] Lb. [N]
Rof■ Spring Free Length No. Diameter Length Worn New New
No. Part No. lnch [mm] Coils lnch [mm] lnch [mm] Limit Minimum Maximum
9. 178869 2.920 9.5 0.177 1.765 150 155 189
[74.17] [4.50] [44.83] [667] [689] [841]
211999 2.685 9 0.177 1.724 143 147.25 162.75
[68.20] [4.50] [43.79] [636] [655] [724]
inn Plua Toraua - Ft.-Lbs. [N»m]
No! Plug Size

10. 1/16 lnch 3 [4] 6 [8]
1/8 lnch 5 [7] 10 [14]
3/8 lnch 35 [47] 45 [61]
1/2 lnch 60 [81] 70 [95]
3/4 lnch 65 [88] 75 [102]
1 lnch 135 [182] 145 [197]
Group 3: Rocker Lever Specifications — inch [mm]

2 lnch Cam Engines 2-1/2 lnch Cam Engines
1. Bushings 1.1286 1.1245 1.1275 1.1286 1.1245 1.1275
lnside Diameter [28.664] [28.562] [28.639] [28.664] [28.562] [28.639]
2. Shaft 1.122 1.123 1.124 1.122 1.123 1.124

Group 4: Cam Follower Dimensions — inch [mm]

« 2 Inch Cam Engines 2-1/2 Inch Cam Engines
Worn New New Worn New New
Measurement Limit Minimum Maximum Limit Minimum Maximum
Shaft 0.748 0.7485 0.749 0.748 0.7485 0.749
Bushing 0.752 0.7501 0.7511 0.752 0.7501 0.7511
lnside Diameter [19.10] [19.053] [19.078] [19.10] [19.053] [19.078]
lnjector Cam Roller
lnside Diameter 0.505 0.503 0.504 0.705 0.703 0.704
[12.83] [12.78] [12.80] [17.91] [17.86] [17.88]
[31.71] [31.72] [31.77] [31.71] [31.73] [31.76]
Valve Cam Rollers
lnside Diameter 0.503 0.5005 0.5015 0.503 0.5005 0.5015
[12.78] [12.713] [12.738] [12.78] [12.773] [12.708]
[31.71] [31.72] [31.75] [31.71] [31.73] [31.76]
Roller Pin Diameter
Valve 0.497 0.4995 0.500 0.497 0.4997 0.500
[12.62] [12.687] [12.70] [12.62] [12.692] [12.70]
lnjector 0.497 0.4995 0.500 0.697 0.6997 0.7000
[12.62] [12.687] [12.70] [17.70] [17.772] [17.780]
Diameter of the Bore
for the Roller Pin
Valve 0.4990 0.4997 0.4990 0.4995
[12.674] [12.692] [12.674] [12.687]
lnjector 0.4990 0.4997 0.6992 0.6997
[12.674] [12.692] [17.759] [17.772]
Group 4: MVT Cam Follower Dimensions — inch [mm]
Worn New New Worn New New
Measurement Limit Minimum Maximum Measurement Limit Minimum Maximum
Cam Follower Shaft 0.748 0.7485 0.7490 Outside Diameter 1.2485 1.2495 1.2505
Bushing Roller Pin
Inside Diameter Outside Diameter
Valve 0.752 0.7501 0.7511 Valve 0.497 0.4997 0.5000
[19.10] [19.05] [19.07] [12.62] [12.692] [12.70]
lnjector 1.3765 1.3775 lnjector 0.697 0.6997 0.7000
[34.96] [34.98] [17.70] [17.772] [17.78]
Injector Cam Roller Diameter Of The Bore
lnside Diameter 0.705 0.703 0.704 For The Roller Pin
[17.91] [17.86] [17.88] Valve 0.4990 0.4995
Outside Diameter 1.2485 1.2495 1.2505 [12.67] [12.68]
[31.71] [31.73] [31.76] lnjector 0.6992 0.6997
[17.76] [17.77]
Valve Cam Roller
0.5015 Eccentric 1.3743 1.3748
lnside Diameter 0.503 0.5005
[12.71] [12.73] Outside Diameter [34.90] [34.92]
[12.78]
13-7
Group 4: Push Rod Length — inch [mm]

2 Inch Cam 2-1/2 lnch <
18.290 [464.57] 17.775 [451.49]
18.320 [465.32] 17.805 [452.25]
18.360 [466.34] 17.880 [454.15]
18.390 [467.11] 17.910 [454.91]
Group 7: Lubricating Oil Pump Specifications — Inch [mm]
Raf. worn Maw New
Single Lubricating Oil Pump
1. Bushings
lnside diameter 0.6185 0.6165 0.6175
[15.710] [15.659] [15.684]
2. Idler and Drive Shaft
Outside diameter 0.6145 0.615 0.6155
[15.608] [15.62] [15.634]
Clearance 0.012
[0.30]
4. Drive Shaft
[0.05] [0.13]
Idler shaft
lnside Body [18.29] [18.80]
Shaft Protrusion 0 855 0.875
[21.72] [22.22]
Single (Double Capacity) Lubncaiing uii r

1. Bushings
[22.33] [22.268] [22.293]
2. Idler and Drive Shaft
[22.17] [22.212] [22 221
Clearance 0.012
[0.30]
4. Drive Shaft
[0.05] [0.20]
Idler Shaft
Shaft Protrusion
Above body to Cover Face 0.955
[24.26]
[26.29] [26.80]
5. Piston Cooling Oil Tube
Protrusion Above Body 2.970 3.000
Mounting Face [75.44] [76.20]
Double Lubricating Oil Pump
1. isusnings
inside Diameter 0.6185 0.6165 0.6175
[15.710] [15.659] [15.684]
18-8
Wear Limits. Specifications and Torque
Group 7: Lubricating Oil Pump Specifications — Inch [mm] (Cont'd.)
2. Idler and Drive .

0.6145 0.615 0.6155
[15.6061 [15.62] [15-634]
0.012
[0.30]
4. Drive Shaft
End 0.004 0.007
[010] [0-181
ldler Shaft
Shaft Protrusion
of Body 2600 2.620
[66.04] [66.55]
Suffix Letter L 2.680 2.690

[68.07] [68.33]
Drive Gear/ Drive
[1.02] [152]
0.6185 0.6165 0.6175

[15.710] [15.659] [15.684]
2. idler and Drive Shaft
05145 0.615 0.6155
[15.608] [15.62] [15.634]
Idler Shaft
Protrusion Rush with front surface of pump.
0.580 .0610
[14.73] [15.49]
Coupling
Protrusion Above 0.990 1.010
Coupling Face [25.15] [25.64]
Coupling/Drive Shaft
[1-27] [178]
Drive Shaft
[0.10] [0-25]
Bushings
Inside Diameter 0.841 0.840 0.8405
[21.36] [21.34] [21.349]
[2126] [21272] [2129]
Protrusion Flush with front surface of pump.
Driven Gea
[14.73] [15.49]
18-9
Group 7: Lubricating Oil Pump Specifications — Inch [mm] (Cont'd.)

Ref. Worn New New
Coupling Dowels
Protrusion Above 0.990 1.010
Coupling Face [25.15] [25.65]
Coupling/ Drive Shaft
[1.27] [1.78]
4. Drive Shaft
[0.10] [0.25]
FFC Filter/Cooler or Non-FFC Lubricating Oil
Pump
Free Length 3.410
[86.36]
Load at 2.125 inch 45 50
[53.98 mm] lb. [N] [200] [222]
Recommended Oil " 50 70
psi [kPa] [345] [483]
FFC Lubricating Oil
Free Length 2.500
163.50]
Load at 1.780 inch 79 91
145.21 mm] lb. IN] [351] [406]
Oil
DFC
Pres
Free Length 3.310
[84]
Load at 1.820 inch 21.9 25.7
[46.2 mm] lb. IN] l»7«3 H™]
Oil Pressure
psiTKPa] *275-7!
lOHr
"Jf -— —1 " n niA
Free Length
Load at 1.145 incti 59.2 72.4
[29.07 mm] lb [N] [263] 1322]
Oil Pressure
psi [kPa] t1034?
Group 7: NTE Oil Pump Specifications — Inch [mm]
in.-.
worn M—
nww Mann
r*ww
0.8785 0.8765 0.8775

