Cummins Serie k Calibracion de Valvulas

8/22/2019 Cummins Serie k Calibracion de Valvulas

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CUMMINS "K" SERIES 6-CYLINDERArticle Text

For cyph8r pacific la ca 921011996 Mitchell International, All Rights Reserved.

Tuesday, September 25, 2012 11:03PM

CLE BEGINNING

DIESEL ENGINESCummins K Series 6-Cylinder

ENGINE IDENTIFICATION

Engine model, serial number and Control Parts List (CPL)ber is listed on engine data plate. Engine data plate is mounted onside of cylinder block below cylinder head surface.

INE IDENTIFICATION CODE

ne Code

0" (18.7L) ........................... K

INTAKE & EXHAUST MANIFOLDS

EXHAUST MANIFOLD

Removal1) Remove retainer straps and cap screws from air crossover

. Remove air crossover tube. Cover inlet openings on turbochargeraftercooler. Remove and plug oil supply and drain line fromocharger. Remove turbocharger mounting nuts. Remove turbocharger.

2) Bend tabs on lock plate away from exhaust manifold capws (if used). Remove 4 cap screws. Install guide studs. Removeaining cap screws. Remove exhaust manifold.

Installation1) There are two types of gaskets being used, metal and

position. Each gasket requires different torque value on capws. Two types of locks are used, external lockplates with capws or self-locking flange cap screws with hardened washer. Installgaskets onto cylinder head. Sides marked "OUT" face away fromder head.2) Install the exhaust manifold onto the guide studs. Coat

cap screws with anti-seize. Install the cap screws and lock platesed). Remove the guide studs. Install remaining cap screws. Checkthe exhaust manifold sets flat against the cylinder heads. Capws must be tightened in sequence. See Fig. 1. Tighten cap screws.

r to TORQUE SPECIFICATIONS table. Bend lock plates down on capw (if used).

1: Exhaust Manifold Tightening Sequencertesy of Cummins Engine Co., Inc.


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3) Install new mounting gasket for turbocharger with raisedd toward turbocharger. Install turbocharger. Tighten cap screws.TORQUE SPECIFICATIONS table. Install new gasket and oil drainInstall oil drain and supply lines. See TORQUE SPECIFICATIONS

e. Center of oil drain line must be located within 35 vertical

ion when turbocharger is installed.4) Turbocharger bearing housing must be rotated if drain line

t correct. On through bolt type turbochargers, bend over lockes. Remove bearing housing-to-turbine housing cap screws. Rotateing housing to proper angle. Install and tighten cap screws toINCH lbs. (12 N.m). Bend over lock plates. Check that turbochargers freely.

5) On clamping plate style turbochargers, bend over lockes. Loosen cap screws in all clamping plates. Rotate bearinging until proper angle. Tighten cap screws to 105 INCH lbs.

N.m). Bend over lock plates. Check that turbocharger spins freely.6) Install new "O" rings on air crossover tube. Coat "O"with vegetable oil. Install air crossover tube. Check alignment

r crossover tube at turbocharger. Rotate turbocharger housing ifment is not sealing properly. Install retainer straps and capws. See TORQUE SPECIFICATIONS table.

INTAKE MANIFOLD

RemovalRemove air crossover tube. Remove air line from aftercooler

el pump. If engine contains crankcase breather in cam followerr, remove cam follower cover. Remove HVT oil connection. Removenting cap screws. Remove intake manifold.

Installation1) Check that gasket surfaces are clean. Install guide studs

pper row of cap screw holes. Install gaskets with raised bead onet against cylinder head. Install grommets in upper row of capw holes of manifold. Grommets are used to prevent dirt entry.2) Install the manifold onto the guide studs. Install washers

cap screws in bottom cap screw holes. Tighten the cap screwsugh to hold manifold in place. Remove guide studs. Install washerscap screws. Tighten cap screws in same sequence used forcooler installations. See Fig. 2. Tighten cap screws. Refer to

TORQUE SPECIFICATIONS table.

2: Aftercooler Tightening Sequencertesy of Cummins Engine Co., Inc.

3) Install air tube from manifold to fuel pump. Install camwer cover (if removed). Install HVT oil connection. Install newrings on air crossover tube. Install air crossover tube and


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CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 3

ning straps.

AFTERCOOLER

Removal1) Remove air crossover tube from turbocharger to

cooler. Loosen hose clamps on water inlet and outlet hoses. Slides back on water tubes. Remove air tube from aftercooler to fuelp. Remove HVT oil connection from rear of aftercooler.2) If engine contains crankcase breather in cam follower

r, remove cam follower cover. Remove two mounting cap screws fromcooler. Install two guide studs. Use hoist to support assembly.ove remaining cap screws. Remove aftercooler.

DisassemblyRemove cap screws from gasket cover plate at water inlet and

et connections. Remove cover plate, gasket and seal from eachection. Remove cap screws from aftercooler cover. Remove cover,et and element from housing.

Checking1) Check housing for cracks or bad threads in cap screw

s. Check plate around element for cracking. Aftercooler elementld be pressure tested for leaks. Clamp hose on outlet connection.and clamp hose with solid plug. Clamp hose on inlet connection.ll pressure gauge with air fitting into hose on inlet connection.

ck that all hose clamps are tight before applying air pressure.2) Submerge element in tank of water. Check that entire

ment is covered. Use air pressure regulator. Adjust air pressure tosi (210 kPa). Apply air pressure to element. Check for airbles. Replace element if leaks appear. Remove air pressure. Remove

ment and disassemble testing equipment. Dry element with compressed

Reassembly1) Check that all gasket surfaces are clean. Install lower

et on housing. Install element in housing. Install upper gasketcover. Install cap screws. DO NOT tighten cap screws at this time.2) Lubricate water connection seals and sealing areas of

cooler element with oil. Install seals on retainers. Installet on retainers. Install seal and retainer on tube of element.ll cap screws in retainer. Tighten retainer cap screws first,tighten cover cap screws. See TORQUE SPECIFICATIONS table.

Installation1) Install guide studs in upper row of cap screw holes ofder heads. Install gaskets on cylinder heads with raised bead ofet against cylinder head. Install grommets in upper row of capw holes on aftercooler. Grommets are installed to prevent dirty.

2) Install the aftercooler assembly onto the guide studs.ll washers and cap screws in bottom row of cap screw holes.ten cap screws lightly to hold assembly in position. Remove guides. Install remaining washers and caps screws. Cap screws must beened in sequence. See Fig. 2. Tighten cap screws. Refer to theQUE SPECIFICATIONS table.3) Install new "O" rings on air crossover tube. Coat "O"

with vegetable oil. Install air crossover tube and retainingps. Install cam follower cover (if removed). Install air line from


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cooler to fuel pump. Install HVT oil connection at rear ofcooler. Install water hoses on aftercooler.

CYLINDER HEAD (REPLACEMENT)

Removal1) Remove exhaust manifold. See INTAKE & EXHAUST MANIFOLDS.ove aftercooler or intake manifold. See INTAKE & EXHAUST MANIFOLDSs article. Remove fuel lines from fuel manifold. Remove capws from fuel manifold. Remove fuel manifold. Plug fuel passages inder head and fuel manifold to keep areas clean.2) On engines equipped with Hydraulic Variable Timing (HVT),

ove oil line from rear of oil manifold mounted to rocker leverings. Remove cap screws from oil manifold. Remove manifold. Plug passages. Note location of rocker lever cover with crankcasether. Remove cap screws. Remove rocker lever covers. Disconnectg connection from cover for J acobs Brake (if equipped). Loosensting screw lock nut on rocker levers. On HVT equipped engines,

injector link when loosening lock nut. Remove HVT injector link.

TION: When loosening adjusting screw lock nut on HVT equippedengines, hold injector link. Injector link can fall intoengine.

3) Remove cap screws from rocker lever assemblies. Mark eacher lever assembly as to location. Remove rocker lever assemblies.NOT drop rocker levers from shaft during removal. Remove cap screws

Jacobs Brake housing (if equipped). Mark each housing as totion. Remove J acobs Brake housing. Remove rocker lever assemblies.4) Mark push rods as to location. Remove push rods. Loosen

sting screw lock nut on crossheads. Mark each crosshead as to

tion. Remove crossheads. On engines equipped with Jacobs Brake,location of special crosshead.5) Remove water outlet line from air compressor. Remove cap

ws from thermostat housing. Remove thermostat housing and watersfer tube. Remove retaining clips from water manifold. See Fig. 3.g Water Tube Driver (ST-1319), push water tube toward front ofder block. Water tube must slide forward until rear of tubers rocker lever housing.

3: Removing Water Railrtesy of Cummins Engine Co., Inc.

6) On engines equipped with HVT, remove banjo connector capw. See Fig. 4. Remove connector and "O" ring from tappet. Remove

screws from rocker lever housing. DO NOT drop washers into engine.ove rocker lever housing and gasket. Remove injector hold-down.


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4: Removing Banjo Connectorrtesy of Cummins Engine Co., Inc.

7) Injectors are removed to prevent damage during cylinderd removal. Use Injector Puller (3376000) for standard injectors.Injector Puller (3376497) for top stop injectors. All enginespped with HVT use top stop injectors. DO NOT let tappet fall outector when removing injector from HVT equipped engines. Removetors and place in clean material. Keep injector sealing ring withtor which it was located. Place in proper rack to prevent damage.8) Remove air compressor water outlet line. Remove cap screwscylinder head. Remove cylinder head.

Installation1) Clean sealing surface of both cylinder head and cylinder

k. Special attention should be given to ensure surface aroundder liner flange is clean. Check that small sealing ridge on toplinder liner is not damaged. Clean cap screw holes in cylinder

k.

TION: Cylinder head cap screw holes in cylinder block must beclean and dry before installation. Failure to clean willcause breakage of cylinder block when tightened tospecifications.

2) Clean cylinder head cap screw threads using wire brush.ck cap screws for pitting or cracking of threads. Replace ifaged. Two different lengths have been used. Engines with serialber greater than 31103629 and service blocks use 8" (203 mm) capws. Engines with serial number less than 31103629 use 6 3/4"mm) cap screw.

