TRUCK SERVICE MANUAL

ENGINE

1. linger 8.Dust Lap I5. Nut 23.Dust cap

2. Keys 9. Oil Seal 16. Coupling 24. Governor Drive Gear
3. Oil Seal 10. Driven Gear 17. Snap Ring 25. Bearing
4. Snap Ring 11. Bushing 19. Drive Gear 26. Drive Gear
5. Drive Shaft 12. Spacer 20. Support 27. Drive Shaft
6. Bushing 13. Spacer 21. Oil Seal
7. Adapter 14. Drive Coupling 22. Adapter

Fig. 9-2, (N10906). Fuel pump, hydraulic governor and hourmeter drive

ASSEMBLY DISASSEMBLY AND INSPECTION

1. Install shaft (7) through housing (5) and bushing (4). 1. Remove nut (15, Fig. 9-2) (if used). With suitable
Slip on larger thrust washer (3) with face up. puller, remove drive coupling (14). Remove spacer (13).
2. Install key (11) and press on drive gear (2). 2. Pull governor drive gear (24) from shaft. Inspect for
3. Turn assembly over; slip on small thrust washer (8) chipped, cracked or worn teeth. Remove key (2).
(face up) and clamp washer. Install coupling key (11). 3. Press drive shaft (27) assembly from support (20).
4. Press on coupling (10), hub end down. Secure with Check for wear or damaged threads.
locknut (9) or washer and capscrew. 4. Press drive gear (26), spacer (12) and hourmeter
5. Install slinger (6) over gear end of shaft. drive gear (19) from shaft. Remove key (2). If used,
6. Check end clearance. It should be as listed in Table press bearing (1) from shaft (27).
9-1(33) with unit assembled. 5. Unscrew dust caps (8 and 23).
Fuel Pump And Hourmeter Drive 6. Using a suitable puller, remove adapters (7 and 22)
The hydraulic governor and hourmeter drive is used to from hourmeter drive. Press drive shaft (5) from support.
drive a hydraulic governor and hourmeter as well as the Remove and discard seals (9) and (21).
fuel pump. Note: One of the drive gear bushings (6 or 11) and the
drive shaft (5) may be damaged during removal of the
shaft. Be sure to check shaft for straightness.

386
 TRUCK SERVICE MANUAL
ENGINE

7. Withdraw drive gear bushings (6 and 11) and driven

gear (10) from support. Remove snap ring (4), bearing
(25) and seal (3) from support.
8. Check all parts for cracks, breaks, wear or rough
mating surface. Replace bushing if worn beyond limits
as shown in Table 9-1(6-11).
ASSEMBLY
1. Press driven gear (10) onto drive shaft (5) to distance
of 3.435 to 3.440 inch [87.25 to 87.38 mm].
2. Press drive gear bushing (11) into bottom of support.
3. Press long end of drive with gear into top of support.
Clearance between gear face and bushing must be 0.015
to 0.040 inch [0.38 to 1.02 mm]).
4. Press second drive gear bushing (6) into top of
support over drive gear. Clearance between gear face
and bushing must be 0.015 to 0.040 inch [0.38 to 1.02
mm].
5. Install oil seals (9 and 21) into top and bottom of
support and seat against bushings. Install adapters (7
and 22) in support. Install dust caps.
6. Press seal (3) and bearing (25) into support; secure
with snap ring (4). Install key (2) in shaft (27) and press
gear (26) onto shaft against shaft shoulder.
7. Install spacer (12) and press hourmeter drive gear
(19) onto shaft (27). Press drive gear assembly into
support.
8. Install key (2) and press governor drive gear (24) onto
shaft. Install spacer (13) and press on drive coupling
(14). Install locknut (if used).

9. Install slinger (1) or press on bearing as used.

DRIVE PULLEYS INSPECTION AND REPAIR

1. Check for cracks and chips in hub, web and groove

areas and for wear in grooves and oil seal sleeve. If
wear on sleeve is visible:
a. Remove worn oil sleeve by splitting with chisel. Do
not damage pulley hub.

b. Press new sleeve onto pulley hub with mandrel, until it

is flush to 0.015 inch [0.38 mm] below face of hub.
Consult latest Parts Catalog for correct pulley/sleeve
combination.

387
 TRUCK SERVICE MANUAL
ENGINE

The intake air system group consists of intake manifolds,

Intake Air System connections, air cleaners, piping, cold-starting aids, and
turbochargers. The turbochargers are covered in separate
Group 10 manuals.

INTAKE MANIFOLDS AND CONNECTIONS

CLEANING AND INSPECTION CAUTION
1. Clean intake manifold or air connection with steam. 6 and 12-volt plugs are not interchangeable.
2. Inspect for chips, cracks, distortions and damaged
threads. Discard unusable parts. 5. Assemble clamp washer (5, Fig. 10-1) and nozzle (2)
3. Damaged threads may be repaired by installing Heli- to adapter (6).
Coils. 6. Tighten nozzle to 15 to 20 ft-lbs [2.1 to 2.8 kg m] and
COLD-STARTING AIDS bend washer over one of hexagonal sides of nozzle.
Preheater 7. Install assembled adapter in intake manifold.
Due to the lower compression ratio of turbocharged Ether-Starting Aids
engines, they may not start unaided below 50 deg. F [10 A pressurized spray can or a rag wet with ether will
deg. C]. For this reason, the glow plug cold-starting aid usually provide quick starting as low as -10 deg. F [-23
is supplied as standard on these engines. deg. C] . Below this temperature, some means of
This aid uses engine fuel which is pressurized by a hand injecting a carbureted ether vapor directly into intake
pump and atomized in a nozzle in the intake system. manifold is necessary.
The
atomized spray is ignited by the glowing coil of the glow
plug and provides sufficient heat for combustion of fuel in CAUTION
the cylinders. Do not attempt to use ether compound type starting
Fuel supply should be obtained from fuel tank. If this is aids near heat, open flame or on engines equipped
impractical, supply may be taken from pipe plug in center with glow plug system.
bottom of fuel pump housing or by a connection in engine
fuel supply line. These methods are not desirable due to
possible deterioration of hand pump seals which may
allow air to be pulled into engine fuel system.
Preheater Servicing
1. Remove preheater adapter (6, Fig. 10-1) and glow
plug (1) from intake manifold.

2. Remove nozzle (2) and clamping washer (5) from

adapter (6).

3. Clean adapter and nozzle with Bendix carburetor

cleaner, or equivalent. Be sure nozzle screen (3, Fig.
10-1) and spray holes are open and clean. Check "O"
ring (4) for damage.
4. Check glow plug on 6-volt or 12-volt source, as
applicable. 1. Glow Plug 4. "0" Ring
2. Nozzle 5. Washer
3. Screen 6. Adapter
Fig. 10-1, (N21019). Glow plug preheater adapter spray
nozzle

388
 TRUCK SERVICE MANUAL
ENGINE

AIR CLEANERS AND PIPING 6. The cleaner requires ’no separate gaskets for seals;
Dry Type Servicing therefore, care must be taken when inserting cartridge to
1. Disassemble cleaner. Clean element with insure a proper seat within air cleaner housing. Firmly
compressed air. press all edges and corners of cartridge with fingers to
2. Wipe out housing with clean cloth. effect a positive air seal against sealing flange of
3. Inspect gasket, replace if not reusable. housing. Under no circumstances should cartridge be
4. Install new or cleaned element. pounded or pressed in center to effect a seal.
5. Assemble cleaner.
7. Assemble cleaner.
Heavy Duty Single And Dual Type Servicing
1. Wipe dirt from cover and upper portion of cleaner. CLEANER RESTRICTION INDICATOR
2. Disassemble cleaner and remove element. 1. The restriction indicator signals when to change
3. Blow out element from clean air side using cartridges. The red flag (1, Fig. 10-2) in window
compressed air of not more than 100 psi [7 kg/sq cm]. gradually rises as cartridge loads with dirt. Do not
4. Wash element with non-sudsing detergent and warm change cartridge until flag reaches top and locks in
water. Dry with compressed air not exceeding 40 psi [2.8 position. When locked, flag will remain up after engine is
kg/sq cm]. shut down. After changing cartridge, reset indicator by
5. Inspect element for holes. pushing re-set button (2). Push button all the way in
6. Install new or cleaned element. firmly; then release. If button sticks, repeat pushing
7. Check air restriction indicator, if air restriction is slowly.
excessive, disassemble air cleaner, remove wing nut and 2. A second method is utilization of a vacuum gauge and
replace safety element. warning light that performs the same function as
8. Reassemble air cleaner. described in Step 1. Components for vacuum gauge
include electrical source (1, Fig. 10-3) air piping (2),
Cartridge Type Air Cleaner Servicing vacuum switch (3) and red warning light (4).
1. Disassemble cleaner. Remove dirty Pamic cartridge
by inserting fingers in cartridge opening. Loosen all four
corners, one at a time by pulling straight out.
2. Clean pre-cleaner or moisture eliminator (where
applicable). Wipe out housing with clean cloth.
3. Inspect housing and all other parts. Replace if
defective.
4. It is not recommended to clean and reuse cartridge.
5. Install a new cartridge; hold cartridge in same manner
as when removing from housing. Insert clean cartridge
into housing; avoid hitting cartridge tubes against sealing
flange on edges of air cleaner housing.

1. Red Flag
2. Re-set Button

Fig. 10-2, (CGS-20). Air cleaner restriction indicator

389
 TRUCK SERVICE MANUAL
ENGINE

TURBOCHARGERS

Refer to TURBOCHARGER SECTION.

Exhaust System
Group 11

The exhaust system group consists of engine exhaust

manifolds, piping and mufflers or silencers.
EXHAUST MANIFOLDS

Exhaust Manifold (Dry Type)

INSPECTION

Inspect exhaust manifold for cracks and distortions;

discard defective parts.

When ordering replacement parts, order same part as

presently used.

390
 TRUCK SERVICE MANUAL
ENGINE

Engine Assembly The engine assembly section covers assembly of all units
and Testing Group 14 and subassemblies to the cylinder block as well as
adjustments and engine testing.

1. Main Bearings 10. Water Pump/Idler Assy. 19. Water By-Puss Tube 28. Rear Cover Assembly
2. Connecting Rod Bearings 11. Fan Hub Assembly 20. Thermostat Housing 29. Flywheel and Housing
3. Crankshaft and Gear 12. Water Inlet Connections 21. Water Manifold Assy 30. Lubricating Oil Pump
4. Cylinder Liner 13. Exhaust Manifolds 22. Rkr Lvr Hsg, Cover/Cap 31. Vib. Damper/Pulley
5. Conn Rod/Piston Assy 14. Fan Hub Mtg Brkt/Supp. 23. Cyl Head and Gasket 32. Cam Follower/Push Tubes
6. Camshaft Gear 15. Cyl Liner Pack Rings 24. Cranking Motor/Spacer 33. Acc Drive/Air Comp/Fuel
7. Camshaft 16. Cylinder Liner Shim 25. Intake Manifold Assy Pump
8. Camshaft Bushings 17. Lub Oil Cooler/Filter 26. Main Bearing Cap 34. Oil Pan and Gasket
9. Gear Cvr/Trunion Bushing 18. Rocker Levers/Shaft 27. Cylinder Block 35. Thermostat

Fig. 14-1, (N 1142356). Engine exploded view

391
 TRUCK SERVICE MANUAL
ENGINE

Table 14-1: Assembly Specifications - Inch [mm] (Reference Fig. 141)

Ref Worn New New
No Measurement Limit Minimum Maximum
1 Main Bearing
Journal Clearance 0.007 0.0015 0.005 ,
[0.18] [0.038] [0.13]
2 Connecting Rod Bearing
Journal Clearance 1 0.007 0.0015 0.0045
’U
[0.18] [0.038] [0.114]
3 Crankshaft
End Clearance 2 0.022 0.007 0.017
[0.56] [0.18] [0.43]
4 Cylinder Liner
Protrusion 3 0.003 0.006
[0.08] [0.15]
,
Out of Round 0.003
Top One(1) Inch 4 [0.081]
Out of Round 0.002
Packing Ring (Lower) area 5 [0.05]
5 Connecting Rod
Side Clearance 6 0.0045 0.013
[0.114] [0.33]
6 Gear Train (Gear to Gear) Crankshaft,
Camshaft, Accessory Drive and
Lubricating Oil Pump
Backlash 0.020 0.0045 0.0105
[0.511 [0.114] [0.267]
7 Camshaft (With Thrust Plate)
End Clearance 0.001 0.005
[0.031 [0.13]
(With Outboard Bearing Support)
End Clearance 0.008 0.013
[0.20] [0.33]
8 Injection Timing 7
Refer to Table 14-3
9 Injector, Crosshead and Valve Adjustments
Refer to Injector and Valve Adjustment
10 Dynamometer Testing
Refer to Test Procedure
11 Lubricating Oil Pressure
Refer to Table 14-15
12 Blow-By
Refer to Test Procedure
13 Back Pressure
Refer to In-Chassis Run-In

Crankshaft Flange Capscrew Torque Specifications - ft-lb. [kg m]

Engine Model Part No Minimum Maximum
14 NT-Series 196653 Capscrew 250 270
196654 Retainer [34.9] [38.8]

392
 TRUCK SERVICE MANUAL ENGINE

Service Tools (Or Equivalent) Required 2. Lift cylinder block and secure to block mounting plate
Service Tool with lockwashers and capscrews.
Tool Number Name Crankshaft And Main Bearings
ST-112 Dial Gauge Attachment 1. Turn cylinder block upside-down.
ST-435 Pressure Gauge 2. Using a clean rag, wipe main bearing bores and main
ST-487 Blow-By Checking Tool bearing shells clean. Lay upper main bearing shells in
ST-547 Gauge Block block. All upper main bearing shells are grooved and
ST-593 Timing Fixture
drilled for lubrication. No’s. 1, 3 and 5 are alike and
ST-835 "O" Ring Loader
ST-997 Seal And Sleeve Driver No’s. 2, 4 and 6 are alike; No. 7 shell has oil groove off-
ST-1172 Seal Mandrel center. The wide portion of the shell is installed toward
ST-1173 Seal Mandrel flywheel end of block. Groove on each shell for dowel
ST-1 176 Piston Ring Compressor Sleeve ring must match with counterbore at capscrew hole on
ST-1170 Injector Indicator exhaust manifold side of block.
ST-1182 Valve Spring Spray Nozzle 3. Install main bearing ring dowels. Coat upper main
Locator
bearing shells thoroughly with clean lubricating oil.
(80 deg. Tilt Engine)
ST-1193 Rocker Lever Actuator 4. Lift crankshaft into position, using hooks protected
ST-1229 Liner Driver with
ST-1259 Seal Mandrel (Teflon Seal) rubber hose or a rope sling at two crank throws. Check
ST-1260 Seal Pilot (Teflon Seal) rear counterweight of crankshaft to see if oversize thrust
Desirable (Or Equivalent) Service Tools rings are to be used and where installed, front or rear.
ST-163 Engine Support Stand Roll upper thrust rings into position, babbitt or grooved
ST-386 Pulley Assembly Tool sides next to crankshaft flanges. Upper thrust rings are
ST-406 Drill Reamer Fixture not doweled to block; lower halves are doweled to cap.
ST-548 Engine Rebuild Stand
5, Coat lower main bearing shells and crankshaft
ST-669 Torque Wrench Adapter
ST-763 Piston Ring Expander surface, with clean lubricating oil. Snap into place over
ST-756 Engine Lifting Fixture crankshaft. 6. Install lower thrust rings, rings must be
ST-805 Block Mounting Plate located over dowels in No. 7 main bearing cap.
ST-968 Belt Gauge 7. Install main bearing caps with numbers corresponding
ST-1138 Belt Gauge to those stamped on block on camshaft side of engine.
ST-1184 Cylinder Liner Hold-Down Tool 8. Lubricate main bearing capscrew threads with clean
ST-1190 Fuel Consumption Measuring
engine lubricating oil, coat under head of capscrew and
Device
None Smoke Meter (order from lockplates with SAE 140W gear lubricant and install
Cummins lockplates, start each capscrew; tighten alternately and
Distributors) slowly, to set caps into position.
Standard Tools - Obtain Locally 9. Tighten main bearing capscrews by template method.
0-150 Inch-pound Torque Wrench a. Tighten main bearing capscrews to 140 to 150 ft-lbs
0-250 Foot-pound Torque Wrench [19.4 to 20.7 kg ml .
0-600 Foot-pound Torque Wrench b. Continue to tighten capscrews to 300 to 310 ft-lbs
Dial Indicator (Starret No. 196A) [41.5 to 42.9 kg ml to "set" shells, caps and lockplates.
Dial Indicator Sleeve (Starret No. 196- c. Loosen completely; retighten to 140 to 150 ft-lbs [19.3
L)
Manometer (Mercury or Water) to 20.7 kg ml .
0-1 Micrometer d. Tighten both capscrews on each cap alternately and
Impact Wrench evenly to 300 to 310 ft-lbs [41.5 to 42.9 kg ml torque.
Engine and/or Chassis Dynamometer Note: There are two torque methods which are
Hoist (Power or Chain) acceptable:
Straight Edge Template and Torque method. Refer to Groups 1 and 8.
Feeler Gauge
10. Attach dial indicator gauge securely to rear of
cylinder block with contact point of gauge resting on
ENGINE ASSEMBLY crankshaft flange end face. With a pry bar, pry
Mount Cylinder Block To Engine Stand crankshaft toward front of engine. Remove pry bar and
1. Secure ST-805 Block Mounting Plate to ST-548 Engine set gauge at "O."
Rebuild Stand. Secure water header cover plate adapter and 11. Pry crankshaft toward rear of engine. Total gauge
adapter plate to cylinder block. reading should be 0.007 to 0.017 inch [0.18 to 0.43 mm],
with a new crankshaft and thrust rings.
393
 TRUCK SERVICE MANUAL ENGINE

12. If reading is less than 0.007 inch [0.18 mm]: not over-expanded. The measured gap should not be
a. Loosen bearing cap capscrews slightly. expanded more than eight (8) times the nominal radial
b. Shift crankshaft first toward front and then toward rear wall thickness of the ring. Stagger ring gaps so they are
of engine. not in line with each other or piston pin. Lubricate piston
c. Retighten capscrews by template method, Step 9. and rings with clean engine lubricating oil.
d. Recheck clearance. 4. Slide connecting rod cap from bolts. Make certain
13. If reading is more than 0.022 inch [0.56 mm], bolt heads are seated squarely on rod shoulder. Keep
crankshaft must be reworked or oversize thrust rings rod cap with mating connecting rod.
used. 5. Turn engine to vertical position on engine stand and
Cylinder Liners rotate crankshaft so any two crank throws are at bottom-
1. Before installing cylinder liners, check protrusion. If center position.
’necessary, install shims around liner to maintain 0.003 to 6. Compress rings with ST-1176, insert piston and rod
0.006 inch [0.08 to 0.15 mm] protrusion. assembly into cylinder. Position numbered side of rod
2. Just prior to installation lubricate packing rings with a toward camshaft side of block. Push piston and rod
light coat of clean lubricating oil, roll into position and assembly through ring compressor until rings are in liner.
install crevice seal. Using mold mark on ring as guide, Use care to prevent scratching of liners.
straighten as required. 7. Pull piston and rod assembly down by rod bolts, leave
Caution: To prevent swelling of "0(’ rings, lubricate assembly short of seating to allow insertion of bearing
lightly with clean engine lubricating oil, just prior to shell.
installation. Make sure proper part numbers are 8. Coat crank side of rod bearing shells with clean
used. lubricating oil, roll rod bearing shell into rod. Shell locking
3. Lubricate machined portions of block on which rings tang must fit in milled recess. Seat rod on crank journal.
seat with a light coat of clean engine lubricating oil. 9. Seat lower shell in rod cap and install rod cap over
4. Place liner in block by hand, being careful to avoid bolts so numbered side of cap is matched with numbered
dislodging "O" rings and crevice seal. Press liner into side of rod.
position. Use ST-1229 Liner Driver to drive liner securely Note: Lubricate hardened washers with SAE 140W gear
into the block so it fits squarely into block bore. lubricant before installation.
5. Install ST-1184 Cylinder Liner Hold-Down Tool so foot 10. Lubricate bolt and nut threads on 855 C.lI.D.
of tool rests upon cylinder liner "fire ring." Secure tool, Engines
space capscrews so even load will be applied. Tighten with clean lubricating oil. Install new hardened
capscrews to 50 ft-lbs [6.9 kg m] torque. flatwashers and nuts to bolts. Tighten nuts by Template
8. Use’ ST-547 Gauge Block to determine if protrusion Method, see Table 14-2.
meets specifications.
7. Check liner bore with precision dial bore gauge, for Table 14-2: Tightening Connecting Rod Nuts
roundness at several points within range of piston travel. Tightening Sequence Tightening Values
If liner is more than 0.002 inch [0.05 mm] out-of-round in With Hardened Washer Ft-Lb [kg ml
packing ring area, remove liner and check for cause of Step 1 Tighten to 70 to 75 [9.7 to 10.3]
distortion. It is permissible to have 0.003 inch [0.08 mm] Step 2 Tighten to 140 to 150 [19.4 to 20.7)
out-of-round at the top 1 inch [25.4 mm] of liner bore. Step 3 Loosen all Completely
Connecting Rods And Pistons Step 4 Tighten to 25 to 30 [3.5 to 4.1]’
1. Install rings on piston with word "TOP" toward top, Step 5 Advance to 70 to 75 [9.7 to 10.3]
using ST-763.Piston Ring Expander. Step 6 Advance to 140 to 150 [19.4 to 20.7]
2. Over-expanding a piston ring during installation on the
Camshaft And Gear
piston can cause distortion resulting in damage leading
1. Coat- both sides of thrust ring with high pressure
to failure. The ring should only be expanded enough to
lubricant and install over end of camshaft with oil grooves
allow it to pass over the piston.
toward camshaft gear.
3. A simple formula can be applied to insure that a ring
2. Lubricate cam lobes with high pressure lubricant.
is
Install camshaft, rotating slowly, being careful not to
damage lobes and bushings.
3. Index timing mark on camshaft gear with mark on
crankshaft gear. Fig. 14-3.

394
 TRUCK SERVICE MANUAL
ENGINE

4. Attach dial indicator gauge to block, Fig. 14-4, check Cylinder Heads
the camshaft to crankshaft gear backlash. Rotate gear 1. Plug breather hole on turbocharged engine heads with
as far as it will move, zero the gauge. Rotate gear in 1/8 inch [3.18 mm] pipe plug. Breather hole is located at
opposite direction and read dial. top of head above intake air port.
5. Normal backlash is 0.0045 to 0.0105 inch [0.114 to 2. Install gasket over dowels so word "TOP" on gasket is
0.267 mm] on a new gear, with a minimum of 0.002 inch visible. Use gasket with standard (white) grommets
[0.05 mm]. (0.097 to 0.103 inch [3.8 to 4.1 mm] thick) if water holes
6. Gears will rattle if backlash exceeds 0.010 inch [0.25 are free of erosion. Use service (black) grommets (0.107
mm]. If noise is not objectionable, do not replace gears to 0.113 inch [4.2 to 4.4 mm] thick) if there is evidence of
unless backlash exceeds 0.020 inch [0.51 mm] . erosion. No grommet retainers are required.
3. Insert two guide studs in block and lower head into
place on block.
Note: All turbocharged engines must use cylinder head
capscrews that have letters NT forged on head. Do not
intermix.
4. Lubricate entire cylinder head capscrew with rust
preservative lubricant. Allow excess lubricant to drip
from capscrew before installation.
Note: Rust preservative lubricants with 2 percent or
higher sulfated ash content must be used.
5. Install washers and capscrews. Torque capscrews to
25 ft-lbs [3.5 kg ml in sequence shown in Fig. 145.
Continue torquing in increments of 80 to 100 ft-lbs [11.1
to 13.8 kg m] to final torque of 280 to 300 ft-lbs [38.7 to
41.5 kgm] .

Fig. 14-3, (N114167). Timing marks on camshaft and

crankshaft gear

Fig. 14-5,(N11427). Cylinder head torquing sequence

Fuel Cross-Over

Install "0" rings in end of each cylinder head and

cross-over, secure cross-over with springtite screws.
Tighten with torque wrench and screwdriver adapter to
34 to 38 inch-lbs [0.4 to 0.5 kg m .

Fig. 14-4, (N11424). Checking gear backlash

Lubricating Oil Pipes

Coat new "O" ring with clean lubricating oil, position "O"
ring in groove in oil pipe, install oil pipes in block.

395
 TRUCK SERVICE MANUAL
ENGINE

Compression Release Shaft 3. install push tubes. Injector push tube is largest and
Install new "0" ring over shaft. Insert shaft into cylinder fits in middle socket. On engines equipped with
block and secure at rear end of block with copper washer compression release, exhaust push tube is equipped with
and lockscrew. Coat expansion plug with sealant, install collar to match with milled lift of compression release.
plug in counterbore at rear of block, until it seats. On engines without compression release, intake and
Cam Followers And Push Tubes exhaust tubes are identical.
1. Install cam follower gaskets. It may be necessary to Timing The Engine
add or remove gaskets to obtain correct injection timing. Use ST-593 to obtain precise timing of push tube travel
2. Position cam follower assembly to block. Torque with piston travel. The travel readings for engine model
capscrews in sequence as shown in Fig. 14-6 in must be as listed in Table 14-3. Adjustments to timing
increment of 15 to 20 ft-lbs [2.1 to 2.8 kg m] to 30 to 35 are made by altering thickness of cam follower housing
ft-lbs [4.1 to 4.8 kg ml . gaskets.
1. Position ST-593 Timing Tool in injector sleeve.
Engage rod of push rod indicator in injector push tube
socket. Secure tool in place by tightening knurled hold-
downs evenly by hand. Be sure tool is straight in the
cylinder. Fig.14-7.
Note: Each of the two dial indicators used in timing
engine must have total travel of at least 0.250 inch [6.35
mml .
2. Loosen both indicator supports to prevent damage.
Bar engine crankshaft to bring piston to top center.
Position piston indicator to compress indicator stem to
Fig. 146, (N114236). Cam follower torquing sequence within 0.010 inch of inner travel stop. Carefully bar
crankshaft to bring piston to exactly top center (1, Fig.
14-8). Zero the indicator dial at this point.

TOP CENTER 90 DEG. AFTER TOP CENTER 45 DEG. BEFORE TOP CENTER 19 DEG. BEFORE TOP CENTER
“O” Indicator Over Piston. “O” Indicator Over Rod. .
Both Indicators Move In some Direction If Not .
Both indicators retate Twice Step 0.032
Bar Engine One Revolution For Proper Position. (0.2032 Before”O” On Indicator
.
Over Piston Read Push Rod Indicator.
Fig. 14-7, (FWC-34). Injection timing
396
 TRUCK SERVICE MANUAL ENGINE
Table 14-3: Injection Timing
Piston
Travel Push Tube Travel (Inches)
Engine Model (Inches) Nominal Fast Slow
NT-855-310 (All) NT-855 Series -0.2032 -0.0360 -0.0340 -0.0380

b. Recheck indicator positioning. Be sure indicators are

not bottoming or binding.
c. Carefully recheck top center position. Be sure each
step is carried out as described.
7. If push tube travel is greater than limits indicated in
Table 14-3, engine timing is slow; if push tube travel is
less, timing is fast. Injection timing may be advanced or
retarded by adding or removing cam follower gaskets.
Remove gasket on right hand engine to retard timing.
Add gaskets on left hand engines to retard timing.
Note: If required, an extra-thick gasket should be used
when needed instead of several thin gaskets.
Injectors

1. Lubricate the injector body "O" rings with light coat of

Fig. 148, (Ni1432). injection timing procedure clean lubricating oil.

3. Bar crankshaft in rotating direction (2) until piston 2. Start the injector assembly into bore, from intake side
follower rod top is opposite 90 deg. ATC mark on timing of engine, injectors are to be placed with filter screen at
tool. At this point, position push tube indicator on push twelve o’clock, guide by hand until injector is aligned.
rod follower to about 0.020 inch from its inner travel stop.
Zero indicator dial at this point. 3. Place ST-448 Valve Spring Compressor on top of
4. Bar crankshaft opposite rotating direction (3) to injector plunger coupling and "seat" injector by giving a
position piston follower rod at 45 deg. BTC. quick, hard push.
Note: Both indicators move in same direction when
cylinder is on proper stroke. If push tube indicator does 4. Place hold-down plate over injector body with
not move same direction as piston indicator, bar counterbore up. Start hold-down capscrews. Do not
crankshaft one complete revolution to place cylinder on tighten.
compression stroke.
5. Bar crankshaft in direction of rotation until piston 5. Carefully insert injector plunger link. Torque hold-
follower rod is almost in contact with indicator stem. down capscrews to 11 to 12 ft-lbs [1.5 to 1.7 kg ml in 4
Gently move crankshaft to position piston indicator to ft-lb [0.6 kg m] increments.
0.0032 inch before 0. This position is actually 0.2032
inch before 0, since the indicator will have receded (hand Fuel Fittings And Lines Coat fuel fittings with sealer.
will have gone around twice) over 0.200 inch as the Inlet and drain fittings may be installed either in front of
crankshaft was moved to 45 deg. BTC. Since exact No. 1 head or rear of No. 3 head as used. Connect
reading in ten-thousandths must be estimated, exercise tubing to appropriate fitting.
care in bringing piston travel indicator to reading.
6. Read push tube travel indicator. It should read the VALVE CROSSHEAD ADJUSTMENT
number of thousandths before zero that is called for in
Table 14-3. Notice that a range of about 0.004 inch is 1. Position crossheads over guides with adjusting screw
within specification. toward water manifold. Loosen adjusting screw locknut,
Note: Never make a change in cam follower gaskets for back adjusting screw off one turn.
timing purposes before making following checks:
a. Be sure cam follower housing capscrews are Note: Engines using Jacobs Brake use special
tightened to 30 to 35 ft-lbs [4.1 to 4.8 kg ml torque. crossheads on exhaust side of head. See Group 20.