Inside Diameter [22.31] [22.26] [22.28]
Idler and Drive 0.8740 0.8745 0.8750
0.955 0.985
Protrusion [24.25] [25.02]
Drive Shaft 2.305 2.325
Protrusion [58.54] [59.05]
18-10
Group 7: Oil Pan Capacity — U.S. Gallons [Litres] and Degrees of Angularity
F.P. Exhaus
Part Sump Front Front Side Side
Number Location High Low Up Down Down Down
10451 Center 6-1/2 [25] 4 [15]
10474-2 Rear 7 [26] 5-1/2 [21] 19 21 35 35
10492-2 Rear 6-1/2 [25] 4 [15] 19 21 35 35
10668-1 Rear 8-1/2 [32] 5-1/2 [21] 16 16 16 16
10774 Rear 7 [26] 5-1/2 [21] 19 20 30 25
10777 Front 7 [26] 5-1/2 [21] 40 40 45 35
10779 Rear 8-1/2 [32] 5-1/2 [21] 16 16 16 16
10809 Full 11 [42] 3 [11]
10811 Center 7 [26] 5-1/2 [21] 32 40 37 35
10850 Rear 7 [26] 5-1/2 [21] 14 12 45 20
10850-A Rear 7 [26] 5-1/2 [21] 14 12 45 20
11055 Front 7 [26] 5-1/2 [21] •
11102 Front 7 [26] 5-1/2 [21]
11150 Dry
11194 Dry
103949 Front 7 [26] 5-1/2 [21] 15 36 35 35
110626 Rear 7 [26] 5-1/2 [21] 40 25 45 19
116916 Rear 7 [26] 5-1/2 [21] 20 15 37 35
118784 Rear 7 [26] 5-1/2 [21] 14 12 45 20
119330 Center 7 [26] 5-1/2 [21] 45 45 45 45
119382 Full 7 [26] 5-1/2 [21] 42 1 19 40
119586 Front 7 [26] 5-1/2 [21]
120905 Center 7 [26] 5-1/2 [21]
121089 Front 6 [23] 4-3/4 [18] 15 30 30 30
121244 Front 6 [23] 4 [15] 36 45 45 40
121862 Center 6-1/2 [25] 4-1/2 (17] 22 24 40 40
121377 Rear 6 [23] 4 [15] 45 38 42 40
125318 Rear 6-1/2 [25] 4 [15] 28 15 38 38
126818 Rear 7 [26] 5-1/2 [21] 40 25 45 19
129434 Rear 6 [23] 4 [15] 45 38 42 40
133879 Rear 7 [26] 5-1/2 [21] 36 11 32 30
134070 Center 6 [23] 4 [15] 35 33 35 35
134271 Front 7 [26] 5-1/2 [21] 10 35 40 40
134279 Rear 7 [26] 5-1/2 [21] 19 21 35 35
134283 Rear 7 [26] 5-1/2 [21] 19 20 30 25
137158 Full 7 [26] 4 [15] 45 8 42 40
139493 Front 6 [23] 4 [15] 36 45 45 40
139745 Rear 6 [23] 4 [15] 45 38 42 40
146866 Dry
148160 , Rear 8 [23] 4 [15] 45 39 40 42
151079 Rear 6 [23] 4 [15]
152410 Rear 8 [23] 4-1/2 [17] 27 15 25 35
153729 Rear 7 [26] 5-1/2 [21] 19 12 25 25
154418 Full 6 [23] 4 [15] 15 15 15 15
161206 Front 6 [23] 4 [15] 36 45 45 40
162377 Rear 7 [26] 5-1/2 [21] 45 38 42 40
164436 Front 6 [23] 4 [15] 40 40 45 35
164776 Rear 7 [26] 5-1/2 [21] 40 25 45 19
167186 Rear 7 [26] 5-1/2 [21] 19 12 25 25
167429 Rear 7 [26] 5-1/2 [21] 40 25 45 19
169348 Front 6 [23] 4 [15] 40 40 45 35
177155 Rear 8 [23] 4 [15] 45 39 40 42
181768 Rear 7 [26] 5-1/2 [21] 20 15 37 35
187756 Center 6-1/2 [25] 4 [15] 24 24 32 30
18-11
Group 7: Oil Pan Capacity — U.S. Gallons [Litres] and Degrees of Angularity (Cont'd.)
Capacity of Angularity
F.P. Exhaust
N8rtbe Sump Front Front Side Side
Location High Low Up
189672 Full 12 [45] 3-1/2 [13]
193625 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193629 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193631 Rear 7 [26] 5-1/2 [21] 16 12 .35 39
193634 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193635 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193636 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193637 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193638 Rear 7 [26] 5-1/2 [21] 16 12 35 39
193639 Rear 7 [26] 5-1/2 [21] 16 12 35 39
200787 Rear 7 [26] 5-1/2 [21] 16 12 35 39
201836 Rear 5 [19] 3-1/2 113] 27 15 25 35
201837 Rear 5 [19] 3-1/2 [13] 27 15 25 35
201839 Rear 7 [21] 5-1/2 [21] 16 12 35 39
201841 Rear 5 [19] 3-1/2 [13] 27 15 25 35
201842 Rear 7 [26] 5-1/2 [21] 16 12 35 39
201843 Rear 7 [26] 5-1/2 [21] 16 12 35 39
201844 Rear 5 [19] 3-1/2 [13] 27 15 25 35
202283 Front 7 [26] 5-1/2 [21] 10 35 40 40
202284 Front 7 [26] 5-1/2 [21] 10 35 40 40
203561 Rear 7 [26] 5-1/2 [21] 19 12 25 25
203563 Rear 7 [26] 5-1/2 [21] 19 12 25 25
203564 Rear 7 [26] 5-1/2 [21] 19 12 25 25
203841 Front 7 [26] 5-1/2 [21] 10 35 40 40
3002151 Center 6-1/2 [25] 5-1/2 [21] 24 24 32 30
3002152 Center 7 [261 5-1/2 [21]
3005178 Rear 7 [26] 5-1/2 [21] 19 12 25 25
3005179 Rear 7 [26] 5-1/2 [21] 19 12 25 25
3005181 Rear 7 [26] 5-1/2 [21] 19 12 25 25
3005183 Rear 7 [26] 5-1/2 [21] 19 12 25 25
Group 7: Hose Size Group 7: Hose Bends — Inch [mm]
Location Minimum Hose Size (Rubber-Lined)
Turbocharger Oil Supply No. 6 Hose lnside Outside Minimum
Full Flow Filter No. 16 Size Diameter Diameter
Turbocharger Oil Drain No. 16 4 3/16 [4.76] 31/64 [12.30] 2 [50.80]
Group 7: Hose Bends — Inch [mm] 5 1/4 [6.35] 35/64 [13.89] 2-1/4 [57.15]
6 5/16 [7.94] 39/64 [15.48] 2-3/4 [69.85]
(Teflon-Lined) 8 13/32 [10.32] 47/64 [18.65] 4-5/8 [117.48]
Hose Inside Outside Minimum 10 1/2 [12.70] 53/64 [21.031 5-1/2 [139.70]
Size Diameter Diameter Bend Radius 12 5/8 [15.87] 61/64 [24.21] 6-1/2 [165.10]
16 7/8 [22.23] 1-13/64 [30.56] 7-3/8 [187.34]
6 5/16 [7.94] 39/64 [15.48] 4 [101.60] 20 1-1/8 [28.58] 1-31/64 [37.70] 9 [228.60]
16 7/8 [22.23] 1 -13/64 [30.56] 7-3/8 [187.33] 24 1-3/8 [34.93] 1-23/32 [43.66] 11 [279.40]
Group 8: Cooling System Specifications — Inch [mm]

Eccentric and FFC Water Pump
Housing Bearing Bores 2.4408 2.4414 2.4494
[61.996] [62.012] [62.215]
lmpeller End [15.905] [15.918]
Seat Location [15.905] [15.918]
lnner Bearing [25.001] [25.011]
Outer Bearing [25.001] [25.011]
.5. Shaft Diameter 0.6693 0.6696
Pulley End [17.000] [17.008]
[15.85] [15.88]
lmpeller Vane to Body
Clearance
(Cast lron) 0.020 0.040
[0.51] [1.02]
(Phenolic) 0.030 0.050
[0.76] [1.27]
Pulley Bore Diameter 0.6663 0.6673
[16.924] [16.949]
Minimum Press-Fit BetweeiK
[0.03]
[0.03]
Housing Bore 2.8345 2.8351 2.8431
Outer Bearing [71.996] [72.012] [72.215]
Housing Bore 2.0471 2.0477 2.0557
lnner Bearing [51.996] [52.012] [52.215]
Outer Seal [76.162] [76.238]
lnner Seal [34.90] [34.95]
lmpeller End [15.905] [15.918]
Seat Location [15.905] [15.918]
lnner Seal [22.15] [22.30]
18-13
Group 8: Specifications — Inch [mm]

Eccentric and FFC Water Pump (Cont'd.)
lnner Bearing Surface [24.999] [25.009]
Outer Bearing Surface [29.997] [30.008]
Pulley End [29.997] [30.008]
[15.85] [15.88]
Impeller Vane to Body 0.020 0.040
Clearance [0.51] [1.02]
D.bIIau
ruiioy Dam
Bore 1.1787 1.1798
[29.939] [29.967]
Wear Sleeve O.D. 2.2540 2.2560
Outer Seal Surface [57.252] [57.302]
Minimum rre»o"rn
minimum Proas.Fit Rahul
Dviwv
[0.03]
[0.03]
Group 9: Drive Unit Specifications — Inch [mm]

Rof. Worn New New
1. Shaft
(Bushing Location) [33.27] [33.312] [33.32]
Bushing
[33.55] [33.43] [33.50]
[36.80] [36.83]
Out-of-Round 0.002
[0.05]
Press-Fit Between 0.002 0.0045
Housing and Bushing [0.05] [0.11]
Accessory Drive
End Clearance NH/NT 0.002 0.012
[0.05] [0.26]
End Clearance NTA 0.004 0.024
[0.10] [0.61]
Hydraulic Governor Drive
[0.08] [0.15]
Group 14: Assembly Specifications — inch [mm]

Ret. Worn New New
No. ^ Measurement Limit Minimum Maximum
1. Main Bearing
[0.18J [0.038] [0.13]
2. Connecting Rod Bearing
[0.181 [0.038] [0.114]
3. Crankshaft
End Clearance 0.022 0007 0.017
[0.561 [0.18] [0.43]
4. Cylinder Liner
[0.08] [0.15]
Out-of-Round 0.003
Top One (1) lnch [0.08]
Out-of-Round 0.002
Packing Ring (Lower) Area [0.05]
B. Connecting Rod
Side Clearance 0.0045 0.013
[0.114] [0.33]
6. Gear Train (Gear to Gear)
Crankshaft, Camshaft,
Accessory Drive and
Backlash 0.020 0.0045 0.0105
[0.511 [0.114] [0.267]
7. Camshaft (With Thrust Plate)
[0.03] [0.13]
(With Outboard Bearing Support)
[0.20] [0.33]
8. Injection Timing
Refer to Table 6, Page 14-15.
t. Injector, Crosshead and
Valve Adjustments
Refer to Injector and Valve
Adjustment, Page 14-32 through
14-36
10. Dynamometer Testing
Refer to Text Procedure,
Page 14-44
11. Lubricating Oil Pressure
Refer to Page 14-48
12. Blow-By
Refer to Test Procedure,
Page 14-48
Group 14: Crankshaft Flange Capscrew Torque Specifications — ft.-lb. [N»m]

Engine Model Part No. Minimum Maximum
NT Series 196653 Capscrew 250 270
196654 Retainer [339] [366]
NH Series 140410 Capscrew 180 200

140411 Retainer [244] [271]
18-15
Group 14: Vibration Damper Capscrew Group 14: Alternator/Generator Torque

Torque Values Values (To Adjusting Link)
Capscrew SAE Grade Minimum Maximum Nominal Bolt Torque
Size Number ft.-lbs. [N»m] ft.-lbs. [N-m] Inch Ft.-Lb. [N-m]
1/2 inch 8 115 [156] 125 [170] 5/16 15 to 19 [20 to 26]
5/8 inch 8 180 [244] 200 [271] 7/16 25 to 30 [34 to 41]
5/8 inch 5 150 [203] 170 [231] 1/2 50 to 55 [68 to 75]
Group 14: Cam Follower Gasket Group 14: Alternator/Generator Torque