3) To check for proper length cap screw to be used, measurence from top of cylinder block to first thread in cap screw hole.tance is 1 3/4" (44 mm) 8" (203 mm) cap screw is used. Installgasket with "TOP" facing upward. Gasket must slide easily overin cylinder block. Install all grommets and cylinder head. Ensure

d sets on pins in cylinder block. Current production head capws are Black, early production are Silver. DO NOT mix cap screws.

E: Oversize head gasket must be used on cylinder blocks thathave had .010-.030" (.25-.76 mm) removed from deck surface.

4) Coat the cap screws with 140W oil. Allow excess oil ton from the cap screws. Install cap screws and washers. Tighten thescrew in sequence. Refer to the TORQUE SPECIFICATIONS table. Also,Fig. 5. Install rocker lever housing gasket. Check that water tube


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ng areas are clean in rocker lever housings. Install new "O"on water tubes. Lubricate "O" rings with vegetable oil. Install

er tubes in rocker lever housings. Water tube with two grooves muststalled in rear cylinder head.

5: Cylinder Head Tightening Sequencertesy of Cummins Engine Co., Inc.

5) Install rocker lever housings. Housing with only one "O"bore must be installed on No. 6 cylinder head. Check that housingproperly on pins in cylinder head. Install cap screws in properion. One cap screw is shorter than the others. Tighten cap screwsquence. See Fig. 6. On engines equipped with Jacobs Brake, capw must be installed when J acobs Brake housing is installed.

6: Rocker Lever Tightening Sequencertesy of Cummins Engine Co., Inc.

6) Using Water Tube Driver (ST-1319), drive water tubes intocent housing. Install retaining clips. Install thermostat housingwater transfer tube.7) Check that injector sleeves in cylinder head are clean.

ll new "O" rings on injector. Check that proper size "O" ringsused. Coat "O" rings with oil. Position inlet screen toward hold-n cap screw hole on intake side of cylinder block. Place bluntument on body of injector. Push injector into bore.8) A snap will be heard and felt when injector is seated.

ll hold-down and cap screws. Tighten the cap screws. Refer to theQUE SPECIFICATIONS table. Check that injector plunger mover freely.nger does not move freely, loosen hold-down and retighten.9) On HVT equipped engines, position injector in bore so that

assage in top stop screw faces oil supply hole in rocker levering. Rotate injector using jumper tube to align injector. Installtor in bore. A snap will be heard and felt when injector ised. Install hold down. See TORQUE SPECIFICATIONS table. Install

"O" ring on jumper tube. Lubricate "O" ring with oil. Installper tube and sealing washers. Install connector screw. Tighten


7/63CUMMINS "K" SERIES 6-CYLINDERArticle Text

nector screw. See TORQUE SPECIFICATIONS table.10) Lubricate crosshead guides and valve stems with oil.

ll crossheads in original location. Adjust crossheads. Refer toOSSHEAD ADJ USTMENTS in this article. Install push rods in original

ions. Injector push rods are thinner in the middle. Valve pushare the same. Install injector links. DO NOT install injector

on HVT engines until rocker lever assembly is installed.11) Check that dowel for rocker lever assembly is installed

cker lever housing. Install rocker lever assembly. Check thatmbly sets on dowels in rocker lever housings. Install cap screws.ngines with J acobs Brake, housing must be installed whilelling rocker lever assembly. Align push rods and injector link.

HVT engines, install injector link. Turn adjusting screw far enoughold injector link. Tighten cap screws. See TORQUE SPECIFICATIONS.

12) Check that push rods are seated in cam followers. Adjustes and injectors. See INJ ECTOR & VALVE CLEARANCE ADJUSTMENTS inarticle. Install rocker lever covers and gaskets in originalion. On engines with J acobs Brake, connect wiring connectione rocker lever housing. See TORQUE SPECIFICATIONS table.

13) Install air compressor water outlet line. Install new "O"on fuel manifold. Lubricate "O" rings with vegetable oil.ll fuel manifold. Tighten cap screws from center working towardr edges. See TORQUE SPECIFICATIONS table. Install fuel lines tomanifold. Install new "O" rings on HVT oil manifold (ifpped). Lubricate "O" rings with vegetable oil. Install oilifold. Tighten cap screws from center working toward outer edges.TORQUE SPECIFICATIONS table. Install HVT oil line on manifold.14) Install exhaust manifold. See INTAKE & EXHAUST MANIFOLDS

s article. Install the aftercooler or intake manifold. Refer toAKE & EXHAUST MANIFOLDS in this article.

VALVE ARRANGEMENT

2E-2I-2E-2I-2E-2I-2E-2I-2E-2I-2E-2I (Front-to-rear).

INJECTOR & VALVE CLEARANCE ADJ USTMENTS

E: When checking injector clearance, ensure tool is tight.Injector plunger is under spring tension and can cause injuryand damage tool, if released quickly. If equipped with J acobsbrake model K-1150, adjust slave piston before adjustingvalves. See JACOBS BRAKE ADJ USTMENT in this article.

1) Push barring shaft in and turn counterclockwise, to rotate

ne. Align timing mark, located on pulley, to pointer on front gearr. See Fig. 7. On engines with 2 piece front cover, remove clip,shaft in, and turn shaft counterclockwise.


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MMINS "K" SERIES 6-CYLINDERArticle Text (p. 8)For cyph8r pacific la ca 921011996 Mitchell International, All Righ

7: Barring Shaft & Timing Mark Locationrtesy of Cummins Engine Co., Inc.

2) Align mark "A" ("1-6 VS" on older engines) with pointer.ck valves on cylinder No. 5 are closed and can be moved easily. Ifes are not open and cannot be moved easily, rotate engine 1

plete revolution and recheck valves. Check valve clearance betweener arm and crosshead. See VALVE CLEARANCE SPECIFICATIONS table.3) Adjust intake and exhaust valves clearance. See Fig. 8.

ten lock nut to 45 ft. lbs. (60 N.m). If using torque wrench withpter (ST-669), tighten lock nut to 35 ft. lbs. (45 N.m). Installtor Adjuster (3375004) on cylinder No. 3. Adjust dial indicatorp is touching top of injector plunger.

8: Adjusting Valve & Injector Clearancertesy of Cummins Engine Co., Inc.

4) On engines with HVT (Hydraulic Variable Timing) tip musth tappet between ends of retainer rings. See Fig. 9. Tip must noth rocker lever. Lower dial indicator to .50" (12.7 mm) and lock inion. Using Rocker Lever Actuator (3376869), depress lever 2 or 3s until injector bottoms, to remove fuel and oil from cup.


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MMINS "K" SERIES 6-CYLINDERArticle Text (p. 9)For cyph8r pacific la ca 921011996 Mitchell International, All Righ

9: Checking Injector Clearancertesy of Cummins Engine Co., Inc.

5) Loosen lock nut and tighten adjusting screw until injectorger bottoms in cup. Zero dial indicator. Turn adjusting screw bothtions 2 or 3 times to confirm zero reading on dial indicator.st injector clearance. See VALVE CLEARANCE SPECIFICATIONS table.

6) While holding adjusting screw, tighten lock nut to. lbs. (60 N.m). If using torque wrench with Adapter (ST-669),en to 35 ft. lbs. (45 N.m). Using rocker arm actuator, bottomtor plunger and allow rocker lever to slowly return.7) Confirm dial indicator reads zero. Recheck clearance and

just if necessary. Remove injector adjuster and rotate engine tomark. See VALVE & INJ ECTOR SEQUENCE table. Adjust valves andtors.

VE CLEARANCE SPECIFICATIONS

cation In. (mm)

aust ....................................... .027 (.69)ke ........................................ .014 (.36)torh HVT ................................... .304 (7.72)hout HVT ............................... .403 (10.24)

VE & INJECTOR SEQUENCE

k On Adjust No. Adjust No.y Valves Injector

) .................... 5 ......................... 3) .................... 3 ......................... 6) .................... 6 ......................... 2) .................... 2 ......................... 4) .................... 4 ......................... 1) .................... 1 ......................... 5

"1-6 VS" on older engines."2-5 VS" on older engines."3-4 VS" on older engines.

J ACOBS BRAKE ADJ USTMENT

E: Sequence for each J acobs brake adjustment is the same asvalve adjustment. See VALVE & INJ ECTOR SEQUENCE table


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for proper cylinder adjustment.

K-1150 Models1) With engine set to adjust cylinder No. 5 valves, loosenust valve adjusting screw. Check clearance between slave pistonacobs brake crosshead. Clearance should be .018" (.46 mm). If

rance is as specified, no adjustment is needed. If clearance isas specified, loosen lock nut.

2) Starting with adjusting screw, nearest to water manifoldturn screw 1/8 turn then adjust screw under rocker lever 1/8Adjust screws evenly until proper clearance is obtained. Using

pter (3840) and a torque wrench, tighten lock nut to 48 ft. lbs.N.m). Adjust exhaust valve and rotate engine to adjust nextder.

K-1200 Models1) With engine set to adjust cylinder No. 5 valves, check

rance between the slave piston and crosshead. Clearance should be" (.46 mm). If clearance is as specified, no adjustment is

ssary. If clearance is not as specified, loosen lock nut.2) Adjust screw until proper clearance is obtained. Tighten

sting screw to 30-40 ft. lbs. (41-54 N.m). Rotate engine to adjustcylinder. To bleed brake unit, if necessary, start engine andlerate to 1800 RPM. Release throttle and manually depress solenoidature 5-6 times.

CROSSHEAD ADJ USTMENTS

E: Adjusting screw must always be toward exhaust side of engine.

1) While pushing crossheads down, loosen lock nut and turnsting screw until it touches valve stem but does not raiseshead. Tighten the lock nut to 30 ft. lbs. (40 N.m) without J acobse.2) Using torque wrench and Adapter (ST-669), tighten to lbs. (35 N.m). If equipped with J acobs brake, tighten to. lbs. (45 N.m) without adapter or 30 ft. lbs. (40 N.m) with

pter.

CYLINDER HEAD (OVERHAUL)

VALVES

Disassembly

Clean cylinder head. Mark each valve as to location. Usinge Spring Compressor (ST-448) with Spring Compressor Plate3375043), compress valve spring. Remove valve spring collets,ners, valve spring guides and valve springs.