397
 TRUCK SERVICE MANUAL ENGINE

2. Use light finger pressure at the rocker lever contact properly located.
surface to hold crosshead in contact with.valve stem Compression Release Lever
nearest the push tube. Turn adjusting screw down until it 1. Install dowel in cylinder block if removed.
contacts its mating valve stem. 2. Position upper lever and bracket assembly to front
Note: With new crossheads and guides, advance rocker arm housing and secure.
adjusting screw one-third of one hex to straighten stem in 3. Using screwdriver in slot in end of compression
its guide and to compensate for slack in threads. With release shaft, turn shaft clockwise until lifting notch
worn crossheads and guides, it may be necessary to contacts a valve push tube collar, move compression
advance the screw as much as 1/2 of hex in order to release shaft lever to middle of travel; secure with
straighten the stem in its guide. clamping screw.
3. Hold adjusting screw in position and torque locknut to 4. Secure spring on cylinder head with capscrew; hook
25 to 30 ft-lbs [3.5 to 4.1 kg m]; or, if ST-669 Torque spring in lever on compression release shaft. Attach link
Wrench Adapter is used, tighten to 22 to 26 ft-lbs [3.0 to to lower and upper lever; secure with’ cotter pins.
3.6 kg m]. Fuel Pump/Compressor Drive/Accessory Drive
4. Check clearance between crosshead and valve spring Bar ’engine to No. 1 cylinder, TDC position (firing
retainer with wire gauge. There must be a minimum of stroke), continue rotating to 90 deg. ATC. In this
0.020 inch [0.51 mm] clearance. position, the two center-punched marks on drive gear will
Rocker Lever Housing mesh or index with two dash marks on camshaft gear.
1. Position new rocker lever housing gasket on cylinder This timing. is required so external timing marks on
head. accessory drive pulley will be properly aligned with timing
2. Loosen locknuts and back off rocker lever adjusting mark on gear case to show valve and injector adjustment
screws two or three turns. Holding rocker levers in place, positions, keyway of drive shaft will be at top. Secure
position housing on heads with ball ends of rocker levers drive to cylinder block. Using a scrap gear case cover,
fitting into their respective push tube sockets. Install fabricated as illustrated in Fig. 14-10, check accessory
lifting brackets and fan hub bracket support bell crank, if drive gear backlash.
used. 1. Attach a dial indicator gauge to the block with plunger
3. Secure housing, brackets and support with on accessory drive gear tooth. Fig. 14-10. Rotate gear
capscrews. Torque in sequence, Fig. 14-9, to 55 to 65 as far as it will move to take up backlash, zero indicator.
ft-lbs [7.6 to 8.9 kg mi.

Fig. 14-10, (N114132). Checking accessory drive gear

Fig. 14-9, (N11463). Rocker lever housing torquing backlash
sequence 2. Rotate gear in opposite direction and read backlash
Note: On 80 deg. tilt engines use ST-1182 Valve Spring on dial gauge. Backlash should be 0.0045 to 0.0105 inch
Spray Nozzle Locator to check that oil spray nozzles are [0.114 to 0.267 mm].

398
 TRUCK SERVICE MANUAL
ENGINE

Air Compressor at bottom of each intake manifold port. Lift manifold into
For balance of engine and air compressor reciprocating place with slots over capscrews.
force, the coupling driven air compressor must be timed Note: Extra long capscrews are used to install
to engine firing order. aftercooler.

1. Bar engine to "B" or "2-5" valve set mark.

2. Rotate air compressor crankshaft so male splined

coupling half key-way will be pointing directly away from
engine (3 o’clock position when looking at coupling end
of compressor).

3. Assemble splined coupling to air compressor drive

shaft.

4. With a new gasket in place, position air compressor

coupling to accessory drive shaft; secure air compressor Fig. 14-11, (N114129). Checking lubricating oil pump
to accessory drive housing. Connect air and water lines gear backlash
to compressor.
2. Install remaining flatwashers, lockwashers and
Note: Bendix Westinghouse Tu-Flo 500 Compressor air capscrews;
intake may be plumbed to engine intake manifold, torque all capscrews to 20 to 25 ft. lbs. [2.8 to 3.5 kg mi.
5. Position and secure air compressor support bracket to 3. Position and secure air inlet connection with new
block and air compressor. gasket on air intake manifold.

Fuel Pump 4. Using new hose and "O" ring, position water transfer
1. Position and secure fuel pump to fuel pump drive or air tube assembly to aftercooler connection and block
compressor with new gasket and buffer or spline in adapter, secure transfer tube connection using new "0"
place, use same part number as removed. ring into block adapter with snap ring. Install new hose to
aftercooler connection and transfer tube connection.
2. Install line from fuel pump shut-down valve to cylinder Tighten hose clamps.
head fuel drilling connection previously installed.
Aneroid Control
Lubricating Oil Pump 1. Secure aneroid control and bracket to fuel pump side
1. Place lubricating oil pump gasket to gear case. Make of engine.
certain oil passages are open. 2. Install fuel pressure line from bottom of fuel pump (out-
board fitting) to "IN" connection on aneroid control and
2. Mesh drive gear teeth with camshaft gear as pump is fuel return line from "OUT" connection on aneroid control
installed. Secure pump. to fuel inlet connection.
3. Use same procedure to check pump gear backlash, 3. Install air line and fittings, if removed, from top of
Fig. 4-1 1, as used for checking accessory drive gear aneroid to air intake manifold.
backlash.
Fuel Filter Replaceable Element Type
Note: If power steering pump is driven by lubricating oil
pump, position coupling to shaft, install power steering 1. Position and secure mounting bracket in desired
pump. location.
2. Check fittings in filter head for leaks, torque to 30 to 40
4. When used, secure oil filter can with new element and ft-lb. [4.1 to 5.5 kg mi.
sealing "O" ring to lubricating oil pump by torquing center 3. Install filter head to mounting bracket; using a new
bolt to 25 to 35 ft-lb. [3.5 to 4.8 kg m] . gasket, assemble case and element. Torque center bolt
to 20 to 25 ft-lb. [2.8 to 3.5 kg m] .
Intake Manifold Or Aftercooler 4. Connect fuel supply line between fuel filter and fuel
1. Install new gasket, flatwasher, lockwasher and pump.
capscrew
399
 TRUCK SERVICE MANUAL
ENGINE
Gear Case Cover

1. Shellac new gasket to gear case cover. Check current 0.001 to 0.005 inch [0.03 to 0.13 mm] camshaft end
Parts Catalog for correct gear case cover and gear case clearance for engines with camshaft thrust plate, 0.008 to
cover 0.013 inch [0.20 to 0.33 mm] for engines with camshaft
gasket part numbers. outboard bearing support.
2. Install gear cover in place over dowels. Torque
capscrews to 45 to 50 ft-lb. [6.2 to 6.9 kg ml, trim off c. Install spacers and "0" ring seal; secure thrust plate to
excess gasket material at pan flange mounting area. gear case cover.
3. Make sure that bottom surface of cover is within
+0.004 inch [0.10 mm] of flush with oil pan surface of Rear Cover Plate And Oil Seal
block. Fig.14-12. 1. Clean crankshaft sleeve or seal area with crocus cloth
and coat area with clean lubricating oil.

Note: If wear sleeve is required, refer to Parts Catalog

for correct seal and sleeve combination.

2. Insert wear sleeve, if used, in ST-997 Seal and Sleeve

Driver with beveled end of sleeve facing sleeve driver;
drive sleeve on crankshaft until sleeve driver bottoms on
end of crankshaft.
3. Install rear cover and gasket to cylinder block. Tighten
capscrews finger tight so rear cover plate will move for
alignment and position sleeve driver over end of
crankshaft, rear cover plate should pilot over tool.
4. Tighten so cover can be shifted. Remove sleeve driver
Fig. 14-12, (N114134). Checking gear case cover to
and mount indicator on crankshaft with point on cover
block alignment
trunnion. Rear cover must be aligned within 0.005 inch
[0.13 mm] total indicator runout. Fig. 14-13. Tighten
4. Install crankshaft oil seal and fuel pump compressor
cover capscrews to 24 to 29 ft-lb. [3.3 to 4.0 kg m] and
drive shaft oil seal.
trim off excess gasket material.
a. Check concentricity of oil seal bore in relation to
5. Install and tighten two ST-997-6 Buttons into the two
crankshaft. If total indicator reading exceeds 0.010 inch
threaded holes inside of ST-997 Seal Driver. Position
[0.25 mm] remove, clean and relocate gear cover.
correct seal in rear cover plate bore and drive in until
buttons bottom.
b. Coat oil seal outside diameters and seal bore with
6. Use ST-1263 Seal Pilot when using Teflon oil seal.
lubricating oil. Install Teflon crankshaft seal with ST-1259
Seal Mandrel using ST-1260 Seal Pilot. ST-1172 Mandrel
Note: Clearance on inside diameter of some 101092 or
is used on tapered crankshaft. Install accessory drive
123982 Rear Cover Plates and 151621 Oil Seal Retainer
seal in gear case cover with ST-1173 Mandrel and ST-
may not be sufficient to allow plates to slide over wear
386 Pulley Assembly Tool, ST-1173 Mandrel will insert
sleeve, if not, grind 0.015 to 0.030 inch [0.38 to 0.76 mm]
seal to required depth.
from inside diameter of rear cover plate seal stop lip.
c. Check clearance between seal and shoulder on gear
case cover bore, if so equipped. Minimum clearance is
0.030 inch [0.76 mm]. Seal must not bottom on shoulder
of bore.

d, Front face of oil seal must be square with crankshaft

axis within 0.010 inch [0.25 mm] total indicator reading.

5. Install camshaft thrust plate or support bearing.

a. Remove "O" ring seal and spacers. Push plate or

support against camshaft so camshaft rests against
thrust washers. Measure dimension between thrust plate
and gear case cover with feeler gauge.
b. Using micrometer, select enough spacers to provide
400
 TRUCK SERVICE MANUAL
ENGINE

Table 14-4: Flywheel Housing Specifications Inch [mm]

SAE No. Bore Diameter (For Reference Only) True Location Tolerance Face Run Out Tolerance

00 31.000 to 31.010 [787.40 to 787.65 mm] .012 [0.30 mm] TIR .012 [0.30 mm] TIR
0 25.500 to 25.510 [647.70 to 647.95 mm] .010 [0.25 mm] TIR .010 [0.25 mm] TIR
1/2 23.000 to 23.008 [584.00 to 584.20 mm] .010 [0.25 mm] TIR .010 [0.25 mm] TIR
1 20.125 to 20.130 [534.27 to 534.40 mm] .008 [0.20 mm] TIR .008 [0.20 mm] TIR
2 17.625 to 17.630 [447.68 to 447.80 mm] .008 [0.20 mm] TIR .008 [0.20 mm] TIR
3 16.125 to 16,130 [409.58 to 409.70 mm] .008 [0.20 mm] TIR .008 [0.20 mm] TIR
4 14,250 to 14.255 [361.95 to 362.08 mm] .006 [0.05 mm] TIR. .006 [0.05mm] TIR
5 12.375 to 12.380 [314.33to 314.45 mm] .006 [6.05 mm] TIR .006.[0.05 mm] TIR
6 10.500 to 10.505 [266.70 to 266.83 mm] .006 [0.05 mm] TIR .006 [0.05 mm] TIR

Flywheel Housing
1. Clean mating surface of flywheel housing to block and
install new cork camshaft bore gaskets in flywheel
housing with gasket cement. Allow sufficient time for
drying.
Gasket slippage will allow oil to leak from rear of
camshaft bore.

2. If new flywheel housing is being installed, or if dowels

are worn, sheared or loose, remove dowels from block.
Snug housing to block with lockwashers and capscrews.

INDICATE FLYWHEEL HOUSING BORE

1. Draw chalk marks at 12, 6, 9 and 3 o’clock. Attach ST-

112 and a dial gauge to crankshaft flange. Fig. 14-14.

2. Check readings at 9 and 3 o’clock. If run-out exceeds

specifications in Table 14-4, move housing one-half of
Fig. 14-15, (N11448). Indicating flywheel housing face
distance to center horizontally.
INDICATE FLYWHEEL HOUSING FACE
3. Check readings at 12 and 6 o’clock. If run-out exceeds
1. Attach ST-112 and a dial gauge as shown in Fig. 14-
specifications, move housing to center vertically.
15.

2. Push crankshaft forward to take up end clearance and

turn crankshaft to obtain readings on housing face. Take
up crankshaft end clearance in same direction each time.

3. Total flywheel housing tape run out must exceed

specifications in Table.14.4.

4. If both bore and face run-out readings are within limits

and dowels were removed, ream dowel holes to smallest
permissible oversize with ST-406 Drill Ream Fixture.

5. If necessary to correct for housing face run-out after

the bore has been aligned, remove housing and recheck
mating surfaces. Then reinstall, realign and dowel. After
readings are within limits, tighten capscrews alternately
Fig. 14-14, (N 11447). Indicating flywheel housing bore
and evenly to 150 ft-lb. [20.7 kg m] .
401
 TRUCK SERVICE MANUAL
ENGINE
Oil Pan Note: Flywheel housing must be on engine.

With Body-Fit Bolts 1. Install guide studs in oil pan flange of block.
2. Shellac new oil pan gasket to oil pan flange of block.
1. Two oil pan capscrew holes at flywheel end of block 3. Position oil pan over guide studs and start oil pan
are reamed for body-fit bolts. If not previously installed, flange capscrews, flatwashers and lockwashers by hand.
install bolts in block. 4. Install and tighten middle buttress to flywheel housing
capscrews with washers on both sides of oil pan. This
2. Shellac new oil pan gasket to cylinder block. pulls pan tight and square with flywheel housing.
5. Lock pan in position by tightening two (2) center
a. When using new "tab-lock" gasket; paint oil pan flange capscrews on each side of block.
with a non-hardening gasket compound. Allow gasket 6. Loosen and remove buttress capscrews assembled
compound to dry. Start at either end of oil pan, lay gasket and tightened in Step 4. (Capscrews must be removed to
sections on oil pan flange. Proper assembly is assured provide socket clearance to buttress corner capscrews.)
by matching letters located on end of each gasket 7.. Tighten two (2) rear corner pan flange to block
section. capscrews. This pulls the block and pan flanges together
and ensures that pan is pulled firmly into corner by
b. Insert several capscrews through gasket and oil pan housing and block. Remove guide studs.
flange capscrew holes to line up. When gasket sealing 8. Insert and tighten all capscrews from 28 to 40 ft-lb.
compound dries, remove guide capscrews. [3.8 to 5.5 kg m] torque.
9. Insert pan to rear cover plate flatwashers, lockwashers
3. Check oil pan screen to make certain that it is properly and capscrews; tighten to 15 to 20 ft-lb. [2.1 to 2.8 kg m]
assembled and that all screws are tight. torque.

4. Assemble pan to block with nuts, lockwashers and Oil Suction Tube
capscrews. On aluminum oil pans, install flat steel
washers between pan and lockwashers. 1. Assemble tube nuts and rubber sleeves lubricated with
clean engine lubricating oil, to suction tube. Start nuts on
5. If new pan is being installed prior to installing oil pump adapter and oil pan flange, do not tighten.
flywheel housing: 2. Position oil pan flange with new gasket to oil pan. Do
a. Position so buttress-end of pan is flush with end of not tighten capscrews.
block. Check with straight-edge. Fig. 14-16. 3. Push tube and sleeve into oil pump adapter until it
bottoms and tighten nut 1 to 1-1/4 turn from finger tight.
b. Ream holes to next oversize and install oversize body- 4. Tighten tube nut on oil pan suction flange finger tight.
fit bolts.
Torque suction flange to oil pan capscrews to 30 to 35 ft-
lb. (4.1 to 4.8 kg m]. Tighten tube nut against stop on
suction flange.

Crankshaft Flange And Vibration Damper

Lapping

Each time the crankshaft flange or pulley is removed or

replaced, it must be lapped to the crankshaft to provide
maximum contact area between mating parts.

Fig. 14-16, (N114136). Checking oil pan to block 1. Insure that all mating surfaces are free of burrs, nicks
alignment and fretting. Do not attempt lapping until all Imperfections
have been removed.
Less Body-Fit Bolts 2. Inspect flange with a magnetic particle process for
Oil pan currently used on 80 deg. tilt engines have cracks or inclusions.
bosses drilled to accommodate oil gauge and filler
bracket, alternator mounting bracket and’ lifting eyes.
Brackets, lifting eyes and spacers, as used, should be
installed during oil pan installation.
402
 TRUCK SERVICE MANUAL
ENGINE

3. Coat inside diameter of flange with Grade A (280 grit) not exceed 0.0025 inch [0.064 mm] per one (1) inch
lapping compound and lap by turning flange one-fourth radius of damper (as measured from center of damper).
(1/4) to one-half (1/2) turn each way, until both crank Crankshaft must be kept at front or rear limit of thrust
nose and flange inside diameter are mated. clearance while wobble is being checked. See Vibration
Damper.
4. Clean all compound from flange and crankshaft nose;
allow no compound to reach seal or enter engine.

Contact Check
1. Apply a light even coat of Prussian Blue on nose of
crankshaft. Hold flange or pulley perpendicular to
centerline of crankshaft and position on nose, turn flange
one-eighth (1/8) turn and pull straight off.
2. Contact area should be 100% for a distance of 1/2
inch [12.70 mm] at large diameter of crank nose,
remainder of taper must have 70% to 100% of bluing
contact.
3. Clean all Prussian Blue from the crank nose and
flange.
Fig. 1420, (N114156). Checking crankshaft flange
INSTALLATION eccentricity and wobble
CAUTION

Lubricate crankshaft nose in flange area with SAE 30

rust preservative lubricant with 2 percent or higher
sulfated ash content DO NOT use lubricant when cast
iron flanges 115562, 115563, 175183 or 175185 are
used.

1. Install crankshaft flange over end of crankshaft. Center

line of key-way in flange and key-way in crankshaft
should be aligned within plus or minus 1/8 inch [3.18 mm]
.

2. Install retainer and capscrew, check current Parts

Catalog for correct capscrew and retainer, torque to A. Outer Machined Surface
specifications listed in Table 14-1 B. Inner Machined Surface
3. With dial gauge mounted to gear case cover, check Fig. 14-21, (N114140). Checking vibration damper run-
crankshaft flange eccentricity and wobble. Eccentricity out
must not exceed 0.004 inch [0.10 mm] total indicator
reading; wobble must not exceed 0.003 inch [0.08 mm] Vibration Damper And Pulley
measured at 2-3/4 inch [69.85 mm] radius. Fig. 14-20. 1. Position front engine support to block, if used, maintain
a minimum of 1/32 inch [0.79 mm] clearance between
4. Install vibration damper to crankshaft flange with support and gear case cover. Tighten capscrews to 55 ft-
lockplates and capscrews. Torque to 60 ft-lb. [8.3 kg m] lb. [7.6 kg m] torque.
and lock in place. CAUTION
5. Position a dial gauge to gear case cover and rest arm Do not use any lubricant on pulley or crankshaft mating
on outer machined surface at point (A, Fig. 14-21) to surfaces. Wipe with clean dry cloth.
check eccentricity and at point (B) on inner machined
surface of outer member to check wobble. Run-out must

403
 TRUCK SERVICE MANUAL
ENGINE
2. Align capscrew holes and install pulley and vibration c. Final torque in rotation to 30 ft-lb. [4.1 kg m] .
damper assembly to crankshaft, tap into position with soft
hammer. Coat capscrews with clean lubricating oil, 2. Position belts over water pump, idler and accessory
secure pulley and damper assembly to crankshaft torque drive pulleys. Tighten idler adjusting screw to obtain, 120
to 85 ft-lb. [11.8 kg m]. to 140 lb. belt tension using ST-968 or ST-1274 Belt
Tension Gauge.
Note: Check capscrew marking, if ’1/2 inch Grade 8 3. Secure idler shaft to bracket with flatwasher and
capscrews are used tighten capscrews to 115 to 125 ft- locking nut. Tighten to 50 ft-lb. [6.9 kg ml torque. Back off
lb. [15.9 to 17.3 kg m] torque. If 5/8 inch Grade adjusting screw 1/2 turn.
capscrews are used tighten to 210 to 240 ft-lb. [29.0 to 4. If not previously installed, position fan hub assembly to
34.0 kg m] torque. See Capscrew Markings and Torque mounting bracket. Tighten capscrews finger tight.
Values, 5. Position and secure fan hub assembly and bracket to
water pump housing.
3. If vibration damper was removed from pulley, wipe 6. Secure fan bracket support to fan bracket and install
mating surface of damper and pulley clean, position adjusting screw and hardened washer (if used).
damper to pulley, install and torque capscrews to 85 ft-lb. 7. Position belts over fan hub pulley and accessory drive
[11.8 kg mi. pulley, tighten fan hub adjusting screw to obtain 90 to
110 lb. belt tension using ST-968 or ST-1138 Belt
4. Check damper for eccentricity and wobble as Tension Gauge.
described in Step 5 preceding. 8. Secure fan hub assembly to fan mounting bracket,
torque capscrews to 50 ft-lb. [6.9 kg m] .
Accessory Drive Pulley
Fan Hub And Pulley
Note: Remove pipe plug in gear cover, check to make
sure timing marks are lined up, Fig. 14-22. Replace pipe 1. Assemble fan pulley to fan bracket, if not previously
plug. installed. Position flatwasher and locking nut on shaft.
Start nut on thread, do not tighten.
1. Install oil slinger over accessory drive shaft, with key
and keyway seal, if used, on accessory drive shaft. 2. Avoid stretching belts, loosen adjusting screw, position
Lubricate shaft with clean lubricating oil, start accessory belts over fan hub and drive pulleys.
drive pulley over shaft and key; use ST-386 to position
pulley on shaft. 3. Tighten adjusting screw to obtain proper tension of
drive belts. See Table 14-5.
2. Remove ST-386; install flatwasher and pulley nut.
Torque nut to 90 to 110 ft-lb. [12.4 to 15.2 kg ml] Table 14-5: Belt Tension Inch [mm]
Deflection Per Ft.
Belt Width [0.3 m] of Span

1/2 [12.70] 13/32 [10.14]

11/16 [17.46] 13/32 [10.14]
3/4 [19.05] 7/16 [11.11]
7/8 [22.23] 1/2 [12.70]
1 [25.40] 9/16 [14.29]
4. Torque fan hub shaft-to-bracket nut to 400 to 450 ft-lb.
[55.3 to 62.2 kg m]. Do not overtighten. Back off
Fig. 14-22, (N114143). Camshaft and accessory drive adjusting screw 1/2 turn.
gear timing marks 5. As an alternate method, tighten nut hand tight; rotate
75 deg., mark bracket in line with corner of nut and turn
one full hex or 60 to 70 deg.
Water Pump And Idler
1. Using new gasket, position water pump and idler
Oil Spray Nozzles
assembly to block. Torque as follows.

a. Torque in rotation to 10 ft-lb. [1.4 kg m . 1. Lubricate new "0" rings with clean lubricating oil and
position on nozzle using ST-835 "O" Ring Loader. Be
b. Repeat rotation torque to 20 ft-lb. [2.8 kg m . sure "O" rings are not twisted in groove.
404
 TRUCK SERVICE MANUAL
ENGINE

2. Insert nozzles in block and secure. Using a 2. Install water inlet support bracket to cylinder block.
screwdriver adapter torque slotted screw to 5 to 8 ft. lb. Start capscrews with lockwasher into block, do not
[0.7 to 1.1 kg m] . Torque Hex Head capscrews to 16 to tighten. Position water inlet assembly to water pump and
21 ft. lb. [2.2 to 2.9 kg mi. support bracket. Torque water inlet to water pump
capscrews to 30 ft-lb. [4.1 kg m].
Note: Identification numbers stamped on the mounting 3. Tighten support bracket to block and bracket to inlet
flange of oil spray nozzles are: No. 5 FFC Series housing capscrews. Install water header cover plate.
Engines, No. 1 all others. 4. Coat "O" rings with clean lubricating oil, position on
water transfer tube. Be sure "O" rings are not twisted.
Remove Engine From Stand Position water transfer tube in water header cover.
1. Attach lifting arrangement and remove engine from 5. Install oil cooler to block bracket. Do not tighten
stand; mount front and rear supports to engine. capscrew. Position oil cooler assembly to block and
2. Remove engine stand support plates from water transfer tube. Torque cooler support, bracket to housing,
header and replace with proper gaskets and cover and bracket to block capscrews to 30 ft-lb. [4.1 kg ml .
plates. Install water return to thermostat housing tube (FFC
Series).
Oil Gauge Bracket 6. Using new sealing "O" ring and filter element, position
oil filter can to oil cooler housing. Torque center bolt to 25
Install oil bayonet gauge bracket, using new gaskets. to 35 ft-lb. [3.5 to 4.8 kg m] .
Water Manifold And Thermostat Housing Generator Or Alternator
1. With "O" ring on water manifold connection, slip
connection into manifold. Grease new water manifold 1. Secure generator or alternator mounting bracket to
and thermostat housing sealing rings and place rings in cylinder block. Position hardened steel washers or
cylinder heads; position and secure water manifolds to spacers as needed between alternator or generator and
cylinder head. mounting bracket.
2. Position and secure assembled thermostat housing to
front section of water manifold and install water Note: Do not use lockwashers or sott steel washers
crossover, if used. when securing generator or alternator to bracket or
adjusting link.
Exhaust Manifold
2. Check capscrew size and torque mounting capscrews
1. Assemble sections of exhaust manifold and install to values in Table 14-6.
new steel exhaust manifold gaskets. Side of gasket Table 14-6: Torque Values (To Bracket)
marked "OUT" must be installed outward or next to
manifold. Nominal Bolt Size Torque
2. Coat capscrew threads with anti-seize compound. On Inch Ft-Lb [Kg ml
turbocharged engines, if heat shield is used, install
special capscrews with threaded heads. These
capscrews are used to mount both heat shield and 3/8 29 to 31 [4.0 to 4.3]
manifold. 7/16 63 to 65 [8.7 to 9.0]
3. Torque mounting capscrews to 25 ft-lb. [3.5 kg m] 1/2 77 to 80 [10.6 to 11.1]
Bend lockplate tangs up against capscrew heads. When
washers or lockplates are not used, increase torque to 40 3. Position adjusting link to alternator or generator
ft-lb. [5.5 kg m] and install heat shield if used. termination point. Install capscrew and hardened washer
securing adjusting link to alternator, do not tighten. Install
Thermostat Housing By-Pass Connection belt(s), pry unit away from block to tighten belt(s) to
Water Pump Mounted Oil Filter Remove by-pass operation tension. Torque capscrews to values in Table
connection from thermostat housing, insert transfer tube 14-7.
into oil filter housing. Position and secure by-pass
connection to thermostat housing. Table 14-7: Torque Value (To Adjusting Link)

Compressor Water Lines Nominal Bolt Size Torque

Install water supply and drain lines to compressor, Inch Ft-Lb [Kg ml
cylinder block and water by-pass connections. Tighten
just enough to bring brass sleeves snugly against nuts; 5/16 15 to 19 [2.1 to 2.6]
this will compress rubber grommets and provide a 7/16 25 to 30 [3.5 to 4.1]
positive seal. 1/2 50 to 55 [6.9 to 7.6]
Lubricating Oil Cooler/Filter
1. Install water pump to thermostat housing by-pass tube.
Secure with hose clamps.
405
 TRUCK SERVICE MANUAL
ENGINE
Note: If generator or alternator pulley has been removed
or a new pulley is installed, use hardened steel washer
and locknut. Torque to values in Table 14-8.