Specifications Values (To Bracket)
Change ln
Gasket Thickness Push Rod Travel Nominal Bolt Torque
lnch Ft.-Lb. [N-m]
Part No. lnch [mm] lnch [mm] Application
3020001 0.006 to 0.008 0.0015 to 0.002 Big Cam 3/8 29 to 31 [39 to 42]
[0.15 to 0.20] [0.04 to 0.05] 7/16 63 to 65 [85 to 88]
1/2 77 to 80 [104 to 108]
3020002 0.014 to 0.020 0.0035 to 0.005 Big Cam
[0.36 to 0.51] [0.09 to 0.13]
3020003 0.020 to 0.024 0.005 to 0.006 Big Cam Group 14: Alternator/Generator Torque
[0.51 to 0.61] [0.13 to 0.15]
Values (Pulley to Alternator
3020004 0.027 to 0.033 0.007 to 0.008 Big Cam
[0.69 to 0.84] [0.18 to 0.20] or Generator)
9266-A* 0.006 to 0.008 0.0015 to 0.002 Small Cam Nominal Bolt Size Torque
[0.15 to 0.20] [0.04 to 0.05] Ft.-Lb. [N-m*
9266 0.014 to 0.020 0.035 to 0.005 Small Cam 1/2 50 to 60 [68 to 81]
[0.36 to 0.51] [0.09 to 0.13] 5/8 55 to 65 [75 to 88]
3011272 0.020 to 0.024 0.005 to 0.006 Small Cam 3/4 90 to 100 [122 to 126]
[0.51 to 0.61] [0.13 to 0.15]
Note: Exceptions to the
120819 0.027 to 0.033 0.007 to 0.008 Small Cam
[0.69 to 0.84] [0.18 to 0.20] Delco-Remy Torque
3011273 0.037 to 0.041 0.009 to 0.010 Small Cam Alternators Ft.-Lb. [N-m]
[0.94 to 1.04] [0.23 to 0.25] 10 DN 150
25 SI 70 to 80 [95 to 108]
'Must not be used alone.
CAV
Group 14: Timing Key Information
AC 5 40 to 42 [54 to 57]
Equivalent AC 7 60 to 70 [81 to 95]
Gasket AC 90 60 to 70 [81 to 95]
Stack
% Inch 1 Inch Thickness
Key Key Offset Timing Change
Part No. Part No. lnch [mm] Change lnch [mm] Group 14: Injector and Valve Set Position
3021601 69550 None None None Bar in Pulley Set Cylinder
3021595 200722 0.0060 [0.15] Retard 0.012 [0.30] Direction Position lnjector Valve
3021593 200712 0.0075 [0.19] Retard 0.015 [0.38]
3021592 200707 0.0115 [0.29] Retard 0.023 [0.58] Start A or 1-6 VS 3 5
3021594 200713 0.0185 [0.47] Retard 0.037 [0.94] Adv. To B or 2-5 VS 6 3
3021596 200723 0.0255 [0.65] Retard 0.051 [1.30] Adv. To C or 3-4 VS 2 6
3021598 208746 0.0310 [0.79] Retard 0.062 [1.57] Adv. To A or 1-6 VS 4 » 2
3021597 202600 0.0390 [0.99] Retard 0.078 [1.98] Adv. To B or 2-5 VS 1 4
3021600 3012307 0.0510 [1.30] Retard 0.102 [2.59] Adv. To C or 3-4 VS 5 1
3021599 3012328 0.0115 [0.29] Advance 0.023 [0.58]
3022352* 0.0185 [0.47] Advance
3022353* 0.0310 [0.79] Advance Group 14: Engine Firing Order
*For Mechanical Variable Timing (MVT) Engines) Right Hand: 1-S-3-6-2-4 Left Hand: 1-4-2-6-3-5
18-16
Group 14: Adjustment Limits Group 14: Injector Adjustment

Using Dial Indicator Method — Inch [mm] (Torque Method)
Oil Injector Plunger Valve Clearance Cold Set Hot Set
Temp. Travel lntake Exhaust Cast Iron Rocker Housing
Aluminum Rocker Housing 48 inch-lb. 72 inch-lb.
Cold 0.170 ± 0.001 0.011 0.023 [5.4 N»m] [8.1 N»m]
[4.32 ± 0.03] [0.28] [0.58] Aluminum Rocker Housing
Hot 0.170 ± 0.001 0.011 0.023 72 inch-lb. 72 inch-lb.
[4.32 ± 0.03] [0.28] [0.58] [8.1 N»m] [8.1 N-m]
Cast Iron Rocker Housing
Cold 0.175 ± 0.001 0.013 0.025 Group 14: Valve Clearance
[4.45 ± 0.03] [0.33] [0.64] (Torque Method) — Inch [mm]
Hot 0.170 ± 0.001 0.011 0.023 Intake Valves Exhaust Valves
[4.32 ± 0.03] [0.28] [0.58] Cold Set Hot Set Cold Set Hot Set
NTE 85S (European Big Cam Only) Aluminum Rocker Housing
0.225 0.011 0.023 0.014 0.014 0.027 0.027
[5.72] [0.28] [0.58] [0.36] [0.36] [0.69] [0.69]
NT-8S5 (Australian Big Cam Only) Cast Iron Rocker Housing
0.228 0.011 0.023 0.016 0.014 0.029 0.027
[5.79] [0.28] [0.58] [0.41] [0.36] [0.74] [0.69]
18-17
Capscrew Markings and Torque Values

Current Usage Much Used Much Used Used at Times Used at Times
Minimum Tensile To 1/2 - 69,000 [476] To 3/4 - 120,000 [827] To 5/8 — 140,000 [965] 150,000 [1 034]
Strength — To 3/4 — 64,000 [421] To 1 - 11 5,000 [793] To 3/4 - 133,000 [917]
PSI [MPa] To 1 - 55,000 [379]
Minimum Medium Best
Quality of Material Indeterminate
Commercial Commercial Commercial
SAE Grade Number 1 or 2 5 6 or 7 8
Capscrew Head
Markings
Manufacturer's
marks may vary 6
These are all SAE

Grade 5 (3 line)
7
Capscrew Body Size Torque Torque Torque Torque

(Inches) - (Thread) Ft.-Lbs. [N»m] Ft.-Lbs. [N»m] Ft.-Lbs. [N»m] Ft.-Lbs. [N»m]
1/4 -20 5 [7] 8 [11] 10[14] 12[16]
— 28 6 [8] 10[14] 14[19]
5/16 — 18 11 [15] 17 [23] 19(26] 24 [33]
- 24 13 [18] 19 [26] 27 [37]
3/8 — 16 18 [24] 31 [42] 34(46] 44 [60]
- 24 20 [27] 35 [47] 49 [66]
7/16 — 14 28(38] 49 [66] 55 [75] 70 [95]
- 20 30 [41] 55 [75] 78 [106]
1/2 — 13 39 [53] 75 [102] 85[115] 105 [142]
- 20 41 [56] 85[115] 120 [163]
9/16 — 12 51 [69] 110 [149] 120 [163] 155 [210]
- 18 55 [75] 120 [163] 170 [231]
5/8 - 11 83[113] 150 [203] 167 [226] 210 [285]
- 18 95 [129] 170 [231] 240 [325]
3/4 - 10 105 [142] 270 [366] 280 [380] 375 [508]
- 16 115 [156] 295 [400] 420 [569]
7/8 - 9 160 [217] 395 [536] 440 [597] 605 [820]
— 14 175 [237] 435 [590] 675 [915]
1 - 8 235 [319] 590 [800] 660 [895] 910[1234]
— 14 250 [339] 660 [895] 990 [1342]
Notes:
1. Always use the torque values listed above when specific torque values are not available.
2. Do not use above values in place of those specified in other sections of this manual; special attention should be observed
when using SAE Grade 6, 7 and 8 capscrews.
3. The above is based on use of clean, dry threads.
4. Reduce torque by 10% when engine oil is used as a lubricant.
5. Reduce torque by 20% if new plated capscrews are used.
6. Capscrews threaded into aluminum may require reductions in torque of 30% or more of Grade 5 capscrews torque and must
attain two capscrew diameters of thread engagement.
Caution: If replacement capscrews are of a higher grade than the original capscrew, tighten the replace
ment capscrew to the torque value used for the original capscrew.
^-18
Lubricating Oil Inhibitors to maintain the stability of the oil, prevent

acids from attacking metal surfaces and prevent
The Functions of Lubricating Oil
rust during the periods the engine is not
The lubricating oil used in a Cummins engine operating.
must be multifunctional. lt must perform the pri
Other Additives that enable the oil to lubricate
mary functions of: highly loaded areas, prevent scuffing and seizing,
Lubrication by providing a film between the mov control foaming and prevent air retention in the
ing parts to reduce wear and friction. oil.
Cooling by serving as a heat transfer media to
Oil Performance Classification System
carry heat away from critical areas.
The American Petroleum lnstitute (APl), The
Sealing by filling in the uneven surfaces in the
American Society for Testing and Materials
cylinder wall, valve stems and turbocharger oil
(ASTM) and the Society of Automotive Engineers
seals.
(SAE) have jointly developed and maintained a
Cleaning by holding contaminants in suspension system for classifying lubricating oil by perform
to prevent a build up of deposits on the engine ance categories. The following are brief descrip
surfaces. tions of the APl catagories used in the Cummins
ln addition, it must also provide: oil performance recommendations.
Dampening and cushioning of components that CC (Equivalent to MlL-L-2104B.) This category

operate under high stress, such as gears and describes oils meeting the requirements of the
push tubes. military specification MlL-L-2104B. These oils pro
vide low temperature protection from sludge and
Protection from oxidation and corrosion. rust and are designed to perform moderately well
Hydraulic Action for components such as Jacobs at high temperature. For moderate-duty service.
Brake and hydraulic controls. CD (Equivalent to Series 3 and MlL-L-45199B.)
Engine lubricating oil must be changed when it This category describes oils meeting the require
can no longer perform its functions within an ments of the Series 3 specification and MIL-L-
engine. Oil does not wear out, but it becomes con 45199B. These oils provide protection from de
taminated to the point that it can no longer satis posits and oxidation at high temperature. For
factorily protect the engine. Contamination of the severe-duty service.
oil is a normal result of engine operation. During SC (Equivalent to 1964 MS Oils.) This category
engine operation a wide variety of contaminants describes oils meeting the 1964-1967 require
are introduced into the oil. Some of these are: ments of automobile manufacturers. Primarily for
Byproducts of Engine Combustion — asphal- use ln automotibles, it provides low temperature
tenes, soot and acids from partially burned fuel. anti-sludge and anti-rust protection required in a
ligh-duty diesel service such as a stop-and-go
Acids, varnish and sludge which are formed as a operation.
result of the oxidation of the oil as it breaks down
or decomposes. SD (Equivalent to 1968-1971 MS Oils.) This cate
gory describes oils meeting the 1964-1967 require
Dirt entering the engine through the combustion ments of automobile manufacturers. Primarily for
air, fuel, while adding or changing lubricating oil. use in automobiles, it provides low temperature
The oil must have an additive package to combat anti-sludge and anti-rust protection required in a
these contaminates. The package generally con light-duty diesel service such as a stop-and-go
sists of: operation. lt may be substituted for SC category.
Detergents/Dispersants which keep insoluble SE (Equivalent to 1972 MS Oils.) This category de
matter in suspension until they are filtered from scribes oils meeting the 1972 requirements of au
the oil or are removed with the oil change. This tomobile manufacturers. Primarily for use in auto
prevents sludge and carbon deposits from form mobiles, it provides protection from high tempera
ing in the engine. ture oxidation and low temperature anti-sludge
18-19
and anti-rust as required in a light-duty diesel Break-In Oils