Cleaning & Inspection1) Clean valves and polish with crocus cloth. Check thickness

e valve head rim thickness using Gauge Block (ST-547). Refer toVALVE HEAD THICKNESS SPECIFICATIONS table. Check diameter of valve

m in 3 areas. Refer to the VALVES table at end of article. Replacen valves.

2) Check that collets fit tightly in valve stem grooves.ck valve for cracks. Replace damaged valves. When replacing valves,k that proper valve is installed. See Fig. 10.


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10: Valve Identificationrtesy of Cummins Engine Co., Inc.

VE HEAD THICKNESS SPECIFICATIONS

cation (1) In. (mm)

aust ...................................... .120 (3.00)

ke ....................................... .085 (2.16)

Minimum thickness.

Valve GrindingUsing Valve Facing Machine (3376256), grind valve to proper

e. See VALVES table at end of article. Measure valve headness. Replace valve if not within specification.

Reassembly1) Clean and inspect cylinder head. Inspect, repair or

ce the following components: valve seats, valve guides, valvegs, crosshead guides and crossheads. See appropriate sectionn this article.2) Apply oil to valve stem. Install valve in original

ions. Install valve spring guide, spring and retainer. Compresse spring. Install new collets. Slowly release valve springpressor. Check that collets are seated in valve stem groove.

TION: New valve spring collets must always be used.

CYLINDER HEAD

Checking

Cylinder head should be clean. Cylinder head should be testedracks using the magnetic method before performing other tests.g straightedge, check flatness of head gasket surface in severals. See CYLINDER HEAD SPECIFICATIONS table. Cylinder head thicknesst be checked before resurfacing. Replace cylinder head if beyonds.

NDER HEAD SPECIFICATIONS

cation In. (mm)

ness ................................. (1) .003 (.076)kness ............................. (2) 4.715 (119.76)

Maximum clearance.


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Minimum thickness.

Testing (Air Pressure)

E: Valves and valve springs must be removed before pressure

testing.

1) Use Water Test Adapter Plate (3375070) and Adapter PlateRings (3375071). Install lower adapter plate on cylinder head.

guide pins must fit in water passages. Install "O" rings oner adapter plate. Install upper plate on cylinder head. Installping assembly over adapter plates. Guide pins on clamping assemblyt fit in holes on lower adapter plate.2) Install air hose with pressure regulator on upper adapter

e. Install lifting arm over clamping assembly. Adjust air pressure0 psi (552 kPa). Install cylinder head in tank of water. Check forubbles. Repair or replace cylinder head if leaks appear. Removeng equipment.

VALVE GUIDE SERVICING

InspectionInspect guide for damage. Using dial bore gauge, measure bore

areas 90 apart. See VALVE GUIDE SPECIFICATIONS table. Replacen guides.

VE GUIDE SPECIFICATIONS

cation In. (mm)

lled Bore I.D. .......... .4961-.4987 (12.600-12.667)nder Head Guide Bore ....... .8435-.8445 (21.43-21.45)lled Heighte 3 & 4 .................. 1.375-1.390 (34.93-35.31)e 5 ...................... 1.175-1.190 (29.85-30.23)

RemovalInstall cylinder head in hydraulic press. Press valve guidecylinder head. Measure bore of cylinder head at two areas 90t. See VALVE GUIDE SPECIFICATIONS table. Valve guide bore must be

med for oversized valve guide if beyond limit.

TION: Valve seat must be ground if valve guide is replaced.

InstallationValve guide must be identified before installing. Proper

e guide driver must be used with different guides. See Fig. 11.g hydraulic press and proper valve guide driver, install valvee. Valve guide must be installed to proper height. Measurence from top of valve guide to surface of cylinder head. SeeVE GUIDE SPECIFICATIONS table.


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11: Valve Guide Identificationrtesy of Cummins Engine Co., Inc.

VALVE SEAT INSERTS

InspectionCarefully tap the head of the valve seat with a rubber

mer. Note any movement of the valve seat. Replace the valve seat ife. Measure the valve seat width area. See Fig. 12. Refer to theVES table at end of article. Replace valve seat if worn.

12: Measuring Valve Seatrtesy of Cummins Engine Co., Inc.

Removal1) Different valve seat extractors are used for intake andust valves. Use Valve Seat Extractor (ST-1323-1) for exhaust

es and (3376799) for intake valves. Install valve seat extractorlve seat. Using slide hammer, remove valve seat. Remove anti-plate from intake ports. Small groove may be machined in valveinsert to allow valve seat extractor to be used.

2) Check for cracks around the valve seat area. Measure thee diameter and depth of insert bore of cylinder head. Refer toVALVE SEAT BORE SPECIFICATIONS table. Cylinder head must behined for oversized valve seat if not within specifications.

VE SEAT BORE SPECIFICATIONS

cation In. (mm)

meterake ....................... 2.377-2.378 (60.37-60.40)haust ...................... 2.377-2.378 (60.37-60.40)h

ake ......................... .512-.517 (13.00-13.13)haust ........................ .492-.497 (12.50-12.62)


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TION: Intake valve seat insert has wider valve seat area thanexhaust valve seat inserts. DO NOT install improper valveseat insert.

Installation1) Check that proper valve seat insert is used. Both valve

inserts must be installed with 30 angle upward. Exhaust seatsolor coded to identify 30 angle side of seat. Some engines doequire anti-swirl plate. Insert spacer plate must be used ifswirl plate is not used.2) Install anti-swirl plate (if used). Use arbor press and

drel. Install valve insert. Check that valve seat bottoms interbore.

Valve Seat GrindingCheck valve seat width. Using Valve Seat Grinding Machine

685), grind valve seat insert to angle and seat width. See VALVES

e at end of this article.

Valve Seat Testing1) Assemble valve and springs in cylinder head. Valve and

e seats must be clean and dry. Use Valve Vacuum Tester (ST-1257).e the vacuum cup over the valve. Turn shutoff valve to the openion. Operate the vacuum pump until a reading of 18 in. Hg ished. Turn valve off. Stop vacuum pump.2) Check amount of time it requires for vacuum reading tofrom 18 to 8 in. Hg. Total time should not be less than

econds. If time is less than 10 seconds, lightly tap on valve stema soft hammer. Check connections of vacuum tester. Hold cupnst a flat surface. Operate vacuum pump. The gauge must not show aease. Perform vacuum test again.3) Apply a light coat of grease to outside diameter of valve

insert. This makes a seal between the insert and counterbore.uum test and recheck grease seal. Break in seal indicates a leakeen insert and counterbore.4) If no leak appears at insert and counterbore, grind valveor valve seat insert.

CROSSHEAD GUIDES

InspectionUse micrometer to measure outside diameter of crosshead

e. See CROSSHEAD SPECIFICATIONS table. Check that guide isght. Guide must be at right angle to surface of cylinder head.ace any worn or bent guide.

Removal & InspectionUsing Dowel Pin Extractor (ST-1134), remove damaged guide.

sure inside diameter of guide bore in cylinder head. Refer to theSSHEAD SPECIFICATIONS table. Bore may be reamed for oversizedes if not within specifications.

InstallationUse Crosshead Guide Spacer (ST-1264) and hydraulic press.

ll new guide. Measure distance from top of guide to cylinder head

ace. See CROSSHEAD SPECIFICATIONS table. Guide must be installedoper height.


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SSHEAD SPECIFICATIONS

cation In. (mm)

shead Bore I.D. .............. .434-.440 (11.02-11.17)

e O.D. ..................... .4320-.4335 (10.97-11.01)e Bore I.D. ................ .4314-.4325 (10.96-10.99)e Installed Height ............... 2.35-2.37 (59.69-60

CROSSHEADS

Inspection1) Use magnetic method to check crossheads for cracks. Check

e diameter of crosshead bore. Check bore measurement at 4 areass apart. Replace crosshead if bore is out-of-round. Refer to theSSHEAD SPECIFICATIONS table.2) Inspect rocker lever contact surface and valve stem

act surface for wear. Check adjusting screw and threads inshead for wear or damage. Replace crosshead if damaged.

INJECTOR BORE

Inspection1) Inspect injector bore for cracks or damage. Install

ng ring on injector. Coat sealing ring with Prussian blue.port cylinder head. Install injector. Tighten hold-down cap screws45 INCH lbs. (16 N.m). Using Gauge Block (ST-547), measuretor tip protrusion. See INJ ECTOR PROTRUSION SPECIFICATIONS table.

otrusion is not within specifications, oversize sealing rings areable.

CTOR PROTRUSION SPECIFICATIONS

cation In. (mm)

tor Tip Protrusion ............ .090-.110 (2.29-2.79)

2) Remove injector. Check contact pattern in injector bore.act area must be at least .060" (1.52 mm) wide and 360mference. If contact area is not correct, check for damage orn injector bore.

ROCKER LEVER ASSEMBLY & PUSH RODS

Disassembly & Inspection1) Remove cap screws. Mark rocker lever as to location.

ove rocker levers. Inspect shaft for scoring or roughness. Checket area of rocker lever for excessive wear. If excessive wear isarent, check push rods for damage. Inspect bushing bore area ofer levers for wear or damage. Inspect for wear in crossheadact area. Inspect push rods for damage or cracks.2) Check threads in rocker lever and on adjusting screw.

sting screw must turn freely in rocker lever. Using dial borege, measure inside diameter of rocker lever at two areas 90 apart.

sure rocker lever shaft in two areas 90 apart where rocker leversn shaft. See ROCKER LEVER SPECIFICATIONS table. Replace worn or


16/63CUMMINS "K" SERIES 6-CYLINDERArt

aged parts.3) Replace bushing if worn. Using hydraulic press and Rocker

r Bushing Mandrel (ST-1284), press bushing from rocker lever.ck that bore area is free of burrs. Using dial bore gauge, measuree diameter of rocker lever at two areas 90 apart. Refer to theKER LEVER SPECIFICATIONS table.

KER LEVER SPECIFICATIONS

cation In. (mm)

hing Bore I.D. .......... 1.3735-1.3776 (34.890-34.990)r Bore I.D. ................ 1.436-1.437 (36.47-36.50)t O.D. ................. 1.3710-1.3725 (34.820-34.860)

Reassembly1) Align oil hole in bushing and rocker lever. Using

aulic press and bushing mandrel, install bushing. Check that oil

s are aligned.2) Lubricate shaft with oil. Install rocker levers in

nal locations. Rocker lever oil passages must align with oilages in rocker lever shaft. Rocker levers must be installed inence. See Fig. 13. Install cap screws in shaft.