Table 148: Torque Values (Pulley to Alternator or

Generator)
Nominal Thread Size Torque
Inch Ft-Lb [Kg m]
1/2 50 to 60 [6.9 to 8.3]
5/8 55 to 65 [7.6 to 9.0]
3/4 90 to 100 [12.4 to 13.8]
Note: Exception to the above limits are:
1. Belt Deflection
Delco-Remy Torque 2. Belt Free Span
Alternators Ft-Lb [Kg ml
1 0 DN 150 Fig. 14-24, (N11471). Checking belt tension manually
25 SI 70 to 80 [9.7 to 11.1]
Belt Tension ADJUST INJECTORS, CROSSHEADS AND VALVES

1. Installation: Before adjusting injectors and valves be sure to

2. determine if rocker housings are cast iron or aluminum
a. When two or more identical belts are used on the and use appropriate setting.
same drive, they must be replaced as a matched set.
Two methods of adjusting injectors and valves are
b. Shorten distance between pulley centers and install described in this manual. The preferred method is
belt(s). Do not roll or pry belt over pulley. Uniform Plunger Travel. This method involves adjusting
plunger with ST-1270 Injector Indicator Kit (consists of
c. Pulley misalignment must not exceed 1/16 inch [1.59 ST-1170 Dial Indicator, ST-1 193 Actuator and ST-1251
mm] for each foot [304.8 mm] of distance between pulley Actuator) to a specified travel. The second method
centers. involves setting plunger adjusting screw to a specified
torque setting. It is essential that injectors and valves be
d. Belts should not bottom on pulley grooves, nor should in correct adjustment at all times.
they protrude over 3/32 inch [2.38 mm] above top edge
of groove. Injector "Plunger Free Travel," as described below, must
be checked before adjustments are made.
e. Belt riding depth should not vary over 1/16 inch [1.59
mm] on matched belt sets.
Check Plunger Free Travel
f. Do not allow belts to rub against any adjacent part. In order to prevent excessive loading of injector actuating
train and possible failure, check as follows:
2. Adjusting:
1. Back injector adjusting screw out 1-1/2 turns from
a. Use ST-968 for 3/8 to 1/2 inch [9.53 to 12.70 mm] normal operating position, tighten locknut.
width belts. Use ST-1138 for 11/16 to 7/8 inch [17.46 to
22.23 mm] width belts. 2. With ST-1170 Dial Indicator extension on injector
plunger top, bar engine and record total amount of each
b. When belts are installed, tighten until a reading of 90 plunger travel. This is called "Plunger Free Travel" and
to 110 lb. force is obtained. New belts will loosen after MUST NOT exceed 0.206 inch [5.23 mm] on any one (1)
running for an hour or more and may require re- cylinder of engine.
adjustment. Recheck belt tension and re-adjust to 90 to
110 lbs. if reading is less than 80 lbs. 3. On engines with plunger Free Travel exceeding 0.206
c. As an alternate method, tighten belts so pressure of inch [5.23 mm] the Torque Method of adjustment must
index finger extended straight down, Fig. 14-24 will be used unless component changes (rocker levers
depress belt to the value shown in Table 14-5. Force and/or cam followers) are made which will allow 0.206
applied (1) will be approximately 13 lb. [5.9 kg] for each inch [5.23 mm] limit of Free Travel to be obtained.
foot [0.30 ml of free span (2).
406
 TRUCK SERVICE MANUAL
ENGINE
Temperature Settings extension on injector plunger top at No. 3 cylinder, Fig.
14-27. Make sure indicator extension is secure in
The following temperature conditions provide the indicator stem and not against rocker lever,
necessary stabilization of engine components to assure
accurate adjustments. Note: Cylinder No. 3 for injector setting and cylinder No.
5 for valve setting are selected for illustration purposes
Cold Setting only. Any cylinder combination may be used as a starting
point, see Table 14-9 and firing order Table 14-10.
Engine must have reached a stabilized temperature (oil
and/or component temperature to be within 10 deg. F of
ambient air temperature).

Note: At rebuild period this setting is obtained through

normal room temperature.

Hot Setting

1. Set injectors and valves immediately after the engine

has reached normal stabilized operating oil temperature.

2. If oil temperature gauge is unavailable, set injectors Fig. 14-25, (N114220). Valve set timing mark
and valves immediately after engine has operated at
rated speed and load or at high idle for a period of 40
minutes. If slotted thread adjusting screws are used, 20
minutes is sufficient.

Adjustment After Engine Rebuild

During rebuild, adjust injectors and valves using

appropriate values in the "Cold Set" column. The engine
must then run until normal oil operating temperature has
been obtained to allow stability of structural components
as affected by gasket replacements. Recheck injectors
and valves. See Engine Test Procedure, Phase 4,

INJECTOR AND VALVE ADJUSTMENT

DIAL INDICATOR METHOD USING ST-1170

1. If used, pull compression release lever back and block Fig. 14-26, (N114230). Accessory drive pulley markings
in open position while barring engine, this allows
crankshaft to be rotated without working against
compression.

2. Bar engine until "A" or 1-6 "VS" mark on pulley,

Fig’s.14-25 and 14-26, is aligned with pointer on gear
case cover. Remove block from compression release. In
this position, both valve rocker levers for cylinder No. 5
must be free (valves closed). Injector plunger for cylinder
No. 3 must be at top of travel; if not, bar engine 360 deg.,
realign marks with pointer.

3. Turn adjusting screw down on cylinder being adjusted

until plunger contacts cup and advance an additional 15
degrees to squeeze oil from cup. Loosen adjusting screw Fig. 14-27, (N l14231). Dial indicator in place - extension
two full turns. contact with plunger

4. Set up ST-1170 Indicator Support with indicator

407
 TRUCK SERVICE MANUAL
ENGINE

Table 14-9: Injector and Valve Set Position

Bar in Pulley Set Cylinder

Direction Position Injector Valve
Start A or 1-6VS 3 5
Adv. To B or 2-5VS 6 3
Adv. To C or 3-4VS 2 6
Adv. To A or 1-6VS 4 2
Adv. To B or 2-5VS 1 4
Adv. To C or 3-4VS 5 1

Table 14-10: Engine Firing Order - Inline

Right Hand Rotation Left Hand Rotation
1-5-3-6-2-4 14-2-6-3-5
Fig. 14-28 (N114237), Bottoming Injector plunger in cup
5. Using ST-1193 Rocker Lever Actuator, Fig. 14-28, or
equivalent, bar lever toward injector until plunger is Crosshead Adjustment
bottomed. Allow injector plunger to rise, bottom again,
set indicator at zero (0). Check extension contact with 1. Loosen valve crosshead adjusting screw locknut and
plunger top, turn adjusting screw until Adjustment Value, back off adjusting screw, Fig. 14-29, one turn.
Table 14-11 is obtained.

6. Bottom plunger again, release lever; indicator must

show travel as indicated.

7. Tighten locknut to 30 to 40 ft-lb. [4.1 to 5.5 kg m] and

actuate injector plunger several times as a check of
adjustment. Tighten to 25 to 35 ft-lb. [3.5 to 4.8 kg m]
when using ST-669 Adapter.

Table 14-11: Uniform Plunger Travel Adjustment

Limits

Oil Injector Plunger Travel Valve Clearance

Temp. Inch [mm] Inch [mm] 1. Crosshead 4. Adjusting Screw
2. Valve Stem 5. Crosshead Guide
Adj. Recheck 3. Valve Stem
Value Limit Intake Exhaust
Fig. 14-29, (N21461). Valve croshead
Aluminum Rocker Housing
2. Use light finger pressure at rocker lever contact
Cold 0.170 0.169 to 0.171 0.011 0.023 surface(1) to hold in contact with valve stem (2). Turn
[4.32] [4.29 to 4.34] [0.28] [0.58] down adjusting screw until it touches valve stem (3).
Hot 0.170 0.169 to 0.171 0.008 0.023
[4.32] [4.29 to 4.34] (0.201 [0.58] 3. Advance setscrew an additional 20 to 30 deg. to
straighten stem on its guide. Using ST-669 Torque
Cast Iron Rocker Housing Wrench Adapter, tighten locknuts to 22 to 26 ft-lb. [3 to
3.6 kg m] . If ST-669 is not available, hold screws with
Cold 0.175 0.174 to 0.176 0.011 0.023 [
4.45] [4.42 to 4.471 (0.281 [0.58] screwdriver and tighten locknuts to 25 to 30 ft-lb. [3.5 to
Hot 0.175 0.174 to 0. 176 0.008 0.023 4.1 kg m].
[4.45] [4.42 to 4.47] 10.20] [0.58]
4. Check clearance between crosshead and valve spring
retainer with wire gauge. There must be a minimum of
0.025 inch [0.64 mm] clearance.
408
 TRUCK SERVICE MANUAL
ENGINE
Valve Adjustment 1. Turn adjusting screw down until plunger contacts cup
and advance an additional 15 degrees to squeeze oil
The same engine position (VS Mark) used to adjust from cup.
injectors is used for setting intake and exhaust valves,
however, the valves to be adjusted are not the same 2. Loosen adjusting screw one turn; then, tighten
cylinder as injectors. In this position adjust valves for adjusting screw making two or three passes with torque
cylinder No. 5. See Table 14-9. wrench, to values shown in Table 14-12.

1. While adjusting valves, make sure compression

release, on those engines so equipped, is in running
position.

2. Loosen locknut and back off adjusting screw. Insert

feeler gauge between rocker lever and crosshead. Valve
clearances are shown in Table 14-11. Turn screw down
until lever just touches gauge and lock in this position.
Tighten locknut to 30 to 40 ft-lb. [4.1 to 5.5 kg m] torque.
When using ST-669, torque to 25 to 35 ft-lb. [3.5 to 4.8
kg m]

3. Always make valve adjustment after injector

adjustment. Move to next cylinder as indicated in Table Fig. 14-30, (N1 1466). Adjusting injector plunger
14-9 and repeat adjustments.
Note: Set ST-753-1 Torque Wrench on value required
ADJUST INJECTORS AND VALVES and pull to "O". Break adjusting screw loose and pull
(TORQUE METHOD) torque to value shown on each tightening pass.

1. If used, pull compression release lever back and block Table 14-12: Injector Adjustment (Oil Temperature)
in open position while barring engine, this allows Cold Set Hot Set
crankshaft to be rotated without working against
Cast Iron Rocker Housing
compression.
48 inch-lb 72 inch lb.
[0.6 kg ml [0.8 kg ml
2. Loosen the injector rocker lever adjusting nut on all
cylinders. This will aid in distinguishing between cylinders
Aluminum Rocker Housing
adjusted and not adjusted.
72 inch-lb 72 inch-lb
3. Bar engine in direction of rotation until a valve set [0,8 kg ml [0.8 kg ml
mark (Fig’s. 14-25 and 14-26) aligns with the boss on the
gear case cover. Example: A or 1-6 "VS." 3. Tighten locknut to 30 to 40 ft-lb. [4.1 to 5.5 kg ml
torque. If ST-669 torque wrench adapter is used, torque
4. Check the valve rocker levers on the two cylinders to 25 to 35 ft-lb. [3.5 to 4.8 kg mi.
aligned as indicated on pulley (Example: 1 and 6
cylinders for A or 1-6 "VS"). On one cylinder of the pair, Croshead Adjustment
both rocker levers will be free and valves closed, this is
cylinder to be adjusted. See Crosshead Adjustment (Dial Indicator Method)

5. Adjust injector plunger first, then crossheads and Valve Adjustment - Torque Method
valves to clearances indicated in the following
paragraphs. The same engine position used in adjusting injectors is
used for setting intake and exhaust valves.
Injector Plunger Adjustment - Torque Method
1. While adjusting valves, make sure that the
The injector plungers are adjusted with a torque wrench compression release, on those engines so equipped, is
and a screwdriver adapter to a definite torque setting. in running position.
See Fig. 14-30.
409
 TRUCK SERVICE MANUAL
ENGINE

2. Loosen locknut and back off adjusting screw. Insert Rocker Housing Covers
feeler gauge between rocker lever and crosshead. Valve Position covers and gaskets on rocker housings or
clearances are shown in Table 14-13. Turn screw down Jacob’s Brake. Tighten all cover capscrews using
until lever just touches gauge and lock in this position. combination cork and rubber gaskets to 75 to 95 inch-lb.
Fig.14-31. Tighten locknut to 30 to 40 ft-lb. [4.1 to 5.5 kg [0.9 to 1.1 kg ml, tighten all cover capscrews using cork
m] torque. When using ST-669 torque to 25 to 35 it-lb. gaskets to 12 to 17 ft-lb. [1.7 to 2.4 kg ml torque.
[3.5 to 4.8 kg mi.
Note: Check current Parts Catalog for correct cover-
3. Continue to bar engine to next "VS" mark and adjust gasket combination.
each cylinder in firing order. See Table 14-10. After
injector and valve adjustment is completed, bar or crank Breather Tube
(in chassis overhaul) engine several revolutions to Install breather tube, if used, to rocker housing cover and
secure to block with clamp.
Table 14-13: Valve Clearance - Inch [mm] (Torque
Method) Cranking Motor
Intake Valves Exhaust Valves 1. Check cranking motor; see that it is the same type as
Cold Set Hot Set Cold Set Hot Set removed. Cranking motors are designed with different
type drives and must be used with a matching flywheel
ring gear.
Aluminum Rocker Housing
0.014 0.014 0.027 0.027
2. Mount cranking motor (and spacer if used) to flywheel
[0.36] [0.36] [0.69] [0.69]
housing.
Cast Iron Rocker Housing
Note: When wet type clutch is used, use "O" rings and
Nylok capscrews when installing starter.
0.016 0.014 0.029 0.027
[0.41] [0.36] [0.74] [0.69]
Water Filter
1. Secure water filter head to engine, or mounting
bracket, attach shut-off valves and lines in proper
position.
2. Install pre-charge element, tighten until seal touches
filter head then tighten an additional 1/2 to 3/4 turn.

Turbocharger

1. Coat turbocharger mounting stud or capscrew threads

with anti-seize compound. Place gasket on exhaust
manifold with convex side toward turbocharger.
2. Install turbocharger to exhaust manifold and secure
with hug-lock nuts. Oil drain line must always be in a
vertical or down position or within 30 deg. of that position.
3. Connect No. 6 oil inlet line or equivalent size tubing
from top of turbocharger to oil cooler or transfer housing.
Fig. 14-31, (N114215). Adjusting valves 4. Connect No. 16 oil drain line or equivalent size tubing
from turbocharger to large boss on side of cylinder block.
properly seat adjusting screws, plunger links, push tubes,
etc. to mating surfaces. Take break-away torque reading Note: If turbocharger "vee clamp" is loosened to align oil
on injector plunger adjusting screws. Break-away torque drain line, tighten to 32 to 36 inch-lb. [0.37 to Q.41 kg ml
must be the same as adjustment torque. See Table 14- torque.
12. Re-adjust as necessary.
5. Install air intake crossover between turbocharger outlet
Jacob’s Brake and air intake manifold or aftercooler. Install new rubber
tubing connection and T-bolt type clamps.
Install Jacob’s Brake, if used. See Group 20.
410
 TRUCK SERVICE MANUAL ENGINE
Electric Connections

Secure electric connections to mounted equipment,

using wire as specified. See engine wiring diagram.

Fan Installation
Note: When installing fan to fan hub 5/16 inch [7.94 mm]
capscrew must have 15/32 inch [11.91 mm] thread
engagement, 3/8 inch [9.53 mm] capscrews must have
9/16 inch [14.29 mm] thread engagement, 1/2 inch
[12.70 mm] capscrews must have 3/4 inch [19.05 mm]
thread engagement. Check decal on fan hub or water
pump pulley for proper thread length. The fan may be
installed before or after engine dynamometer testing.

ENGINE TESTING
Engine break-in and testing are accomplished 1-2. Priming Points
Fig. 1433, (N11963). Lubricating system priming point
simultaneously. Break-in on a new or rebuilt engine is
necessary because it provides an operating period
CAUTION
during which moving parts acquire their final finish and Do not prime engine lubricating system from bypass
mating surfaces reach a full seat. Engine testing helps filter.
detect possible assembly errors, need for adjustments
as engine "break-in " and establishes a period for final 3. Connect a hand or motor driven priming pump
adjustments for best engine performance. line from source of clean lubricating oil to plug boss in
housing. Prime until a 30 psi [2.1 kg/sq. cm] maximum
Priming The Fuel System pressure is obtained.
4. Crank engine at least 15 seconds (with fuel
1. Fill fuel tanks and filter(s) with clean No. 2 diesel
shutoff valve closed or disconnect to prevent starting),
fuel oil meeting the specifications in Group 18.
while maintaining external oil pressure at a minimum of
a. With PT (type G) fuel pump, fill pump through
15 psi [1.1 kg/sq. cm].
plug next to tachometer with clean fuel.
5. Remove external oil supply line and replace
plug.
2. If injector and valve or other adjustments have
been disturbed, be sure they have been properly WARNING
adjusted before starting engine. Clean area of any lubricating oil spilled while priming
or filling crankcase.
Priming The Lubricating System
6. Finish filling crankcase to "H" (high) mark on
Note: If engine is equipped with a turbocharger, remove
dipstick.
oil inlet line and lubricate bearing with approximately 2 to
3 oz [60 cc] of clean engine lubricating oil. Reconnect oil
Lubricating Cranking Motor And Generator
inlet line.
Use 6 or 8 drops of clean lubricating oil to lubricate
1. Fill crankcase to "L" (low) mark on dipstick. See cranking motor and generator or alternator bearings (if
Lubricating Oil Specifications, Group 18. required), Avoid excessive oiling which would cause
damage to wire insulation.
equipped with hydraulic governed fuel pumps. This
Note: Some engine dipsticks have dual markings with
governor uses lubricating oil (of the same weight as used
high and low level marks; static oil marks on one side
in the engine) as an energy medium. Oil level in
and engine running at low idle speed marks on opposite
governor sump must be at full mark on dipstick, or
side. Be sure to use proper scale.
halfway level on inspection glass.
2. Remove plug from head of lubricating oil filter
Engine Dynamometer
housing or gear case to prime system. (See 1 or 2, Fig.
1433.) Check dynamometer capacity, Make sure capacity is
sufficient to allow testing at 96 to 100% maximum engine
horsepower. If capacity is insufficient, testing
procedures must be modified to prevent damage to
dynamometer
411
 TRUCK SERVICE MANUAL ENGINE

INSTALLATION OF ENGINE three or four seconds of cranking, close compression

1. Place engine on dynamometer test stand, release and continue to crank until engine fires.
secure engine mounting pads to engine support risers. CAUTION
2. Position dynamometer drive shaft flange to Do not crank engine continuously for more than 30
engine flywheel. Check for proper alignment per seconds. If engine does not fire, wait two to five
manufacturers instructions. minutes before repeating to avoid cranking motor
3. Connect water supply and return hose to the damage.
water cooling arrangement.
4. Attach ST1190 Fuel Consumption Measuring Cold Start With Preheater
Device to engine. 1. Set throttle in idle position, turn glow plug toggle
5. If engine is equipped with an aneroid control, switch to "ON" position. (Red indicator light must be on.)
disconnect fuel pressure and fuel return line and plug After red’ light has been on for 20 seconds, start
lines. The aneroid is reconnected just after "power cranking engine. As soon as engine begins rotating,
check" is made. operate preheater priming pump to maintain 80 to 100
6. Connect throttle linkage instruments, exhaust psi [5.6 to 7.0 kg/sq. cm] fuel pressure. (Use of primer
piping and air intake piping to engine. before 20second interval will wet and cool glow plug and
7. On naturally aspirated engines, plug vent holes prevent heating.)
in cylinder heads before making blowby check. After
testing, remove pipe plugs. Note: On engines equipped with an oil pressure switch,
8. Install ST487 BlowBy Checking Tool in the fuel bypass switch must be In "START" position
crankcase breather opening or special rocker cover. before use of priming pump. Hold in "START" position
Use water manometer and fill to "O" mark at middle of until engine oil pressure reaches 7 to 10 psi [0.5 to 0.7
scale. Close all openings that would allow blowby kg/sq. cm]then move to "RUN" position.
pressure to escape. 2. If engine does not start within 20 seconds, stop
9. Start engine, see "Starting Procedure," open cranking, wait two to five minutes and repeat cranking
coolant supply to engine water connection. Introduce operation.
water to dynamometer per manufacturer’s instructions. 3. After engine starts, pump primer slowly to keep
Check all tubing, hose, lines, fittings and plugs for leaks. engine idling smoothly. Do not accelerate engine.
Correct as necessary. See "Check Turbocharger Oil 4. When engine has warmed up so it does not
Flow" following. falter between primer strokes, stop pumping. Close and
10. For engine run-in, see "Test Procedure. lock primer. Turn off glow plug toggle switch.

Check Turbocharger Oil Flow Failure To Start

1. Disconnect turbocharger oil drain line. 1. If engine gives no indication of starting during
2. Start engine and maintain rpm at low idle. first three full strokes of preheater pump, check intake
3. Observe oil drain. Oil should flow in 10 to 15 manifold for heat. If there is no heat, check electric
seconds. If no oil flows in 30 seconds, shut down engine wiring. If wiring is all right, remove pipe plug from
and correct fault. manifold and observe glow plug. Glow plug should be
4. Reconnect oil drain line when flow is established. white hot; if not, connect plug to a six or twelve volt
source and check amperage which should be 30
STARTING PROCEDURE (minimum). If glow plug is all right, check manual switch
and resistor; replace if necessary.
Normal Without Cold-Starting Aid TEST PROCEDURE
1. Set throttle for idle speed, open manual fuel Horsepower Ratings
shutdown valve, if used. Electric fuel shutdown valves 1, The maximum horsepower ratings at rpm shown in
operate automatically. Table 1414, "Dynamometer Test Chart," are for engines
operating at No. 1 Curve or intermittent duty applications
Note: The manual override knob provided on forward at sea level, 60 deg. F [16 deg. C] intake air
end of electric shutdown valve, allows valve to be temperature and 29.92 inch [760.0 mm] Hg (Mercury)
opened in case of electric power failure or if power is not barometric pressure.
available during testing. To use, open by turning fully 2. Where it is necessary to derate because of high
clockwise. altitude operation, the derating may be done by reducing
2. Pull compression release if so equipped, press maximum governed rpm or maximum fuel rate. Refer to
starter button or turn switch key to "start" position. After FUEL PUMP SYSTEM

412
 TRUCK SERVICE MANUAL ENGINE

3. Naturally aspirated engines must be derated 3% to assure lowest smoke potential and avoid excessive
for each 1000 ft. [304.8 ml altitude above sea level, and injector train loads.
1% for each 10 deg. F [6 deg. C] ambient temperature
rise above 60 deg. F [16 deg. C]. POWER CHECK
4. Turbo-charged engines do not require fuel 1. Run engine at rated speed for 5 minutes. It
derating below maximum altitudes shown in the should develop 96% of rated horsepower at standard
"Dynamometer Test Chart." Above maximum altitudes, fuel rate. Check crankcase pressure (blowby). If
derate at 4% for each 1000 ft. [304,8 ml additional pressure exceeds value shown in Table 1414 reduce
altitude and 1% for each 10 deg. F [6 deg. C] air engine speed and load to preceding phase; run engine
temperature rise above 12 deg. F [52 deg. C]. 30 to 45 minutes.
5. New or newly rebuilt engines during 2. Repeat procedure described above until engine
dynamometer tests are not required to deliver more than develops 96% rated horsepower at standard fuel rate
96% of maximum horsepower at power checks. within permissible crankcase pressure limit.
3. After power check is completed, remove pipe
BREAKIN RUN plugs in naturally aspirated engine cylinder heads and
install vent plugs. On turbocharged engines connect
Initial Starting aneroid, if used.

Start engine and idle at approximately 800 rpm no load CHECKS DURING RUNIN TEST
for five to ten minutes. Check oil pressure and water During the period of engine runin, the following checks
circulation; look for leaks. should be made frequently.

At Each Phase Lubricating Oil

1. Apply dynamometer load to (+10%) horsepower 1. Lubricating oil pressure should remain at or near
at (+5%) speed shown in Table 1414 "Dynamometer a constant figure at constant engine speed and load (see
Test Chart". Table 1415) after normal operating temperature has
2. Check crankcase pressure (blowby) with ST487. been reached. Abnormally high pressures may indicate
If pressure continues to drop, reduce run-in time by half; blocked lubricating oil lines. Abnormally low pressures
otherwise, run engine for time period shown on indicate an insufficient supply of lubricating oil from the
dynamometer chart. pump or increased oil clearances which may be due to
bearing failure.
At Phase 1 2. If oil temperature rises sharply above 225 deg.
1. Run engine until normal oil operating F [107 deg. C] shut down engine and correct as
temperature has been obtained. necessary.
2. Add lubricating oil to bring level up to "H" mark 3. New lubricating oil filter elements will absorb oil;
on bayonet gauge, allow oil temperature to stabilize. therefore, engine must be shut down after five or ten
minutes of operation and additional oil added to bring oil
At Phase 2 level to "H" mark on bayonet oil gauge. Check oil level
Set engine Idle, governed speed and fuel rate. every phase during runin test.

At Phase 3 Smoke Level

If blow by rises, reduce load to preceding phase and run See Service Tool Instructions,
for 30 minutes; then return to original phase
specifications. Engine Coolant
After engine is started, add coolant as necessary to
At Phase 4 completely fill cooling system and replace entrapped air.
1. Run at speed and horsepower indicated. Coolant should not exceed 200 deg. F [93 deg. C] or
2. Check for leaks and tighten all exposed drop below 160 deg. F [71 deg. C] during engine
capscrews. operation. Do not turn engine off immediately after a
3. Recheck valves and injectors. Use "Hot load run. Heat stored in the iron masses will boil coolant
Setting," refer to Tables 1411, 14.12 and 1413. in the jackets if air and coolant circulation is immediately
stopped while engine is hot. Allow engine to idle for a
Note: Readjustment after 1 hour operation is necessary few minutes before shutting down.

413
TRUCK SERVICE MANUAL ENGINE

Table 1415: Normal Lubricating Oil Pressure

Idle (525620rpm} Rated Speed
PSI [kg/sq. cm]PSI [kg/sq. cm]
10 [70] Minimum 40/75 [2.80/5.25]
Note: Individual engines may vary from above
pressures.

Fuel Pressures
For fuel pressure reading and adjustment, refer to Fuel
Pump Calibration

Overspeed Stop
Overspeed stops, when used, are set to trip and shut off
fuel supply when engine exceeds maximum rated speed
by approximately 15%. After determining and correcting
cause of overspeed stop trip, reset in running position.

Engine Fuel Rate

ST1190 Fuel Consumption Measuring Device operates
by drawing fuel from fuel tank, then through flow meter.
Return fuel from injector drain is routed through float
tank so when float tank is filled, float valve opens and
allows return fuel flow to flow meter. Makeup fuel or
amount of fuel being consumed by engine will flow
through flow meter thus showing rate of fuel
consumption in pounds per hour. See fuel pump
calibration manuals.

Blow-By Readings
1. Manometer readings must be taken frequently during
runin test so mechanic will note any blowby increase at a
given speed and load. If there is any indication of blowby
increase, engine speed must be reduced for a few
minutes and then brought back to the original setting.

2. During each power check, keep a constant check on

the manometer; if pressure rises, more runin is required.

Representative pressure limits for engine running at

governed speed and pulling 96 to 100% of rated
horsepower are given in Table 1414. If pressure is
greater than values listed at end of testing period, engine
should be checked as follows:

a. Naturally aspirated engines:

Operate 30 minutes extra at 96 to 100% rated load and

rpm. If there is no rapid change in excess of 1 inch [25.4
mm] of water and maximum reading does not exceed
100% of representative pressure, blowby is acceptable.

414
 TRUCK SERVICE MANUAL ENGINE

b. Turbocharged engines: Operate 30 minutes extra at c. Operate with a power requirement low enough to
96 to 100% rated load and rpm. If there is no rapid allow acceleration to governed speed under any
change in excess of 2 inches [50.8 mm] of water and condition.
reading does not exceed 100% of representative
pressure, blowby is acceptable. 6. Check exhaust restrictions (back pressure)
as follows:
Note: Manometer readings not exceeding 0.3 inch [7.62
mm] surge are desirable. a. Using a mercury or water manometer, take
readings when engine is developing maximum
CHASSIS DYNAMOMETER TESTS horsepower at maximum engine speed.
If the engine is installed In equipment, it may be tested b. Maximum permissible back pressures are:
on a chassis dynamometer as follows:
All Models
1. Check instruments, follow manufacturer’s (1) 3.0 inch [76 mm] Hg. or 20 inches [508 mm] of water
instructions. for all naturally aspirated engines.
2. Perform all phases of engine dynamometer BreakIn
Run. See Table 1414. (2) 3.0 inch [76 mm] Hg. or 25 inches [635 mm] of water
for all turbocharged engines.
Maintenance Of Dynamometer
Follow manufacturer’s maintenance instructions to 7. Check smoke level,
service dynamometer.
ANEROID CONTROL ADJUSTMENT
Calibrating Instruments
Keep beam or spring scales properly calibrated. Follow The aneroid bellows spring is preset and sealed at
manufacturer’s recommendation when recalibrating or Cummins Engine Company, Inc. The following
instrument adjustment is necessary. adjustment can be made while the engine is on a
dynamometer.
In-Chassis Run-In 1. Start engine and check idle speed. In most
Inchassis repaired engines should receive runin cases, idle will be low and must be adjusted upward with
equivalent to that on an engine dynamometer. Follow fuel pump governor idle screw.
procedure given below after an inchassis repair or 2. Check engine rated power and speed. If smoke
rebuild. is not excessive during first 15 seconds of full throttle
operation, but becomes excessive thereafter, aneroid is
1. Start engine. Idle at 800 to 1000 rpm, noload, not at fault.
for 5 to 10 minutes. Check oil pressure and water 3. Check fuel system and turbocharger before
circulation. Correct any leaks. readjusting aneroid control.
2. Operate at 1/4 to 1/2 throttle for first 5 to 10 4. If hard starting is encountered, the aneroid
hours. pressure valve may be sticking in open position, closed
3. Operate at 1/2 to 2/3 throttle for next 45 to 50 position will result in excessive smoke. Replace if
hours. necessary.
4. After 50 hours of operation, do not operate PAINT ENGINE
engine at full load and speed in excess of 5 minutes 1. Prior to painting, clean surface for maximum
continuously at any time. After 5 minutes full power run, paint adherence. Dry with compressed air.
drop back to 3/4 throttle. 2. Cover all openings, pulley grooves, instrument
5. During the first 100 hours’ service: faces and belts. Cover all data plates, exposed threads,
wire terminals, hose fittings and pipe openings with water
a. Do not idle engine for long periods. proof paper or tape.
b. Watch instruments closely. Decrease engine 3. Cover clutch contact surface on flywheel with
rpm if oil temperature reaches 250 deg. F [121 deg. C] antirust compound, if engine is not going into immediate
or if coolant temperature exceeds 190 deg. F [88 deg. service.
C] . 4. Spray outside surfaces of castings and
corrodible parts with a primer coat of yellow lacquer to
serve as a base for the second coat of engine enamel.