service such as a stop-and-go operation. lt may be Special "break-in" lubricating oils are not recom
substituted for SC category. mended for new or rebuilt Cummins engines. Use
CB (No equivalent Specification.) These oils were the same lubricating oils used in normal engine
usually referred to as Supplement 1 oils. This cat operation.
egory describes oils which met the requirements
of the military specification MlL-L-2104A where Viscosity Recommendations
the diesel engine test was run using fuel with a The viscosity of an oil is a measure of its resist
high sulphur content. For moderate duty service. ance to flow. The Society of Automotive Engi
Oils in this performance category should not be neers has classified engine oils in viscosity
used in Cummins Engines. grades; Table 1 shows the viscosity range for
these grades. Oils that meet the low temperature
The Engine Manufacturers Association (EMA)
( - 18 °C [0°F]) requirement carry a grade designa
publishes a book entitled "Lubricating Oils Data
tion with a "W" suffix. Oils that meet both the low
Book". Copies may be purchased from the Engine
and high temperature requirements are referred to
Manufacturers Association, 111 E. Wacker Drive,
as multigrade or multi-viscosity grade oils.
Chicago, lL 60601. This book lists commercially
available oils by oil company and brand name Multigraded oils are generally produced by add
with the APl performance categories met by each ing viscosity index improver additives to retard
brand. the thinning effects a low viscosity base oil will
experience at engine operating temperatures.
Oil Performance Recommendations Multigraded oils that meet the requirements of
the APl classifications, are recommended for use
Cummins Engine Co., lnc. does not recommend
in Cummins engines.
the use of any specific brand of engine lubricating
oil. Cummins recommends the use of oil designed Cummins recommends the use of multigraded
to meet the following APl categories: lubricating oil with the viscosity grades shown in
Table 2. Table 2 shows Cummins viscosity grade
CC for use in naturally aspirated engines.
recommendations at various ambient tempera
CC/CD for use in turbocharged engines. tures. The only viscosity grades recommended
CC/SC for use only in engines that operate in a are those shown in this table.
light-duty service including standby and emer Cummins has found that the use of multigraded
gency operation. lubricating oil improves oil consumption control,
Dual Categories are used where more protection improves engine cranking in cold conditions while
is required than is provided by a single category. maintaining lubrication at high operating temper
CC/CD and CC/SC categories indicate that the oil atures and may contribute to improved fuel con
is blended to meet the performance level required sumption. Cummins does not recommend single
by each single category. grade lubricating oils. ln the event that the recom
mended multigrade oil is not available, single
A sulfated ash limit has been placed on grade oils may be substituted.
lubricating oil for use in Cummins engines. Past
experience has shown that oils with a high ash Caution: When single grade oil is used be sure
content may produce deposits on valves that can that the oil will be operating within the tempera
progress to guttering and valve burning. A maxi ture ranges shown in Table 3.
mum sulfated ash content of 1.85 mass % is rec The primary criterion for selecting an oil viscosity
ommended for all oil used in Cummins engines grade is the lowest temperature the oil will experi
except engines fueled with natural gas. For natu ence while in the engine oil sump. Bearing prdblems
ral gas engines a sulfated ash range of 0.03 to 0.85 can be caused by the lack of lubrication during the
mass % is recommended. Cummins Engine Co., cranking and start up of a cold engine when the oil
lnc., does not recommend the use of ashless oils being used is too viscous to flow properly. Change
for natural gas engines. When the ash content is to a lower viscosity grade of oil as the tempera
below .15 mass %, the ash should represent or- ture of the oil in the engine oil sump reaches the
gano-metallic anti-wear additives. lower end of the ranges shown in Table 2.
-20
Table 1: SAE Viscosity Numbers for Lubricating Oils

Viscosity Range
SAE millipascal-second, mPa»s millimetre'/second, rnm'ls
Viscosity (centipoise, cP) @ - 18°C (0°F) (centistoke, cSt) a2> 100°C (212°F)
Grade maximum minimum maximum
5W 1250 3.8
10W 2500 4.1
15W 5000 5.6
20W 10000 5.6 —
20 _ 5.6 less than 9.3
30 — 9.3 less than 12.5
40 — 12.5 less than 16.3
50 — 16.3 less than 21.9
1. SAE Recommended Practice J300d
2. 1 mPa»s = 1 cP
3. 1 mm'/s = 1 cSt
Table 2: Cummins Recommendations for Synthetic Lubricating Oil

Viscosity Grade vs. Ambient Temperature Synthetic oils for use in diesel engines are
SAE Viscosity Ambient primarily blended from synthesized hydrocarbons
Grade* Temperature** and esters. These base oils are manufactured by
Recommended chemically reacting lower molecular weight ma
10W-30 -250Cto 350C[-130Fto 950F] terials to produce a lubricant that has planned
15W-40 predictable properties.
or - 10 "C & above [14 "F & above]
20W-40 Synthetic oil was developed for use in an extreme
'SAE-5W mineral oils should not be used environment where the ambient temperature may
**For temperature consistently below -25"C be as low as - 45 °C [ - 50 °F] and extremely high
engine temperatures at up to 205 °C [400 °F].
[-13"F] See Table 4.
Under these extreme conditions petroleum base
stock lubricants (mineral oil) do not perform
Exception to Table 2
satisfactorily.
For standby and emergency engine applications
Cummins Engine Co., lnc. recommends synthetic
such as electric generators and fire pumps where
lubricating oil for use in Cummins engines operat
the engine is located in a heated room or enclos
ing in areas where the ambient temperature is
ure use an SAE 10W-30 oil. For unheated standby
consistently lower than - 25 °C [ - 13 °F]. Synthet
and emergency applications, consult yourCummins
ic lubricating oils may be used at higher ambient
service representative for advice.
temperatures provided they meet the appropriate
APl Service categories and viscosity grades.
Cummins Engine Co., lnc. recommends the same
Table 3: Alternate Oil Grades oil change interval be followed for synthetic
10W -25*Cto 0"C [-13"F to32*F] lubricating oil as that for petroleum based
20W - 5*Cto20°C[-23°Fto68,F] lubricating oil.
20W-20* - 5°C to 20*C [- 23*F to 68°F]
20 - 5,Cto20,C[- 2J°Fto68*F] Arctic Operations
30 4 "C and above [39 °F and above]
40 10 *C and above [50 *F and above] For engine operation in areas where the ambient
'20W-20 is not considered a multigrade even though it temperature is consistently below - 25 °C [ - 13 *F]
meets two grades. and where there is no provision to keep the engine
18-21
warm when it is not operating, the lubricating oil

should meet the requirements in the following TEST TEST PROCEDURE
table. Oil meeting these requirements usually
have synthetic base stocks. SAE 5W viscosity Worked ASTM D 217
grade synthetic oils may be used provided they 250-300
meet the minimum viscosity requirement at 100 °C Bomb Test, PSI Drop ASTM D 94£
[212°F]. 100 Hours 10 max.
500 Hours 25 max.
*FTM 5309
Table 4: Arctic Oil Recommendations Pass
Dirt Count, Particles/cc *FTM 3005
(Test Method) Specifications 25 Micron + 5,000 max.
Performance APl Classification CC/SC 75 Micron + 1,000 max.
Quality Level APl Classification CC/CD 125 Micron + None
Viscosity 10,000 mPa»s Max. at *FTM 3603
-35"C (31 °F] 10 max.
4.1 mmVs Min. at 'Federal Test Method Standard No. 791a.
100 °C [212°F]
Pour Point Min. of 5*C [9°F] Below the Caution: Do not mix brands of grease. This can
(ASTM D-97) Lowest Expected Ambient
Temperature cause damage to the bearings. Excessive lubrica
Sulfated Ash Content 1.85% by Weight Maximum tion Is as harmful as Inadequate lubrication. After
(ASTM D-874) lubricating the fan hub, replace the pipe plugs.
Use of fittings will allow lubricant to be thrown
out, due to rotative speed.
Grease
Cummins Engine Company, lnc., recommends Fuel Oil
use of grease meeting the specifications of MlL-
Recommended Fuel Specification
G-3545, excluding those of sodium or soda soap
thickeners. Contact lubricant supplier for grease Cummins recommends that fuel meeting the
meeting these specifications. Grade No. 2-D requirements of the American Soci
ety for Testing and Materials (ASTM) D-975, Stand
TEST TEST PROCEDURE ard Specifications for Diesel Fuel Oils be used.
High-Temperature Performance Cummins Diesel Engines have been developed to
Dropping point, °F ASTM D 2265 take advantage of the high energy content and
350 min. generally lower cost of No. 2-D diesel fuels. Exper
Bearing life, hours at 300 °F *FTM 331 ience has shown that a Cummins Diesel Engine
10,000 rpm 600 min. will also operate satisfactorily on fuels within the
Low Temperature specification in Table 5.
Torque, GCM ASTM D 1478
Start at 0°F 15,000 max. Fuel Additives
Run at 0"F 5,000 max.
In extreme situations, when available fuels are of
Rust Protection and Water Resistance poor quality or problems exist which are peculiar to
Rust Test ASTM D 1743 certain operations, additives can be used; however,
Pass Cummins recommends consultation with the fuel
Water resistance, % ASTM D 1264 supplier or Cummins Service Engineering Depart
20 max.
ment prior to the use of fuel additives.
Stability
Oil separation, % *FTM 321
30 Hours @ 212 "F 5 max.
-22
Table 5: Recommended Fuel Properties