13: Rocker Lever Sequencertesy of Cummins Engine Co., Inc.

TION: Oil passages in rocker lever shaft and rocker levers mustbe aligned.

ACCESSORY DRIVE & PULLEY

FUEL PUMP

RemovalRemove wire to shutoff solenoid. Remove throttle linkage.ove wires to micro switch for J acobs Brake (if equipped). Removeometer cable. Remove all lines connected to fuel pump. Remove capws. Remove fuel pump.

InstallationInstall new gasket on fuel pump. Install new fuel pump drive

er. Install fuel pump. Install and tighten cap screws. Install allto fuel pump. Install throttle linkage, tachometer cable andto shutoff solenoid. Install wiring to micro switch for J acobs

e (if equipped). Ensure accelerator linkage goes into full fueln operated.


17/63CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 17)For cyph8r pacific la ca 921011996 Mitchell

AIR COMPRESSOR

RemovalRemove fuel pump. Remove air intake to air compressor. Remove

ne to air governor. Remove air compressor output line. Remove

er supply lines. Remove cap screws from lower support bracket (ifpped). Remove mounting cap screws from air compressor. Remove airpressor and drive coupling.

Installation1) Install new gasket on air compressor. Install air

pressor on splined coupling. Install cap screws and nuts. DO NOTen at this time. Install cap screws for rear support bracket.support bracket must fit flat against the cylinder block. Tighten

ompressor mounting cap screws. Tighten the rear support-to-blockscrews. Tighten the rear support-to-pump cap screw. Refer to theQUE SPECIFICATIONS table. Cap screws must be tightened in thisence to prevent failure.

2) Install air line for air governor. Install air compressorke and output line. Install water lines. Install fuel pump.

ACCESSORY DRIVE PULLEY

RemovalInstall Puller (ST-647) on accessory drive pulley using twocap screws. Remove accessory drive pulley using puller. Replace

eal if needed.

TION: DO NOT use cap screws that extend past rear face ofaccessory drive pulley. Long cap screws damage gear cover.

Installation1) Install oil slinger. Install new accessory drive seal.

ace wear ring on accessory drive pulley. Apply film of Lubriplateto accessory drive shaft. Check that drive key is in accessory

e shaft. Align keyway in pulley with key. Push pulley on by handr as possible.2) Install Pulley Installer (3376326) on accessory drive

t. Press pulley on until it contacts step on shaft. Remove pulleyller.

ACCESSORY DRIVE SEAL

Removal & Installation1) Remove accessory drive pulley. Drill two 1/8" holes 180t in seal casing. Install two No. 10 sheet metal screws. Use slidemer puller to remove seal.2) Clean seal mounting surface. Use crocus cloth to remove

h edges. Install seal on proper mandrel. Part number on seal facesmandrel. Check that accessory drive shaft is clean and dry.

E: DO NOT use lubricant on accessory drive shaft or seal. Sealmust be installed dry.

3) Push seal into seal bore until seal casing is belowmfer edge of front engine cover. Install accessory drive pulley.

PULLEY WEAR SLEEVE


18/63CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 18)For cyph8r pacific la ca 921

RemovalSecure pulley in soft-jawed vise. Using chisel lightly strike

r sleeve in four different positions. This relieves press fit.ove wear sleeve. Clean surface with crocus cloth. Inspect forks in pulley keyway.

InstallationPlace pulley in arbor press. Install wear sleeve on pulley

chamfer facing away from pulley. Place flat steel on wear sleeve.s wear sleeve on until steel plate contacts pulley. Check wearve for burrs.

ACCESSORY DRIVE

Removal1) Remove fuel pump and air compressor. See FUEL PUMP and

COMPRESSOR in this article. Rotate engine until "A" mark onssory drive aligns with pointer on gear cover. Remove accessory

e pulley. See ACCESSORY DRIVE PULLEY in this article. Removeection plugs from upper and lower timing plug holes in front ofcover. Plugs are located just below accessory drive seal area.2) Check that timing mark on camshaft idler gear and

ssory drive are aligned. See Fig. 14.

14: Accessory Drive Timing Markswith following legend. Courtesy of Cummins Engine Co., Inc.

END FOR FIGURE 14

ber Description

.................................. Key

............................... Pulley......................... Wear Sleeve................................. Seal......................... Oil Slinger................................ Gear....................... Thrust Washer.................................. Key............................... Shaft................................ Gasket.............................. Housing.............................. Bushing........................ Thrust Washer...................... Clamping Washer............................. Coupling


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CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 19)For cyph8r pacific la ca 92

.................... Special Cap Screw................................ Washer

TION: DO NOT use "A" marks on camshaft idler gear for accessorydrive alignment unless "X" marks on camshaft and camshaft

idler are aligned and centered in upper timing plug hole.

3) Remove drive key from accessory drive shaft. Removenting cap screws. Remove accessory drive assembly.

DisassemblyRemove cap screw, washer from rear of drive shaft. Place cap

w back in drive shaft after washer is removed. Install Couplingr (3376663) on coupling. Remove coupling. Remove clamping washer.ove inner and outer thrust bearings. Remove drive shaft and gearhousing. Place gear and shaft in press. Press shaft from gear.

Fig. 15.

15: Accessory Drivertesy of Cummins Engine Co., Inc.

Inspection1) Check inside diameter of bushings. Check drive shaft for

ks around keyways. Check for wear in bushing areas. Replace driveif any teeth are chipped, cracked or flaking.2) Measure outside diameter of drive shaft. See Fig. 16.

sure inside diameter of drive gear bore. Measure thrust bearingness. Measure drive pulley bore inside diameter. See

VE UNIT SPECIFICATIONS table.


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16: Measuring Accessory Drive Shaftrtesy of Cummins Engine Co., Inc.

END FOR FIGURE 16ber Description

... 1.3765-1.3770" (34.963-34.976 mm)

... 1.5616-1.5620" (34.662-39.674 mm)

....... 1.311-1.312" (33.30-33.33 mm)

... 1.0030-1.0035" (25.476-25.489 mm)

VE UNIT SPECIFICATIONS

cation In. (mm)

hing I.D. ................... 1.316-1.319 (33.43-33.50)e Gear Bore I.D. ........... 1.564-1.565 (39.73-39.75)t End Play ....................... .002-.012 (.05-.30)t Gear Fit Area O.D. ... 1.5665-1.5670 (39.789-39.802)

ey Bore I.D. ........... 1.3745-1.3755 (34.912-34.938)

Reassembly1) Coat shaft with oil. Install key in shaft. Using hydraulic

s, install shaft into gear. Using feeler gauge, check clearanceween shoulder of shaft and surface of gear. Clearance must not bee than .002" (.05 mm).

2) Install thrust bearing on housing. Grooved side of thrusting goes away from housing. Coat thrust bearing with LubriplateInstall shaft and gear assembly in housing. Install rear thrusting with grooved side away from housing. Install clamping washerbevelled edge toward housing. Using arbor press, press couplinghaft. Clamping washer must be positioned tightly between couplingshoulder of shaft.3) Install washer and cap screw. Cap screw must contain oil

ng if air compressor is mounted on engine. Tighten 3/8" capw to 35 ft. lbs. (45 N.m). Tighten 1/2" cap screw to 75 ft. lbs.N.m). Check drive shaft end play. See DRIVE UNIT SPECIFICATIONS

e. Oversize thrust bearings are available to adjust end play.

Installation1) Install new gasket. Rotate accessory drive so that "A"


21/63CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 2

k on accessory drive gear aligns with "A" mark on camshaft idler. Install mounting cap screws. See TORQUE SPECIFICATIONS table.

ck that timing marks are aligned.

TION: DO NOT use "A" marks on camshaft idler gear for accessorydrive alignment unless "X" marks on camshaft and camshaft

idler are aligned and centered in upper timing plug hole.

2) Install oil slinger. Install key in drive shaft. Installssory drive seal. Install plugs in inspection holes. Tighten plugs

0 ft. lbs. (25 N.m). Install accessory drive pulley. Install fuelp. Install air compressor.

CAMSHAFT & TIMING GEARS

VIBRATION DAMPER

E: Cummins engines use two types of vibration dampers: rubber

element and viscous. Vibration damper cannot be repaired.Replace if defective.

Checking Vibration Damper EccentricityInstall dial indicator to front gear cover. Place indicator

n outside diameter of damper. Check that indicator tip does notnto balance hole of damper. Rotate crankshaft 360. Replacetion damper if reading exceeds limits. See

RATION DAMPER SPECIFICATIONS table.

Checking Vibration Damper WobbleInstall dial indicator to front gear cover. Place indicator

n front of vibration damper 1/2" from outer edge of damper.

ator tip must be located on smooth area of inertia member. Pushkshaft to front of engine. Zero dial indicator. Rotate engine. Replace the vibration damper if reading exceeds limits. SeeRATION DAMPER SPECIFICATIONS table.

RATION DAMPER SPECIFICATIONS

cation (1) In. (mm)

ntricitybber Damper .............................. .055 (1.40)cous Damper ............................. .040 (1.02)ble ....................................... .040 (1.02)

Maximum reading.

RemovalRemove cap screws. Using rubber hammer tap on vibration

per. DO NOT allow vibration damper to fall during removal.

TION: DO NOT use metal hammer or screwdriver to remove damper.

Inspection (Rubber Element Damper)1) Check mounting hub for cracks. Check for deterioration or

ing chunks of elastic member. Elastic member should not be more1/8" (3 mm) below metal surface.2) Check alignment marks on vibration damper. Outer member


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CUMMINS "K" SERIES 6-CYLINDERArticle Tex

nner member have alignment marks. See Fig. 17. Replace vibrationper if marks are more than 1/16" (1.5 mm) out of alignment. Checkouter member is not sliding out of alignment with hub.

17: Vibration Damper Alignment Marksrtesy of Cummins Engine Co., Inc.

3) Outer member must not be higher or lower than hub area.ace if outer member is more than .050" (1.3 mm) out of alignment.