415
 TRUCK SERVICE MANUAL ENGINE

ENGINE STORAGE preservative oil U. S. Military Specification MI LL644

On any engine not in service, the unpainted machined Type P9.
surfaces are subject to rust and corrosion. The rate of 5. Start engine with fuel line to filter using diesel
corrosion varies with climatic conditions. An engine fuel. The injector drain line can flow into the container
stored in a climate with a high amount of moisture in the with diesel fuel. After engine is running smoothly, switch
air will corrode more rapidly than an engine stored in a fuel line to container with preservative oil. Operate five
dry climate. to ten minutes on the preservative oil. Stop the engine
and reconnect the fuel lines.
Temporary Storage 6. Drain oil sumps of pumps, compressors,
If an engine remains out of service for three or four coolers, filters and crankcase, etc. Replace all plugs
weeks (maximum six months), special precautions after draining.
should be taken to prevent rust. The operations listed 7. Remove intake and exhaust manifolds. Spray all
below are required to minimize or prevent damage to intake and exhaust ports, including air compressor intake
temporarily stored engines. port, with preservative oil. Replace intake and exhaust
manifolds.
1. Engine must be started and operated until 8. Inspect cooling system if coolant is
thoroughly warm. Disconnect fuel lines to engine fuel contaminated, drain and flush, fill with rust preventive
filter and injector drain line. Fill two containers, one with compound.
diesel fuel and a second with preservative oil. 9. If air starter is used, remove exhaust plate, spray
2. Start engine with fuel line to filter using diesel with preservative oil and replace plate. Loosen V belt
fuel. The injector drain line can flow into the container tension.
with diesel fuel. After engine is running smoothly, switch 10. Rush or spray a film of rust preventive
fuel line to container with preservative oil. Operate five compound on all exposed, unpainted surfaces of engine.
to ten minutes on preservative oil. Stop engine and Use a rust preventive conforming to Type P2, Grade 1 or
reconnect the fuel lines. 2, U.S. Military Specification MILC16173C.Remove
3. Drain oil sump, fuel filters and fuel tank and cylinder head covers and spray rocker levers, valve
reinstall drain plugs. Sump may remain empty until stems, springs, guides, crossheads and push tubes.
engine is ready for use, tag engine with warning tag. Replace cover.
4. Disconnect electrical wiring and turn full pump 11. Cover all engine openings with heavy paper and
manual shutoff valve fully counterclockwise. Spray tape. Tag engine to indicate that it has been treated
lubricating oil into intake manifold and air compressor with preservatives and crankshaft should not be barred
while cranking engine slowly. over.Tag should show coolant has been removed, date
5. Cover all openings with tape to prevent entrance of treatment and indicate that engine is not ready to run.
of dirt and moisture. 12. Store engine in an area where air is dry and
6. Drain coolant from cooling system unless it is temperature uniform.
permanent type antifreeze with rust inhibitor added.
7. Store engine in dry and uniform temperature Note: Engines in storage more than 24 months should
area. be flushed out with a suitable solvent or light, hot oil and
8. Bar engine crankshaft two or three revolutions then be reprocessed with rust preventive materials.
each three to four weeks. Periodically inspect engines for rust or corrosion. Take
corrective action if necessary.
Permanent Storage
1. When engine is to be stored six months or more, 13. Although the preservative materials may be
the lubricating system, cooling system, fuel system, added to and used for the same purpose repeatedly,
crankcase and external parts must be protected against they must be kept clean, the accumulated deposits
rust and corrosion. should be removed after being allowed to settle.
2. Start engine and operate at fast idle until the
engine is thoroughly warm. Stop engine and drain old PREPARING A STORED ENGINE FOR SERVICE
oil. When an engine is removed from storage and put into
3. Fill crankcase to full mark on bayonet gauge or service, the following operations should be performed.
dipstick with preservative oil, U. S. Military
Specification MILL21260, Type P10, Grade 2 SAE 30. Clean Engine
416 WVICE MANUAL 4. Disconnect fuel lines to 1. Clean accumulated dirt from exterior of engine.
engine fuel filter and injector drain line. Fill two Remove covers, tape and wrappings.
containers, one with diesel fuel and a second with
416
 TRUCK SERVICE MANUAL ENGINE

2. Use suitable cleaner to remove rust preventive 6. Reduce load and rpm.
compound from unpainted surfaces.
3. Refill crankcase with clean lubricating oil. Flush 7. Accelerate engine to rated rpm, no load (when
and fill cooling system. chassis dynamometer is used shift to a lower gear that
would allow full acceleration in approximately 3 to 5
seconds.) Return to idle.
Inspection
8. Using 0100 scale on opacity meter, zero the
1. When an engine has been stored for six months meter and place on exhuast stack(s).
or less, it is necessary to adjust injectors, valves and
belts, tighten cylinder head capscrews and connections; 9. Accelerate to rated rpm, no load, record the
replace filters and check air filter and screens. “highest” opacity reading. Remove meter.
2. When an engine has been stored for six months
or more, the following procedure should be followed: Note: When rechecking zero during a test and the
readjustment to zero is off by more than two (2) percent
a. Flush fuel system with clean fuel oil until all clean lenses on opacity meter before rezeroing the scale.
preservative oil is removed.
b. Remove plug from oil gallery and force hot, light Federal Tests require averaging five (5) one half (1/2)
mineral oil through the oil passages to flush away all second smoke peak intervals for lug down tests and
preservative oil. Bar over engine crankshaft three or four fifteen (15) second smoke peak intervals for
revolutions during flushing operation. acceleration, to determine smoke levels. Consult Local
c. Replace all filters and clean all screens before Air Pollution Agency for environmental regulations
engine is started. covering smoke opacity limits.
d. After inspecting engine and parts, make sure all
preservative oil and gummed oil has been flushed away.
Start engine as described in Engine Testing.

INSTRUCTIONS FOR USE OF SERVICE TOOLS

Smoke Level Check With ST1294 Model 101 B

Celesco Opacity Meter
1. Engine must be at normal oil operating
temperature.

2. Apply dynamometer load as rpm is increased;

(shift to direct drive gear when chassis dynamometer is
used) until rated rpm and H.P. is reached and load is
stabilized. Refer to Table 1414.

3. Using 020 scale on opacity meter zero the meter

and place on exhaust stack(s); record readings.
Remove meter after readings are completed.

Note: An accurate smoke reading can usually be

obtained in ten to fifteen seconds.
4. Increase load until rpm is reduced to 60 percent
of rated rpm.
5. Recheck zero on opacity meter, place on
exhaust stack(s); record readings and remove meter

417
TRUCK SERVICE MANUAL ENGINE

418
 TRUCK SERVICE MANUAL ENGINE

Instrument and Control Group 15 when engine is new to serve as a guide for indication of
progressive engine condition. Instruments and gauges
TACHOMETER show at all times how to get the most satisfactory service
Rated engine speed is the rpm attained at full load. from an engine. Safety controls are used on Cummins
Governed engine speed is the highest rpm a properly Engines to shut down the engine because of high coolant
adjusted governor will allow the engine to turn, no load. temperature, low or loss of lubricating oil pressure and
Governed engine speed must never be exceeded on engine speeds above rated rpm.
downgrades or any other condition in which the load
drives the engine. NASON SAFETY CONTROLS
The Nason (formerly Hawk) Safety Control System
Operate at partial throttle in continuous duty situations to provides protection from low lubricating oil pressure and
give required torque with the tachometer showing rpm excessively high coolant temperature of preset values.
approximately 15 percent below governed speed. When either is exceeded, the controls disrupt the
electrical circuit to the fuel solenoid shutdown valve and
OIL TEMPERATURE GAUGE shuts down the engine. The oil pressure safety control is
mounted directly in the main oil gallery. The temperature
The oil temperature gauge normally should read between safety control mounts directly into the water manifold.
180 deg. F [82 deg. C] and 225 deg. F [116 deg. C] for
best lubrication. Any sudden increase in oil temperature During cranking of engine a permissive start switch is
which is not caused by load increase is a warning of used to bypass the low lubricating oil pressure safety
possible mechanical failure and should be investigated at control.
once. Actual cranking is accomplished by use of a push button
type starting switch wired into the cranking circuit. See
WATER TEMPERATURE GAUGE wiring diagram Fig’s. 151, A and B.

A water temperature of 165 deg. to 195 deg. F [74 deg.

to 91 deg. C] is the best assurance that cylinder liners
are heated to the proper .temperature to support good
combustion and that working parts of the engine have
expanded evenly to the most favorable oil clearances.

Overheating problems require mechanical correction. It

may be caused by loose water pump belts, a clogged
cooling system or heat exchanger, or insufficient radiator
capacity. Report cases of overheating to the
maintenance department for correction; 200 deg. F
[93.3 deg. Cl maximum engine coolant temperature
should not be exceeded.

OIL PRESSURE GAUGE

The oil pressure gauge indicates any drop in lubricating

oil supply or mechanical malfunction in the lubricating oil
system. The operator should note loss of oil pressure
immediately and shut down the engine before the
bearings are ruined. Individual engines may vary from
above normal pressures. Observe and record pressures

419
 TRUCK SERVICE MANUAL ENGINE

Fig. 15-1 (VI1306). Wiring diagram

420
 TRUCK SERVICE MANUAL ENGINE

Fig. 16-1A (V11306A). Wiring diagram (cont’d.)

421
 TRUCK SERVICE MANUAL ENGINE

Fig. 15-18 (V11306B). Wiring diagram (cont’d.)

422
 TRUCK SERVICE MANUAL ENGINE

Specifications and Wear Limits Group 18 Worn limits as stated in this manual indicate that the
part may be reused if it is at the worn limit. Discard only
if it exceeds the worn limit. All engine models are the
same unless otherwise stated. Limits are given in U.S.
and Metric measurements. All Metric units are enclosed
in brackets [].
WEAR LIMITS
New New Worn
Part or Location Minimum Maximum Limit
GROUP 1. CYLINDER BLOCK

Installed Camshaft Bushing Inside Diameter 1.999 2,0005 2.0015

[50.77] [50.813] [50.838]

Camshaft Bushing Bore in Block 2.1285 2.1295 2.1305

[54.064] [54.089] [54.115]
Cylinder Liner Counterbore
Inside Diameter 6.5615 6.5635
[166.662] [166.713]
Counterbore Depth 0.350 0.352 0.412
[8.89] [8.94] [10.46]
Liner Protrusion 0.003 0.006
[0.08] [0.15]
Liner-to-B lock Clearance
Lower Bore 0.002 0.008
[0.05] [0.20]
Cylinder Block Lower Liner Bore 6.124 6.126
[155.55] [155.60]
Main Bearing Bore 4.7485 4.750 4.7505
[120.612] [120.65] [120.663]
Main Bearing Bore Alignment See Page 347
Main Bearing Capscrew
Tightening Ft-Lb. [kg m]
1. Tighten to 145 155
[20.05] [21.44]
2. Advance to 300 310
[41.49] [42.87]
3. Loosen All All
4. Tighter to 140 145
[19.36] [20.05]
5. Advance to 30 deg 30 deg
Cylinder Block Height From Main Bearing
Bore Center Line 19.004 19.006 18.994
[482.70] [482.75] [482.45]
From Top of Alignment Bar 16.629 16.631 16.619
[422.38] [422.43] [422.12]
Cylinder Liner Counterbore 0.350 0.352 0.412
[8.89] [8.94] [10.46]
Cylinder Liner Counterbore Shims
Part No. 143938 0.0063 0.007
[0.160] [0.18]
Part No.,143939 0.0072 0.0088
[0.183] [0.223]

423
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit

Part No. 143946 0.0081 0.0099

[0.206] [0.251]
Part No. 143947 0.018 0.022
[0.46] [0.56]
Part No. 143948 0.028 0.034
[0.71] [0.86]
Part No. 143949 0.056 0.068
[1.42] (1.73]
Cylinder Liner
Cylinder Liner Inside Diameter 5.4995 5.501 5.505
[139.6871 [139.73] [139.83]

Note: New cylinder liners dimensions at 60 to 70 deg F [16 to 21 deg C];

may be 0.0002 to 0.0006 inch [0.005 to 0.015 mm]
smaller than indicated due to lubrite coating.

Cylinder Liner Protrusion 0.003 0.006

[0.081 [0.15]
Bearings

Standard Size (Thickness)

Main Bearing (All) 0.123 0.1238 0.1215
[3.12] [3.144] [3.086]
Connecting Rods (855 Series) 0.0724 0.0729 0.071
[1.839] [1.852] [ 1.80]

Journal Clearance
Main 0.0015 0.005 0.007
[0.038] [0.13] [0.18]
Connecting Rods 0.0015 0.0045 0.007
[0.038] [0.114] [0.18]
Crankshaft Thrust Ring Thickness
Part No’s.: 157280 0.245 0.247
[6.22] [6.27]
157281 0.255 0.257
[6.48] [6.53]
157282 0.265 0.267
[6.73] [6.78]
Crankshaft End Clearance 0.007 0.017 0.022
[0.18] [0.43] [0.56]
Vibration Dampers
Misalignment of Index Marks 0.0625
[1.587]
Wobble and Eccentricity Refer to Page 403
Connecting Rods

Nut Tightening (855 C.I.D Series) Refer to Table 1-1 (19).

Crankpin Bore Refer to Table 1-1 (6).
Out-of-round 0.0015
[0.038]

424
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
Piston Pin Bushing 2.001 2.0015 2.0025
[50.83] [50.8381 [50.863]

Connecting Rod Length

Center to Center 11.998 12.000

[304.75] [304.80]

Connecting Rod Alignment

Without Bushing 0.008
(0.20)
With Bushing 0.004
[0.10]
Twist
Without Bushing 0.020
[0.51]
With Bushing 0.010
[0.25]
Connecting Rod Bolt (855 C.I.D Series)
Minimum O.D 0.541 0.545 0.540
[13.74] [ 13.84] [ 13.72]
Pilot O.D 0.6245 0.625
[15.852] [15.87]

Bolt Hole Inside Diameter Pilot

855 Series Rod 0.6243 0.6248 0.6249
[15.857] [15.870] [15.872]
Cap 0.6246 0.6251 0.6252
[15.865] [ 15.877] [15.880]

Piston and Piston Rings

Ring Gap Refer to Table 1-1 (14).
Piston Skirt Diameter at 70 deg F [21 deg C] Refer to Table 1-1 (12).
Piston Pin Bore
Aluminum 1.9985 1.9989 1.999
[50.762] [50.772] [50.77]

Piston Pin Diameter 1.9988 1.999 1.9978

[60.7691 [50.77] [50.754]

425
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
Camshaft
Journal Diameter 1.997 1.998 1.996.
[50.72] [50.75] [50.70]
Camshaft Support Bushing 1.3725 1.3755 1.370
[34.861] [84.938] [34.80]
Camshaft Outboard Bearing Support 1.751 1.754 1.757
[44.48] [44.55] [44.63]

Gear Case Cover

Accessory Drive Bushing
Part No 132770 1.565 1.569 1.571
[39.75] [39.85] [39.90]
Part No 132771 1.555 1.559 1.561
[39.41] [39.60] [39.65]
Part No 132772 1.545 1.549 1.551
[39.24] [39.34] [39.40]

GROUP 2. CYLINDER HEAD

Height 4.370 4.380 4.340
[111.00] [111.25] [110,24]
Injector Sleeve
Top Inside Diameter 1.145 1.155
[29.08] [29.34]
Injector Cup Protrusion 0.060 0.070
[1.52] [1.78]
Valve Seat Insert
Run-out 0.002
[0.05]
Sizes Available Refer to Table 2-1 (8).

Valve Crossheads and Guides

Crosshead Stem Inside Diameter 0.434 0.436 0.440
[11.02] [11,071 [11.18]
Guide Outside Diameter 0.433 0.4335 0.432
[10.99] [11.011] [10.97]
Guide Assembled Height 1.860 1.880
[47.24] [47.75]
Depth Valve Stem Pocket 0.120 0.140
[3.05] [3.56]

Valve, Guides and Springs

Valve Stem Outside Diameter 0.450 0.451 0.449
[11.43] [11.46] [11.40]
Valve Guide Inside Diameter 0.4525 0.4532 0.455
[11.493] [11.511] [11.56]
Valve Guide Protrusion 1.315 1.325
[33.40] [33.65]
Valve Spring Data Refer to Table 2-1 (9).

426
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
GROUP 3. ROCKER LEVERS

Bushing Inside Diameter 1.1245 1.1275 1.1286

[28.562] [28.638] [28.664]
Shaft Outside Diameter 1.123 1.124 1.122
[28.52] [28.55] [28.50]

GROUP 4. CAM FOLLOWERS

Shaft Outside Diameter 0.7485 0.749 0.748

[19.012] [19.02] [19.00]
Bushing Inside Diameter 0.7495 0.7505 0.7515
[19.037] [19.063] [19.088]
Cam Roller
(Injector Inside Diameter) 0.503 0.504 0.505
[12.78] [12.80] [12.83]
(Injector Outside Diameter) 1.249 1.251 1.247
[31.72] [31.78] [31.67]
(Valve Inside Diameter) 0.5005 0.5015 0.503
[12.713] [12.738] [12.78]
(Valve Outside Diameter) 1.249 1.250 1.247
[31.72] [31.75] [31.67]
Pin Outside Diameter 0.4995 0.500 0.497
[12.687] [12.70] [12.62]
Push Tubes
Ball End Radius 0.623 0.625
[15.82] [15.87]
Socket (Spherical Inside Diameter) 0.505 0.520
[12.83] [13.21]

GROUP 5. FUEL SYSTEM Refer to Fuel Pump Section

GROUP 6. INJECTOR Refer to Injection Section

GROUP 7. LUBRICATING SYSTEM

Lubricating Oil Pan

Capacities Refer to Table 7-1
Drain Plug Torque ft-lb. [kg m] 60 70
[8.30] [9.68]
Lubricating Oil Dipstick
Dipstick Length (Blank) Refer to Page 373
Lubricating Oil
Hose Size Refer to Tables 7-2 and 7-3

Lubricating Oil Pump

Flange-Mounted Horizontal Filter
Bushings 0.6165 0.6175 0.6185
[15.659] [15.654] [15.710]
Idler and Drive Shaft Outside Diameter 0.615 0.6155 0.6145
[15.61] [15.634’ [15.608]

427
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
Double Lubricating Oil Pump
Body, Filter Head and Cover
Idler Gear Bushing Inside Diameter 0.6165 0.6175 0.6185 -
[15.659] [15.684] [15.710]
Idler and Drive Shaft Outside Diameter 0.615 0.6155 0.6145
[ 15.62] [15.634] [15.608]
Single Scavenger Pump
Idler Gear Drive Shaft and
Cover Bushing Inside Diameter 0.6165 0.6175 0.6185
[15.659] [15.684] [15.710]
Idler and Drive Shaft Outside Diameter 0.615 0.6155 0.6145
[15.61] [15.634] [15.608]
Double Scavenger Pump
Idler Gear Drive Shaft and
Cover Bushing Inside Diameter 0.840 0.8405 0.841
[21.34] [21.349] [21.36]
Idler and Drive Shaft Outside Diameter 0.8375 0.838 0.837
[21.272] [21.29] [21.26]
Single Double Capacity Lubricating Oil Pump
Body and Cover Bushing Inside Diameter 0.8767 0.8777 0.879
[22.268] [22.293] [22.33]
Drive Shaft 0.8745 0.875 0.873
[22.212] [22.22] [22.17]
Idler Shaft Outside Diameter 0.8745 0.875 0.873
[22.212] [22.22] [22.17]

GROUP 8. COOLING SYSTEM

Water Pump
Impeller to Shaft Press-Fit 0.001
[0.03]
Impeller to Body Clearance 0.020 0.040
[0.51] [1.02]

Fan Hub
End Clearance 0.003 0.010
[0.08] [0.25]
Bearing to Shaft Press-Fit 0.000 0.001
[0.00] [0.03]

Thermostats
Operating Range
Low 160 deg F 175 deg F.
[71 deg C] [79 deg C]
Medium 175 deg F 185 deg F
[79 deg C] [85 deg C]
High 180 deg F 195 deg F
[82 deg C] [91 deg C]

428
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
GROUP 9. DRIVE UNITS

Fuel Pump and Compressor Drive

Bushing Inside Diameter 1.312 1.315 1.321
[33.32] [33.40] [33.55]
Drive Shaft Outside Diameter 1.3115 1.312 1.310
[33.312] [33.32] [33.27]
End Clearance 0.005 0.010
[0.13] [0.25]
GROUP 10. INTAKE AIR SYSTEM
Cold Starting Aids Refer to Page 388
Air Cleaner
Restriction (Inch/Water) Naturally Aspirated
Oil Bath 15
[381.001
Dry Type (Normal Duty) 10 20
[254.00] [508]
Dry Type (Medium Duty) 12 20
[304.80] [508]
Dry Type (Heavy Duty) 15 20
All Turbocharged Engines 25 in.H20 [ 381.00] [508]
Turbocharger
VT-50 Refer To Turbocharger Section

GROUP 11. EXHAUST SYSTEM See Page 390

GROUP 14. ENGINE ASSEMBLY AND TESTING

Crankshaft End Clearance 0.007 0.017 0.022

[0.18] [0.43] [0.56]
Cylinder Liner Protrusion 0.003 0.006
[0.08] [0.15]
Cylinder Liner Out-of-round
Top/inch [25.40] 0.003
[0.08]
Lower Area 0.002
[0.05]
Connecting Rod Side Clearance 0.0045 0.013
[0.114] [0.33]
Gear Backlash - Gear to Gear
Crankshaft, Camshaft, Fuel Pump Drive, 0.002 0.009 0.020
Idler, and Lubricating Oil Pump Gears [0.05] [0.23] [0.50]
Camshaft End Clearance Refer to Table 14-1 (7).
Injection Timing Refer to Table 14-3, Page 397
Injector and Valve Adjustment Refer to Page 407

429
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
Engine Firing Order Refer to Table 14-10, Page 408
Belt Tension Refer to Table 14-5, Page 404
Main Bearing Capscrew Refer to Table 1-1 (18).
Connecting Rod Nuts ft. lb. [kg m] Refer to Table 1-1 (19).
Injector Hold-down Capscrew ft. lb. [kg m]
Nylock Capscrews 11 12
[1.52] [1.66]
Rocker Housing Capscrews ft. lb. [kg ml 55 65
[7.61] [8.89]
Note: Refer to Fig. 14-9 for Torque Sequence.
Fuel Filter ft. lb. [kg ml 20 25
[2.771 [3.46]
Flywheel Housing Capscrews ft. lb. [kg m] 150 [20.74]
Flywheel Capscrews ft. lb. [kg ml 190 200
(Lockwire) [26.28] [27.66]
(Hardened Flatwashers) 200 220
[27.66] [30.43]
Camshaft End Clearance
(with thrust plate) 0.001 0.003
[0.03] [0.08]
(with outboard bearing support) 0.008 0.010
[0.20] [0.25]
Crankshaft Flange Capscrew ft. lb. [kg ml
Engine Model Part No.

NT Series 196653 Capscrew 250 270

196654 Retainer [34.9] [38.8]

Vibration Damper Capscrews ft. lb. [kg ml 60

Vibration Damper and Pulley ft. lb. [kg ml [8.30]
Pulley to Damper 85
[11.76]
Damper and Pulley to Crankshaft 85
[11.76]
Accessory Drive Pulley Nut ft. lb. [kg ml 90 110
[12.45] [15.21]
Fan Hub Nut ft. lb. [kg ml 400 450
[55.30] [62.23]
4 Bolt Fan Hub to Mounting Bracket ft. lb. [kg ml 50
[6.91]
Idler Pulley Nut 45 55
[6.22] [7.60]
Exhaust Manifold Capscrews
ft. lb. [kg ml 25
[3.46]
Oil Cooler and Filter Assembly Refer to Page 405
Rocker Housing Cover Capscrews
Combination cork and rubber gaskets
in. lb. [kg ml 75 95
[0.861 [1.09]
Cork Gaskets ft. lb. [kg ml 12 17
[1.66] [2.35]
430
 TRUCK SERVICE MANUAL ENGINE

New New Worn

Part or Location Minimum Maximum Limit
Engine Testing Refer to Page 411
Dynamometer Test Chart Refer to Table 14-14, Page 414
Lubricating Oil Pressure
Idle Speed P.S.I. [kg/sq. cm] 5 20
[0.35] [1.41 ]
Rated Speed P.S.I. [kg/sq. cm] 40 75
[2.80] 15.25]
Blow-by Refer to Page 414
Back Pressure Refer to Page 415
Smoke Level Refer to Page A17

431
 TRUCK SERVICE MANUAL ENGINE

LUBRICATING OIL Viscosity Recommendations

The use of quality lubricating oil, combined with
appropriate oil drain and filter change intervals, is an 1. Multigraded lubricating oils may be used in
important factor in extending engine life. Cummins applications with wide variations in ambient temperatures
Engine Company, Inc. does not recommend any specific if they meet the appropriate performance specifications
brand of lubricating oil. The responsibility for meeting and ash content limits shown in Table 181. Multigraded
the specifications, quality and performance of lubricating oils are generally produced by adding viscosity index
oils must necessarily rest with the oil supplier. improve additives to a low viscosity base stock to retard
thinning effects at operating temperatures. Poor quality
Oil Performance Specifications multigraded oils use a
The majority of lubricating oils marketed in North
America (and many oils marketed worldwide) are Table 18-1: Oil Recommendations
designed to meet oil performance specifications which
have been established by the U.S. Department of
Defense and the Automobile Manufacturers Association.
A booklet entitled "Lubricating Oils for Heavy Duty
Automotive and Industrial Engines" listing commercially
available brand name lubricants and the performance
classification for which they are designed, is available
from Engine Manufacturing Association, 111 East
Wacker Drive, Chicago, Illinois 60601.
Following are brief descriptions of the specifications most
commonly used for commercial lubricating oils.

API classification CC is the current American Petroleum

Institute classification for lubricating oils for heavy duty
gasoline and diesel service. Lubricating oils meeting this
specification are designed to protect the engine from
sludge deposits and rusting (aggravated by stop and go
operation) and to provide protection from high
temperature operation, ring sticking and piston deposits.

API classification CD is the current American Petroleum

Institude classification for severe duty lubricating oils to
be used in highly rated diesel engines operating with high
loads. Lubricating oils which meet this specification have
a high detergent content and will provide added
protection against piston deposits and ring sticking
during high temperature operation.

API classification SC, SD and SE were established for

the Automobile Manufacturers Association. They require
a sequence of tests for approval. The primary
advantage of lubricating oils in these categories is low
temperature operation protection against sludge, rust,
combustion chamber deposits and bearing corrosion.
The test procedure for these specifications are published
by the American Society for Testing and Materials as
STP315.