Recommended
Property Specifications General Description
Viscosity 1.3 to 5.8 centistokes The injection system works most effectively when the fuel
(ASTM D-445) [1.3 to 5.8 mm per has the proper "body" or viscosity. Fuels that meet the
second] at 104 °F [40 °C] requirements of ASTM 1-D or 2-0 diesel fuels are satisfac
tory with Cummins fuel systems.
Cetane Number 40 Minimum. ln cold Cetane number is a measure of the starting and warm-up
(ASTM D-613) weather or in service with characteristrics of a fuel.
prolonged low loads, a
higher cetane number is
desirable.
Sulfur Content Not to exceed 1.0 mass Diesel fuels contain varying amounts of various sulfur
(ASTM D-129or 1552) percent compounds. A practical method of neutralizing high sulfur
fuels is to use lubricating oils which meet the APl CD
classification.
Active Sulfur Copper Strip Corrosion Some sulfur compounds in fuel are actively corrosive.
(ASTM D-130) not to exceed No. 2 rating Fuels with a corrosion rating of three or higher after three
after three hours at hours at 122°F [50 °C] can cause corrosion problems.
122oF[50°C].
Water, and Sediment Not to exceed 0.1 volume The amount of water and solid debris in the fuel is gener
(ASTM D-1796) percent ally classified as water and sediment. It is good practice to
filter fuel while it is being put into the fuel tank. More water
vapor condenses in partially filled tanks due to tank
breathing caused by temperature changes. Filter ele
ments, fuel screens in the fuel pump and fuel inlet connec
tions on injectors must be cleaned or replaced whenever
they become dirty. These screens and filters, in performing
their intended function, will become clogged when using a
poor or dirty fuel and will need to be changed more often.
Carbon Residue Not to exceed 0.25 mass The tendency of a diesel fuel to form carbon deposits in
(Ramsbottom, ASTM D- percent on 10 volume an engine can be estimated by determining the Ramsbot
524 or Conradson, ASTM percent residuum. tom or Conradson carbon residue of the fuel after 90 per
D-189 cent of the fuel has been evaporated.
Flash Point At least 125°F[52°C] or The flash point is the fuel temperature when enough vola
(ASTM D-93) legal temperature if tile material evaporates so that a combustible mixture of
higher than 125°F [52 °C]. fuel and air is formed above the fuel.
density 42° to 30° APl gravity at Gravity is an indication of the high density energy content
KASTM D-287) 60 "F [0.816 to 0.876 g/cc of the fuel. A fuel with a high density (low APl gravity) con
at 15*C]. tains more BTU's per gallon than a fuel with a low density
(higher APl gravity).
Cloud Point 10"F [6"C] below lowest The cloud point of the fuel is the temperature at which
(ASTM D-97) ambient temperature at crystals of paraffin was first appear. Crystals can be
which the fuel is detected by a cloudiness of the fuel. These crystals will
expected to operate. cause filters to plug.
Ash Not to exceed 0.02 mass The small amount of non-combustible metallic material
(ASTM D-482) percent. found in almost all petroleum products is commonly called
ash.
Distillation The distillation curve At least 90 percent of the fuel should evaporate at less
(ASTM D-86) should be smooth and than 680 "F [360 °C]. All of the fuel should evaporate at
continuous. less than 725 *FpeVci
18-23
Alternate Fuels coolant from the system via a filtering and

treating element which must be replaced
Note: Cummins Engine Company is not responsi
periodically.
ble and cannot warrant the emissions or perform
ance of their engines when using other than the 1. ln summer, with no antifreeze, fill the system
recommended fuels shown in Table 1. with water.
During periods when the supply of No. 2-D diesel 2. In winter select an antifreeze, except those
fuel is limited, alternate fuels, whose properties with anti-leak compounds. Mix the antifreeze
are within those defined in Table 6 can be used. with water as required by temperature.
3. Install or replace DCA Water Filter Element as
The following fuel specifications generally define
follows and as recommended in Cummins
alternate fuels within the prescribed limits:
Engine Operation and Maintenance Manuals.
Caution: Although anti-leak antifreezes are
Table 6: Alternate Fuels chemically compatible with the DCA water treat
ment, the anti-leak compound can clog the coolant
1. ASTM D-975 (grades No. 1-D and No. 3-D filters. Therefore "anti-leak" antifreeze can not be
diesel fuel). used in Cummins Engines.
2. -ASTM D-396 (grades No. 2 fuel oil) — heating Engines Equipped with DCA Water Filters
oil.
1. New engines shipped from the factory are
3. ASTM D-1655 (grades Jet A and Jet A-1 avia equipped with water filters containing a "DCA
tion turbine fuel) — commercial jet fuel. precharge" element. See Table 7. This ele
4. ASTM D-2880 (grades No. 1 GT and No. 2 GT ment is compatible with plain water or all
non-aviation gas turbine fuel). permanent-type antifreeze except anti-leak
antifreeze.
5. ASTM D-3699 (grades No. 1-K and No. 2-K) —
Note: The corrosion resistor cartridge part
kerosine.
numbers listed in Table 7 are recommended for
6. VV-F-800 (grades DFA, DF-1 and DF-2) — service replacement use on engines using the
military diesel fuel. Chart Method to determine the "B" Maintenance
Check. Refer to the Opeation and Maintenance
7. VV-F-815 (grades FS-1 and FS-2) — military
Manual(s) for details on using the Chart Method
heating oil.
for extending the "B" Maintenance Checks. Refer
8. MlL-F-16884 (grade DFM) — military marine to Table 8 for liquid DCA part numbers and to the
diesel fuel. Parts Status Table or a listing of old and new part
numbers.
9. MlL-T-5626 (grade JP-5) — military jet fuel.
ln order to obtain the number of DCA units re
10.. MIL-J-25656 (grade JP-6) — military jet fuel. quired to precharge the cooling system multiply
11. MIL-T-83133 (grade JP-8) — military jet fuel. the number of U.S. gallons by 1.0, the number of
Imperial gallons by 1.2 (one unit of DCA will treat
12. VV-K-211 (kerosine) — military kerosine. one gallon of coolant). Use a corrosion resistor
cartridge (S) from Table 7 (which contains that
Coolant chemical charge) or use the regular service car
Water must be clean and free of any corrosive tridge and add enough DCA liquid to reach the re
chemicals such as chloride, sulphates and acids. quired protective level. See Table 8.
lt must be kept slightly alkaline with a pH value in 2. At the first "B" Check (oil change period) the
the range of 8.0 to 9.5. Any water which is suitable DCA pre-charge element must be changed to
for drinking can be treated as described in the the DCA Service Element.
following paragraphs for use in an engine.
3. Replace the DCA Service Element at each suc
Maintain the Fleetguard DCA Water Filter on the ceeding "B" Check except under the follow
engine. The filter by-passes a small amount of ing conditions.
18-24
Table 7: Corrosion Resistor Cartridges for Extended Maintenance Intervals — Miles [Kilometers]
Cooling System Capacity Corrosion Corrosion Corrosion
Resistor Resistor Resistor
Part No's. Part No's. Part No's.
U.S. Imperial 10,000 - 14,000 DCA 15,000 - 19,000 DCA 20,000 - 25,000 DCA
Gallons Gallons Liters [16,000 - 22,500] Units [24,000 - 30,500] Units [32,000 - 40,225] Units
0-10 0-8 0-38 3305366 2 3305366 2 3305367 4
(WF-2050) (WF-2050) (WF-2051)
11 -20 9- 17 42-76 3305367 4 3305367 4 3305368 6

(WF-2051) (WF-2051) (WF-2052)
21 -30 17-25 79- 114 3305367 4 3305368 6 3305369 8
(WF-2051) (WF-2052) (WF-2053)
31 -50 26-42 117-189 3305369 8 3305370 15 3305371 23

(WF-2053) (WF-2054) (WF-2055)
or or or
(2) 3305367 4 each (2) 3305368 6 each (2) 3305370 15 each
(WF-2051) (WF-2052) (WF-2054)
51 - 100 42 - 83 193 - 379 3305370 IS 3305371 23 3305371 23
(WF-2054) (WF-2055) (WF-2055)
or or or
(2) 3305368 6 each (2) 3305370 15 each (2) 3305370 15 each
(WF-2052) (WF-2054) (WF-2054)
or or or
(4) 3305367 4 each (4) 3305368 6 each (4) 3305368 6 each
(WF-2051) (WF-2052) (WF-2052)
101 - 150 84 - 125 382 - 568 3305371 23 (2) 3305371 23 each (2) 3305371 23 each
(WF-2055) (WF-2055) (WF-2055)
or or or
(2) 3305370 15 each (4) 3305370 15 each (4) 3305370 15 each
(WF-2054) (WF-2054) (WF-2054)
or
(4) 3305369 8 each
(WF-2053)
a. If make-up coolant must be added be Table 8: Liquid DCA Products

tween element changes, use coolant from Part No. DCA Units Part Name
a pretreated supply, as stated in "Make-up
Coolant Specifications", in Group 2 of 3305372 4 Liquid DCA
(DCA-30L) (1 pint)
Operation and Maintenance Manual.
b. Each time the system is drained, go back 3305373 16 Liquid DCA
(DCA-35L) (1/2 gallon)
to the pre-charge element.
To make sure of adequate protection, have the 3305374 32 Liquid DCA
(DCA-40L) (1 gallon)
coolant checked at each third element change
or more often. 3305375 160 Liquid DCA
3305377 1760 Liquid DCA

18-25/(18-26 Blank)
(
Vehicle Braking
This group describes different types of engine

GrOUP 20 brakes. These include compression brakes and
exhaust brakes with air intake suppressors. The
operation and installation of the Jacobs Engine
Brake is also described.
Vehicle Braking
The Compression Brake exhaust system and energy is not returned to the
(Jacobs Engine Brake) engine through the power stroke.
The Method of Operation of the The following describes the process of opening
Compression Brake the exhaust valves to release the compressed air
from the cylinder. Refer to the diagram shown in
When the compression brake is energized, it
Fig. 20-1 to help you to understand the process.
causes the engine to perform like a power absorb
ing air compressor. The brake opens the exhaust 1. When you energize the solenoid vaive, engine
valves before the compression stroke is complete lubricating oil flows under pressure through
and combustion does not occur in the cylinder. the control valve. Then, the oil fiows to both
The compressed air is released into the engine the master piston and the slave piston.
Fig. 20-1. Schematic Diagram Of The Compression Brake (Jacobs Engine Brake).
20-1
NT/NTA 855 C.I.D. Engim Shop Manual
2. The oil pressure causes the master piston to

move down against the adjusting screw of the
injector rocker lever.
3. The push rod moves the adjusting screw end
of the rocker lever up during the injection
cycle. This causes the adjusting screw to
push against the master piston. The move
ment of the master piston causes high oil
pressure in the oil passage from the master
piston to the slave piston. The ball check valve
in the control valve holds the high pressure in
the oil flow from the master piston to the slave
piston.
4. The high pressure in the oil flow causes the
slave piston to move down against the cross- Fig. 20-2. Remove The Setscrew From The Rocker Lever Housing.
head and opens the exhaust valves. The ex
haust valves open as the piston moves to near 9. lnstall the Jacobs Brake adjusting screws into
the end of the compression stroke. The com the injector rocker levers.
pression braking cycle is completed as the
compressed air is released from the cylinder. 10. lnstall the rocker lever housings. Follow steps
1,2and3on page 14-31 to install the housings.
To Install the Compression Brake 11. lnstall the Jacobs Brake steel washers into
(Jacobs Engine Brake) the mounting holes of the rocker lever hous
1. Remove the rocker lever housings if they had ings, Fig. 20-3.
been previously installed. Caution: Do not use the Jacobs Brake washers If
2. Remove the adjusting screw and locknut from the engine has cast iron rocker lever housings.
the exhaust valve crossheads. Remove the ex 12. Install the Jacobs Brake studs to fasten the
haust valve crossheads. rocker lever housings onto the engine. Make
3. lnstall the adjusting screws and locknuts into sure that you install the correct length studs
the Jacobs Brake crossheads. into the correct location on the engine. If the
engine is equipped with a fan bracket, install
4. lnstall the Jacobs Brake crossheads onto the
exhaust crosshead guides. The adjusting
screw end of the crosshead must be toward
the water manifold of the engine.
5. Adjust the crossheads. Follow the instruc
tions on page 14-30 to adjust the crossheads.
6. Remove the rocker lever shaft setscrew from
the rocker lever housings, Fig. 20-2.
7. lnstall the Jacobs Brake oil supply screw into
the rocker lever housings. Tighten the screw
so that the top of the screw is even with the
boss in the housing.
8. Remove the adjusting screw and locknut from
the injector rocker levers. Remove the locknut
from the adjusting screw. lnstall the locknuts
onto the Jacobs Brake adjusting screws. Fig. 20-3. lnstall The Jacobs Brake Steel Washers.
20-2
Vehicle Braking
the longest studs into the rocker lever housing