Inspection (Viscous Damper)1) Check mounting hub for cracks. Check for dents, or raisedces. Remove paint from vibration damper on both sides in fourions. Measure thickness 1/8" (3 mm) from outside of vibrationper. Measure in four locations. Replace vibration damper ifness varies more than .010" (.25 mm).2) Spray vibration damper with Spotcheck Developer Type

-NF. Place vibration damper in 200F (93C) oven for two hours.ove and check for leaks. Replace if any leaks appear.

InstallationPlace vibration damper on crankshaft adapter. Rubber member

per does not require a crankshaft adapter. Install cap screws. SeeQUE SPECIFICATIONS table. Install vibration damper and adapter onkshaft. Check that pilot on adapter is aligned with crankshaft.ll cap screws. See TORQUE SPECIFICATIONS table.

ENGINE FRONT COVER

Removal1) Remove cap screws from gear driven fan hub (if equipped).

ne piece covers, clamping plate fits on rear of cover in front ofder head. Remove fan hub assembly.

2) Remove plastic plug from end of alternator drive shaft.Pulley Installer (3376326). Install adapter in the end of shaft.ll puller on pulley. Remove pulley. Remove adapter from shaft.3) Remove vibration damper. Remove front engine support. On

piece covers, master dowel must be removed. See Fig. 18. Removessory drive pulley. Remove key from accessory drive shaft.


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18: Removing Master Dowelrtesy of Cummins Engine Co., Inc.

4) One piece covers have five cap screws on the bottom ande on rear of cover. Two piece covers have only two cap screws onof cover. Remove cap screws. Note length and location of cap

ws. Remove front engine cover and gasket.

Inspection1) Inspect barring mechanism bushing for wear. Inspect shaft

worm gear for wear. Check for movement of shaft in bushing.ect front engine cover for cracks or damage in seal areas.

2) Measure inside diameter of all drive bushings at two areasapart. See FRONT COVER BUSHING SPECIFICATIONS table. Inspect fors of bushings moving in housing. Check that all oil feed holes areed. Replace worn or damaged bushings.

NT COVER BUSHING SPECIFICATIONS

cation In. (mm)

essory Drive Bushing ...................... 1.696-1.697(43.078-43.104)

aulic Pump Drive Bushing ................. 1.625-1.626(41.275-41.301)

er Pump Drive Bushing ..................... 1.696-1.697(43.078-43.104)

Bushing Replacement (Barring Mechanism)1) Remove retaining ring from barring mechanism. Remove

t, spring and worm gear. Remove "O" ring from shaft. Inspect

ng mechanism thrust washer for damage. Remove bushing using smallin. DO NOT damage housing while removing bushing. Install newing assembly in bore. Use barring mechanism shaft as a mandrel.

e new bushing in bore.2) Install new "O" ring on shaft. Lubricate "O" ring with

etable oil. Install spring, worm gear and shaft in cover. Installning clip. Check for freedom of rotation.

Bushing Replacement (Drive Bushing)1) Using Mandrel (ST-598), remove accessory drive and water

p drive bushings from cover. Using appropriate mandrel, removeaulic pump drive bushing. Measure inside diameter of bushing bore

ont engine cover. See FRONT COVER BUSHING BORE SPECIFICATIONSe. Replace cover if beyond limits.2) Align oil hole in bushing with that of cover. Using proper


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CUMMINS "K" SERIES 6-CYLINDERArticle Text (p

drel, install bushing in cover. Use an 1/8" (3 mm) Allen wrench tok oil hole alignment.

NT COVER BUSHING BORE SPECIFICATIONS

cation In. (mm)

ssory Drive .............. 1.696-1.697 (43.078-43.104)raulic Pump Drive ......... 1.625-1.626 (41.275-41.301)er Pump Drive ............. 1.696-1.697 (43.078-43.104)

Installation1) Check that gasket surfaces are clean. Install guide studs

linder block. Install new gasket. Install front engine cover. Onpiece covers, clamping plate must be installed.2) DO NOT tighten clamping plate cap screws until fan hub or

r plate is installed. Install cap screws in proper location.ll master dowel. Drive dowel in until it bottoms in cylinder

k.3) Check that all cap screws are installed. Cap screws must

ghtened in sequence. See Fig. 19. Tighten cap screws. See theQUE SPECIFICATIONS table. Install front engine support.

19: Front Cover Tightening Sequencertesy of Cummins Engine Co., Inc.

4) See TORQUE SPECIFICATIONS table. Install front crankshaftInstall vibration damper. Install key in accessory drive shaft.ll accessory drive oil slinger and seal. Install accessory drivey.

5) Install alternator drive seal. Check that alternator drivet is clean and dry. Place installation sleeve provided with seal,shaft. Push seal onto shaft. Push seal into bore until it is .


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CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 2

(3.18 mm) below surface of engine front cover. Using Pulleyllation Kit (3376326), install alternator drive pulley on shaft.

ck that pulley touches step on shaft. Install plastic cap in end oft.6) Install new gasket for fan hub on front engine cover. Oil

age hole in gasket must be aligned with oil hole in the cover.

ll fan hub. See TORQUE SPECIFICATIONS table. Rotate fan backwardforward to check fan hub backlash. See FAN HUB SPECIFICATIONS.ove and check gears for wear if not within specifications.

HUB SPECIFICATIONS

cation In. (mm)

r Backlash ........................ .003-.012 (.08-.30)

FRONT CRANKSHAFT SEAL

RemovalRemove vibration damper. Using Seal Remover and Installer

1131), remove seal.

Installation1) Check that seal surfaces are clean and dry. Place

llation sleeve provided with seal on crankshaft. Push seal onkshaft until it touches front engine cover. Install seal installerrankshaft. Install cap screws into crankshaft.2) Tighten cap screws in an alternately and evenly until tool

oms on crankshaft. Check that both seal lips are clear of repairve (if used). Seal should be approximately .140" (3.56 mm) belowce of engine front cover. Install vibration damper.

IDLER GEARS

Removal (Bolt-in Design)1) Remove vibration damper. See VIBRATION DAMPER in thise. Remove engine front cover. See ENGINE FRONT COVER in thise. Note timing marks before removing idler gears. Removening cap screw from idler gear. Bolt in idler shaft has a flangeh requires idler gear and thrust washers to be removed as anmbly.2) Slide hammer assembly must be threaded into idler gear

t. Remove idler gear assembly. See Fig. 20. Mark each idler gear

thrust washer as to location.

20: Removing Idler Gearsrtesy of Cummins Engine Co., Inc.


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CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 26)For cyph8r pacific la

Removal (Press Fit Design)1) Remove vibration damper. See VIBRATION DAMPER in thise. Remove engine front cover. See ENGINE FRONT COVER in thise. Note timing marks before removing idler gears.2) Remove retaining cap screw from idler gear. Idler gear

ts are a press fit into cylinder block. Shaft does not have to beoved to remove idler gear assembly. Remove idler gear and thrusthers from shaft.

Inspection1) Inspect gears for broken, chipped or flaking teeth.

ect thrust washers for damage. Measure inside diameter of idlerbushings. Measure outside diameter of gear shafts at gear area

pilot area.2) Pilot area is the area that fits into cylinder block.

sure thickness of thrust washers. See IDLER GEAR SPECIFICATIONSe. Replace if worn or damaged.

R GEAR SPECIFICATIONS

cation In. (mm)

mshaft Idlerr Bushing I.D. ......... 1.8755-1.8785 (47.638-47.714)r Backlash ........................ .003-.012 (.07-.30)r End Play ........................ .004-.014 (.10-.36)raulic Pump Idler Gear .. 1.7517-1.7535 (44.488-44.539)aulic Pump Idler Shaftt Area O.D. .......... 1.4390-1.4395 (36.551-36.563)

ar Area O.D. ........... 1.7470-1.7490 (44.370-44.425)Shaft (Bolt-In)t Area O.D. ............ .9995-1.000 (25.397-25.400)

ar Area O.D. ........... 1.8720-1.8740 (47.549-47.600)st Washer Thickness ............ .088-.095 (2.24-2.41)er Pump Idlerr Bushing I.D. ......... 1.8755-1.8785 (47.638-47.714)er Pump Idlerft (Press Fit)ot Area O.D. ......... 1.5600-1.5605 (39.624-39.627)ar Area O.D. .......... 1.8720-1.8740 (47.549-47.600)

Installation (Bolt-in Design)

1) Coat thrust washers and gear bushings with Lubriplate 105.olt-in design assemblies, install shaft and thrust washer into. Grooves on thrust washers must face the gear. Install thrusther on rear side of idler gear. Coat cap screw with oil.

2) Start idler gear cap screw into cylinder block. Rotateto align timing marks. See Fig. 21. Camshaft idler gear is onlygear with timing marks. DO NOT allow inner thrust washer to fallshaft.


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21: Aligning Timing Marksrtesy of Cummins Engine Co., Inc.

3) Tighten cap screw to install shaft in bore of cylinderk. See TORQUE SPECIFICATIONS table. Check that timing marks areed. If no hydraulic pump drive is used, install cap screw and

washer in place of shaft. Washer must be larger than bore inder block. Tighten cap screw to 50 ft. lbs. (65 N.m).

TION: Engines that do not have hydraulic pump idler must have pluginstalled in place of idler shaft. Low oil pressure willresult is plug is left out.

4) Check that the cap screw does not protrude beyond theder block and hit the crankshaft. Install a dial indicator on theof the cylinder block. Check end play of each idler gear. Refere IDLER GEAR SPECIFICATIONS table. If end play is not withinifications, remove gear and check thrust washers. Oversized thrusthers are available.

5) When all gear assemblies are installed, check gearlash on all idler gears. Install dial indicator on front ofder block. Position tip against tooth of gear. Rotate gearkwise. Adjust dial indicator to "O" (zero). Rotate gear counter-kwise and note reading. See IDLER GEAR SPECIFICATIONS table.6) If backlash in not within limits, gear must be replaced.

ump gear backlash can be adjusted by rotating oil pump. Installengine cover. Install vibration damper.

TION: Engines with press fit idler assemblies must have hydraulicpump idler gear installed even if no hydraulic pump is used.No plug is available to block oil drillings.