Break-In Oils
Special "BreakIn" lubricating oils are not recommended
for new or rebuilt Cummins Engines. Use the same
lubricating oil as will be used for the normal engine
operation.
432
 TRUCK SERVICE MANUAL ENGINE

viscosity index improve additive which has a tendency to GREASE

lose its effectiveness after a short period of use in a high Cummins Engine Company, Inc., recommends use of
speed engine. These oils should be avoided. grease meeting the specifications of MIL-G-3545,
excluding those of sodium or soda soap thickeners,
2. Oils which meet the low temperature SAE Contact lubricant supplier for grease meeting these
viscosity standard (O deg. F [18 deg. C]) carry a suffix specifications.
"W." Oils that meet the high temperature viscosity SAE
standard (210 deg. F [99 deg. C] ) as well as the low TEST TEST PROCEDURE
temperature carry both viscosity ratings example: High-Temperature Performance
2020W. See Table 182. Dropping point, deg F ASTM D 2265
350 min.
Table 18-2: Operating Temperatures Vs Viscosity Bearing life, hours at 300 deg F *FTM 331
10,000 rpm 600 min.
Ambient Temperatures Viscosity
Low-Temperature Properties
10 deg F. [-23 deg. C] and below See Table 18-3 Torque, GCM ASTM D 1478
10 to 30 deg. F. [-23 to - 1 deg. C] 1OW Start at 0 deg F 15,000 max.
20 to 60 deg. F [-7 to 16 deg. C] 20-20W Run at 0 deg F 5,000 max.
40 deg. F. [4 deg. C] and above 30
Rust Protection and Water Resistance
Arctic Operations Rust test ASTM D 1743
For operation in areas where the ambient temperature is Pass
consistently below 10 deg. F [23 deg. C] and there is no Water resistance, % ASTM D 1264
provision for keeping engines warm during shutdowns, 20 max.
the lubricating oil should meet the requirements in Table Stability
18-3. Oil separation, %
30 Hours @ 212 deg F *FTM 321
5 max.
Table 18-3: Arctic Oil Recommendations
Penetration
Parameter Worked ASTM D 217
(Test Method) Specifications 250-300

Bomb Test, PSI Drop

Performance API class CC/SC
Quality Level API class CC/CD 100 Hours 10 max.
500 Hours 25 max.
SAE Viscosity Grade 10W-20, 10W-30, 10W-40
Copper, Corrosion *FTM 5309
Viscosity @ -30 deg F 10,000 Centistokes Pass
(ASTM D-445) Maximum
Dirt Count, Particles/cc *FTM 3005
Pour Point At least 10 deg F 25 Micron + 5,000 max.
[6 deg C] 75 Micron + 1,000 max.
(ASTM D-97) below lowest expected 125 Micron + None
ambient temperature Rubber Swell *FTM 3603
10 max.
Ash, sulfated 1.85 wt % Maximum
(ASTM D-874) *Federal Test Method Standard No 791a.
CAUTION
Do not mix grease and lubricating oil as damage to
Due to extreme operating conditions, oil change intervals
bearings may result. Excessive lubrication is as harmful
should be carefully evaluated paying particular attention
as inadequate lubrication. After lubricating fan hub,
to viscosity changes and total base number decrease.
replace both pipe plugs. Use of fittings will allow
Oil designed to meet MIL-L-10295-A, which is void, and
lubricant to be thrown out, due to rotate speed.
SAE 5W oils should not be used.
433
 TRUCK SERVICE MANUAL ENGINE

FUEL OIL Maintain the Fleet guard DCA Water Filter on the engine.
The filter by-passes a small amount of coolant from the
Cummins Diesel Engines have been developed to take system via a filtering and treating element which must be
advantage of the high energy content and generally replaced periodically.
lower cost of No. 2 Diesel Fuels. Experience has shown
that a Cummins Diesel Engine will also operate 1. In summer, with no antifreeze, fill’ system with
satisfactorily on No. 1 fuels or other fuels within the water.
following specifications. 2. In winter, select an antifreeze, all except Dow
there 209 are compatible with DCA, use with water as
Recommended Fuel Oil Properties required by
temperature.
Viscosity Centistokes 1.4 to 5.8 @ 100
(ASTM D-445) deg. F (30 to 45 SUS) Note: Some antifreezes also contain anti-leak additives
Cetane Number 40 minimum except in cold such as inert inorganic fibers, polymer particles or ginger
(ASTM D-613) weather or in service with root, these antifreezes should not be used in conjunction
prolonged idle, a higher with the water filter. The filter element will filter out the
cetane number is desirable. additives and/or become clogged and ineffective.
Sulfur Content Not to exceed 1% by weight.
(ASTM D-129 or 1552) 3. Install or replace DCA Water Filter element as
Water and Sediment Not to exceed 0.1% by follows and as recommended in Cummins Engine
(ASTM D-1796) weight. Operation and Maintenance Manuals.
Carbon Residue Not to exceed 0.25% by
(Ransbottom ASTM weight on 10% residue. Engines Equipped With
D-524 or D-189) DCA Water Filters
Flash Point At least 125 deg for legal
(ASTM D-93) temperature if higher than 1. New engines shipped from the Factory are
125 deg F. equipped with water filters containing a "DCA pre-
charge" element. See Table 18-4. This element is
Gravity 30 to 42 deg A.P.I at 60 deg.
compatible with plain water or all permanent-type
(ASTM D-287) F (0.815 to 0.875 sp gr.)
antifreezes except Dowtherm 209.
Pour Point Below lowest temperature
(ASTM D-97) expected.
Active Sulfur-Copper Not to exceed No 2 rating Table 18-4: Spin-On Type D C A Water Filter
Strip Corrosion after 3 hours at 122 deg F. Corresponding
(ASTM D-130) Cooling DCA DCA Obsolete
Ash Not to exceed 0.02% by System Pre-charge Service Chromate
(ASTM D-482) weight. U.S. Gal. Element Element Element
Distillation The distillation curve should 0 to 8 299082 299080 209604
(ASTM D-86) be smooth and continuous. 8 to 1 5 299083 299080 209604
At least 90% of the fuel 15 to 30 299084 299080 209605
should evaporate at less than 30 to 60 (2) 299084 (2) 299080 (2) 209605
675 deg F. All of the fuel
should evaporate at less than 2. At the first "B" Check (oil change period) the
725 deg F. DCA Precharge element should be changed to DCA
Service Element. See Table 184.
Coolant 3. Replace the DCA Service Element at each
succeeding "B" Check except under the following
Water should be clean and free of any corrosive conditions:
chemicals such as chloride, sulphates and acids. It a. If makeup coolant must be added between
should be kept element changes, use coolant from a pretreated supply,
slightly alkaline with pH value in range of 8.0 to 9.5. Any as stated In "MakeUp Coolant Specifications", in Group 2
water which is suitable for drinking can be treated as of Operation and Maintenance Manual.
described in the following paragraphs for use in an b. Each time system is drained revert back to
engine. precharge element.

434
 TRUCK SERVICE MANUAL ENGINE

4. To insure adequate protection have the coolant Engines Now In Service With Package (Bag) Or
checked at each third element change or oftener. Canister Type Chromate Corrosion Resistor
Elements
Engines Now In Service With Spin-On Type
Chromate Corrosion Resistor Element 1. Remove chromate package or canister, discard
1. Remove chromate element. package element and plates or canister, retain spring for
2. Flush cooling system. use with DCA service element.

3. Install pre-charge DCA element and operate 2. Flush cooling system.

engine to next "B" Check. See Table 18-4. 3. Pre-charge system with coolant and dri-charge,
Part No. 299050, (DCA 4), according to Table 18-5
4. Install DCA Service Element; replace DCA using applicable
Service Element at each succeeding "B" Check, except service canister.
under the following conditions’ 4. Install DCA Service Element; replace DCA
Service Element at each succeeding "B" Check, except
a. If make-up coolant must be added between under the following conditions:
element changes use coolant from a pre-treated supply. a. If make-up coolant must be added between
canister changes use coolant from a pre-treated supply.
b. Each time system is drained revert back to pre- b. Each time system is drained revert back to Step
charge element. 3 instructions.
Table 18-5: Package or Canister D C A Water Filter
Corresponding
DCA DCA Obsolete
Pre-Charge Service Chromate
Canister Canister Canister or Bag

None * 299071 132732, 299001

None * 299074 171645, 299004
None* (2) 299091 (2) 132732, 299021

*299050 (DCA4) Pre-Charge Containers To Be Used

With Service Elements Are:
Cooling Service Service Service Service
System Element Element Element Element
U.S. Gal. 299074 299071 299091 (2) 299091
0-5 1
5-9 2 1
9-13 3 2 1
13-17 0 3 2
17-21 0 4 3 1
21-25 0 5 4 2
25-28 0 0 5 3
28-32 0 0 6 4
32-36 0 0 7 5
36-40 0 0 8 6
40-45 0 0 0 7
45,49 0 0 0 8
49-53 0 0 0 9
53-57 0 0 0 10
57-61 0 0 0 11
61-65 0 0 0 12
65-69 0 0 0 13
69-73 0 0 0 14
73-79 0 0 0 15
435
 TRUCK SERVICE MANUAL ENGINE

Vehicle Braking Group 20

COMPRESSION BRAKE 2. Install special locking plates on two studs

located in center of each housing. Tighten nuts to 55 to
Jacobs Brake (Compression) 60 ft-lb. [7.6 to 8.3 kg m] torque in sequence as shown in
Fig. 14-9.
CHECK CROSSHEAD.TO ROCKER LEVER 3. Bend long tab of each special locking plate down
CLEARANCE over housing surface, bend one short tab up against flat
of each hex nut.
Barr engine in direction of rotation until valves are closed
on each cylinder as checked through firing order, hold Slave Piston Adjustment Procedure
lever in contact with Jacobs Brake crosshead and check
interference between crosshead and lever, clearance Loosen and back off locknut, Insert socket head wrench
must be as shown in Fig. 202 (A). If feeler gauge will and back slave piston adjusting screw out of housing
not pass until slave piston seats in it’s bore.

Slave piston adjustment must be made with the engine

stopped (warm or cold) and the exhaust valves closed.
Bar the engine in direction of rotation until "A" or "16
V.S." mark on accessory drive pulley lines up with the
timing mark on the gear case cover. With the engine in
this position, the exhaust valves of cylinders 16 are
closed.
Insert a 0.18" feeler gauge between the slave piston and
the crosshead, turn the adjusting screw in until a slight
drag is felt on the feeler gauge. Continue turning engine
in direction of rotation and set slave piston clearance on
cylinders 25 and 34.

To bleed brake units for immediate operation, manually

depress solenoid armature five or six times in
succession with engine running to permit oil to fill
A. 0.060 Inch [1.524 mm] Clearance passages in housing.
B. Grind Area Attach electrical harness to terminal in Engine Brake
housing.
Fig. 20-2. (N12045 J). Clearance area between lever and
crosshead Mount fuel pump switch and actuating arm using
capscrews on fuel pump to secure switch.
through area, remove rocker lever and grind sufficient
clearance in area (B), grinding must cover complete area Actuating arm may be bent or relocated to contact switch
in a continuous arc. Grind smooth all sharp edges. when throttle lever is in idle position.

INSTALLATION Adjustment
Adjust screw in actuating. arm so that audible "click" is
1. Install new gaskets and Jacobs Brake units to heard when throttle arm moves to an idle fuel position.
rocker housings.
Note: Check PT Fuel Pump throttle shaft to insure that
Note: If studs were removed from rocker housings, throttle pedal will move throttle shaft to full fuel position
replace and tighten to 65 to 75 ft-lb. [9.0 to 10.4 kg m] after installing the actuating arm.
torque in sequence as shown in Fig. 14-9.

436
 TRUCK SERVICE MANUAL ENGINE

the top of the normal compression stroke releasing the

compressed cylinder charge to exhaust.

The blow down of compressed air to atmospheric

pressure prevents the return of energy to the engine
piston on the power stroke, the effect being a net energy
loss since the work down in compressing the cylinder
charge is not returned during the expansion process.

Exhaust blow down occurs as follows:

1. Energizing the solenoid valve permits engine

lubricating oil to flow under pressure through slave piston
control valve to both the master piston and slave piston.
2. Oil pressure causes the master piston to move
down, coming to rest on injector rocker arm adjusting
screw.
3. The injector rocker arm adjusting screw begins
upward travel (as in normal injection cycle) forcing the
master piston upward and creating a high pressure oil
flow to the slave piston. The ball check valve in the
control valve imprisons high pressure oil in the master
slave piston system.
1 Dash Switch 8
Diode-Exploded View 4. The slave piston under the influence of high
2 Black 9
To Switch Terminal pressure oil flow moves down, momentarily opening
For exhaust valve, while the engine piston is near its top
3 Fuse Negative Ground dead center position, releasing compressed cylinder air
4 To Key Switch 10 Diode Position For to the exhaust manifold.
5 Clutch Switch No. 1495 Negative Ground 5. Compressed air escapes to atmosphere
6 Green 11 Red completing a compression braking cycle.
7 Fuel Pump Switch 12 Brake Units
Fig. 20-5. (N12032 J). Wiring diagram Operating A Vehicle With Jacobs Brake
In order to retard a vehicle on a downgrade using the
Jacobs Compression Brake, and if the engine speed
exceeds maximum rated R.P.M. for a desired road
speed, a lower gear should be selected. The selection of
a lower gear will generally allow complete control of the
OPERATION vehicle by the Jacobs Compression Brake, leaving the
vehicle service brakes in reserve to be used for
Energizing the Jacobs Brake effectively converts a power emergency stops.
producing diesel engine into a power absorbing air
compressor. This is accomplished when desired by
motion transfer through a master slave piston
arrangement which opens cylinder exhaust valves near

437
 TRUCK SERVICE MANUAL ENGINE

Index
Subject Page

ACCESSORY DRIVE PULLEY

Installation .......................................................................................................................................... 404
Removal ............................................................................................................................................. 323
ADJUST INJECTORS AND VALVES ............................................................................................................. 406

AIR CLEANER (CARTRIDGE TYPE)

Assembly............................................................................................................................................ 389
Cleaning and Inspection..................................................................................................................... 389
Disassembly ....................................................................................................................................... 389

AIR CLEANER (COMPOSITE AND HEAVY DUTY TYPES)

Assembly............................................................................................................................................ 389
Disassembly ....................................................................................................................................... 389
Inspection ........................................................................................................................................... 389

AIR CLEANER (DRY TYPE)

Assembly............................................................................................................................................ 389
Cleaning and Inspection..................................................................................................................... 389
Disassembly ....................................................................................................................................... 389

AIR CLEANER RESTRICTIONS..................................................................................................................... 389

AIR COMPRESSOR (SPLINE DRIVEN)

Installation .......................................................................................................................................... 399
Removal ............................................................................................................................................. 323

AIR COMPRESSOR DRIVE

Installation .......................................................................................................................................... 399
Removal ............................................................................................................................................. 323

ALTERNATOR/GENERATOR
Installation .......................................................................................................................................... 405
Lubrication.......................................................................................................................................... 411
Removal ............................................................................................................................................. 322

ANEROID CONTROL
Adjustment ......................................................................................................................................... 415
Installation .......................................................................................................................................... 399
Removal ............................................................................................................................................. 323

BEARING SHELL INSPECTION..................................................................................................................... 336

BELTS
Adjustment ......................................................................................................................................... 406
Installation .......................................................................................................................................... 406

BREAK-IN RUN............................................................................................................................................... 413

BREATHER TUBE .......................................................................................................................................... 410

438
 TRUCK SERVICE MANUAL ENGINE

Subject Page
CAM FOLLOWER HOUSING
Assembly............................................................................................................................................ 368
Disassembly ....................................................................................................................................... 367
Inspection ........................................................................................................................................... 367
Installation .......................................................................................................................................... 396
Repair ................................................................................................................................................. 367
CAMSHAFT
Assembly’ ........................................................................................................................................... 342
End Play ............................................................................................................................................. 400
Inspection ........................................................................................................................................... 341
Installation .......................................................................................................................................... 394
Removal ............................................................................................................................................. 324
CAMSHAFT GEAR
Installation .......................................................................................................................................... 342
Removal ............................................................................................................................................. 342
CHASSIS DYNAMOMETER TEST ................................................................................................................. 415

CHECKS DURING RUN-IN............................................................................................................................. 413

COLD STARTING AIDS

Ether ................................................................................................................................................... 388
Preheater............................................................................................................................................ 388
Procedure........................................................................................................................................... 412
Wiring ................................................................................................................................................. 412
COOLANT SPECIFICATIONS ........................................................................................................................ 434

COMPRESSION RELEASE LEVER

Installation .......................................................................................................................................... 398
Removal ............................................................................................................................................. 323
COMPRESSION RELEASE SHAFT
Installation .......................................................................................................................................... 396
Removal ............................................................................................................................................. 324
CONNECTING ROD
Inspection ........................................................................................................................................... 337
Installation .......................................................................................................................................... 394
Removal ............................................................................................................................................. 324
Repair ................................................................................................................................................. 339
CONVERTER COOLER.................................................................................................................................. 383

CORROSION RESISTOR (WATER FILTER)

Installation .......................................................................................................................................... 410
Removal ............................................................................................................................................. 322
CRANKCASE BREATHER
Assembly............................................................................................................................................ 364
Cleaning and Inspection..................................................................................................................... 364
Disassembly ....................................................................................................................................... 364
Installation .......................................................................................................................................... 364
CRANKCASE PRESSURE (BLOW-BY) ......................................................................................................... 414

CRANKCASE VENT
Removal ............................................................................................................................................. 322
Installation .......................................................................................................................................... 410

439
 TRUCK SERVICE MANUAL ENGINE

Subject Page
CRANKING MOTOR (ELECTRIC)
Installation .......................................................................................................................................... 410
Removal ............................................................................................................................................. 322
CRANKSHAFT
Assembly............................................................................................................................................ 335
Cleaning and Inspection..................................................................................................................... 335
Disassembly ....................................................................................................................................... 335
End Clearance.................................................................................................................................... 393
Installation .......................................................................................................................................... 393
Removal ............................................................................................................................................. 324
CROSSHEADS
Adjustment ......................................................................................................................................... 397, 406
Installation .......................................................................................................................................... 397
Removal ............................................................................................................................................. 323
CYLINDER BLOCK
Assembly............................................................................................................................................ 393
Cleaning ............................................................................................................................................. 324
Inspection ........................................................................................................................................... 331
Repair ................................................................................................................................................. 333
CYLINDER HEAD
Assembly............................................................................................................................................ 359
Disassembly ....................................................................................................................................... 353
Inspection ........................................................................................................................................... 354
Installation .......................................................................................................................................... 395
Removal ............................................................................................................................................. 324
Repair ................................................................................................................................................. 356
Tightening........................................................................................................................................... 395
CYLINDER LINERS
Cleaning and Inspection..................................................................................................................... 335
Installation .......................................................................................................................................... 394
Removal ............................................................................................................................................. 324
DRAIN WATER AND OIL................................................................................................................................ 321

DRIVE (FUEL PUMP/COMPRESSOR)

Assembly............................................................................................................................................ 386
Disassembly ....................................................................................................................................... 385
Inspection ........................................................................................................................................... 385
Installation .......................................................................................................................................... 398
Removal ............................................................................................................................................. 323
DRIVE (FUEL PUMP AND HOURMETER)
Assembly............................................................................................................................................ 387
Cleaning and Inspection..................................................................................................................... 386
Disassembly ....................................................................................................................................... 386

DRIVE PULLEY INSPECTION AND REPAIR................................................................................................. 387

ELECTRICAL CONNECTIONS
Installation .......................................................................................................................................... 411
Removal ............................................................................................................................................. 322

ENGINE BREAK-IN......................................................................................................................................... 413

440
 TRUCK SERVICE MANUAL ENGINE

Subject Page

ENGINE DYNAMOMETER
Horsepower ........................................................................................................................... 412
Installation ............................................................................................................................. 412
Power Check ......................................................................................................................... 413
Test Procedures .................................................................................................................... 412
ENGINE SAFETY CONTROLS.......................................................................................................... 419
ENGINE SERIAL NUMBER ............................................................................................................... 321
ENGINE STORAGE
Permanent............................................................................................................................. 416
Preparation............................................................................................................................ 416
Temporary ............................................................................................................................. 416
ENGINE TESTING ............................................................................................................................. 411
ENGINE TIMING ................................................................................................................................ 396
EXHAUST MANIFOLDS
Cleaning and Inspection........................................................................................................ 390
Installation ............................................................................................................................. 405
FAN HUBS
Installation ............................................................................................................................. 404
Removal ................................................................................................................................ 322
FLYWHEEL HOUSING
Installation ............................................................................................................................. 401
Removal ................................................................................................................................ 324
FRONT ENGINE SUPPORT
Installation ............................................................................................................................. 403
Removal ................................................................................................................................ 323
FUEL CONNECTOR
Installation ............................................................................................................................. 397
Removal ................................................................................................................................ 323
FUEL FILTER
Installation ............................................................................................................................. 399
Removal ................................................................................................................................ 322
FUEL PUMP
Installation ............................................................................................................................. 399
Removal ................................................................................................................................ 323
FUEL OIL SPECIFICATIONS ............................................................................................................ 434
FUEL PUMP DRIVE
Assembly............................................................................................................................... 386
Disassembly .......................................................................................................................... 385
Installation ............................................................................................................................. 398
Inspection .............................................................................................................................. 385
Removal ................................................................................................................................ 323
FUEL SYSTEM................................................................................................................................... 369
GEAR BACKLASH ............................................................................................................................. 395

441
 TRUCK SERVICE MANUAL ENGINE

Subject Page

GEAR CASE COVER

Assembly............................................................................................................................... 400
Inspection .............................................................................................................................. 342
Installation ............................................................................................................................. 400
Removal ................................................................................................................................ 324
Repair.................................................................................................................................... 342
GENERATOR/ALTERNATOR
Installation ............................................................................................................................. 405
Lubrication............................................................................................................................. 411
Removal ................................................................................................................................ 322
GREASE SPECIFICATIONS ............................................................................................................. 433
IDLER PULLEY ASSEMBLY
Assembly............................................................................................................................... 381
Disassembly .......................................................................................................................... 381
Inspection .............................................................................................................................. 381
IN-CHASSIS RUN-IN ......................................................................................................................... 415
INJECTION TIMING........................................................................................................................... 396
INJECTOR ADJUSTMENT
Cold Setting........................................................................................................................... 407
Dial Indicator Method ............................................................................................................ 407
Hot Setting............................................................................................................................. 407
Torque Method ...................................................................................................................... 409
INJECTORS
Installation ............................................................................................................................. 397
Removal ................................................................................................................................ 323
INJECTOR PLUNGER FREE TRAVEL ............................................................................................. 406
INJECTOR SLEEVES
Inspection .............................................................................................................................. 354
Installation ............................................................................................................................. 358
Removal ................................................................................................................................ 358
INSTRUMENTS AND CONTROLS.................................................................................................... 419
INTAKE CONNECTIONS................................................................................................................... 388
INTAKE MANIFOLD
Cleaning and Inspection........................................................................................................ 388
Installation ............................................................................................................................. 399
INTRODUCTION................................................................................................................................ 319
JACOBS BRAKE
Adjustment ............................................................................................................................ 436
Operation............................................................................................................................... 437
LUBRICATING OIL COOLER
Assembly............................................................................................................................... 376
Inspection .............................................................................................................................. 376
Disassembly .......................................................................................................................... 376
Installation ............................................................................................................................. 405
Removal ................................................................................................................................ 322
Repair.................................................................................................................................... 376

442
 TRUCK SERVICE MANUAL ENGINE

Subject Page

LUBRICATING OIL COOLER AND FILTER

Installation ............................................................................................................................. 405
Removal ................................................................................................................................ 322
LUBRICATING OIL COOLER (AUXILIARY)
Assembly............................................................................................................................... 378
Cleaning ................................................................................................................................ 377
Disassembly .......................................................................................................................... 376
Inspection and Repair ........................................................................................................... 377, 378
Removal ................................................................................................................................ 322
LUBRICATING OIL FILTER
Installation ............................................................................................................................. 405
Removal ................................................................................................................................ 323
LUBRICATING OIL FILTER (BY-PASS TYPE)
Assembly............................................................................................................................... 375
Inspection .............................................................................................................................. 375
Disassembly .......................................................................................................................... 375
Flow Characteristics and Specifications................................................................................ 375
Hose Size .............................................................................................................................. 376
Mounting................................................................................................................................ 375
LUBRICATING OIL FILTER (FULL-FLOW PAPER ELEMENT TYPE)
Assembly............................................................................................................................... 375
Inspection .............................................................................................................................. 374
Disassembly .......................................................................................................................... 374
LUBRICATING OIL PUMP
Assembly............................................................................................................................... 378
Inspection and Repair ........................................................................................................... 378
Disassembly .......................................................................................................................... 378
LUBRICATING OIL SPECIFICATIONS ............................................................................................. 432
MAIN BEARING CAPS
Installation ............................................................................................................................. 393
Removal ................................................................................................................................ 324
Tightening.............................................................................................................................. 393
MECHANICAL CONTROLS: WATER, AIR AND FUEL CONNECTIONS
Removal ................................................................................................................................ 322
MOUNT CYLINDER BLOCK.............................................................................................................. 393
MOUNT ENGINE TO STAND ............................................................................................................ 322
OIL GAUGE DIPSTICK ...................................................................................................................... 373
OIL GAUGE TUBE AND BRACKET
Installation ............................................................................................................................. 405
Removal ................................................................................................................................ 322
OIL PAN
Inspection .............................................................................................................................. 373
Installation ............................................................................................................................. 402
Removal ................................................................................................................................ 324
Repair.................................................................................................................................... 373

443
 TRUCK SERVICE MANUAL ENGINE

Subject Page

OIL PASSAGE PLUGS

Installation ............................................................................................................................. 325
Removal ................................................................................................................................ 325
OIL PIPES
Installation ............................................................................................................................. 395
Removal ................................................................................................................................ 325
OIL SPRAY NOZZLES
Installation ............................................................................................................................. 404
Removal ................................................................................................................................ 322
PAINT ENGINE .................................................................................................................................. 415
PISTONS
Assembly............................................................................................................................... 341
Cleaning and Inspection........................................................................................................ 340
Installation ............................................................................................................................. 394
Removal ................................................................................................................................ 324
PISTON RINGS
Installation ............................................................................................................................. 394
Removal ................................................................................................................................ 340
POWER CHECK ................................................................................................................................ 413
PRIME FUEL SYSTEM ...................................................................................................................... 411
PRIME LUBRICATING SYSTEM ....................................................................................................... 411
PUSH TUBES
Cleaning ................................................................................................................................ 324
Inspection .............................................................................................................................. 368
Installation ............................................................................................................................. 396
Removal ................................................................................................................................ 323
REAR COVER AND SEAL
Installation ............................................................................................................................. 400
Removal ................................................................................................................................ 324
REMOVE ENGINE FROM STAND .................................................................................................... 405
ROCKSHIELD .................................................................................................................................... 322
ROCKER HOUSINGS
Assembly............................................................................................................................... 364
Disassembly .......................................................................................................................... 363
Inspection .............................................................................................................................. 363
Installation ............................................................................................................................. 398
Removal ................................................................................................................................ 323
ROCKER LEVER ASSEMBLY
Assembly............................................................................................................................... 364
Cleaning and Inspection........................................................................................................ 363
Disassembly .......................................................................................................................... 363
Repair.................................................................................................................................... 363
ROCKER HOUSING COVER
Assembly............................................................................................................................... 365
Inspection .............................................................................................................................. 365

444
 TRUCK SERVICE MANUAL ENGINE

Subject Page

ROCKER HOUSING COVER (Continued)

Installation ............................................................................................................................. 410
Removal ................................................................................................................................ 323
SAFETY CONTROLS
Nason .................................................................................................................................... 419
SMOKE LEVEL .................................................................................................................................. 413
STARTING PROCEDURE ................................................................................................................. 412
STEAM CLEAN ENGINE ................................................................................................................... 322
STEAM CLEANING............................................................................................................................ 324
TABLE OF CONTENTS ..................................................................................................................... 317
TEST PROCEDURES........................................................................................................................ 412
THERMOSTAT HOUSING
Assembly............................................................................................................................... 383
Inspection .............................................................................................................................. 382
Disassembly .......................................................................................................................... 382
Installation ............................................................................................................................. 405
TIMING THE ENGINE........................................................................................................................ 396
TORQUE SPECIFICATIONS ............................................................................................................. 431
TURBOCHARGER
General.................................................................................................................................. 390
Installation ............................................................................................................................. 410
Removal ................................................................................................................................ 322
VALVE GUIDE SEALS....................................................................................................................... 353
VALVES
Grinding................................................................................................................................. 359
Inspection .............................................................................................................................. 355
Installation ............................................................................................................................. 359
Removal ................................................................................................................................ 353
Testing................................................................................................................................... 359
VALVE ADJUSTMENT....................................................................................................................... 407
VALVE CROSSHEADS
Adjustment ............................................................................................................................ 397, 408
Inspection .............................................................................................................................. 355
Installation ............................................................................................................................. 397
Removal ................................................................................................................................ 323
VALVE CROSSHEAD GUIDES
Inspection .............................................................................................................................. 355
Installation ............................................................................................................................. 357
Removal ................................................................................................................................ 357
VALVE GUIDES
Inspection .............................................................................................................................. 355
Installation ............................................................................................................................. 357
Removal ................................................................................................................................ 357

445
 TRUCK SERVICE MANUAL ENGINE

Subject Page

VALVE SEATS AND INSERTS

Grinding................................................................................................................................. 358
Inspection .............................................................................................................................. 354
Installation ............................................................................................................................. 357
Removal ................................................................................................................................ 357

VALVE SPRINGS
Inspection .............................................................................................................................. 359
Installation ............................................................................................................................. 359
Removal ................................................................................................................................ 353
Testing................................................................................................................................... 359

VENT HOLES..................................................................................................................................... 359

VIBRATION DAMPER
Cleaning ................................................................................................................................ 336
Inspection .............................................................................................................................. 336
Installation ............................................................................................................................. 403
Removal ................................................................................................................................ 323

WATER PUMP AND IDLER ASSEMBLY (FFC SERIES)

Assembly............................................................................................................................... 381
Disassembly .......................................................................................................................... 381
Inspection .............................................................................................................................. 381
Installation ............................................................................................................................. 404
Removal ................................................................................................................................ 322

WEAR LIMITS AND SPECIFICATIONS ............................................................................................ 423

446
 TRUCK SERVICE MANUAL FRAMES

FRAMES

INDEX

Subject Page

ALIGNMENT:
Axle Alignment with Frame.................................................................................................... 448
Method of Checking .............................................................................................................. 448

BOLT SPECIFICATIONS AND TORQUES ....................................................................................... 451

GENERAL .......................................................................................................................................... 448

IDENTIFICATION............................................................................................................................... 448

REPAIR AND REINFORCEMENTS (Aluminum Alloy Frames) ......................................................... 451

REPAIR AND REINFORCEMENTS (Heat Treated Frames):

Drilling.................................................................................................................................... 453
Frame Reinforcements.......................................................................................................... 453
Frame Straightening.............................................................................................................. 453
Preparation of Frame for Repairs.......................................................................................... 451
Welding ................................................................................................................................. 453

REPAIR AND REINFORCEMENTS (Non-Heat Treated Frames):

Cutting ................................................................................................................................... 448
Frame Reinforcements.......................................................................................................... 448
Frame Straightening.............................................................................................................. 451
Positioning of Frame ............................................................................................................. 451
Preparation of Frame for Repair ........................................................................................... 450
Riveting.................................................................................................................................. 450
Welding ................................................................................................................................. 453

TYPES OF FRAMES.......................................................................................................................... 448

447
FRAMES MOTOR TRUCK SERVICE MANUAL

GENERAL
After each measurement point has been carefully
Since the frame is depended upon to keep the major marked on the floor, proceed as follows:
components of a vehicle in their relative positions, it is 1. Locate center line of chassis by measuring front and
highly important that the frame be kept in good condition rear end widths, using marks on floor. If frame
at all times. widths check, draw center line on floor, full length of
chassis. If frame widths do not check, lay out center
TYPES line as follows:
Because International chassis are manufactured with 2. Center line can be drawn through the inter-section of
frame rails of either cold rolled steel, heat treated steel, any one pair of equal diagonals (A-A, B-B, C-C, D-D)
or aluminum alloy, each must be handled in a specific and center point of one end of frame or through
manner to assure maximum service life. points of intersection of any two pairs of equal
diagonals.
IDENTIFICATION 3. Measure distance from center line to opposite points
No unusual difficulty should be encountered in marked over entire length of frame. Measurements
identifying aluminum alloy frames. These side rails and should not vary more than 1/8” at any point.
cross members are made of thicker material than are the 4. Measuring diagonals (A-A, B-B, C-C, D-D) will
components of a comparative size steel frame. If there indicate point where misalign-ment occurs. If
is any doubt, use a file to expose the material hardness diagonals in each pair check within 1/8”, that part of
or color. There are several methods of identifying heat frame included between points of measurement may
treated frame rails, the most common of which is a be considered in satisfactory align-ment. These
stencil marking on the inside middle section of the rail or diagonals should intersect within 1/8” of center line.
a stencil mark on one of the cross members. The stencil
notes that the rail is heat treated and rail flanges must Axle Alignment With Frame
not be drilled or welded. This is to caution against the
welding of addi-tional brackets or crossmembers or the After determining that the frame is properly aligned,
weld-ing of full length reinforcement rails. Minor repairs the axle alignment with the frame should be checked by
as indicated in later paragraphs are acceptable. comparing diagonals.
A number of the heat treated frame rails have small Dimensions for side elevation of frame should be
patches covering “Brinell” test mark along the inside checked at the points indicated and should not vary more
(web) of the rail. These patches are at about three or than 1/8”.
four foot intervals. The patch can be removed to expose
the “Brinell” marking. REPAIR AND REINFORCEMENTS
Some rails are stamped “H” for heat treat-ed, on the (Non Heat Treated Frames)
upper face of the rail flange about three inches from the
rail end. Cutting
Whenever it is necessary to cut the frame, the side
ALIGNMENT rail should be cut at an angle of 45 degrees. This
Method Of Checking method distributes the cut and weld over a greater area
A satisfactory method of checking the frame and than a cut made at right angles with the rail.
axle alignment, particularly when a body and cab is on a Reinforcing
chassis, is to mark on a level floor all points at which Reinforcements can be made with flat, channel or
measurements are to be taken. Tack or tape pieces of angle stock. Because of difficulties encountered when
paper to the floor directly under each point of inserting channel reinforcements into the frame side
measurement on the chassis as indicated by the letter rails, the use of angle reinforcements is acceptable.
“K” in Figs. 2. Use a plumb bob since the points of When ever possible, the reinforcement should extend
measurement must be accurately marked in relation to from the front axle to slightly beyond the rear spring front
the frame in order to obtain a satisfactory alignment mounting bracket
check. This procedure, of course, may

448
 MOTOR TRUCK SERVICE MANUAL FRAMES

be impractical because of the position of attached units and existing crossmembers. The reinforcement thickness should
not exceed that of the side rail to be reinforced.