nearest to the front of the engine. See Fig.
20-4 to find the correct location for the studs.
13. Tighten the studs to 65 to 75 ft.-lbs. [88 to 102
N»m] torque. Tighten the studs in the se
quence shown in Fig. 20-6.
14. Adjust the valves and injectors. Follow the in
structions that begin on page 14-32 to adjust
the valves and injectors.
15. lnstall the rubber seal into the hole in the bot
A Stud - 8* in. C Stud - 7 in. tom of the Jacobs Brake unit. The hole is
B Stud - 8% in. D Spacer located approximately in the center of the
side that installs against the rocker lever
housing, Fig. 20-7. Apply a light coat of clean
Fig. 20-4. Locations For The Stud And Spacer In The Rocker grease or lubripiate onto the rubber seal to
Lever Housings.
hold the seal into the hole.
Fig. 20-7. Install The Rubber Seal Into The Jacobs Brake Unit.
16. lnstall the Jacobs Brake gaskets onto the

rocker lever housings. The surfaces of the
rocker lever housings must be clean and
smooth when you install the gaskets.
17. lnstall the Jacobs Brake units onto the rocker
lever housings. lnstall the spacers and nuts
onto the studs. See Fig. 20-4 to find the cor
rect locations for the spacers.
18. Tighten the nuts to 55 to 60 ft.-lbs. [75 to 81
N»m] torque. Tighten the nuts in the sequence
shown in Fig. 20-6.
To Adjust the Slave Piston

Fig. 20-6 (N11463). The Tightening Sequence For The Jacobs
Brake Studs ln The Rocker Lever Housings. The slave piston adjustment must be made with
20-3
the engine stopped and cold. Use the same pro

cedure to adjust the slave piston that you used to
adjust the valves. When the engine rotation is in
the correct position to adjust the exhaust valve
clearance it is also in the correct position to ad
just the slave piston clearance. The exhaust valves
for the cylinder to be adjusted must be in the closed
position.
engine rotation. Align the "A" or "1-6VS" mark
on the accessory drive pulley with the pointer
on the gear cover.
2. When the "A" or "1-6VS" mark is aligned, the
intake and exhaust valves must be closed for
cylinder number 5. The injector plunger for Fig. 20-8. Adjust The Slave Piston In The Models 25C And 44.
cylinder number 3 must be at the top of its
travel. lf the plunger is not at the top of its
travel, rotate the crankshaft one complete rev
olution. Then, align the valve set mark.
Note: The instructions using the "A" or "1-6VS"
mark to begin the adjustments are for illustration
purposes. You can begin the adjustments with
any of the cylinders as shown in Table 1.
Table 1: Injector and Valve Set Position

Bar ln Pulley Set Cylinder
Direction Position Injector Valve
Start A or 1-6VS 3 5
Adv. To B or 2-5VS 6 3
Adv. To C or 3-4VS 2 6
Adv. To A or 1-6VS 4 2
Adv. To B or 2-5VS 1 4 Fig. 20-9. Adjust The Slave Piston In The Models 44A And 44B.
Adv. To C or MVS 5 1
piston touches the feeler gauge. The feeler
Note: Use an alien wrench to adjust the slave gauge must have only a light amount of fric
piston in the Jacobs Brake Model 25C and Model tion between the slave piston and the cross-
44, Fig. 20-8. Use a screwdriver to adjust the slave head. Hold the adjusting screw in position
piston in the Jacobs Brake Model 44A and Model and tighten the locknut to 15 to 18 ft.-lbs. [20.3
44B, Fig. 20-9. Use the same adjustment proced to 24.4 N»m] torque.
ure and clearance for the Models 25C, 44, 44A and 5. Use the same procedure to adjust the remain
44B. der of the slave pistons.
3. Loosen the locknut for the adjusting screw. 6. lnstall the electrical wiring onto the svlenoid
Loosen the adjusting screw until the piston is in the Jacobs Brake units, Fig. 20-10. Connect
against the bottom of the bore in the engine the other end of the wiring to the inside ter
brake housing. minal of the leadout assembly in the brake
housing.
4. Put a 0.018 inch [0.46 mm] feeler gauge be
tween the slave piston and the crosshead. Note: Some applications use a 2-wire dual lead
Tighten the adjusting screw until the slave solenoid valve. Either solenoid electrical wiring
4
Vehicle Braking
Caution: When the engine is running and the

rocker housing covers are removed, be sure to
wear eye and face protection.
8. Install new rocker housing cover gaskets onto
the Jacobs Brake units. Make sure that the
surfaces for the gaskets are clean and free
from any damage.
9. lnstall the rocker housing covers. Follow the
instructons given on page 14-36 to tighten the
capscrews.
Install the Clutch Switch

1. lnstall the clutch switch inside the vehicle
cab. Use a location in the cab so that the ac
Fig. 20-10. Install The Electrical Wiring To The Solenoid Valve. tuating arm of the switchjs against the clutch
pedal arm, Fig. 20-12.
can be connected to the vehicle electrical system
and the other wire to the ground system.
7. Remove the air from the oil passages in the
brake units.
a. Start the engine. Run the engine at idle
RPM for 4 to 5 minutes.
b. lncrease the engine RPM to approximately
1800 RPM.
c. Decrease the engine RPM to the normal
idle RPM. Push down on the solenoid 5 or
6 times to let the engine oil fill the
passages in the brake units. Use your
hand to push down on the solenoid, Fig.
20-11.
d. Stop the engine.
Fig. 20-12. The Clutch Switch Arm Against The Clutch Pedal Arm.
2. Adjust the clutch switch. The switch must be

adjusted so that when the clutch pedal is
pushed down (clutch disengaged) the switch
will be in the open position. When the switch
is in the open position it stops the electrical
current to the solenoid in the brake unit.
a. Put the actuating arm of the switch
against the clutch pedal arm so that the
free movement of the clutch pedal causes
the switch to open. You can loosen the
outer nut that holds the actuating arm to
the switch so that you can move the arm to
the correct position. lf necessary, you can
bend the arm so that it is in the correct
Fig. 20-11. Push On The Solenoid To Fill The Oil Passages. position. Tighten the outer nut.
20-5
Install the Fuel Pump Switch

1. Install the fuel pump switch onto the fuel
pump as shown in Fig. 20-13. Use two of the
fuel pump housing capscrews to fasten the
switch onto the fuel pump.
2. lnstall the actuating arm for the switch onto
the fuel pump throttle shaft. Adjust the ac
tuating arm so that it causes the switch to be
in the closed position when the throttle shaft
is at the idle position. The switch must be in
the open position when the throttle shaft is
not at idle. When the switch is in the open
position it stops the electrical current to the
solenoid in the brake unit. Tighten or loosen
the adjusting screw to adjust the arm to the
Fig. 20-14. Remove The Control Valve Cover Plate.
correct position.
Fig. 20-15. Remove The Control Valve Springs.

Fig. 20-13. The Fuel Pump Switch Installed Onto The Fuel Pump.
Caution: Make sure that the fuel pump throttle

shaft moves freely from full throttle position to
idle position after you have Installed the switch.
Maintenance of the Engine Brake

The Control Valve
Disassembly
1. Remove the capscrew that fastens the cover
plate to the housing, Fig. 20-14.
Warning: Remove the capscrew carefully. The
cover plate holds the control valve springs In a
compressed position.
2. Remove the control valve springs, Fig. 20-15. Fig. 20-16. Remove The Control Valve.
Vehicle Braking
Note: The Jacobs Engine Brake Model Numbers Replacement

20, 25, 25A and 25B uses one spring for the control
1. Remove the O-ring seals from the solenoid
valve.
valve.
3. Rimove the control valve. Use needle nose 2. Apply a coat of oil onto the new O-ring seals.
pliers to pull the control valve straight up and
out of the bore, Fig. 20-16. 3. lnstall the new O-ring seals onto the solenoid
valve, Fig. 20-18. Make sure that the O-rings
Inspection, Cleaning and Replacement are correctly installed onto the solenoid valve.
1. Check the springs for wear and damage.

2. Replace the springs if they are worn or damaged.
3. Check the control valve. The control valve
must move freely in the bore. If it does not
move freely, clean the valve and check it for
damage. Replace the valve if it is damaged.
Assembly
1. lnstall the control valve into the bore.
2. lnstall the springs into the bore.
3. Install the cover plate.
The Solenoid Valve

Fig. 20-18. Install The O-Ring Seals Onto The Solenoid Valve.
Disassembly
1. Remove the electrical wiring from the Assembly
solenoid valve. 1. lnstall the solenoid valve into the bore in the
2. Remove the solenoid valve. Use the solenoid housing. Make sure that the O-rings do not
wrench to loosen the solenoid valve, Fig. move from their position on the solenoid
20-17. valve.
2. Use the solenoid wrench to tighten the sole
noid valve.
3. Install the electrical wiring onto the solenoid
valve.
The Master Piston

Disassembly
1. Remove the capscrew and flat spring, Fig.
20-19. Take notice of the position of the flat
spring before you remove it. The spring must
be installed in the same position as when it
was removed.
Note: Some models use a capscrew and washer
to fasten the flat spring onto the housing. Some
models use a spring retainer. The spring retainer
Fig. 20-17. Use The Solenoid Wrench To Loosen The Solenoid must be installed in the same position as when it
was removed.
20-7
remove the tension against the snap ring. Use

an arbor press to push against the spring
retainer. Remove the snap ring, Fig. 20-20.
Slowly raise the arbor press until all of the ten
sion is released from the slave piston spring.
Fig. 20-19. Remove The Capscrew And Flat Spring.
2. Remove the master piston from the bore.
Inspection and Replacement