Installation (Press Fit Design)1) Check that small plugs are installed in ends of shafts. If

ts are to be installed in cylinder block, put shafts in freezer atF (0C) for eight hours. Heat cylinder block bores using heat lampswo hours before installing shafts. Install shafts in bores. Allows to warm to room temperature before installing gears.

2) Coat gears and thrust washers with Lubriplate 105. Installthrust washer on shaft. Grooves in thrust washer must face gear.ll gear. Align timing marks on idler gear with crankshaft gear.Fig. 21. Camshaft idler gear is only gear with timing marks.ll front thrust washer and retaining washer. Install cap screw.TORQUE SPECIFICATIONS table. Check that timing marks are aligned.3) Install dial indicator on front of cylinder block. Check

play of each idler gear. See IDLER GEAR SPECIFICATIONS table. Ifplay is not within specifications, remove gear and check thrust


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CUMMINS "K" SERIES 6-CYLINDERArticle Text

hers. Oversized thrust washers are available.4) When all gear assemblies are installed check gear backlashl idler gears. Install dial indicator on front of cylinder block.ion tip against tooth of gear. Rotate gear clockwise. Adjust dialator to "O" (zero). Rotate gear counterclockwise and noteing. See IDLER GEAR SPECIFICATIONS table.

5) If backlash in not within limits, gear must be replaced.ump gear backlash can be adjusted by rotating oil pump. Installengine cover. Install vibration damper.

CRANKSHAFT GEAR

RemovalRemove front engine cover. See ENGINE FRONT COVER in this

e. Remove oil pump and camshaft idler gears. Install Crankshaftr Puller Kit (3375840) on crankshaft gear. Turn pressure screw toove crankshaft gear. Slight heat may be applied to gear duringoval. Remove key from crankshaft.

InspectionInspect gear teeth for cracking, broken or chipped teeth.

ect keyway in gear and crankshaft for cracks or burrs. Check keyurrs. Replace damaged parts. Measure crankshaft gear journalde diameter in two areas 90 apart. SeeNKSHAFT GEAR SPECIFICATIONS table.

NKSHAFT GEAR SPECIFICATIONS

cation In. (mm)

r J ournal Area O.D. ....... 4.380-4.381 (111.25-111.28)

InstallationInstall key in crankshaft. Heat gear in oven at 450F (230C)

ne hour. Lubricate crankshaft with Lubriplate 105. Install gearrankshaft with timing mark facing away from crankshaft. Align keykeyway. Install gear on crankshaft. Install camshaft and oil pumpgears. Install front engine cover.

CAM FOLLOWERS

RemovalRemove the rocker lever covers. Remove push rods. Refer to

NDER HEAD (REPLACEMENT) in this article. Remove cam followerrs. Note location of cam follower cover with crankcase vent.ove cap screws from cam followers. Special cap screws are used.

k these cap screws as to location. Remove cam follower assemblies.k cam follower assemblies as to location.

DisassemblyMark each cam follower lever as location. Remove retaining

rom shaft. Remove levers from shaft.

Inspection1) Check that shaft rotates freely in cam followers. Inspect

rs for flat spots or flaking. Check that rollers rotate freely.

ect shaft for scoring or wear. Inspect for wear in push rodets. If wear is excessive check push rods for damage. Check cam


29/63CUMMINS "K" SERIES 6-CYLINDERArticle T

wers for cracks using magnetic method.2) Check for clearance between roller and pin. Measure shaftarea of each cam follower lever. Measure shaft outside diameter

ach cam follower lever area. See CAM FOLLOWER SPECIFICATIONS.ace worn or damaged parts.

FOLLOWER SPECIFICATIONS

cation In. (mm)

r Shaft Bore I.D. ........ .8750-.8770 (22.225-22.275)t O.D. ................... .8730-.8740 (22.174-22.200)

ReassemblyLubricate shaft and cam follower bores with oil. Install cam

wer levers on shaft in original location. Install retaining clip.ck that cam followers move freely on shaft.

Installation1) Lubricate rollers with oil. Install cam follower assemblyginal location. Check that cam follower shaft fits properly ondowels in cylinder block. Install special cap screws.2) Cap screws have slot which allows oil to flow to cam

wer assembly. See TORQUE SPECIFICATIONS table. Check injectiong if cam followers are replaced. See INJ ECTION TIMING in thise.3) Two types of cam follower cover gaskets are used. Onegasket has bead of sealant which must be against cam followerr. Another style of gasket is used, which must be installed dry.4) Gasket material expands when exposed to engine oil.

ll gaskets. Install cam follower covers in original positions.follower cover with crankcase vent must be installed on No. 4der. Install cap screws. See TORQUE SPECIFICATIONS table. Installrods. Install rocker lever covers. Adjust valves and injectors.

CAMSHAFT

Removal1) Remove the front engine cover. See ENGINE FRONT COVER in

article. Remove the rocker lever covers and push rods. Refer toNDER HEAD (REPLACEMENT) in this article. Remove cam followermblies.2) Bend lock plates on cap screws on camshaft thrust plate.

ove cap screws. Install Camshaft Installation Pilots (3376280) onr base circle of valve lobes of last two cylinders. See Fig. 22.te camshaft while removing.


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22: Installing Camshaft Pilotsrtesy of Cummins Engine Co., Inc.

InspectionRemove camshaft pilots. Inspect camshaft for flaking or flat

s. Use magnetic method to check camshaft for cracks. Usingometer, measure each journal. See CAMSHAFT table at the end of

article. Replace camshaft if worn. Measure camshaft nose andst plate. See CAMSHAFT GEAR in this article.

Installation1) Install camshaft pilots on valve lobes for last two

ders. Lubricate camshaft and camshaft bushings with LubriplateInstall camshaft. Rotate camshaft backward and forward whilelling.2) Align timing mark on camshaft gear with mark on camshaftgear. See Fig. 21. Check that gear spacer plate gasket is notenting thrust plate from fitting flat against cylinder block.ll cap screws in thrust plate. See TORQUE SPECIFICATIONS table.

d locks over cap screws.

3) Check camshaft end clearance. Install dial indicator onof cylinder block. Place tip of indicator against face of

shaft gear. Push camshaft toward rear of engine. Adjust dialator to "O" (zero). Pull camshaft forward and note reading. SeeSHAFT CLEARANCE SPECIFICATIONS table. If end clearance is notn specifications, check for foreign material or gasket underst plate.

SHAFT CLEARANCE SPECIFICATIONS

cation In. (mm)

Clearance ........................ .006-.013 (.15-.33)

4) Check camshaft gear backlash. See IDLER GEARS in thise. Check injection timing if camshaft gear, camshaft gear key orshaft is replaced. See INJ ECTION TIMING in this article. Installengine cover.

CAMSHAFT GEAR

RemovalPlace camshaft in hydraulic press. Place "V" blocks under

shaft gear. Place wooden block under camshaft to prevent damage

n camshaft drops from camshaft gear. Press camshaft from gear. Marktion of key in camshaft.


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Inspection1) Check camshaft gear for cracks, chipped or broken teeth.

ect bore for fretting, burrs or cracking in keyway. Replaceshaft gear if fretting cannot be removed with a fine crocus cloth.2) Measure inside bore diameter of camshaft gear. SeeSHAFT GEAR SPECIFICATIONS table. Replace camshaft gear if beyond

s. Measure thickness of thrust plate. SeeUST PLATE SPECIFICATIONS table.3) Check camshaft keyway for cracks, fretting or burrs.

sure camshaft gear area in two areas 90 apart. SeeSHAFT GEAR SPECIFICATIONS table. Replace camshaft if beyond limitskeyway is cracked.

SHAFT GEAR SPECIFICATIONS

cation In. (mm)

r J ournal O.D. .......... 2.2520-2.2525 (57.200-57.210)r Bore I.D. ............. 2.2490-2.2500 (57.124-57.150)

UST PLATE SPECIFICATIONS

cation In. (mm)

st Plate Clearance ............... .006-.013 (.15-.33)st Plate Thickness ............. .359-.372 (9.12-9.44)

Installation1) Using a soft hammer, install key in camshaft. Check that

s installed in original position. If using new key, check thate part number key is used. Install thrust plate on camshaft.ved side must be against the camshaft gear.2) Heat gear in over at 450F (235C) for at least one hour.

ll camshaft in hydraulic press. Install heated gear on camshafting key and keyway. Timing mark on camshaft gear must face awaycamshaft. Press gear onto camshaft.3) Keep camshaft in vertical position until gear has cooled.

g feeler gauge, check clearance between gear and thrust plate. SeeUST PLATE SPECIFICATIONS table. Check injection timing when key orshaft gear is replaced. See INJ ECTION TIMING in this article.

CAMSHAFT BEARINGS

Inspection1) Inspect bearings for turning in cylinder block. Check

ment of oil passage holes. If bearings have turned, measureshaft bearing bore in cylinder block. See CYLINDER BLOCK in thise.2) Using dial bore gauge, measure inside diameter of camshaft

ings. Replace bearings if worn larger than specification. SeeSHAFT BEARING SPECIFICATIONS table.

SHAFT BEARING SPECIFICATIONS

cation In. (mm)

ing I.D. ............... 3.0000-3.0035 (76.200-76.289)


32/63CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 32)For

Removal1) Camshaft bearing bore in cylinder block must be determined

re removing camshaft bearings. Engines serial numbers greater than03629 have 3.354" (8.26 mm) bores. Engines serial numbers less than

03629 have 3.188" (8.10 mm) bores. Use Camshaft Bearing Driver6637) and Mandrel (3376634) for 3.188" (8.10 mm) bores. Usedrel (3376635) for 3.254" (8.26 mm) bores.2) Install tool assembly through camshaft bore until driver

ainst No. 1 camshaft bearing. Hit slide hammer against shaftmbly until camshaft bearing is removed. Remove remaining camshaftings.