Fig. 2.

449
FRAMES MOTOR TRUCK SERVICE MANUAL

Riveting

Hot rivets are acceptable, as they can be more easily

driven with hand tools. Cold rivets should only be used
where tools of sufficient power to properly set the rivets
are provided.

Rivets should be from 50% to 100% as heavy in

diameter as the total thickness of the plates to be riveted.

Welding

Electric arc-welding is recommended for all frame

welding.
Fig. 5 Suggested Types of Reinforcing Plates and
The reinforcements should be welded to the frame Method of Attaching to Frame Rail.
after the reinforcements are riveted. All unused holes
should be filled with welding material. The welding rod IMPORTANT: Do not weld into the corners of the
should be substantially the same material as that used in frame or along the edges of the frame side rail flanges
the frame. "A", Fig. 5. Welding at these points tends to weaken the
frame and encourage development of new cracks.
Preparation Of Frame For Repair
Use only the shielded-arc method for all frame
Before welding the reinforcement to the cracked welding. Heat generated during welding is localized and
section of the frame side rail, certain preparations are burning of material is minimized whenever this method is
necessary to insure strength and stableness of repair. used. (Fig. 6) Additional advantages are that the finished
To prevent further spreading of the crack, a hole should weld can be ground, filed, and drilled as necessary.
be drilled at the starting point of the crack, Fig. 4. Widen
the crack its full length, using two hacksaw blades With the reinforcement positioned in the frame side
together. Groove or bevel both sides of the crack to rail, follow the welding patterns shown in Fig. 5 as
permit the weld to penetrate to the surface and establish closely as possible.
a solid contact between the reinforcement and the frame
side rail. Grooving can be accomplished by grinding or
with a cape chisel.

Fig. 4 Showing Method of Drilling Frame Rail to Stop Fig. 6 Weld Sample Showing Lower Heat Dissipation
Progress of Crack. Also shows Method of Preparing Possible with Shielded Arc Welding.
Crack for Welding.

450
 MOTOR TRUCK SERVICE MANUAL FRAMES

Important though more costly does provide the field with a time
saving advantage when replacing cross-members or
In addition to the specific recommendations given in frame attaching parts.
these paragraphs, always remember the following
general rules of welding “good housekeeping”. If bolting is used for altering or adding to the frame,
the following precautions must be observed.
1. Surface areas and edges to be joined must be
clean and free of oil or grease. NOTE: Bolts to be used for installing fifth wheels
must be 5/8” diameter high strength material such as I.
2. Always avoid craters, notching, and H. type 8 (SAE grade 8) bolts. Type 8 bolts can be
undercutting. identified by the six radial lines on the head of the bolt.
Nuts must be of corresponding type.
3. Peen new welds to relieve stresses caused by
shrinkage. The torque value for tightening these bolts is 220-
250 ft. lbs. and is based on new bolts and nuts
Positioning of Frame Reinforcements lubricated with engine oil. If frame components are
Whenever practical, the welding of frame aluminum, flat washers must be used next to the
reinforcements should be confined to the web of the side aluminum whether under head, nut or both.
rail rather than the flanges. This procedure provides the
strongest possible assembly. Proper tightening of bolts and nuts is most important,
Avoid at all times welds made square with the side since the strength of the joint depends on the maximum
rail, either on webs or flanges. When welds are made at clamping force between the members.
an angle of at least 30 degrees from square, there is less
possibility of setting up dangerous stress concentrations REPAIR AND REINFORCEMENTS
in the rail. Physical tests of the strength of various welds (Heat Treated Frames)
have shown that a weld made at an angle of at least 30
degrees from the direc-tion of strain will retain the With the use of heat treated frame rails in
original physical properties of the complete rail section. International vehicles, it becomes advisable to outline
Frame Straightening some of the procedures to be followed whenever these
Use of heat is not recommended when straightening frames require repair.
frames. Heat weakens the structural characteristics of Heat treated frame rails must not, of course, be
frame members and all straightening should be done intermixed with non-heat treated rails. If one side rail is
cold. Frame members (except aluminum) which are to be replaced, the new rail material must match the old
bent or buckled sufficiently to show cracks or weakness frame rail.
after straightening, should be replaced or reinforced.
Repair and Reinforcements Preparation Of Frame For Repair
(Aluminum Alloy Frames)
A good method to follow when repairing a cracked
The cutting and welding of aluminum alloy frames for frame where the crack is accessible from both sides is
repair or reinforcement can be accomplished providing as follows:
correct procedures are followed and proper welding
equipment is utilized. The use of heat for straightening a. Grind a V notch or groove extending along the full
aluminum frame rails is not recommended. length of the crack and slightly beyond each end of
the crack. A heavy copper strip or “chill” should be
BOLT SPECIFICATIONS AND TORQUES clamped to the rail side away from the groove to help
While most IH frames are of riveted construction, control the temperature and cooling rate. See Fig.
there are some frames which are assembled with bolts 7. NOTE: Discarded short lengths of heavy copper
and nuts. Bolting, electrical bus bars make suitable chills.

451
FRAMES MOTOR TRUCK SERVICE MANUAL

b. Preheat the frame rail along the crack area to 500- of the repair should be deep enough to enter the sound
600 degrees to burn off excess oil or paint then metal of the first weld repair "C" of Fig. 7.
permit heated area to cool to 200 degrees or below
before welding is started. Under no circumstances Frame
should the rail be heated to a temperature exceeding
900-950 degrees F. since this is the tempering Welds on heat treated material tend to reduce
temperature of the rail. physical properties in the weld heat-affected zone.
Because of this, it is recommended that all
c. Either alternating current or direct current reversed reinforcements be designed so that all welds are parallel,
polarity, combined with a short arc and a beading or rather than perpendicular to the frame rail edges. Welds
narrow weave technique may be used. perpendicular to the flange edges will reduce the carrying
Direct current reversed polarity is recommended or capacity of the rail, Fig. 8 and 9.
preferred.

d. Slag should be removed after each pass and an

interpass or constant temp

e. When sufficient metal has been deposited, the weld

bead should be ground flush, Fig. 7, with the surface
being repaired.

Fig. 8.

The edge of the reinforcement flange to the edge of

side rail flange dimension should be held to a minimum
of three quarters of an inch to keep the heat-affected
zone from extending to the sidemember flange edge.
Wherever possible, it is recommended that plug welds of
the type shown in Fig. 9, be substituted for edge welds
when assembling the reinforcement to the side rail. Plug
welds offer the advantages of a reduced heat-affected
zone plus increased flexibility and reduced stress
concentrations. When using this method, one half inch
(minimum) diameter holes should be drilled and
chamfered in the reinforcement on 2" center to center
distances. At no time should these holes be drilled in the
frame rail being repaired. The reinforcement should then
be installed in its proper position on the sidemember and
the holes filled with weld material.

Fig 7. Again a minimum dimension of 3/4" should be

maintained between the weld and the edge of the
f. Where both sides of the frame rail are sidemember flange. The voltage, amperage and pre-
accessible, a V-groove is ground from the side opposite heat specifications listed below should be followed.
the repair and the procedure outlined above repeated.
Dependent upon accessibility, "chill" strips should be
used wherever possible. The V-groove ground on the
opposite side

452
 MOTOR TRUCK SERVICE MANUAL FRAMES

Welding The drill must be held steady during the drilling

Position Amperes Voltage operation. Avoid wobble or change of drill angle during
the drilling operation.
Downhand 13 0/140 21/23
Overhead 130/140 21/23 Frame Straightening
Vertical Up 110/120 22/24
When heat treated frame rails have been bent or
Use low hydrogen electrodes which have superior twisted, they should not be heated for straightening. This
crack resistance and notch toughness similar to AWS-E- work should be done with the frame rails cold. Heating
11018. This type electrode should be stored in a for straighten-ing purposes is likely to destroy the rail
moisture-free container to avoid porosity during welding. temper in localized areas, which will bring about rail
failures.

Fig. 9

Full Length Reinforcement

When heat treated frames are to be rein-forced over

a greater portion of their length, frame channel
reinforcements should be in-stalled using bolts. Bolts of
high strength material conforming to SAE grade 5 or
better should be used. The bolts and nuts should be
inspected periodically and kept tight, since the strength
of the reinforcement depends some-what on the
maximum clamping force between the members.

Drilling

The drilling of heat treated frame rails presents no

unusual difficulty. Standard high speed drills of good
quality will serve provided they are sharpened properly
and not overheated during sharpening or use. There
are, however, special high speed twist drills available
having special materials which will hold a cutting edge
longer. These drills are expensive and require especially
rigid support, otherwise drill breakage will result.

When drilling heat treated rails, like in any other

drilling operation, sufficient pressure must be applied to
the drill bit to maintain continuous cutting. The drill point
should frequently be drenched with cutting oil (soluble oil)
to help cool the drill. Avoid letting a drill bit turn in the
work without cutting. To do so will usually overheat and
ruin the drill.
453
 TRUCK SERVICE MANUAL FUEL SYSTEM

AIR CLEANER

INDEX

Subject Page

AIR CLEANER SERVICE INSTRUCTIONS:

Dry Type Air Cleaner............................................................................................................. 455
GENERAL:
Dry Type Air Cleaner............................................................................................................. 455

454
 TRUCK SERVICE MANUAL FUEL SYSTEM

AIR CLEANER

GENERAL These air cleaners are equipped with an evacuator

valve as shown in Fig. 2, item 6.
Air must be clean if engine is to de-liver proper
performance throughout its life span. Dirty air introduced The vacuator valve should be inspected at regular
into the engine may ruin the carefully engineered close intervals to be sure the valve is not plugged due to the
tolerance of the engine. presence of lint, chaff, etc. which may collect in the
Air cleaners are designed to supply clean air to the valve. The vacuator valve can easily be removed and
engine; and if not kept clean, the supply of air will cleaned.
become restricted. This will cause loss of power,
sluggish performance and poor gas mile age. Do not allow dust level in cup to build up to within ½”
of slot (cutaway lip on baffle flange) in the cup baffle.
Dry Type Air Cleaner

The dry type air intake filter, Fig. 1) em ploys a dry

type paper element which is sealed at the outlet end so
that all air drawn into the engine must enter through the
element. There is no oil used in this unit, hence, the
reference to “dry type.” The direction of air flow in this
filter is from the outside to the inside of element,
permitting excess foreign particles to fall free from the
outside of the element during road operations. This
action prolongs the service period of the filter.

AIR CLEANER SERVICE INSTRUCTIONS

Dry Type Air Cleaners

Heavy-duty: Shown in Figure 2

Loosen clamps and remove dust cap, wipe out dust and
clean gasket. Do not use solvents, gasoline or oil to
clean cup. Daily inspection of the air cleaner dust cup
should be made if dusty conditions warrant. Do not allow
dust deposits to build up past 2” level in cup.

Do not strike the bottom rim of the cartridge against

any hard surface. Damage could result to the rim and
affect the sealing at reassembly.

The dry type filter element can be washed with a Fig. 1 Dry Type Air Cleaner
nonsudsing household detergent. Use warm water
(120°-140°F). Flush filter with gentle stream until drain Excessive smoke or loss of power are good
water is clean. Air dry filter before using. Also inspect indications that the filter element should be re-placed or
after every cleaning for damage or rupture. Re-place cleaned. Clean or replace every 5, 000 to 25, 000 miles
filter every 10, 000 to 20, 000 miles depending on dust or every 150 to 750 hours depending upon dust
conditions. Wipe all internal parts clean before conditions.
reassembly. Replace gaskets regularly.
The filter element can be cleaned several times
before replacement is necessary. Recommended
cleaning methods for the filter element are:

455
FUEL SYSTEM TRUCK SERVICE MANUAL

Compressed Air:

Direct a jet of dry, clean air against inside or clean air

side of the filter element. Holding nozzle about six
inches away from element, move nozzle up and down,
rotating element until no dust is visually being removed
(approxi-mately 10 minutes). Direct air perpendicularly
to pleats using 100 psi maximum air pres-sure. Do not
damage element with the air flow from nozzle.

Washing:

Filter element can be cleaned by washing in water

using a nonsudsing detergent. Proportions are 2 oz. of
cleaner to 1 gallon of water. For best mixing results use
a small amount of cool tap water, then add to warm (70°
- 140°F) water to give proper proportions. The warmer
(100°F) the solution, the better the cleaning. Soak
element for 15 minutes, then rotate element back and
forth with clean water. If a hose is used to wash or rinse
the filter, be careful not to rupture the paper with the
water jet. Rinse the filter element until drain water be-
comes clear. Proper rinsing is very important. Let filter
element air dry completely before using. Do not use
compressed air for drying.

IMPORTANT: After cleaning filter element using either of

the above recommended methods, inspect the filter
element for damage:
Fig. 2 Heavy Duty Dry Type Air 1. Dust on downstream (inside) or clean air
Cleaner side,
2. Slightest ruptures.
Legend for Fig. 2. 3. Damaged gaskets.

1 COVER, Air Cleaner Ruptures can be detected on any dry type element
2 RING, Fin by placing a light inside the filter element. Inspection of
3 NUT, W/Gasket, Wing the element on the outside will then disclose any holes or
4 ELEMENT, Air Cleaner ruptures. Any hole in the filter element, even the
5 CLAMP, Cover (3 Required) smallest, will pass dust to the engine and cause engine
6 VALVE, Evacuator wear.

456
 TRUCK SERVICE MANUAL FUEL SYSTEM

Injectors
PT type

Shop Manual

Table of Contents

OPERATITTG PRINCIPLES ............................................................................. 458

DISASSEMBLY.................................................................................................. 458
CLEANING AND REPAIR.................................................................................. 459
ASSEMBLY........................................................................................................ 462
LEAKAGE CHECKS .......................................................................................... 465
CUP SPRAY PATTERN CHECK....................................................................... 469
ST-790 TEST STAND INSTALLATION AND CALIBRATION ........................... 470
FLOW TESTING PT INJECTORS ON ST-790 ................................................. 477
ST-790 TROUBLE SHOOTING......................................................................... 482

Injector Service Tools

Injector test stands (ST-790) are available in many
Tool Injector Type or different voltages. When a test stand is installed, be
No. Description Engine Series certain the voltage being supplied matches the voltage
requirements on the name plate.
ST-668 Spray Angle Tester All Injectors
ST-708 Orifice Burnishing Tool PT (type B, C & D)
ST-790 Test Stand All Injectors The following list represents the voltages available in ST-
ST-838 Test Stand Adapter PT (type D) 5/16" 790 injector test stands.
diameter series
ST-990 Leakage Detector All Injectors ST-790-A 220 Volt, 3 Phase, 60 Cycle
ST-095 Cup Wrench PT (type D) ST-790-F 230 Volt, 1 Phase, 60 Cycle
ST -1072 Crowfoot Cup Wrench PT (type D) ST-790-G 115 Volt, 1 Phase, 60 Cycle
ST-1089 Plunger Extension PT (type D) ST-790-J 220 Volt, 3 Phase, 50 Cycle
ST-1090 Orifice Torque Wrench PT (type B, C & D) ST-790-M 380 Volt, 3 Phase, 50 Cycle
ST-1129 Flowmeter Kit All Injectors ST-790-P 230 Volt, 1 Phase, 50 Cycle
ST-1145 Installation Torquing Tool All Injectors ST-790-U 208 Volt, 3 Phase, 60 Cycle
ST-1210 Master Injector PT (type D)
(132 cc flow)
ST-1058 Adapter PT (type D)
ST-1298 Injector Assembly Stand All Injectors
ST-1306 Master Injector PT (type D)
(178 cc flow @ 80%)
ST-1332 Orifice Plug Gauge PT (type B, C & D)
3375000 Ultrasonic Cleaner All Injectors
3375048 Cup Wrench 7/8" 6 splined type
3375084 Injector Assembly Stand All Injectors
3375086 Testing Adapter Pot PT (type D)
Spring Tester

457
FUEL SYSTEM TRUCK SERVICE MANUAL

Operating Principles
The PT fuel system is used exclusively on Cummins
Diesels. The identifying letters, “PT,” are an abbreviation
for “pressure time.”
Injector Description
The PT Injector is a simple mechanical unit which
receives fuel from the fuel pump under pressure and
meters, injects and atomizes it through fine injector cup
spray holes into the combustion chamber.
The general description “PT Injectors” is used only to
indicate that the injector is used with the PT fuel system
and not with the former Cummins Disc fuel system.
Cylindrical PT (type D) Injectors
The PT (type D) Injector is a refinement of the PT (type B
and C) cylindrical injectors used in Cummins engines
with internal fuel drillings. The PT (type D) top stop
injector is shown in Fig. 6-1-5.
By parts design changes, the PT (type D) provides more
parts interchangeability and those areas subject to wear Fig. 6-1-5, FWC27. Cylindrical PT (D) injector cross-
are localized in smaller parts for easier servicing. section
Former injectors have a body with the moving part or Top Stop Parts
plunger running the full length, the PT (type D) has a The top stop injector parts are the same as the standard
short barrel and plunger to provide the same function. PT (type D) except the adapter (2, Fig. 6-1-5) is longer
The shorter barrel plunger bore made possible use of to accommodate the stop. The plunger coupling top is
materials with greater wear resistance and results in smaller, allowing it to pass through the stop. The injector
smaller replacement assembly. The barrel/plunger spring washer (15), adjustable stop screw (16) and stop
assembly is made up of a coupling (3, Fig. 6-1-5), screw locknut (17) are parts required only for top stop
plunger (11) and barrel (12); the coupling and plunger injectors.
are swaged assembly.
Disassembly
The “Top-Stop” injector functions like the standard PT The disassembly, cleaning, inspection, repair and
(type D) injector except the upward travel of the injector assembly procedures described on the following pages
plunger is limited by an adjustable stop. The stop is set are those operations that may be performed in a clean,
before the injector is installed in the engine. Fig. 6-1-5. well equipped shop. Operations other than those
Injector Parts-PT (type D) described must be performed in a qualified Cummins
Adapter Rebuild Station.

In Fig. 6-1-5, the adapter (2) houses the plunger return PT (type D) Injectors
spring (1), adjustable orifice (5), orifice gasket (4), fuel
screen (6) and screen retainer (7) and carries the “O” 1. Lift out injector plunger and spring. Remove spring
ring seals (8) on the outside which seal against the head from coupler and test as described on the following
to form fuel inlet and drain passages. Fuel enters pages
through orifice (5) and flows to barrel (12), pass check 2. Store plunger by standing on coupling end.
ball (10) to the cup-to-barrel passage up to the metering
orifice where it is metered into the cup (14). Fuel not Note: Injector barrels and plungers are class fit, do
used circulates past the metering orifice, around the not interchange.
plunger and out the drain passage while the plunger is
seated in the cup. The cup, adapter and barrel are held 3. Remove “O” rings from injector adapter and discard.
in assembled position by the cup retainer (13).
Metering Orifice of PT (type D) Injector 4. Remove button-style screen retainer ring, and
The metering orifice near the cup end of the barrel is of remove screen. Check screen and discard if
fixed size and must not be altered In any way, barrels damaged.
differ for engine model In relation to the size of the
metering orifice as governed by engine fuel requirements
458
 TRUCK SERVICE MANUAL FUEL SYSTEM

Note: Do not remove adjustable orifice plug from Cleaning and Repair
inlet groove. 1. Clean injector parts thoroughly of any carbon varnish
by soaking in a solvent such as "Bendix Metal
5. Insert injector into loading fixture. Cleaner," "Kelite Formula 1006" or equivalent. Ultra-
sonic cleaning in service tool 3375000 is
6. Slide 3375102, Body Wrench, over flats on injector. recommended for barrel, plunger and cup.
Place ST-995, Retainer Wrench, on injector. 2. Neutralize solvent after cleaning by dipping parts in
mineral spirits.
7. Activate air cylinder or tighten special screw to hold 3. Dry with clean compressed air.
injector in place. Loosen cup retainer but do not Caution: Do not use drills or other instruments to
remove. Fig. 6-1-9. clean cup holes that will alter size of holes. Wires
may be used if a smaller size wire is used than the
8. Deactivate air cylinder or loosen special screw. spray hole.
4. A clean shop; clean tools and good cleaning
practices are essential to good injector repair. Most
injector failures occur because of dirt. Clean all
parts before assembly.
PT (type D) Injectors Plunger Link
Replace plunger link if worn excessively. See Fig. 6-1-
23.

Fig. 6-1-9, F60197. Loosening cup retainer

9. Remove injector clamp and ST-995 from fixture.

10. Another method of loosening retainer is to use a 1-

¼ inch box or open end wrench on ST-995 and a 1
inch wrench or injector.
Fig. 6-1-23, F60188. Plunger link wear
11. Screw off cup retainer and remove cup, barrel and Injector Plunger-Coupling
discard gasket. DO NOT LOSE CHECK BALL. 1. Check closely for metal seizure. As a rule this is the
only true indication of scuffing or scoring.
12. Remove check ball from top of barrel. Fig. 6-1-10. 2. Bright spots or surface disruption at top of machined
area plunger, on opposite side at bottom of plunger
or at mid-point, usually are normal results of rocker
lever thrust action. Unless metal is displaced or
wear is measurable at these points, the plunger may
be reused. If worn excessively return barrel and
plunger to a Cummins Rebuild Station for fitting of a
new plunger.
3. Narrow streaks running the length of the plunger
usually are the result of the varying thickness of
penetrant treatment used to prevent rusting. Plunger
is satisfactory for reuse unless a surface disruption is
evident.
4. Check area where plunger is swaged to coupler for
Fig. 6-1-10, F60190. Removing check ball cracks and looseness, by attempting to rotate by
hand.
5. Excessive wear or fretting may be found on spring
contact area of coupling flange.
459
FUEL SYSTEM TRUCK SERVICE MANUAL

Table 6-1-4: Injector Spring Data

Approximate Wire Load Required to Compress Springs to Length
Part Free Length No. Dia. Length New Min. New Max. Worn Limit
No. Inches [mm] Coils Inches [mm] Inch [mm] Lb. [kg] Lb. [kg] Lb. [kg]
166009 1.95 [49.7] 8 0.187 [4.75] 1.663 [42.2] 143,25 [65] 158.75 [72] 138 [63]

6. Check socket for wear or cracking Injector Cup

Caution: Handle injector plunger with care to 1. Inspect injector spray holes and tip with magnifying
prevent damage which could render it useless. glass. Compare with new cup shown in Fig, 6-1-17.
Discard cup if any of following conditions exist.
Injector Spring a. Abrasive wear. This wear can begin internally,
therefore, inspect both interior and exterior. Fig. 6-
1. Check spring for excessive wear or mutilation. 1-18.
b. Corrosion damage and effect of excessive heat:
2. Test spring tension on spring tester, Fig. 6-1-15, This condition usually results from high acid or
that is capable of very accurate measurements of sulphur content in fuel or overload operating
spring lengths and applied load by means of conditions. Fig. 6-1-19.
standards and dial indicator gauge. Table 6-1-4 c. Enlarged or distorted spray holes. Caused by
cleaning with drills or other instruments.

Fig. 6-1-17, F60105. New injector cup tip

Fig. 6-1-15, F60163. Testing injector spring

Fig. 6-1-16, Injector spring Fig. 6-1-18, F60223. Cup tip damaged by wire brushing

3. If injector springs compress to dimensions shown, at 2. Inspect cup for plunger seat pattern. If plunger seat
less than load indicated under "worn limits," springs covers 40 percent continuous area around cup cone
must be discarded. or plunger bore, it is possible cup may be reused, but
it must pass the ST-990 cup-to-plunger leak test.
Seat location is not important. Fig. 6-1-20.

Caution: Never alter size of injector cup spray

holes.

460
 FUEL SYSTEM

3. Inspect inside of cone area on cup seating ledge for

nicks or burrs which could prevent cup seating.
Injector Barrel - PT (type D) Injectors

1. Inspect injector barrel plunger bore for scoring. If

injector will pass the ST-990 leakage test, barrel is
useable. If leakage is too high barrel and plunger
must be replaced.
2. Use strong magnifying glass to check for burrs,
Fig. 6-1-19, F60107. Corroded injector cup tip carbon and distorted radii in orifice. When metering
orifice is damaged, the injector will not function
properly. Do not attempt cleaning with wires, plug
gauges, etc.; use solvent cleaners.
3. Check fuel passage plugs for looseness and barrel
for cracks.
4. Check injector barrel surfaces for mutilation and
flatness in black area as shown in Fig. 6-1-24.

a. Thoroughly clean and dry barrel of all oil film before

Fig. 6-1-20, F60108. Seat pattern of plunger In cup bluing.
3. Check injector cup barrel surface for mutilation and b. Using a surface plate (preferably a lapping plate) and
flatness. "bluing," check for surface flatness.
a. For mutilation check in area (black area) as shown in
Fig, 6-1-21. Table 6-1-6: Cup Contact Area of Barrel
b. Using a flat steel plate (preferably a lapping plate)
"A" Dia "B" Dia. "C" Dia. "D" Dia.
and "bluing" to check for surface flatness.
Inch [mm]
c. If mutilation or unevenness are found, mark for
repair. 0.400 0.540 0.710 0.820
[10.16] [13.72] [18.03] [20.83]

0.337 0.480 0.650 0.706

[8.56] [12.19] [16.51] [17.93]

Fig. 6-1-21, F60161. Cup surface at body contact area

4. PT (type D) injector cups with black finish, are

improved material, and are completely
interchangeable with "old-style" stainless steel cups. Fig. 6-1-24, F60191. Barrel surface at cup contact area

Cup Retainer c. If mutiliation or unevenness are found, lap to repair.