1. Check the master piston for freedom of move
ment in the bore. lf the piston does not move Fig. 20-20. Remove The Snap Ring From The Slave Piston.
freely, check for dirt or damage to the piston.
Replace the piston if it is damaged. 4. Remove the spring retainer, spring and slave
piston. Take notice of the position of the
Assembly spring retainer. lt must be installed in the
same position as when removed.
1. Install the master piston into the bore.
2. lnstall the flat spring, retainer or washer and Inspection and Replacement
capscrew. Make sure that the tabs of the spring
1. Check the spring and spring retainer. Replace
do not touch the sides of the raised center
the parts if they are worn or damaged.
part of the piston.
2. Check the slave piston for freedom of move
Caution: Do not try to adjust the master piston. ment in the bore. If the piston does not move
The master piston has been adjusted at the fac freely, check for dirt or damage. Replace the
tory. Any changes made to the master piston can piston if it is damaged.
cause damage to the engine.
Assembly
The Slave Piston
1. lnstall the slave piston into the bore.
Disassembly
2. Install the spring and spring retainer.
Warning: The slave piston spring is under heavy
compression. You must be very careful when you 3. Use an arbor press to push down on the re
remove the spring. Follow the instructions and tainer and spring so that you can install the
use the correct tools. Wear safety glasses. snap ring. lnstall the snap ring. 9
4. Turn the brake unit over so that the side of the
1. Loosen the adjusting screw locknut.
unit that install against the rocker lever hous
2. Turn the engine brake unit over so that the ing is down. lnstall the adjusting screw and
side of the unit that installs against the rocker locknut.
lever housing is up. Caution: The adjusting screws for the Jacobs
3. Push down against the spring retainer to Brake Models 44A and 446 contain an automatic
20-8
Vehicle Braking
lash adjuster. Do not make any changes to these h. Refer to the manufacturer's instructions
adjusting screws. Any changes can cause damage for the installation, operation, adjustment
to the engine. and maintenance of the exhaust brake.
4. Before you install any new exhaust brake,
The Exhaust Brake
write or call the Cummins Application Engi
1. When an exhaust brake is installed, the neering Department for more details.
engine can be used to reduce the speed of the
vehicle and prevent wear on the mechanical The Air Intake Suppressor
brake system. The exhaust brake operates by
When the engine is equipped with an exhaust
controlling the flow of the exhaust gas from
brake, pulsations can occur in the air intake
the exhaust manifold. On turbocharged en
system. This is caused by the combination of
gines, the exhaust flow is controlled after the
cylinder pressures and the intake valves opening
exhaust flows through the turbocharger. This
during the braking period. The pulsations can
action applies more pressure against the
damage the element and cause the dirt to move
engine piston, which reduces the rotation of
through the element and enter the engine.
the crankshaft and slows the vehicle.
The air intake suppressor can help to prevent this
2. The exhaust brake can generate carbon
problem.
deposits in applications where braking is re
quired for extended periods of time. Hydraulic The air intake suppressor must be installed into
or electric retarders can be used for these the air intake system, between the engine and the
applications. air cleaner. lnstall the suppressor as close to the
engine as possible. Use the following to help you
3. The following conditions are acceptable for
to determine the need for a suppressor.
the use of exhaust brakes:
1. Air intake suppressors are required for
a. The maximum pressure in the exhaust sys
naturally aspirated engines that use a dry ele
tem must never exceed 45 psi [310 kPa].
ment air cleaner.
b. Heavy duty valve springs, Part No. 178869,
2. Check the design of the air cleaner to find if
and valve guides, Part No. 170296, must be
an air intake suppressor is necessary.
installed into the cylinder heads.
3. Oil bath air cleaners must have a seal be
c. The damper plate for the exhaust brake
tween the oil sump and the air cleaner body.
must be fully open when the engine is ac
celerating or pulling a full load. Note: Use the Part No. 147706 air intake sup
pressor with 4.0 inch [101.6 mm] diameter air in
d. When the engine is at idle speed and the
take tubing. Use the Part No. 147707 air intake
exhaust brake is in the closed position. The
suppressor with 5.5 inch [139.7 mm] diameter air
damper plate must be adjusted to permit a
intake tubing.
small amount of exhaust flow through the
plate.
e. For naturally aspirated engines, install an
air intake suppressor into the air intake
system to prevent dirt from going through
the air cleaner and into the engine. The air
cleaner can be used without a relief valve
when the engine has an exhaust brake.
f. The air intake suppressor can be used for
turbocharged engines.
g. The Cummins warranty does not include
■damage caused by the installation and
use of the exhaust brake.
20-9/(20-10 Blank1
«
NTA 855L4 DIESEL ENGINE CUMMINS
SECTION II. MAINTENANCE ALLOCATION CHART
Appendix
(2) (3) (4) (5) (6)

(1)
Maintenance Maintenance Level
Group Tools and
Component/Assembly Remarks
Number function ^ equipment
: 0 F H D
01 Exhaust System
Manifold, Exhaust Inspect 0.5

Replace 6.0
Repair 8.0
02 Cooling, System
Hoses & Clamps Inspect 0. 2

Replace >.0
Thermostat Engine Inspect D.5
Test D.5
Replace 2.0
Heater, External Inspect D.5

Engine Block Replace 1.0
Repair 6.0
Water Manifold Assy Inspect ).5

Replace 6.0
Repair 12. (
Pump, Water Inspect 0.2

Replace 4.0
Repair 8.0
Overhaul 10.0
03 Fuel System Inspect 0.2
Blower Assy Replace 10.0
Repair 12.0
Overhaul L6.0
Lines & Fittings Inspect 0.2

Replace 2.0
Repair 4.0
Filter, Fuel Inspect 0.1

Replace 0.3
Pump, Fuel Recipro Inspect 0.5

cating Test L.5
Replace 3.0
Pumps, Fuel Injectior Repair

LO.O
Overhaul 16. C
Appendix
(3) (4) (5) (6) {
(1) (2)
Maintenance Level Tools and
Group Maintenance Remarks
Component/Assembly function equipment
Number C 0 F H D
(
Injectors, Fuel Inspect 0.5
Test 1.0
Adjust 2.0
Replace 4.0
Repair 3.0
Engine Assembly Inspect 1.5

Test .0
Service 1.5 ■
Replace 40. C
Repair 24. (
Overhaul 30.0
Filter, Oil Inspect 0.2

Replace 0.5
Lube Oil Cooler Inspect 0.2

Replace 4.0
Repair i.O
Drive Mechanism Inspect 1.0

Fuel Pump Replace 3.0
Repair 16. I
Pump, Oil Inspect 2.0

Replace 5.0
Repair 10.1
Overhaul 12. ( 1
Compression Release Inspect l.Q

Mechanism Replace 1.0
Repair i.O
Governor Inspect 0.3

Test 2.0
Replace 2.0
Repair 10. (
Overhaul 16. (
Governor Drive Inspect 2.0

teplace 4.0
tepair 8.0 4
Manifold, Intake Inspect 0.5

teplace 4.0
tepair 6.0

Appendix
"(3) (4) (5) (6)

(1) (2)
Maintenance Level Tools and
Group Maintenance Remarks
Component/Assembly function equipment
Number H
After Cooler Inspect

Replace 8.0
Repair 12.
Fly Wheel & Damper Inspect 1.0

Repl ace 2.0
Rocker Arms Inspect 0.3

Replace 1.5
Repair 3.0
Cylinder Head Assy Inspect 0.5

Replace 4.0
Repair 10.
Overhaul 16.
Valves, Intake & Inspect 1.0

Exhaust Adjust 1.5
Replace 3.0
Repair 12.01
Springs, Valve Inspect 1.0

| Replace 12.0
Oil Pan Inspect 1.0

Replace 16.0
Repair P4.0
Pistons & Connecting Inspect

Rods Replace 2.0
Repair 0.0
Liners, Cylinder Inspect

Replace 2.0
Repair 20.
Camshaft & Bearings Inspect 4.0

Replace 16.
Crankshaft & nspect 2.5

Bearings eplace 40.
Repair 80
Engine Block Inspect 1 1-0

Test
Replace
Repair 24.
Overhaul
21-'
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS
REF. MAINT. NATIONAL/NATO TOOL

NOMENCLATURE STOCK NUMBER NUMBER
CODE CAT,
SECTION IV
MAINTENANCE ALLOCATlON CHART
REFERENCE
CODE REMARKS
SME Fern 1568-3 Praviaui ■<Ht»w iofi 1 May M I* aasalata.

1 M»* 73 21-5/(21-6
*
Index 1
Index
Accessory Drive Assembly Cam Follower (MVT)

Assembly 9-2 Assembly 4-11
Disassembly 9-2 Disassembly 4-7
lnspection 9-2 lnspection 4-9
lnstallation 14-17 lnstallation 14-13
Removal 0-11 Removal 0-13
Accessory Drive Pulley
Camshaft
lnstallation 14-20
Removal 0-10 lnspection 1-33
lnstallation 14-9
Adjust Injectors and Valves 14-32 Removal 0-16
Aftercooler Camshaft Gear

Assembly 10-1 lnstallation 1-33
Disassembly 10-1 Removal 1-33
lnstallation 14-36
Removal 0-7
Chassis Dynamometer Test 14-47
Repair 10-1
Air Compressor Checks During Run-in 14-48
lnstallation 14-21 Coolant Specifications 18-24

Removal 0-9
Repair ; 12-1
Compression Brake
Air Starting Motor Adjustment 20-3
Repair 12-1 Installation 20-2
Maintenance 20-6
Alternator
Connecting Rod
Installation 14-39
Installation 14-7
Alternator Drive Pulley Removal 0-16
lnstallation 14-40 Repair 1-30
Bearings (Main and Rods) 1-25 Crankcase Breather
Bearing Shell Inspection 1-25 Assembly 3-5

Cleaning 3-5
Belts Disassembly 3-5
Adjustment 14-32
Crankcase Pressure (Blow-By) 14-47
lnstallation 14-32
Cam Follower Crankshaft

Disassembly 4-2 Cleaning and lnspection 1-24
lnspection 4-3 Disassembly 1-24
Installation 14-12 lnstallation 14-3
Inde
2 NT/NTA-855 C.I.D. Engine Shop Manual
Engine Testing 14-44

Adjustment 14-30
lnspection 2-12 Engine Timing
lnstallation 14-30 Small Cam and Big Cam 14-14
Removal 0-11 MVT 14-16
Cylinder Block Exhaust Brake 20-9

Cleaning 0-3
Inspection 1-2 Exhaust Manifolds
Cleaning and lnspection 11-1
Cylinder Head
lnstallation 14-37
Assembly and Testing 2-16 Removal 0-7
Cleaning 2-3
Disassembly 2-2 Fan Bracket
lnspection 2-4
Repair 2-5
Fan Hubs
Cylinder Liners Assembly 8-19
Cleaning and Inspection 1-24 Disassembly 8-19
Installation 14-5 Installation 14-32
Removal 0-18 Inspection 8-19
Removal 0-9
Drain Water and Oil 0-2
Fill Hydraulic Governor 14-45
Drive (Fuel Pump/Compressor)
Assembly 9-2 Flywheel
Disassembly 9-2 lnstallation 14-27
Inspection 9-2 Removal 0-14
lnstallation 14-17 Repair 19-1
Removal 0-11
Flywheel Housing
Drive Pulley Inspection and Repair 9-4
Installation 14-25
Electrical Connections Removal 0-15
Installation 14-39
Removal 0-2 Foreword 2
Engine Dynamometer Fuel Crossover