Installation1) Different styles of camshaft bearings are used on 3.188"

0 mm) bores. Some camshaft bearings have a 131 groove on thede diameter of camshaft bearing. This type camshaft bearing mustsed if engine is equipped with J acobs Brake. Camshaft bearings

out groove can be used if not equipped with J acobs Brake.2) Camshaft bearings for the 3.254" (8.26 mm) bores have a

groove around outside diameter of bearing. Notch in bearing mustositioned toward front of cylinder block.3) Align oil holes of camshaft bearings. Using driver and

er mandrel, install camshaft bearings. Bearing must be installedgroove on the back is even with edge of cylinder block. Frontshaft bearing must be installed until it is even or below surfacelinder block.4) Each bearing contains four oil holes. All oil holes must

igned except on front camshaft bearing. There are no oil holes towith upper oil holes of front camshaft bearings. Using 1/4"m) Allen wrench, check alignment of all oil holes.

INJECTION TIMING

1) Remove valve cover. Remove rocker arms and crossheadsmbly from cylinder No. 3. Remove injector from cylinder No. 3.ll Injector Timing Set (3375522) to cylinder head. See Fig. 23.ll push rod plunger support in outside slot in piston plungerort.

23: Injector Timing Set Installedrtesy of Cummins Engine Co., Inc.

2) Align push rod plunger support with mark and tightenning bolts. Ensure rods are straight. Slowly rotate engine, using


33/63CUMMINS "K" SERIES 6-CYLINDERArticle Tex

kshaft, clockwise (viewed from front of engine). When bothgers start moving upward, cylinder is on compression stroke.3) When piston plunger dial indicator goes upward and then

s, piston is at TDC. Rotate engine until dial indicator starts toe downward. Rotate engine in opposite direction until dialator starts to move downward.

4) Cylinder should be slightly BTDC. Slowly move crankshaftterclockwise (viewed from front of engine) until dial indicator

moved downward a minimum of .50" (12.7 mm). Lock dial indicator ine. Slowly rotate engine clockwise (viewed from front of engine)dial indicator stops turning clockwise. Engine should be at TDC.5) Move dial indicator down until there is only .10" (2.5 mm)

ement on dial indicator. Zero dial indicator. Slowly rotate enginekwise and counterclockwise. Dial indicator should always stop atbefore reversing direction.6) If so, dial indicator is adjusted correctly. If not,

just dial indicator. Turn push rod dial indicator so stem touchesger. Carefully lower dial indicator until it bottoms out. Raisendicator when reading is a minimum of .30" (7.6 mm).

7) Slowly turn crankshaft clockwise (viewed from front ofne) until push rod dial indicator stops, and then reversestion and stops. Momentarily reverse movement is the crush of theshaft lobe.8) Carefully lower push rod travel dial indicator until it

oms out. Raise dial indicator until it reads .050" (1.27 mm) andin place. Zero dial indicator. Slowly rotate engineterclockwise (viewed from front of engine) until dial indicators zero.9) Continue to rotate engine counterclockwise (viewed fromof engine) until dial indicator reads .250" (6.35 mm). Slowlye engine until dial indicator reads .2032" (5.16 mm). If enginerotated past .2032" (5.16 mm), rotate engine in opposite direction50" (6.35 mm).10) Rotate engine clockwise (viewed from front of engine) to

2" (5.16 mm). Dial indicator reading should be more thanvolution. Read push rod dial indicator counterclockwise from zero.reading is the injection timing specification. SeeCTION TIMING SPECIFICATIONS table for correct reading.11) If injection timing is as specified and a slip-fit gear

ing used, replace gear with a standard gear. Recheck injectionng after camshaft gear has cooled. If injection timing is not asified, recheck injection timing.12) If injection timing is still not as specified, adjust

ng by replacing camshaft key with an offset key. See

SET KEY SPECIFICATION table in this article. Place offset key inshaft and recheck timing.

CTION TIMING SPECIFICATIONS

ng Code (1) (2) Injection Timing

.............................. .106-.110" (2.7-2.8 mm)

............................... .116-.120" (2.9-3.0 mm)

.............................. .161-.165" (4.1-4.2 mm)

............................. .112-.116" (2.8-2.9 mm)

.............................. .142-.146" (3.6-3.7 mm)

............................... .126-.130" (3.2-3.3 mm)

Push rod travel at .2032" (5.161 mm).


34/63CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 34)For cyph8r pacif

All injection timing readings are negativemeasurements.

SET KEY SPECIFICATIONS

et Key OffsetNo. In. (mm)

294 ...................................... .0035 (.089)711 ...................................... .0070 (.179)782 ...................................... .0110 (.279)709 ...................................... .0150 (.381)704 ...................................... .0197 (.500)708 ...................................... .0230 (.584)0491 ..................................... .0270 (.686)706 ...................................... .0328 (.833)0492 ..................................... .0360 (.914)714 ...................................... .0390 (.991)

0493 .................................... .0430 (1.092)0494 .................................... .0470 (1.194)0495 .................................... .0510 (1.295)

OIL PAN & SUCTION TUBE

RemovalRemove cap screws from oil pan sump. Remove oil cover plate.

Fig. 24. Remove cap screws from suction tube mounting bracket.ove suction tube.

24: Removing Oil Panrtesy of Cummins Engine Co., Inc.

InstallationInstall suction tube and gasket on cylinder block. Tighten

screws to cylinder block, then tighten mounting bracket capws. See TORQUE SPECIFICATIONS table. Install guide studs inpter. Install gasket. Install oil sump and oil cover plate. Capws must be tightened in sequence. See Fig. 25. Tighten cap screws.TORQUE SPECIFICATIONS table.


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25: Oil Pan Tightening Sequencertesy of Cummins Engine Co., Inc.

OIL PAN ADAPTER

RemovalRemove cap screws from rear of adapter-to-flywheel housing.

ove remaining cap screws from adapter. Remove adapter and gaskets.

Installation1) Check that all gasket surfaces are clean. Install four cap

w seals in rear of adapter. Contact adhesive can be used to holdscrew seals. Install two rectangular seals on rear of adapter.angular seals have adhesive on one side. Install gasket on adapterg contact adhesive.

2) Apply Sealant (Part No. 3377132) to areas between adapter

et and rectangular seals. Apply sealant to rear of rectangulars. Install guide studs in cylinder block. Install adapter. Installscrews to support adapter. DO NOT tighten cap screws.3) Install cap screws in rear corners of adapter. Install

er cap screws into flywheel housing. See Fig. 26. Tighten capws to 10, 20 and 35 ft. lbs. (15, 25, and 45 N.m).

26: Install Adapter Cap Screwsrtesy of Cummins Engine Co., Inc.

4) Install lower cap screws from adapter into flywheeling. Tighten cap screws to 35 ft. lbs. (45 N.m). Remaining capws must be tightened in sequence. See Fig. 27. Tighten cap screws

5 ft. lbs. (45 N.m).


36/63MMINS "K" SERIES 6-CYLINDERArticle Text (p. 36)For cyph8r pacific la ca 921011996 Mitchell International, All Rig

27: Adapter Tightening Sequencertesy of Cummins Engine Co., Inc.

PISTON, CONNECTING ROD & CYLINDER LINER

PISTONS & ROD ASSEMBLY

Removal1) Remove cylinder head. See CYLINDER HEAD (REPLACEMENT) in

article. Remove oil pan. See OIL PAN in this article. Use 240emery cloth to remove carbon deposits from cylinder liner. Removee carbon from cylinder liner.

2) Loosen connecting rod cap screws. Using rubber hammer, hitecting rod cap screws to loosen from dowel rings. Connecting rodmblies are numbered for cylinder location. Numbers must faceshaft side of engine. Remove connecting rod cap screws and rod cap.k bearings for location if bearings are to be reused.

3) Install Connecting Rod Pins (3375098) in connecting rod.assembly from cylinder block. Place assembly in container to

ent damage.

DisassemblyUsing Piston Ring Expander (ST-1269), remove piston rings.

ove piston pin snap rings. To remove piston pin, heat piston inng water for 15 minutes. Using blunt tool, push pin from pistonrod assembly.

Cleaning & Inspection (Piston)1) Soak pistons in aluminum cleaner. Clean pistons with a

y solution and non-metallic brush. Steam clean pistons and drycompressed air.

TION: DO NOT clean pistons with wire brush or glass beads. Thiscauses damage to grooves and pin bores.

2) Inspect piston for skirt or pin bore cracks. Insert PistonGroove Wear Gauge (ST-560) into top and second ring grooves.

est part of tool must not come in touch with piston. Replace iflder touches piston. Measure width of oil ring groove. Refer to

PISTON SPECIFICATIONS table.3) Using a dial bore gauge, measure the piston pin bore at

areas 90 apart. Also measure the piston skirt diameter at twoions 90 apart. Refer to the PISTON SPECIFICATIONS table. Also,Fig. 28. Measure piston pin outside diameter at two areas 90t. See PISTON PIN SPECIFICATIONS table. Replace parts not withinifications.


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28: Measuring Piston Skirt Diameterrtesy of Cummins Engine Co., Inc.

ON SPECIFICATIONS

cation In. (mm)

surement 1 ............ 6.2380-6.2390 (158.445-158.471)surement 2 ............ 6.2389-6.2409 (158.468-158.518)

Ring Groove Width .......... .1855-.1895 (4.788-4.813)Bore ................... 2.3985-2.3989 (60.922-60.932)

ON PIN SPECIFICATIONS

cation In. (mm)

O.D. ................... 2.3988-2.3990 (60.929-60.940)

Cleaning & Inspection (Connecting Rod)1) Steam clean connecting rod. Clean oil passages with

e brush. Dry with compressed air. Check connecting rod for nickamage. Connecting rod should be checked for cracks using magnetichod. Replace rod if damaged. Check rod pin bushing for cracking orlignment of oil passage hole. Replace bushing if damaged.2) Install connecting rod cap and cap screws. Tighten cap

ws. Refer to the TORQUE SPECIFICATIONS table. Using a dial boree, measure connecting rod journal bore at two areas 90 apart.r to the CONNECTING ROD SPECIFICATIONS table. Using a dial bore

ge, measure the piston pin bushing at two locations 90 apart. SeeCONNECTING ROD SPECIFICATIONS table. Replace parts not withinifications.