1. Inspect the threads for damage. d. Do not use crocus cloth or wire brush on barrel and
cup contact area.
2. Check outside cone area for nicks or burrs which 5. If 5/16 type injector has been overheated, the barrel
could prevent proper seating with sleeve in head. to adapter gasket can melt. Loss of injector cup
retainer torque will occur; therefore, the following
items should be suspected:

461
 TRUCK SERVICE MANUAL FUEL SYSTEM

a. Lubricating oil dilution or blocked injector spray and assemble to adapter. Screw retainer down finger
holes. tight and loosen ¼ turn.
b. Damaged injector sleeves or damaged injector
plungers.
CHECK BALL AND SEAT
1. Check the ball seat for nicks or burrs.
a. Do not attempt to improve the checkball seat by
inserting a ball and tapping. The barrel is as hard as
the ball and will damage the ball if attempted.
b. If the seat is marred, lap the barrel.
2. If any wear or mutilation is found, replace the ball.
PTD injector check balls are made of special
material. ‘Do not attempt to substitute with a
commercial made ball.
ADAPTER
1. Check balance orifice for burrs or other obstructions.
2. Inspect both fuel passages to be certain they are
open. Fig. 6-1-32, F60194. Installing cup on barrel
3. Inspect cup retainer threads for damage. 6. Immerse injector plunger in clean injector test oil and
4. Check “O” ring areas for nicks or burrs which could install in adapter without spring.
damage “O” rings during installation. 7. Raise 3375103 Special Stud in 3375084 Holding
5. Inspect barrel mating surface for nicks or burrs. If Fixture.
damage is found, lap to repair. 8. Insert injector into loading fixture.
ASSEMBLY
PT (TYPE D) INJECTORS
The ST-1298 and 3375084 are two types of loading
fixture tools.
The ST-1298 has been redesigned so cup to
plunger, alignment pressure is maintained by an air
cylinder. The air cylinder reduces injector assembly
time.
If you have ST-1057 or 3375084 and wish to add the
air cylinder attachment, it is available as ST-1298-5111.
1. Drop check ball into top of barrel.
CAUTION: Be certain all mating surface parts are clean
and free of burrs or other imperfections which could
result in incorrect flow or torque. Lap to repair.
2. In repair of the injector, the gasket between the
barrel and adapter is required for 5/16 type only.
Fig. 6-1-30, Injector Cup Wrench - ST-995
3. Hold barrel with check ball up and place new adapter
9. Slide 3375102 Body Wrench over flats on injector
spiral pins into barrel. (Roll pins are no longer used.)
adapter.
4. Turn adapter and barrel with barrel up and place cup
10. Place ST-995 retainer wrench upon injector retainer
on barrel.
(Fig. 6-1-30).
5. Lubricate cup retainer threads and cup flange
11. Lubricate threads of 3375103 stud and screw in
contact area with 20 or 30W lube oil
3375084 Loading Fixture stand far enough to hold
injector (Fig. 6-1-33).
12. Tighten stud in 3375084 to 75 in. lbs. (8.5 N.m), Fig.
6-1-34, or activate air cylinder on ST-1298 to 70 psi
(483 kPa) to align cup and plunger. Fig. 6-1-35.
13. Tighten cup retainer with ST-1072, Crowfoot
Wrench, and ST-995, Retainer Wrench, to 50 ft. lbs.
torque (Fig. 6-1-36).
462
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 6-1-36, F60197. Torquing cup retainer - injector in

Fig. 6-1-33, F60195. Installing retainer wrench on ST-1298
injector

Fig. 6-1-34, F60196. Torquing loading fixture stud of

3375084 Fig. 6-1-38, F60198. Checking plunger to cup binding

14. Remove injector from loading fixture being

careful not to hit cup on stud.
15. To check cup to plunger alignment, remove
plunger and coat with clean fuel oil or test oil
again. Install ST-1089 on plunger.
16. Hold injector in vertical position (cup down) and
allow plunger to drip a few drops of test oil into
cup.
17. Insert plunger about 1/2 inch (12.7 mm] into
barrel to be certain plunger is started straight.
18. Jam coupling with palm of hand to seat plunger
in cup and rotate 90 deg. while holding plunger
firmly against cup seat.
Fig. 6-1-35, F60235. Adjusting air pressure on ST-1298 19. Hold injector with cup up and plunger should slide
out when injector is lifted quickly.
20. If plunger does not slide out, remove plunger, coat
tip and repeat test.

463
 TRUCK SERVICE MANUAL
FUEL SYSTEM

21. If plunger sticks because of misalignment,

loosen cup retainer, rotate cup one fourth turn,
and retorque. Repeat as necessary.
22. Remove plunger from adapter and lubricate
plunger with test oil. Install spring on plunger
and insert into adapter.
23. Check plunger leakage on ST990 or ST570 as
described c the following pages.
24. Check cup spray pattern on ST668 as described
on the following pages.
25. Another method of checking open cup spray
holes is follows:
a. Remove plunger and spring.
b. Fill barrel and cup full of fuel oil. Fig. 6-1-40, F60200. Size location on Injector adapter
c. Insert plunger with ST1089, less spring, into
inject( forcing fuel out spray holes. Fig. 6138.

Caution: At anytime fuel is forced

from cup spray holes be sure to keep
hands or body out of pray stream to
prevent injury.
d. Remove plunger and install spring.
26. Lubricate and install new "Viton" "O" rings into
proper grooves in adapter.
Note: Viton "O" rings are identified by a A HOLES B SIZE C ANGLE
green band. Fig. 6-1-41, F60201. Size marking on Injector cup
27. Install new fuel inlet screen and retainer. Fig.
6142.
28. After assembly, store in clean place until ready
for leakage test.

Fig. 6-1-42, F60202. Fuel inlet screen and retainer

Fig. 6-1-39, F60199. Marking location on plunger

464
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Leakage Checks This check was incorporated into the ST990 as a time
and labor savings. Very little extra time is required to
The plunger to body and plunger to cup leakage check check the cup to plunger seat while the injector is
gives a measurement of fuel bypass between plunger installed in the machine for the body to plunger tests.
body and plunger cup to help determine if injector is to This check is preferred over the ST570 leakage check.
be rehoned or can be calibrated and reused in an Installation
engine. Requirements Of ST990
The following facilities are necessary for acceptable
ST990 Injector Leakage Tester installation of the ST990:
The ST990 Injector Leakage Tester was developed and 1. A clean area with good lighting. An enclosed
released in order to make available to the field a fuel systems area is preferred. When a tightly
standard tool to accurately determine the degree of enclosed room is used, due to the extreme
acceptability of used injectors. Fig. 6144. sensitivity of the air flow meter, the ball float will
The ST990 performs tests on all current Cummins PT fluxuate slightly during opening and closing of
injectors except L series. These tests are as follows: the door. Other than not being able to obtain an
1. Body to plunger leakage in area below the accurate reading during actual swinging of the
metering orifice. With the plunger retracted door, such a room has no adverse effects and is
off the cup seat by approximately 0.048 inch desirable.
[1.22 mm], air is forced through the cup spray 2. A work bench of standard height which is not
holes past the body to plunger clearance and is subject to pounding or other heavy work. The
measured with a precision flow meter. This bench must not have a vise or other shop
check supersedes the body to plunger leakage equipment which is generally subject to impacts.
test on the ST790, In which injector delivery with 3. An air supply of 80 psi [552 kPa] minimum
a 0. inch [1.3 97 mm] restrictor orifice is pressure. The air line to the ST990 should not
compared to delivery with the standard 0.011, be in a location where intermittent pressure
0.013 or 0.020 inch [.28, .33 or .51 mm] orifices drops are caused by actuation of other shop air
(depending upon injector model). equipment.
2. Cuptoplunger seat. The plunger is seated in the Assembly And Installation Of ST990
cup with 200 lbs. [90.72 kg] load. Any leakage 1. Mount rubber isolation pads to feet with
is measured in bubbles which are released capscrews provided.
under a fluid. level. 2. Mount feet to panel. When feettopanel
capscrews are snug, panel must be installed in a
vertical position to insure proper operation of air
flow meter.
3. Fill air cylinder oiler 1/3 to 1/2 full of injector test
oil. Fig. 6145. Make sure sealing ring is in place
before tightening bowl retainer.

Fig. 6-1-44, F60167. ST990 injector leakage tester Fig. 6-1-45, F60168. Air cylinder oiler oil level

465
 TRUCK SERVICE MANUAL
FUEL SYSTEM

4. Fill bubble checker bowl with injector test oil to oil

level marker. Fig. 6-1-46. To more easily fill bowl to
specified level, it may be filled approximately 3/4 full and
then drained to proper level through valve at bottom of
bowl.
5. Use a vise-grip wrench while connecting air supply
line to prevent disturbance to threads.
6. Install T-handle clamping mechanism backed out
approximately 1/2 thread turn from snug position.
7. Install retraction handle and lock into position with
jam.
8. Set pressure regulator at 60 psi [414 kPa].
9. Operate air cylinder a few times and set final pressure
at precisely 60 psi [414 kPa]. The air pressure must be
Fig. 6-1-46, F60169. Bubble check or bowl oil level held at 60 psi [414 kPa] during all tests.
10. The velocity of air cylinder piston rod may be
adjusted as desired with small valve at rear of panel.
Loosen locknut and screw valve stem in to decrease
piston speed or back screw out to increase piston speed.
Lock the nut on the stem when desired piston speed is
attained.
11. With retraction lever in "A" position, install load cell
and clamp into position. Fig. 6147.
12. Adjust knurled knob until load cell reads 200 psi
[1379 kPa]. Fig. 6148. The psi [kPa] reading on load
cell is a direct reading in pounds [kg] load, since load
cell piston area equals 1 square inch [6.45 sq cm].
Adjust knurled a knob to obtain 200 lbs [90.7 kg) load
during several clamping cycles.
13. With load cell clamped at 200 lbs. [90.7 kg) load,
Fig. 6-1-47, F60170. Installing ST-990 load cell use the feeler gauge to adjust locknuts into position and
tighten. Clamping mechanism should be checked daily
with load cell and locknuts adjusted If necessary. Do not
adjust locknuts unless load cell is used.

ST-990 Plunger-To-Barrel And

Plunger-To-Cup Check

PT (type D) Injector
1. Remove ST10583 locating screw from
Service Tool 3375086 or ST1058 Adapter Pot
Assembly. Oil injector "0" rings. Install ST1089
Plunger Extension on plunger. Remove spring.
2. Align injector delivery orifice with locating screw
hole or burnishing hole in adapter pot.
3. Using hand pressure, ST1298 or 3375084, press
injector into pot until it bottoms. Fig. 6156.
Fig. 6-1-48, F60171. Adjusting load cell pressure
4. Insert and tighten locating screw.
Note: When testing Service Tool
3375089 or ST10586 Spacer must be
used.

466
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. -1-56, F6234. Inserting injector into ST-1058 pot

Fig. 6-1-58, F60205. ST1089 spacer used with injector

Fig. 6157, F60204. Installing injector in ST-990

Fig. 6-1-59, F60173. Adjusting knurled nut for feeler
5. Plug fuel inlet port with ST66814. gauge clearance
6. Install injector into ST990 and clamp into
position. Support plate may be tilted for easier
installation of injector. Fig. 6157.
7. Adjust knurled knob to obtain proper clearance
with feeler gauge between knob and locknuts.
See Fig. 6159. Do not adjust locknuts.
8. Install and tighten transfer line in injector drain
port. This is the port on operator’s right, facing
front of test stand.
9. Tighten T-handle clamp. See Fig. 6-1-60.
10. Shift retraction lever from "A" to "B" position.
See Fig. 6161. This removes load from plunger
and allows it to be retracted from cup seat by
approximately 0.048 inch [1.22 mm] . Make sure
plunger retracts. The adherence of mating
Fig. 6-1-60, F60174. Tighten T-handle clamp
surfaces between plunger and cup sometimes
holds plunger Fig. 6160, F60174. Tighten T-
handle clamp In cup seat.
11. In this position presence of bubbles in bubble-
checker is disregarded. Read air flow meter at
top of ball float.

467
 TRUCK SERVICE MANUAL
FUEL SYSTEM

15. If maximum leakage of injector being checked

exceeds specified values, injector barrel must be
sent to a rebuild station for re-plungering.
16. If maximum leakage does not exceed values
Iisted In Table 6113, shift retraction lever back to
"A" position and loosen T-handle clamp. This
applies 200 lbs. (90.7 kg] load to plunger.
17. The cup-to-plunger seal is acceptable if no
bubbles occur in 10 seconds or if time interval
between consecutive bubbles of air observed in
bubble checker exceeds 5 seconds.
18. If the cup seat is damaged In any way and the
Injector does not pass the ST990 cup-to-plunger
seat test, the plunger may be lapped into the cup
to obtain good seating. This lapping is to be
done in a careful manner, without using the body
or barrel. Use no greater than 600 grade paste
lapping compound: Applying light pressure,
oscillate the plunger in the cup back and forth for
approximately one minute.
Caution: After lapping, both the cup and
plunger must be cleaned thoroughly,
lapping compound will damage fuel
system parts unless removed. The most
effective cleaning process is the use of
Fig. 6-1-62, F60176. Rotating plunger coupling and an "ultrasonic cleaner" and an after rinse
spacer in fuel oil.
19. With checks completed and retraction lever in
12. Rotate plunger top in clockwise direction by very "A" position disconnect transfer line, exhaust the
small increment and observe flow meter reading. air cylinder and remove injector.
See Fig. 6162. Do not touch plunger top or any 20. Remove plunger, reinstall spring and plunger.
part of clamping mechanism while taking reading Altitude Compensation
since external forces will disturb plunger from its The ST990 is an altitude sensitive device and when it Is
normal position and may affect barrel-to-plunger used to check the body or barrel to plunger leakage, unit
leakage in cup area. readings should be corrected to allow for altitude
13. Continue to rotate plunger by small increments variations. For every 1,000 feet [305 m] altitude rise
to fin, highest reading on flow meter. above 600 feet [183 m], 0.2 units should be subtracted
14. Maximum readings on injectors which will from the unit reading. For example, if your shop is 6,600
satisfactorily perform throughout another service feet [2012 m] above sea level, you should subtract 1.2 (6
period are listed in Table 6-1-13. x 0.2) units from your unit measurement. The altitude
does not affect the cup to plunger leakage check.
Maintenance
Table 6-1-13: ST990 Leakage Tester Data - Units of 1. ST990 injector leakage testers are checked for
Leakage gauge and flow meter accuracy, leaks,
Injector Model Size New Worn Limit operation and compatibility with other ST990’s
PT (Type D) 3/8 Plunger 2.5 4.5 before release to the field.
PT (Type D) 5/16 Plunger 2.2 4.5 2. It is strongly recommended that each ST990
location select a clean used injector which has a
maximum leakage in the 8 to 10 unit area and
record the maximum reading. When an injector
such as this is selected and carefully kept in a
secure place, it can be periodically used as an
indicator of test stand condition over extended
periods of use. The careful selection and safe
keeping of an injector such as this is a very
important troubleshooting tool in event that
discrepancies arise.
468
 TRUCK SERVICE MANUAL
FUEL SYSTEM

3. Drain sediment from air inlet trap daily or weekly 6. Maintain air cylinder oiler at 1/2 to 1/3 full of
as required depending upon amount of injector test oil at all times to insure proper
contamination in air lines. cylinder action.
A yellow indicator will appear in upper bulb when 7. All fittings, filter oiler and bubble-checker bowls
sintered filter becomes clogged with foreign (upper and lower) must be kept tight and free
matter. The filter must then be removed and from air leaks.
cleaned with solvent. 8. Any oil that collects in bowl of separator mounted
4. Do not obstruct flow meter vent in any way. Oil by dry type filter must be drained regularly. This
and oil mist must never be allowed to enter separator also contains a sintered filter which
either the drain of inlet of flow meter as this will must be cleaned in solvent at least twice yearly
cause float to stick to the sides of tube. according to all available data.
5. Do not readjust or move injector plate supports 9. All available data indicates that dry type filter
on rods. element should be changed twice yearly under
These have been adjusted at the factory for proper normal conditions if sediment bowl adjacent is
alignment and must not be disturbed. drained regularly.

Cup Spray Pattern Check

Injector Spray Pattern - ST-668

Two models of ST668 are being used to check cup spray

patterns, the first was released in 1960 and contains
black-oxide plated seat and seat spacers; the current
tool contains "bright" cadium plated seat and seat
spacers. The latter unit can be used with all Cummins
injectors, while the earlier model cannot be used with 2
degree spray angle injector cups. To check L series
injector cups with the latest tool, use ST849 cup seat or Fig. 6-1-36, F60207. PT (type D) Injector in ST668
black seat from original ST668 tool.
If you have ST668 with black oxide finish seat and 1. Locate ST668 on or near ST790 Injector Test
spacer, it may be brought up to date by purchasing Stand, (or other source of 22 psi [152 kPa]
ST668, Details 36, 2, 1, 17, 18, 19, 20, 22, 23, 24, 25, 4, constant fuel pressure) so injector inlet
37 and 3 from your nearest Cummins Distributor. connection of test stand will reach Injector to be
The following instructions are written with the spray checked. Use injector test oil or fuel oil to
understanding that all ST668 Spray Test Fixtures have perform test.
been brought uptodate. 2. Attach drain hose to ST668 base and place
loose end in ST790 drain pan.
3. Assemble applicable cup seat spacer (see Table
6114) to seat bracket bore.
4. Place "H2" seat . in seat spacer and bracket
bore (seat bracket bore only, if 2 deg. cups are
to be checked) or if L Series cups are to be
checked use ST849 (black) seat.
Check cup markings as shown in Fig. 6-1-40.
indicates 7 holes, 0.007 inch [.178 mm] diameter
and 17 deg. spray angle).
5. Check cup markings for number of spray holes
and place applicable target ring in base of
ST668. Target rings are marked on the "handle"
Fig. 6-1-65, F60119. ST668 spray test fixture (6 and 9 holes or 5, 7 and 8 holes).

469
 TRUCK SERVICE MANUAL
FUEL SYSTEM

6. Insert PT (type D) Injector in Service Tool 12. attach fuel inlet line from ST790 or other
3375086 or ST-1058 Adapter. Fig. 6-1-36, pressure source to injector inlet On PT (type D)
Note: ST-10585 and ST-1058-6 spacers injectors use ST1 058 adapter.
are not required with ST-668, for PT 13. Start ST790 Test Stand or other source of fuel
(type D) injectors. and set pressure to 22 psi [152 kPa].
Note: Use plunger bore plug assembly 14. Shift target ring in base of tool so one spray
ST-668-5012 for PT (type D) injectors. stream hits center of No. 1 or index window.
This is tallest window and is next to target slide
7. Remove plunger assembly and spring from handle. This window provides +3 degrees
injector. tolerance on injector spray stream location.
8. Select correct size plunger bore plug and rubber On 1974 and later injector cups, +2 degrees
seal and; install in injector plunger bore. Protect tolerance must be maintained on all streams.
injector plunger from dirt or damage during tests. 15. Each spray stream must hit a window in the
9. Install the solid knurled plug in injector drain target ring on 1974 and later cups.
opening, Service Tool 3375086. Note: For a cup to be acceptable no more than
10. Place injector in ST668 seat and adjust one stream must require the increased tolerance
holddown bracket into position required, then of the No. 1 window.
tighten thumb screw. 17. After testing, assemble plunger with spring in
11. Tighten knob against plug and seal in plunger body adapter ’and store in clean place until ready
bore so it seals thoroughly. for flow test.

Table 6-1-14: ST-668 Cup Seat Spacer

Cup Spray Spacer Spacer
Angle Marking Height Inch [mm]
10 deg. H-10 0.563/0.569 [14.30/14.45]

ST-790 Test Stand Installation and Calibration

Injector Test Stand ST790 ST790 Injector Test Stand (Fig. 6-1-68) is used to test all
The ST790 Injector Test Stand is the recommended Cummins PT injectors. ST790 flow tests the complete
calibration equipment for testing and calibrating injector assembly by measuring fuel delivery. The
Cummins injectors, but it must be properly installed and injector is actuated under controlled conditions closely
calibrated to obtain the highest accuracy possible. simulating actual operating conditions. The test stand
counts injection strokes, supplying fuel at a specified
pressure, thereby measuring the delivery in a glass
graduate.
The ST590 Test Stand was used prior to release of
ST790 and may be converted, see your Cummins
Distributor. ST790 provides more accurate results,
better clamping arrangement and easier operation. The
accuracy and advantages of ST790 Test Stand make it
very important that ST590 Test Stands be converted;
meanwhile, your nearest Cummins Distributor can
calibrate Cummins Injectors to the latest specifications.
Test Stand Installation ST790
The ST790 must be located near hot and cold water
connections. Water temperature, controlled by a mixing
Fig. 6-1-68, F60122. Injector test stand ST-790 valve, is used to maintain test oil at an 90/95 deg. F
[32/35 deg. C] temperature range. If temperature
exceeds 95 deg. F [35 deg. C] increase cold water flow.
If temperature exceeds 135 deg. F [57 deg. C] drain and
replace with new test oil.
470
 TRUCK SERVICE MANUAL
FUEL SYSTEM

1. Fill test oil tank 3/4 full of test oil and maintain
this level or higher during test. Test oil capacity
is approximately five gallons. It is available from
Cummins Engine Company as Part No.
9901168 or Mobil Oil Company No. MCL-41.
2. Fill the hydraulic fluid reservoir to half level in
sight bulb with clean Type A automatic
transmission fluid. Be careful not to allow oil to
enter the standpipe in center of reservoir.
3. Fill cambox with SAE 30 nondetergent
lubricating oil to top of sight glass. Refill when oil
level gets low in sight glass.
4. Plug electrical connection into receptacle
carrying the necessary voltage to operate the
test stand. Fig. 6-1-70, F60124. Clamping cylinder and seat
Description Of Operation ST790
1. A motor driven shaft and a cam are housed in
the cam box. The cam actuates the vertical
push rod at the bottom of the housing.
2. The push rod is connected to the injector by a
link so the injector plunger will be actuated by
cam action just as it is in the engine. Fig. 6169.
3. Injectors are clamped in the test stand by
hydraulic pressure from the cylinder, piston rod
and injector seat. The injector seat contains a
removable orifice to restrict the metered fuel flow
and cause a back pressure simulating,
compression pressures as found in the engine. Fig. 6-1-71 F60125. Aligning timing wheel mark
Be sure to use; correct size orifice. Fig. 6170.
4. Before clamping the injector in the test stand, the
cam must be timed by rotating the timing wheel
so the wheel mark and pointer are aligned. Fig.
6171.
5. Shop air pressure regulated by air regulator is
used to apply a balanced force on the hydraulic
system. Fig. 6172. The air gauge at top of
hydraulic reservoir is used as a reference
indicating that pressure has not changed, after
being set using a load test cell during test stand
calibration.

Fig. 6-1-72, F60209. Air pressure and fuel pressure

gauges.

Fig. 6-1-69, F60208. Link and injector in position

471
 TRUCK SERVICE MANUAL
FUEL SYSTEM

6. When the air valve is opened, air travels up the

pipe in the center of the tube type hydraulic
reservoir and exerts a downward pressure
against the column of hydraulic fluid.
7. When both the air valve and the hydraulic valve
are opened, hydraulic fluid is admitted under the
piston in the cylinder and lifts the injector into
clamped position. Any leak in the hydraulic
clamping system will directly affect injector
loading and must not be permitted.
Fig. 6-1-75, F60129. Measuring fuel in vial
8. In clamped position and with the appropriate link
in place, tension on the injector is the same as it
12. Fuel is delivered to the vial during a measured
is in the operating engine. Use of the improper
number of strokes as recorded by the counter.
link will affect clamp load and upset delivery
13. A master injector which has been previously
values.
calibrated at the factory is used in setting the test
stand prior to adjusting other injectors for fuel
delivery. The master must never be tampered
with.
Note: A cylindrical injector in a pot
provides the same conditions as the
flanged injectors.
Injector Test Stand Maintenance ST-790

To obtain best service life from the ST790 Injector Test

Stand, the following maintenance practice must be
Fig. 6-1-73, F60127. Hydraulic valve observed.

9. Fuel is delivered to the injector through the inlet Roller Tappet And Cam Assembly
connector. Fuel pressure here is controlled at The roller tappet and cam assembly will wear, just as any
this point by a connecting line and pressure moving assembly and will require maintenance.
regulator. Fig. 6-1-74. 1. If tappet is worn, it should be replaced as soon
10. The second connection with the clear plastic line as possible to prevent excessive wear on cam.
is the injector drain connection which carries An improved tappet has been used in test
drain fuel from the injector back to the tank. Stands built after Serial No. 0576, using a
needle bearing roller instead of the former
bronze bushed roller.
2. Do not assemble a new tappet with a scuffed
cam. If the scuffing cannot be removed with a
fine hone, the cam must also be replaced.
3. If the cam is worn into the shaft by more than
0.002 inch [.051 mm] the shaft must also be
replaced, as this condition will cause undue
loading on cam, tappet and bearings.
4. Align the cam to track 100% on the tappet roller.
5. Torque clamp type ring to 12 to 15 ft-lbs [16 to
Fig. 6-1-74, F60128. Fuel inlet connector
20 N m] or tighten setscrew in cam hub securely
11. During test stand operation, the operator starts a
and install a second setscrew on top of the
test cycle which diverts fuel to the vial so the
original one as a "jam screw"
amount of fuel being injected can be measured.
Fig. 6-1-75.
472
 TRUCK SERVICE MANUAL FUEL SYSTEM

Clutch Adjustment c. Gauge line contacting frame or other member of

1. Manually engage clutch by fully depressing test stand thereby transmitting mechanical
solenoid plunger (shown above In "Clutch Arm vibration into gauge.
Removal Procedure"). With clutch held in this
position, the cross pin (J, Fig. 6-1-77A) should
clear the driver U-slot by approximately 1/32 inch
as shown in the drawing.
2. Tighten set screw (F, Fig. 6-1-77A) against flat
provided on clutch shaft (G, Fig. 6-1-77A).

A. Nut E. Plunger I. Collar

B. Clutch Arm F. Set Screw J. Cross Pin
C. Plunger Link G. Clutch Shaft K. Driver
D. Clutch Arm H. Camshaft Shaft L. Counter Shaft
Fig, 6-1-77A, F60160. Clutch arm removal and clutch
adjustment
Gauge Damping And Mounting
One area in which increased compatibility can be
realized between factory and field test stands, is fuel
pressure gauge hand stability. Erratic action of gauge
hand is a result of’
one or both of the following factors:
1. Hydraulic pulsations being carried into the gauge
because of damping valve not being properly
adjusted. With the adjustable damping valve it
is impossible to insure that all test stands can be
adjusted to the same degree of damping.
2. Mechanical vibration being transmitted into
gauge as a result of one of the following
conditions.
a. Operation of test stand with gauge mounts
broken.
b. Gauge line positioned so it "pulls" or "pushes" on
gauge and in effect becomes a rigid member
between gauge and test stand frame.
 air bubbles cease to appear, an additional 5
cycles will insure gauge is completely filled with
fluid. Fig. 6179.

