Index Page 1 About the Manual ....................................................................... i-2 Accessory Drive Pulley - Cleaning and Inspection for Reuse . 9-17 Cleaning................................................................................. 9-17 Inspection............................................................................... 9-17 Air Compressor - Cleaning and Inspection for Reuse ............ 12-6 Cleaning................................................................................. 12-6 Inspection............................................................................... 12-6 Air Equipment - General Information ......................................
12-2 Air Intake System - General Information ................................. 10-4 Alternator Adjusting Link - Cleaning and Inspection for Reuse ....................................................................................... 13-3 Inspection............................................................................... 13-3 Alternator Bracket - Cleaning and Inspection for Reuse ....... 13-3 Inspection............................................................................... 13-3 Alternator Bracket (Bus Applications) - Cleaning and Inspection for Reuse ...............................................................
13-4 Cleaning................................................................................. 13-4 Inspection............................................................................... 13-4 Automatic Belt Tensioner Bracket (Bus Applications) - Cleaning and Inspection for Reuse ........................................ 13-6 Cleaning................................................................................. 13-6 Automatic Belt Tensioner (Bus Applications) - Cleaning and Inspection for Reuse ........................................................ 13-5 Cleaning.................................................................................
13-5 Inspection............................................................................... 13-5 CAC Air Intake System - Exploded View ................................. 10-3 Cam Follower Assembly - Cleaning and Inspection for Reuse . 4-4 Assembly ................................................................................. 4-7 Disassembly............................................................................. 4-4 Inspection ................................................................................ 4-5 Cam Follower Assembly - Exploded View ................................ 4-3 Cam Follower Assembly - General Information ........................
4-4 Cam Follower Assembly - Rebuild ............................................ 4-8 Assembly................................................................................ 4-12 Disassembly............................................................................. 4-8 Inspection ................................................................................ 4-9 Cam Follower Lever - Magnetic Crack Inspection (Roller Removed) ................................................................................. 4-17 Cam Follower Lever - Roller Replacement .............................. 4-13 Assembly................................................................................
4-15 Disassembly........................................................................... 4-13 Inspection............................................................................... 4-14 Cam Follower Lever Socket - Replacement (Roller Removed) . 4-18 Assembly................................................................................ 4-19 Disassembly........................................................................... 4-18 Inspection............................................................................... 4-18 Camshaft - Cleaning and Inspection for Reuse ...................... 1-48 Cleaning.................................................................................
1-48 Inspection............................................................................... 1-49 Camshaft - Magnetic Crack Inspection ................................... 1-54 Bearing Journal - Limits of Acceptance................................... 1-56 Definitions of Indications ........................................................ 1-55 Valve and Injector Lobe - Limits of Acceptance ...................... 1-56 Camshaft Bushing - Replacement .......................................... 1-20 Cleaning................................................................................. 1-20 Inspection...............................................................................
1-21 Installation .............................................................................. 1-21 Removal................................................................................. 1-20 Camshaft Gear - Replacement ................................................ 1-50 Cleaning................................................................................. 1-51 Inspection............................................................................... 1-51 Installation.............................................................................. 1-53 Removal.................................................................................
1-50 Camshaft or Idler Gear - Magnetic Crack Inspection ............. 1-57 Camshaft or Idler Gear - Limits of Acceptance........................ 1-58 Definitions of Indication .......................................................... 1-58 Capscrew Markings and Torque Values .................................. V-46 Capscrew Markings and Torque Values - Metric ..................... V-46 Capscrew Markings and Torque Values - U.S. Customary ...... V-47 Chassis Dynamometer .......................................................... 14-37 General Test Procedure ....................................................... 14-39 Charge Air Cooler Restriction.............................................
14-44 Coolant Pressure ............................................................... 14-46 Engine Blowby ................................................................... 14-45 Engine Speed (RPM) With a Verified Tachometer............... 14-40 Exhaust Air Restriction....................................................... 14-45 Fuel Drain Line Restriction................................................. 14-42 Fuel Inlet Restriction .......................................................... 14-41 Fuel Rate ........................................................................... 14-41 Intake Air Restriction..........................................................