NECTING ROD SPECIFICATIONS

cation In. (mm)

J ournal Bore I.D. .... 4.2518-4.2522 (107.995-108.005)n Pin Bushing I.D. .... 2.4010-2.4025 (60.990-61.020)


38/63

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 38)

Reassembly1) Check piston ring end gap. See FITTING PISTON RINGS in

article. Install new snap ring in piston pin bore of each piston.pistons in oven heated to 200F (93C) for 15 minutes. Coat

ecting rod pin bushing and piston pin with 15W-40 oil.2) Remove piston from oven. Install piston pin throughecting rod. DO NOT drive piston pin through piston. Damage willt if piston pin will not slide freely. Install new snap ring inn pin bore. Check that snap rings are properly seated in grooves.

Installation1) Install piston rings. See FITTING PISTON RINGS in this

e. Install piston and ring assembly in container of 15W-40 oil.ove piston assembly. Position piston rings in proper location. See29. Install Connecting Rod Guide Pins (3375098) on connectingUsing Piston Ring Compressor (3375342), compress piston rings.

29: Alignment of Piston Rings

rtesy of Cummins Engine Co., Inc.

2) Install upper connecting rod bearing in connecting rod.g of bearing shell must be in slot of connecting rod. Connectingbearing must be placed in original position if used bearing shellsnstalled. Coat bearing surface with 15W-40 oil.3) Rotate crankshaft until connecting rod journal is at

om dead center. Position piston assembly so that number onecting rod is toward camshaft side of engine. Place piston on toplinder liner.4) Push piston assembly into cylinder liner. DO NOT use metal

ct to install piston. Push piston until top piston ring entersder liner. Piston must move freely from ring compressor into

der liner. If piston does not move freely, remove piston andk for damage to rings.5) Using guide studs, pull connecting rod against crankshaft.

ove guide studs. Install bearing shell in connecting rod cap. Coating surface with 15W-40 oil. Install cap so that bearing slot sidep is against slot side of connecting rod. Number on connecting

and cap must be on same side.

TION: Check that number on connecting rod and cap are on camshaftside of engine. Numbers on connecting rod and cap mustmatch.

6) Coat cap screws with 15W-40 oil. Install cap screws.ten cap screws in alternating sequence. See TORQUE SPECIFICATIONS

e. Connecting rod must move freely from side to side. If


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CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 39)

ecting rod will not move freely, check bearing for damage ander size.7) Check connecting rod side clearance. Push the connecting

o one side as far as possible. Using a feeler gauge, measureance between the connecting rod and the crankshaft. Refer to theNKSHAFT MAIN & CONNECTING ROD BEARINGS table.

8) If side clearance is not within specifications, remove rod. Check bearings for damage, dirt or proper size. Install oil pan.ll cylinder head.

CYLINDER LINER

Removal1) Install Liner Puller (3376015) on top of cylinder block.

st feet of puller to extend below bottom of the cylinder liner.er puller on cylinder block.

TION: When installing and using liner puller use care not todamage piston spray nozzles (if equipped).

2) Rotate liner puller clockwise. Remove liner from cylinderk. Check for shims or counterbore ring used in liner counterbore.k shims or ring and cylinder liners as to cylinder location.

Cleaning & Inspection1) Clean liner seating flange using high quality wire brush.

m clean liners. Dry with compressed air. Check for cracks insideoutside cylinder liners. Inspect or cracks under liner flange.ck outside of liner for excessive pitting or corrosion. Pits mustbe deeper than 1/16" (1.58 mm). Replace if corrosion cannot beoved using fine emery paper. Replace if pitting exceeds limit.2) Replace is signs of scoring exist. Check for a bright

or finish inside cylinder liner. Replace if mirror finish exists20% of piston travel area. With dial bore gauge, measure insideeter in three places 90 apart.3) Compare readings to those in CYLINDER LINER SPECIFICATIONS

e. Replace cylinder liner if not within specifications.

NDER LINER SPECIFICATIONS

Minimum MaximumReading Reading

cation In. (mm) In. (mm)

e Diameter (1) .. 6.2495 (158.74) .. 6.2550 (158.88)r Protrusion (2) ... .003 (.08) ......... .006 (.15)

New cylinder liner dimensions at 60-70F (16-21C) maybe .0002-.0006" (.005-.015 mm) smaller than indicatedue to lubrite coating.Liner installed.

Installation1) Install shims or counterbore ring on liner. Curved edge ofterbore ring must face cylinder block. Install crevice seal in topve of clean cylinder liner. Chamfer on crevice seal goes toward

om of cylinder liner. Install Black "O" ring in second groove.e Red "O" ring in lower groove. Ensure "O" rings are not twisted.


40/63CUMMINS "K" SERIES 6-CYLINDERArticle Te

TION: Cylinder block counterbore must be checked before installingcylinder liner.

2) Check counterbore. See CYLINDER BLOCK in this article.re counterbore and cylinder liner flange are clean. Apply a bead

ealant (3801048) on cylinder liner flange. If counterbore ring is, apply sealant to bottom of ring. Diameter of bead must be at3/64" (1.1 mm) and not more than 1/16" (1.6 mm).3) Lubricate crevice seal and "O" rings with vegetable oil.

e liner in cylinder block. DO NOT allow oil to touch sealant. Pushin with a quick push. Install liner against counterbore ledge

g Cylinder Liner Driver (3375422). See Fig. 30.

30: Installing Cylinder Linerrtesy of Cummins Engine Co., Inc.

4) Install Cylinder Liner Hold-Down (3376944). Tighten capws to 50 ft. lbs. (65 N.m). Use Gauge Block (3376220) to checkprotrusion. Refer to the CYLINDER LINER SPECIFICATIONS table.

Fig. 31. If not within specifications, liner shims or oversize

s may be required.

31: Checking Cylinder Liner Protrusionrtesy of Cummins Engine Co., Inc.

5) Measure inside diameter of cylinder liner at three areasapart. See CYLINDER LINER SPECIFICATIONS table. Check liner boreut-of-round. See Fig. 32.


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32: Cylinder Liner Bore Check Pointsrtesy of Cummins Engine Co., Inc.

6) If measurements are not within specifications, removeCheck for twisted "O" rings. Check liner flange and counterbore

urrs. Remove burrs. Replace damaged parts. Install cylinderCheck liner measurements.

FITTING PISTON RINGS

1) Check new piston rings in the new cylinder liner to whichare to be installed. Make sure ends have correct gap byioning each ring in cylinder liner. Use top of piston to evenin cylinder liner. Measure end gap with a feeler gauge. See

ONS, PINS & RINGS table at the end of this article. If ring gap is

rrect, check part numbers to make sure rings are correct.2) Use Piston Ring Expander (ST-763) to install piston rings.

ll oil control ring first. Install expander ring gap 180 fromng gap. Piston shipping package identifies location of eachn ring by part number. Install piston rings with the part number,k or the word TOP toward the top of piston.

CRANKSHAFT & ROD BEARINGS

MAIN BEARINGS

Removal1) Remove main bearing cap screws, starting at each end andng toward center of crankshaft. Main bearing caps are marked as to

der location. Mark bearing caps if they are not marked. Use twobars. Place pry bars in notches at sides of the caps. Remove maining caps. Care must be taken when removing No. 6 bearing cap tod damage to dowels.

2) Mark all bearings to location. Remove thrust bearings from6 bearing cap. Carefully remove upper thrust bearings using bluntct. Lift crankshaft from cylinder block. Remove upper main bearings.

Cleaning & Inspection1) Clean main bearing caps and cap screws. Clean cap screw

s in cylinder block. Inspect cap screws and main bearing caps forks. Clean bearing and inspect them for scoring, pitting, flaking,

ng, loss of babbitt or signs of overheating.2) Inspect backs of main bearing shells for bright spots


42/63CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 42

h indicate they have been moving in the bearing caps. Replaceing if any of these signs are present.

Installation1) Check that main bearing cap screw holes are clean and dry.

ck that crankshaft journals and oil passages are clean. Main

ing shells are marked on back side for upper and lower location.ll upper bearing shells. Used bearing shells must be installed innal position. Tang on bearing shell must fit in slot of cylinderk. Coat bearing shells with 15W-40 oil. Install crankshaft.2) Push crankshaft toward rear of engine. Coat thrust

ings with 15W-40 oil. Install rear upper thrust bearing. Grooveshrust bearings go toward crankshaft. Push crankshaft toward frontgine. Install front upper thrust bearing.3) Install lower bearing shells in main bearing caps. Coat

n bearings with 15W-40 oil. Install thrust bearings on No. 6 maining cap. Grooves of thrust bearings go toward crankshaft. Install

n bearing caps in proper location.4) Two different types of main bearing cap screws are used.

screws marked "x34" on top have a small radius between shank andhead. Cap screws marked with other markings on top have a largeus between shank and the head. DO NOT mix different cap screws.nes with serial number 31118624 and above have been chamfered atscrew holes for large radius cap screws.5) Use large radius cap screw with chamfered main bearing

. On chamfered main bearing caps, washer is not required with capw. If cap is not chamfered, washer must be used with cap screw.ll radius cap screws may be used on all main bearing caps.6) Coat cap screws with 140W oil. Install cap screws. Cap

ws must be tightened in sequence. See Fig. 33. Tighten cap screws.TORQUE SPECIFICATIONS table. Check that crankshaft rotates freelyand. Check for wrong bearings or improper installation ifkshaft will not rotate freely.

33: Main Bearing Tightening Sequencertesy of Cummins Engine Co., Inc.

THRUST BEARING

1) Install Dial Indicator (3376050) with magnetic base toof cylinder block. Position tip of indicator against crankshaftheel flange. Push crankshaft toward front of cylinder block.st dial indicator to "O" (zero).2) Push crankshaft toward rear of cylinder block and noteng. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table at theof article. If reading is not within specifications, remove No. 4

n bearing cap. Check thrust bearing for burrs or damage. Replace ifaged. If bearings are not damaged, measure outside diameter of


43/63CUMMINS "K" SERIES 6-CYLINDERArticle Te

st bearings. Select proper size thrust bearing to reachification. Install thrust bearing and recheck end play.

E: When an engine is being rebuilt, it may be necessary to bringcrankshaft end play to specifications by using areconditioned crankshaft and oversize thrust bearings.

CONNECTION ROD BEARING

Removal1) Remove oil pan. See OIL PAN in this article. Rotate engine

connecting rod is at bottom dead center. Loosen cap screws. Hitecting rod cap screws with soft hammer. This loosens rod caps fromel r

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