Performance Data 14-46 Removal 0-12
Power Check 14-47
Test Procedures 14-47 Front Engine Support
Engine Run-in Test 14-47 lnstallation 14-23

Removal 0-14
Engine Serial Number 0-1
Fuel Filter
Engine Storage lnstallation 14-37
Long Term 14-49 Removal 0-4
Preparation 14-49
Temporary 14-49 Fuel OH Specifications 18-22
dex 2
lndex 3
Fuel Pi'mp Lubricating Oil Cooler (FFC and Big Cam)

Adjustment 5-1 Assembly 7-19
lnstallation 14-29 Disassembly 7-15
lnstallation 14-38
Fuel Pump Drive (Accessory Drive) Removal 0-5
Assembly 9-2
Disassembly 9-2 Lubricating Oil Cooler (NTE)
lnspection 9-2
Assembly 7-22
lnstallation 14-17
Disassembly 7-20
Removal 0-11
lnspection 7-21
Fuel System 5-1
Lubricating Oil Filter
Gear Backlash 14-10 Assembly 7-11
Disassembly 7-11
Gear Cover
lnspection 7-11
Assembly 1-34 Installation 14-39
lnspection 1-34 Removal 0-6
lnstallation 14-18
Removal 0-15 Lubricating Oil Filter (By-Pass Type)
Repair 1-34
Assembly 7-12
Generator/Alternator Disassembly 7-12
lnspection 7-12
lnstallation 14-39
Removal 0-2
Governors (Hydraulic) Assembly 7-4
Fill 14-45 Bushing Replacement 7-2
Disassembly 7-2
Hose Size 7-12 lnspection 7-2
Installation 14-18
In-Chassis Run-in 14-47 Removal 0-12
Injection Timing Lubricating Oil Specifications 18-19

Small Cam and Big Cam 14-14
MvT 14-16 Main Bearing Caps
Injector Adjustment lnstallation 14-3

Removal 0-17
Dial lndicator Method 14-32 Tightening 14-4
Torque Method 14-36
Mount Cylinder Block to Stand 14-3
Injectors
Calibration 6-1 Mount Engine to Stand 0-7
Installation 14-30
Removal 0-12 Mounting Adaptations 16-1
Injector Tip Protrusion 2-15
Oil Gauge Dipstick 7-14
Intake Manlfold/Aftercooler
Oil Gauge Tube and Bracket
Cleaning and lnspection 10-1
Index 3
4 NT/NTA-855 C.I.D. Engine Shop Manual
Oil Pan Starting Procedure 14-46

lnspection 7-14
lnstallation 14-28 Steam Clean Engine 0-2
Removal 0-15
Repair 7-14 Steam Cleaning 0-3
Paint Engine 14-48 Table of Contents 4

Piston Rings
Test Procedures 14-47
lnstallation 1-31 & 14-7
Thermostat and Housing
Pistons
Cleaning and lnspection 1-31 Disassembly 8-21
lnstallation 14-7 lnspection 8-21
Removal 0-16 Installation 14-30
Removal 0-11
Piston Cooling Nozzles
lnstallation 14-38 Thrust Washers 9-2
Removal 0-6
Timing the Engine 14-14 & 14-16
Prime Fuel System . 14-45
Torque Specifications (Capscrews) 18-18
Prime Lubricating System 14-45
Vacuum Pump 12-1
Push Rods
Cleaning 4-18 Valve
lnspection 4-18
lnstallation 14-12 Grinding 2-10
lnstallation 2-16
Rear Seal Removal 2-2
lnstallation 14-25 Testing 2-16
Removal °-16
Valve Adjustment 14-32 & 14-36
Remove Engine From Stand 14-37
Valve Crosshead
Rocker Housing
Assembly 3-4 Adjustment 14-30
Disassembly 3-2 Inspection 2-12
lnspection 3-2 lnstallation 14-30
lnstallation 14-31 Removal 0-11
Removal 0-11
Valve Crosshead Guides
Rocker Housing Cover
lnspection 2-11
Assembly 3-5 lnstallation 2-11
lnspection 3-5 Removal 2-11
lnstallation 14-36
Removal 0-11
Valve Guides
Starting Motor lnspection 2-8
installation 14-40 lnstallation 2-8
>moval 0-2 Removal 2-8
x 4
Index
Valve Seats and Inserts

Grinding 2-7
Inspection 2-6
lnstallation 2-7
Removal 2-5
Valve Springs
lnspection 2-11
lnstallation 2-11
Removal 2-11
Testing 2-11
Vibration Damper and Flange

Cleaning 1-26
Inspection. 1-26
Installation 14-21
Removal 0-14
Water Filter
lnstallation 14-41
Removal 0-4
Water Manifold
lnstallation 14-30
Removal 0-11 .
Water Pump
Assembly 8-4, 8-9 & 8-15
Disassembly 8-2, 8-6 & 8-12
lnspection 8-3, 8-8 & 8-14
Installation 14-23
Removal 0-9
Wear Limits and Specifications 18-1
Wiring Diagrams 13-1
Index 5/( Index 6 Blan

t
«
TM 5-2815-233-14
By Order of the Secretary of the Army:
JOHN A. WICKHAM, JR.

General, United States Army
Official: ChiefofStaff
R. L. DILWORTH
Brigadier General, United State* Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Operator, Organizational
Direct and General Support Maintenance Requirements for Locomotive, Diesel-Elec,
0-4-4-0 Wheel, 80-T, 420/550 HP, Models NHBIS 600 & 112-5708 (Domestic Service)
TM 55-2210-208 Series)
■ft vs. PRINTING OFFICE: - ZSI-4MAI2Z73

f
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
WITH THIS PUBLICATlON?

FROM (PRINT YOUR UNIT S COMPLETE ADDRESS)
THEN. . JOT DOWN THE
DOPE ABOUT IT ON THIS
FORM, CAREFULLY TEAR IT
OUT. FOLD IT AND DROP IT
IN THE MAIL' DATE SENT
PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE

TM 5-2815-233-14 25 Jul 86 ENGINE, DIESEL, NSN 2815-01-216-09
BE EXACT PIN-POINT WHERE IT IS IN THIS SPACE TELL WHAT IS WRONG
PAGE PARA FIGURE TABLE AND WHAT SHOULD BE DONE ABOUT IT:
NO GRAPH NO NO
PRINTED NAME. GRADE OR TITLE. AND TELEPHONE SIGN HERE
PREVIOUS EDITIONS P S --IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

DA ,SR. 2028-2 ARE OBSOLETE. RECOMMENDATION MAKE A CARBON COPY OF THIS
DRSTS.M Ov.rprlnt 2, | Nov SI AND GIVE IT TO YOUR HEADQUARTERS
1
<
The Metric System and Equivalents
Lioaar Meaaura Liquid Mm

1 centiliter = 10 milliters = .34 fI . ounce
1 centimeter = 10 millimeters = .39 inch 1 deciliter = 10 centiliters = 3.38 fl. ounces
1 decimeter = 10 centimeters = 3.94 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 meter = 10 decimeters = 39.37 inches 1 dekaliter = 10 liters = 2.64 gallons
1 dekameter = 10 meters = 32.8 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 hectometer =10 dek a meters = 328.08 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
1 kilometer = 10 hectometers = 3,280.8 feet
SquMrw Ml
Waifhtm
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 centigram = 10 milligrams = .15 grain 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 decigram = 10 centigrams = 1.54 grains 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 gram =10 decigram = .035 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 dekagram = 10 grams = .35 ounce 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
a
1 hectogram = 10 dekagrams = 3.52 ounces 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds Cubic Maaaun
1 metric ton = 10 quintals =1.1 short tons
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
To change To Multiplv by To change To Multiplv by

inches centimeters 2.540 ounce-inches newton-meters .007062
feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet newton-meters 1.356 metric tons short tons 1.102
pound-inches newton-meters .11296
Temperature (Exact)
°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature

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This is a reproduction of a library book that was digitized

by Google as part of an ongoing effort to preserve the

OPERATOR' S, UNIT, INTERMEDIATE government documents

(DS) AND INTERMEDIATE (GS)

I* CUMMINS MODEL NTA - 855 -L4

UNIVERSITY OF VIRGINIA LIBRARY

(Circle C) Copyright 1983

HEADQUARTERS. DEPARTMENT OF THE ARMY

TECHNICAL MANUAL HEADQUARTERS

OPERATOR'S UNIT, INTERMEDIATE

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

Operating Instructions Specifications and Torque

OPERATION AND MAINTENANCE

Industiral Fire Pump

This is an engine operation and maintenance manual,

Cummins Engine Company, lnc.

A|l^l^|j nt% The en9'ne operator must assume the responsibility

General— All Applications

New or Rebuilt Engines

Check Hydraulic Governor

Starting the Engine

Warning: Never handle starting fluid near an open Engine Maximum

Engine Series Minimum @ Idle Speed Rated Speed

NH/NT 8 [55] 40/70 [276/483]

Caution: Never leave the switch key or the override

Stop Engine Immediately If Any Parts Fail

Fig. 1-17,(OM1009L). Cooling system drain points—KT/KTA-1 150

practical and dependable warm-up of the engine

Industrial Fire Pump Engines

N-855 1460-2100 1750-2520 a. Remove the lockwire from on

c. Secure the and the locking

ment is made by loosening the 7/16 inch locking nut

mm •a Maintenance is the key to lower operating costs. A

Preventive maintenance is the easiest and least

A Good Maintenance Schedule Depends On

Using the Suggested Schedule Check Sheet

Storage for Engines Out of Service

Using The Suggested Schedule Check Sheet

J|V :ip*M0 — JJo t*vaL • • •

— yjouag BuffiJallC ys ujois • • • •

U|«M JOVMMMO ■v»HO - jtV elIui P« Iauno joI uofPMlMU • • •

A'tak Check: - FoiLaaki e e • e •

Fuel Oack: -F«L«k. • e e e e

Engine Check: - For Unu.ul Vibration e • e e e

Electrical — Battery Charging System

Switchgear — Power Distribution Wking

"A" Maintenance Checks— Daily

Make a Daily Report of Engine Operation to the

6. Excessive use of coolant, fuel or lubricating oil. Check Belts

Belt New Belt* Minimum • Used Beift Installation Tension

.380 ST-1274 140-150 60 100

Inline Engine Water Pump Beits

Note: Do not adjust to final tension at this time.

g. Check the belt tension. Inline Engine Water Pump Belts

Fig. 2-5. (OM1016I). Fan hub NTC-350 FFC

Check Oil Bath Cleaner Oil Level

"A" Maintenance Checks— Weekly

Repeat Daily Checks

Check Air Cleaner

Check Inlet Air Restriction

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