14-44 Intake Air Temperature Control - Chassis Dynamometer Test. 14-43 Intake Manifold Pressure.................................................... 14-43 Lubricating Oil Pressure..................................................... 14-46 Operation ............................................................................ 14-37 Component Manufacturers’ Addresses .................................... C-2 Air Compressors...................................................................... C-2 Air Cylinders............................................................................ C-2 Air Heaters ..............................................................................
C-2 Air Starting Motors................................................................... C-2 Alternators ............................................................................... C-2 Auxiliary Brakes....................................................................... C-2 Belts........................................................................................ C-2 Catalytic Convertors................................................................. C-2 Clutches .................................................................................. C-2 Coolant Heaters.......................................................................
C-2 Drive Plates ............................................................................. C-2 Electric Starting Motors............................................................ C-3 Engine Protection Controls ...................................................... C-3 Fan Clutches ........................................................................... C-3 Fans ........................................................................................ C-3 Filters ...................................................................................... C-3 Flexplates ................................................................................
C-3 Fuel Warmers .......................................................................... C-3 Gauges.................................................................................... C-3 Governors................................................................................ C-3 Heat Sleeves ........................................................................... C-4 Hydraulic and Power Steering Pumps ...................................... C-4 Oil Heaters .............................................................................. C-4 Torque Converters....................................................................
C-4 Component Specifications and Torque Values ........................ V-3 Air Equipment - Inspection Specifications............................... V-39 Air Intake System - Inspection Specifications ......................... V-39 Cam Follower Assembly - Rebuild Specifications .................. V-30 Cooling System - Rebuild Specifications ................................ V-34 Cooling System - Torque Values............................................. V-36 Cylinder Block - Rebuild Specifications .................................. V-18 Cylinder Block - Torque Values............................................... V-26 Cylinder Head - Rebuild Specifications ..................................
V-26 Cylinder Head - Torque Values ............................................... V-29 Drive Units - Rebuild Specifications ....................................... V-37 Electrical Equipment - Inspection Specifications..................... V-40 Engine Assembly - Capscrew Torque Values ............................ V-8 Engine Assembly - Specifications............................................. V-3 Engine Testing - Test Specifications ....................................... V-40 Exhaust System - Torque Values ............................................ V-39 Fuel Pump - Rebuild Specifications........................................
V-31 Fuel Pump - Torque Values .................................................... V-32 Injectors - Rebuild Specifications ........................................... V-33 Lubricating Oil System - Specifications .................................. V-33 Lubricating Oil System - Torque Values .................................. V-34 Mounting Adaptations - Rebuild Specifications ....................... V-40 Rocker Lever Assembly - Rebuild Specifications .................... V-29 Vehicle Braking - Rebuild Specifications................................. V-40 Compressed Air System Flow Diagrams ................................ 12-5 Connecting Rod - Bend and Twist Inspection ........................
1-46 Alignment Inspection.............................................................. 1-48 Fixture Calibration .................................................................. 1-46 Twist Inspection...................................................................... 1-48 Connecting Rod - Cleaning and Inspection for Reuse ........... 1-42 Cleaning................................................................................. 1-42 Inspection............................................................................... 1-43 Connecting Rod - Magnetic Crack Inspection ........................ 1-45 Connecting Rod - Limits of Acceptance ..................................
1-46 Connecting Rod Bearings - Cleaning and Inspection for Reuse ................................................................................. 1-36 Cleaning................................................................................. 1-36 Inspection............................................................................... 1-36 Crankcase Breather (Internal) - Cleaning and Inspection ...... 3-16 Crankshaft - Cleaning and Inspection For Reuse ................... 1-28 Cleaning................................................................................. 1-28 Inspection............................................................................... 1-28