Fig. 6-1-78, F60181. Removing snubber from gauge

stem

Removing Air From Fuel Pressure Gauge

1. Remove gauge from test stand. Remove
snubber from gauge stem. Fig. 6-1-78.
2. Fill the gauge filling tube with gauge oil or
injector test oil and screw it into gauge stem. Fig. 6-1-79, F60182. Filling gauge to remove air bubbles
Hold gauge In position so the 210 psi [1448 kPa]
graduation is the lowest point on dial face. While 3. Turn gauge so the stem Is in an up position and
holding gauge in this manner, squeeze tube and remove gauge filling tube. Continue to hold
release it. When tube is squeezed, gauge hand gauge stem upright and finish filling internally
will be actuated indicating fuel is entering gauge. threaded portion of gauge stem with fluid.
When tube is released air bubbles will come up Note: The gauge must be held with stem
through fluid contained in tube indicating air In upright position until installation of
inside gauge is being displaced by fluid Continue gauge on test stand.
to squeeze and release tube several times After
473
 TRUCK SERVICE MANUAL FUEL SYSTEM

4. Screw snubber back into gauge stem. between 370 and 390 when adjusted within
5. Place an injector into operating position In test marked band on dial.
stand. Start the test stand. When solid fuel
begins to flow from the snubber, turn gauge
upright quickly and assemble to snubber. Let
test stand run while gauge is tightened securely
to snubber.
6. Assemble gauge to mounts secure with machine
screws and nuts.
7. Start test stand and observe gauge hand rise
from 0 to 120 psi [0 to 827 kPa]. It should take
approximately 2 to 3 seconds for hand to rise to
120 psi [827 kPa]. If gauge hand is slow to rise
and fall, carefully repeat Steps 1 through 6.
8. Check for gauge hand vibration, it should not
occur if copper line is properly routed and
Fig. 6-1-81, F60131. ST789 load cell
adjusted.
a. Tubing must be adjusted so it is neither "pulling"
or "pushing" on the gauge.
b. Tubing on the gauge must not contact any
member of test stand such as frame, motor or
gear pump cover.
c. Contact of tubing to any member of test stand
will transmit mechanical vibration into gauge and
defeat purpose of snubbers and gauge mounts.
Changing Oil And Filter
When changing oil and filters in test stand, adjust
regulator to lowest possible pressure during pump pickup
to prevent air from being forced into gauge line. If slow
gauge hand response does occur, it is an indication air
entered the system and the bleeding process Steps 1
Fig. 6-1-82, F60132. Air pressure adjustment
through 6 must be performed.
Calibrating The ST790 Test Stand
6. Remove the load test cell by returning the air
1. Before operating the test stand make sure that
valve knob to center position. With the cylinder
the cam box is filled to the top level of the sight
rod in down position, check to make sure the
glass with clean SAE 30 nonfoaming lubricating
hydraulic fluid shows in the hydraulic oil level.
oil.
7. Open the air valve. While the cylinder rod is at
2. Fill the hydraulic fluid reservoir to bulb level with
the top of its travel check to make sure there is
clean Type A automatic transmission fluid. Be
no air in hydraulic fluid sight glass. Fig. 6183.
careful not to allow oil to enter the standpipe in
8. Make sure Injector seat contains 0.020 inch [.51
the center of the reservoir.
mm] restrictor orifice when calibrating test stand.
3. The test oil tank on the stand must be kept at
Fig. 6184.
least 3/4 full of Cummins 9901168 test oil or
9. Place adapter plate over master injector, ST768,
Mobil Oil Company No. MCL41.
ST1210, ST1262 or ST1306, and engage locator
4. Align timing mark (Fig. 6171) and open the
In injector mounting holes. Make sure seat is
hydraulic valve. Place the load cell, ST7905111,
retracted and timing marks are aligned at timing
in the test stand and clamp in place by opening
wheel. Fig 6171.
the air valve. Fig. 6181.
10. Position test stand link (marked NVH, NH, H)
Note: Never operate test stand with load cell in position.
over injector plunger link and place assembly in
5. Adjust air pressure by turning the knurled button
injector seat, tip back until link is below machine
on the air regulator until the load cell indicates
push rod. If necessary, adjust bracket so link is
within marked band on load cell gauge. Lock the
aligned but not rubbing.
knurled button in place with the locknut. Note
the air gauge pressure (gauge at top of Hydraulic
Reservoir). Fig. 6182. Load cell should read
474
 TRUCK SERVICE MANUAL FUEL SYSTEM

Fig. 6-1-83, F60133. Hydraulic fluid sight glass

Fig. 6-1-85, F60135. Position assembly

Fig. 6-1-86, F60136. Close hydraulic valve

Fig. 6-1-84, F60134. Injector seat restrictor orifice

11. the air valve and as the injector goes in clamped

position make sure the link is properly aligned
and engaged. Fig. 6185.
12. Check the air pressure gauge at top of hydraulic
reservoir as originally established with the load
test cell. Close the hydraulic valve to lock the
injector in clamped position. Connect the inlet
and drain connectors to the injector. Fig. 6186.
Caution:
To avoid damage to master injector, do not use ST708
Burnishing Tool when setting up test stand.
13. Start the test stand motor.
Note: Test oil must be a minimum of 90 deg. F [32 deg. Fig. 6-1-87, F60137. Adjust to 120 psi
C] . If temperature is not up to 90 deg. F [32 deg. C]
test stand must be warmed up on a standard injector, not Pressure (120 psi [827 kPa] ) must be maintained at all
the master injector. If temperature exceeds 95 deg. F times during calibration and testing.
[35 deg. C], increase cold water flow. If temperature
exceeds 135 deg. F [57 deg. C] drain and replace with
new test oil.
14. Adjust the fuel pressure by turning the regulator
knob until the pressure gauge shows 120 psi
[827 kPa] . If this pressure cannot be achieved,
the trouble probably is due to a sticking air
regulator, or to a worn gear pump. Fig. 6-1-87.
475
 TRUCK SERVICE MANUAL FUEL SYSTEM

15. All counter wheels must be set at zero (0) as a

starting point. Fig. 6188.
16. Shift the silver-colored counter wheels to the
right, rotate as necessary then release them to
indicate 1020 strokes. Rotate empty vial into
position by turning vial knob.
17. Clear the counter by rotating with thumb screw
for one complete revolution. All white counter
wheels must show zero (0). Fig. 6189.
18. Engage the counter and divert fuel to the
vial for measurement by pressing and releasing
the red flow start switch.
19. Stir the fuel with a rod to settle out the foam,
then, check the amount collected in the vial at Fig. 6-1-88, F60138. Start counter at zero
the end of the 1020 countstrokes.
20. Look directly into the vial at fuel level to avoid
parallax. If this reading shows 129 cc which is 3
cc below the correct injector master delivery
specifications (132 cc @ 120 psi), or another
value, repeat test. Fig. 6190.
21. Dump the fuel from the vial and repeat the test at
least twice to insure consistent results.
22. If 3 cc low, it will be necessary to set the counter
up to approximately 1043 strokes or about 7 to 8
strokes for each cc. Roll the counter back, all
white counter wheels must show zero (0).
Note: If the counter is set beyond 1050 strokes, it is a
good indication test stand is not properly installed or
calibrated. Fig. 6-1-89, F60139. Clear counter
23. Repeat the tests and adjust the counter as
necessary, to obtain 132 cc delivery at 120 psi
[827 kPa] with fuel temperature at 90 deg. to 95
deg. F [32 to 35 deg. C], while the master
injector is in the test stand. Check readings for
three cycles to insure repeatability. After each
four cycles, reclamp injector to insure maximum
accuracy. At this point the test stand is correctly
calibrated.
Note: In reading the level of fuel in vial, be certain to
read it at the fuel level. Fig. 6190. When reading at "C"
height, you are too high. The reading at "B" is the
correct height. You are not looking up or down at the
fuel level, thereby avoiding parallax. Read the correct cc
at the point where fuel appears to change color.
Fig. 6-1-90, F60210. Read vial fuel level

476
 TRUCK SERVICE MANUAL FUEL SYSTEM

Flow Testing PT Injectors On ST-790

Flow Testing Adjustable Delivery Injectors

On ST-790
Test Stand is used to flow test the complete injector
assembly by measuring fuel delivery. The injector is
actuated under controlled conditions closely simulating
actual operating conditions. The test stand counts
injection strokes, supplying fuel at a specified pressure,
thereby measuring the delivery in a glass graduate.
1. Remove master injector ST1210, or ST1306
from test stand after calibrating test stand.
Install correct restrict orifice in cup seat, see
Table 6115, Fig. 6192, and tighten to 6 in-lbs
[Nm .
a. 0.0115 inch [.292 mm] orifice has four notches.
b. 0.013 inch [.33mm] orifice has two notches. Fig. 6-1-92, F60142. Installing restrictor orifice
c. 0.020 Inch [.51 mm] orifice has six notches.
d. 0.026 inch [.66 mm] orifice has one notch.
Note: Delivery for injectors listed in Table 6115 under
heading "Approx. Strokes" as 20% is established by
setting ST790 Stand with ST1210, Master Injector; then
turning back the counter by 20%. For example, if test
stand counter was read at 1050 with master, the
injectors to be tested would be run at 840 counter
strokes.
Comparing Injector Flow With ST1129
A new flowmeter, ST1129, is available to provide a quick
comparative indication of injector flow on the ST790 Test
Stand without running through a complete test cycle.
However, this flowmeter is in no way meant to replace
Fig. 6-1-93, F60221. Front view of ST790 with ST1129
the present method of measuring injector delivery. Fig.
installed
6193.
Operating Instructions
PT (type D) Injectors
1. the first injector of the set to be flowed into the
ST790 Test Stand is used to flow test the complete
ST790 stand per normal procedure and
injector assembly by measuring fuel delivery. The
complete calibration.
injector is actuated. under controlled conditions closely
2. Before removing injector from ST790, note
simulating actual operating conditions. The test stand
flowmeter value.
counts injection strokes, supplying fuel at a specified
3. Install second injector and start test stand, do
pressure, thereby measuring the delivery in a glass
not hit flow start button, observe flow value.
graduate.
Compare with previous injector and burnish
1. Remove master injector from test stand after
orifice until reading is slightly below first injector.
calibrating test stand. Install restrictor orifice In
4. Complete calibration of injector. A little practice
cup seat, see Table 6115, Fig. 6192 and tighten
with the flowmeter will save considerable time In
to 6 inchpounds [.7 Nm]. pounds [.069 kg mi .
"burnishing in" injectors to reach the correct flow value.
a. 0.020 inch [.51 mm] orifice has six notches.
b. 0.026 Inch [.66 mm] orifice has one notch.

477
TRUCK SERVICE MANUAL FUEL SYSTEM

Note: Delivery for injector with approximate strokes of

800 in Table 6115 is established by setting ST790 Stand
with master injector, then turning back the counter by
20%. For example, if test stand counter was read at
1050 with master, the injectors to be tested would be run
at 840 counter strokes.
2. Lubricate inside of Service Tool 3375086,
ST1058 or Body with test oil so Injector "0" rings
will slide into adapter without damage to "0"
rings.

Fig. 6-1-109, F60203. Center injector inlet in ST1058

inlet hole
3. Seat injector in body so injector Inlet aligns with
body inlet hole. Fig. 61109. Tighten locating
screw. Fig. 61110.
4. Remove spring and plunger from injector
adapter. Leave spring off and install plunger into
adapter.
5. Perform ball valve seating check before
calibrating injector.
a. Attach test stand inlet pressure line to drain
connection of Service Tool 3375086, ST1058
Body.

Fig. 6-1-110, F60212. Tighten ST1058 locating screw

478
 TRUCK SERVICE MANUAL FUEL SYSTEM

b. Hold injector plunger down against its seat in Note: All tests on test stand are performed without a
injector cup with injector in a vertical position. screen on injector.
Assembly may be held in hand, do not place in 13. Assemble ST-708 Burnishing Tool into test stand
test stand holding device. Fig. 6-1-111. injector inlet connector. Retract the needle by
Note: Be sure ST-708-1 Needle is retracted. pulling out small knob. With needle retracted
c. Turn on test stand, and adjust pressure to 150 ST-708 tool may be left in connector during all
psi [1034 kPa . test operations.
d. Check orifice plug inlet opening of Service Tool Note: Injector delivery is adjusted by burnishing the inlet
3375086, ST-1058 Body for leakage past ball orifice plug with ST-708 instead of changing the plug.
valve. The replaceable needle point, ST-708-1, is the
Note: Make sure plunger is seated in cup. burnishing member.
e. If leakage is observed, the ball must be 14. Install connector and ST-708 tool into Service
replaced. Slight seepage is not harmful. Tool 3375086, ST-1058 Body inlet by screwing in
the large knob section. Fig. 6-1-112.

Fig. 6-1-111, F60213. Check leakage at inlet port

6. Install injector in Service Tool 3375086, ST-1058

Fig. 6-1-112, F60214. ST-708 installed in inlet
or Body. Disconnect Inlet pressure line from
connection
drain connection of body. Remove injector
plunger.
7. Seat injector so injector inlet aligns with body
inlet hole after injector adapter is located in
sleeve.
8. The location screw must seat in hole of adapter.
9. Check to be sure injector inlet is centered in
body inlet hole to prevent breaking ST7081
Burnishing Tool points when installed later.
10. Install spring and plunger into injector.
11. Assembly retainer plate over injector with pins
engaging in body.
12. Position injector in test stand with correct
adapter link. See Table 611.8.

Table 6-1-18: ST-790 Test Stand Link Data PT (type Fig. 6-1-113, F60215. Assemble ST-70a tool to pot
D)
Length
Inch [mm] Link Marking

6.5 [165] ST-790-331

479
 TRUCK SERVICE MANUAL FUEL SYSTEM

15. Install drain connection. 17. Back off adjusting screw and retract needle, then
Run injector through a test cycle and check the cc check delivery.
delivery. If delivery is lower than specifications given in Table 6-1-16: Injector Orifice Plugs
Table 6-1-15, turn the knob with indicator point until it is Straight Inside Flanged Inside
spaced 3/8 inch [9.5 mm] from the large knob. Fig. 6-1- Part Diameter Part Diameter
Number Inch [mm] Number Inch [mm]
114.
163065 0.015 [0.38] 177283 0.015 [0.38]
163066 0.016 [0.41] 177284 0.016 [0.41]
163067 0.017 [0.43] 177285 0.017 [0.43]
148338 0.018 [0.46] 177286 0.018 [0.46]
163068 0.019 [0.48] 177287 0.019 [0.48]
163069 0.020 [0.51] 177288 0.020 [0.51]
163070 0.021 [0.53] 177289 0.021 [0.53]
163071 0.022 [0.56] 177290 0.022 [0.56]
149726 0.023 [0.58] 177291 0.023 [0.58]
163072 0.024 [0.61] 177292 0.024 [0.61]
163073 0.025 [0.64] 177293 0.025 [0.64]
163074 0.026 [0.66] 177294 0.026 [0.66]
163075 0.027 [0.68] 177295 0.027 [0.68]
163076 0.028 [0.71] 177296 0.028 [0.71]
163077 0.029 [0.74] 177297 0.029 [0.74]
163078 0.030 [0.76] 177298 0.030 [0.76]
Fig. 6-1-114, F60216. Knob spacing 163079 0.031 [0.79] 177299 0.031 [0.79]
16. Slowly push the small knob in until you feel the 128132 0.032 [0.81] 179332 0.032 [0.81]
needle enter the orifice plug inside diameter. 128133 0.033 [0.84] 179333 0.033 [0.84]
Then turn the knob counterclockwise to lock the 128134 0.034 [0.86] 179334 0.034 [0.86]
needle shaft to the larger knob with the indicator. 128135 0.035 [0.89] 179335 0.035 [0.89]
Turn the indicator knob in until you feel the 131092 0.036 [0 91] 179336 0.036 [0.91]
131093 0.037 [0.94] 179337 0.037 [0.94]
needle contact the plug. Index the indicator with
131094 0.038 [0.97] 179338 0.038 [0.97]
a mark on the largest knob and advance one 131095 0.039 [0.99] 179339 0.039 [0.99]
mark. 131096 0.040 [1 02] 179340 0.040 [1.02]
Note: Test stand must be running while burnishing orifice 131097 0.041 [1.04] 179341 0.041 [1.04]
with ST-708. 131098 0.042 [1.07] 179342 0.042 [1.07]
132800 0.043 [1.09] 179343 0.043 [1.09]
132801 0.044 [1.12] 179344 0.044 [1.12]
132802 0.045 [1.14] 179345 0.045 [1.14]
131099 0.046 [1.17] 179346 0.046 [1.17]
131100 0.047 [1.19] 179347 0.047 [1.19]
131101 0.048 [1.22] 179348 0.048 [1.22]
131102 0.049 [1.24] 179349 0.049 [1.24]
131103 0.050 [1.27] 179350 0.050 [1.27]
131104 0.051 [1.29] 179351 0.051 [1.29]
131105 0 052 [1.32] 179352 0.052 [1.32]
131106 0.053 [1.35] 179353 0.053 [1 35]
131107 0.054 [1.37] 179354 0.054 [1.37]
131108 0.055 [1.40] 179355 0.055 [1.40]
132803 0.056 [1.42] 179356 0.056 [1 42]
132804 0.057 [1.45] 179357 0.057 [1.45]
Fig. 6-1-115, F60217. Burnishing operation 132805 0.058 [1.47] 179358 0.058 [1.47]
Note: A very useful tool for checking orifice inside 132806 0.059 [1.50] 179359 0.059 [1 50]
diameter is available directly from the Datcon Inst. Co. 132807 0.060 [1.52] 179360 0.060 [1.52]
East Petersburg, Pa. 17520, or their dealers as "Kwik 132808 0.061 [1.55] 179361 0.061 [1 55]
Chek Hole Gauge", Model No. 10-0, Part No 39899. 132809 0.062 [1.57] 179362 0.062 [1.57]
132810 0.063 [1.60] 179363 0.063 [1.60]
Another version of this tool is available from the Coventry
132811 0.064 [1.63] 179364 0.064 [1.63]
Gauge and Tool Co. Ltd., Coventry, England. Order 132812 0.065 [1.65] 179365 0.065 [1.65]
size No. 1 for 0.010 inch [ 25 mini] to 0.040 Inch [1.02 132813 0.066 [1.68] 179366 0.066 [1.68]
mm] orifice plugs and No. 2 for 0.030 inch [.76 mm] to 132814 0.067 [1.70] 179367 0.067 [1.70]
0.080 Inch [2.03 mm] orifice plugs. These tools are 132815 0.068 [1.73] 179368 0 068 [1.73]
especially helpful If orifice plugs become mixed. 132816 0.069 [1.75] 179369 0.069 [1.75]
Measure orifice at base end (not wrench end) as shown 132817 0.070 [1.78] 179370 0 070 [1.78]
in Fig. 6-1-94. This tool is now available from Cummins
as ST1332.
480
 TRUCK SERVICE MANUAL FUEL SYSTEM

The 1/2 inch [12.7 mm] diameter may be from

3/4 Inch [19 mm] to 2 inch [51 mm] long, down
the link. These 1/2 inch [12.mm] links may be
mixed in an engine. Do not use new 1/2 Inch
[12.7 mm] links with old rocker levers unless
they are converted to take new 1/2 inch [12.7
mm] sockets.
Injector Removal And Installation in Head
PT (type D) Injectors
1. Remove injector holddown plate or yoke.
a. Use ST1297 to remove injectors from cylinder
head.
b. On NH, NT and V12 series engines you may
insert a 3/816 capscrew in tapped hole in
holddown plate and jack injector from head.
Fig. 6-1-94, F60143. Orifice size gauge 2. Remove all carbon from injector copper sleeves.
a. Do not use anything metal to scrape the sleeves.
18. If delivery is more than specified cc (Table 6-1- b. Use a wooden stick with a clean cloth wrapped
15), a new adjustable orifice must be installed in around the end.
the injector. See Table 6-1-16. Tighten orifice 3. Lubricate the "O" rings with 20 to 30 weight lube
plug to 8 to 10 inch-pounds [.9 to 1.1 N m] oil. Do not use Lubriplate.
torque. 4. Start injector into bore, guide by hand until
Note: Orifice plugs have flanges and require a gasket aligned in bore and not binding.
between flange and adapter. a. It is not required to line up any plugs or rotate
19. New inlet orifice plugs contain enough stock in injector around in any position. The PT (type D)
the inside diameter so a small displacement of will perform at any position.
metal by burnishing will increase delivery. The 5. Place a clean blunt object on injector body and
amount of displacement is limited so several "seat" injector by giving a quick hard push. A
orifice plugs are required to cover the delivery for snap should be heard and felt as cup seats in
all the engine models from low to high copper sleeve.
horsepower. See Table 6116. Note: Do not use a wooden hammer handle or similar
20. After each four cycles, reclamp injector to insure tool to install injectors. Dirt or splinters from the
maximum accuracy. When delivery is correct, handle may drop into plunger link seat causing
remove inlet and drain connection. early failure of link or plunger socket.
21. Remove injector from test stand. Caution: If injector is not completely seated, the "O"
22. Remove plunger and spring. rings may be damaged if pulled down with the mounting
23. Remove adapter plate and body from injector capscrews.
adapter. 6. Install holddown plates or yokes, lockwashers
24. Install plunger and spring in injector adapter. and capscrews.
25. Insert disc screen over orifice and assemble Caution: Be certain plates or yokes do not contact
retainer ring to hold screen in place. crosshead stems.
26. Insert link in plunger coupling and store in a 7. Torque capscrews in alternate steps to 11 to 12
clean plate until needed. ftlb [15 to 16 N. mi.
27. When 5/16 inch [7.9 mm] link is used, always Nylok capscrews may be used Torque them alternately
keep part number up. This link has a 5/16 inch to 12 ftlb [15 to 16 No m] .
[7.9 mmj ball on both ends. 8. Test injector plunger for movement after torquing
28. A new 1/2 inch [12.7 mm] diameter ball link is holddown capscrews. If plunger is not free,
currently being used to improve the wear retorque capscrews.
resistance of the upper ball end. This new link
has several optional shapes of the upper end.

481
 TRUCK SERVICE MANUAL FUEL SYSTEM
ST-790 Trouble Shooting
ST790 Trouble Shooting/Maintenance 2. Erroneous flowmeters.
This section of the manual should be fully understood by 3. Erroneous dynamometer load indicators.
the Injector Test Stand operator, and through this c. Neglect of ST790 Maintenance.
knowledge he should be able to correct the test stand 1. Use of hose lengths, diameters, and resiliencies
problems and subsequently produce a properly other than those which are specified.
calibrated injector. Caution: Do not replace any hoses or lines on the
The ST790 Injector Test Stand is the recommended ST790 Test Stand with other than the correct ST hose as
calibration equipment for Cummins injectors and was specified in the tool catalog. Hoses on ST790 should be
developed to provide accurate balancing and testing of replaced periodically since rubber in the hose hardens
Cummins injectors in order to produce the desired with age causing resonance variables.
engine performance. 2. Fuel routing which is not to specifications.
Injector calibration on the ST790 Injector Test Stand 3. Filter assemblies which have a different
combined with fuel pump calibration on dampening effect on the system.
Cummins Fuel Pump Test Stands with flow 4. Critical components of the test stand such as
meters has produced widespread acceptance of check valve, gauge and hydraulic injector
fuel system accuracy. There have been reports clamping poorly maintained.
of erratic results, but investigations have Trouble Shooting The ST790
revealed that the cause for such Injector calibration problems are discovered by
problems fall into three basic categories. inconsistent results in service injectors or inability to flow
1. Mechanic and/or Tester Error: (Not confined to injectors which have been calibrated at the factory or at
injector calibration alone. Includes pump other locations to the proper specifications. When an
calibration, engine and chassis dynamometer injector calibration problem is indicated, the following
checks, etc.) troubleshooting guide is to be used in the diagnosis and
2. Instrumentation Errors: (Range all way from correction of the problem. All injector calibration
gauge used on cuptoplunger seat check to load complaints have been found to fall into the six basic
indicator on chassis dynamometer. categories as follows.
3. ST790 Maintenance Status These three problem 1. Stand repeatability. Stand will not repeat
areas are itemized as follows: consistently on any given injector.
a. Mechanic and/or Tester Error 2. Poor results on all injector models. Injectors do
1. Calibrating a specific injector model to the wrong not perform well in engine and do not correlate
flow value. with injectors calibrated on other stands.
2. Calibrating a specific fuel pump model to the 3. NHRS, NRT injectors heavily overfueled. PT
wrong value. (type B) and PT (type D) injectors slightly
3. Lack of familiarity with this bulletin and/or Bulletin underfueled. Reasonable results on all other
No. 3379068, 983505, 3379084 and No. injectors.
983533. 4. All PT (type B) (type C) and PT (type D) injectors
4. Use of wrong injector assembly in a specific overfueled. Reasonable results on all other
engine model. injectors.
5. Use of camshaft and pistons other than those 5. NHRS, NRT and all PT (type B) (type C) and PT
shown in CPL. (type D) injectors overfueled. Results are
6. Restricted intake air to engine. reasonable with all other injectors.
7. Excessive exhaust back pressure. 6. All PT (type B) (type C) and PT (type D) injectors
8. Restricted fuel supply to engine. underfueled.
9. Aerated fuel supply to engine.
10. Excessively high oil level in engine crankcase.
b. Instrumentation Errors (Other than ST790) 1.
Erroneous fuel manifold pressure gauges on
engine and/or chassis dynamometer.

482
 TRUCK SERVICE MANUAL FUEL SYSTEM

Complaints And Corrections Correction

Charted on the following pages are the complaints, Remove the vials and check the relative accuracy by
showing the items to check for correction of the filling one to various levels and pouring into the other vial.
complaints. Each check is numbered, and the item If there is significant variation between the two vials,
numbers from Fig. 61121 are given for quick location, so mark the vials (spot of paint on one) and record the
you may go immediately to the tabulated description of relative variation for future reference in troubleshooting.
the causes and corrective action as necessary. If the differential is significant at 132 cc, choose one vial
Check 1-Vials (the one marked with a spot of paint above) for machine
calibration use and when trouble-shooting the machine.
Cause Replace with correctly calibrated vials as soon as
Differential of 1 cc or more between the vials. possible.
Adjust solenoid outlet line so that 100% of the metered
fuel enters the vials. (For minimum fuel foam, direct
stream of fuel against side of vial.)
Foam will settle in approximately one minute. To prevent
this time loss a 1" diameter hole may be cut in the top
Metered fuel partially missing vials. panel (with panel removed) and the foam may be stirred
with a wire or rod.

Foam preventing accurate reading of fuel delivery in

vials.

483
 TRUCK SERVICE MANUAL FUEL SYSTEM

Check 2 - Fuel Pressure Regulator Correction

Clean and/or replace regulator as required to maintain
Cause pressure at 120 psi [827 kPa] .
Change plumbing to the right size and length.
Regulator sticking. (Indicated fuel pressure erratic.)
Regulator not plumbed into the fuel circuit per conversion Correction
instructions.
Change gear pump as required. (For gear pump delivery
Check 3 - Gear Pump specifications and gear pump checking procedure see
Complaint No. 6.)
Cause
ST-790 TEST STAND HYDRAULIC SYSTEM LEGEND
Pressure regulator is operating properly but pressure in 1. Air Regulator and Filter 20. Pressure Regulator
2. Filter Drain 21. Dampening Valve
excess of 120 psi [827 kPa] cannot be obtained with an 3. Air Valve 22. Fuel Pressure Gauge
NHRS injector installed. 4. Hydraulic Reservoir 23. Injector Seat Assembly
5. Air Pressure Gauge 24. Restrictor Orifice
6. Hydraulic Oil Level Gauge 25. Check Ball
7. Sight Glass 26. Spring
8. Hydraulic Lock Up Valve 27. Solenoid Valve
9. Hydraulic Loading Cylinder 28. Vials
10, Piston 29. O-Ring (Goshen Part No.
GRG-27-12)
11. Piston Rod (Parker Part No. 2-114)(Lincar Part
12. Piston Return Spring No. 11-114)
13. Cylinder Breather 30. .035 Orifice
14. Bleed Plug 31. Secondary Check Valve
15. Fuel Tank 32. Filter Drain Cock
16. Fuel Strainer
17. Gear Pump
18. Fuel Filter (Part No. 105204)
19. Injector Inlet Connector

A. Air In.
B. Hydraulic Fluid
C. Fuel From Tank To Pump
D. Fuel From Pump To Filter Inlet (Stratoflex #213 M.H.P. #4 21"
Length)
E. Fuel From Injector Inlet To Pressure Regulator (Stratoflex #213
M.l.P.
’4 21 Length)
F. Fuel From Pressure Regulator To Pressure Gauge (3/16 X 18"
Copper Tubing)
G. By-Pass Fuel From Pressure Regulator (3/16 I.D. X 3/8 O.D. X 9
1/2" Long
Clear Vinyl Tubing)
H. Metered Fuel To Vials (3/16 I1.D. X 3/8 O.D. X 46" Long Clear
Vinyl Tubing)
I. By-Pass Fuel From Solenoid Valve (3/16 I.D. X 3/8 O.D. X 7" Long
Clear
Vinyl Tubing)
J. Drain Fuel (5/16 I.D. X 1/2 0.D. X 14" Long Clear Vinyl Tubing)
K. Injector Return Fuel (5/16 I.D. X 1/2 O.D. X 22" Long Clear Vinyl
Fig. 6-1-121, Test stand hydraulic system Tubing)
L. Fuel From Filter Outlet To Injector Inlet Connector (Stratoflex -213
M.II.P.
04 37 1/2" Length)
M. Fuel From Solenoid To Vial (1/8 X 2 1/4" Long Copper Tubing)
X. Original Plumbing (Omit)

484
 TRUCK SERVICE MANUAL FUEL SYSTEM

CHECK 4 FUEL GAUGE Correction

Cause Install new gauge mounts.
Excessive gauge vibration due to machine vibration Adjust the adjustable damping valve.
carrying through gauge mounts. Fig. 6-1-116.
Hydraulic pulsations being carried into gauge because of With ST1210 or ST768 Master Injector running in the
damping valve not being properly adjusted. test stand adjust the needle valve in gauge line until
Excessive gauge hand vibration due to improper gauge hand flutter is eliminated but gauge hand is
damping in gauge line. responsive to any change in pressure. This adjustment
should be made only with the ST1210 or ST768 Master
Gauge out of calibration Injector and before the machine if calibrated with the
master.
Improper plumbing Check with dead weight tester or a master gauge at 120
psi (827 kPa), which is operating pressure. Adjust dial
CHECK 5 STROKE COUNTER hand with adjusting screw.
Cause Make sure plumbing agrees with Fig. 61121.
Stroke counter improperly set Do not add extra fittings, lines, etc.
Stroke counter engagement faulty Correction
Stroke counter fails to disengage. Counter wheels must be set and locked for correct
Stroke counter gears damaged or worn. number of strokes; the numbers must then be cleared to
CHECK 6 AIR SUPPLY "O" by rotating with thumb screw for at least one
Cause complete revolution.
Shop air pressure of less than 80 psi (552 kPa). Align counter shaft with drive shaft.
Air supply on common line with air actuated equipment See Fig. 6-1-122.
which causes intermittent pressure drop. Increase tension on counter return spring at rear of
CHECK 7 AIR SUPPLY GAUGE panel.
Cause Check visually while holding cover back and correct as
Psi setting does not agree with load test cell reading. required.
Air gauge hangs up at a certain point regardless of Correction
regulated pressure. Supply air pressure of 80 psi (552 kPa) or more.
Air gauge is erratic; does not repeat consistently when Rearrange equipment so that ST790 is on a circuit which
actuated several times at same pressure. has constant air pressure.
Correction
Check both air gauge and load test cell when relationship
between gauge and cell changes by more than 3 psi (21
kPa).
Clean, adjust hand to clear face or replace as necessary.
Check inlet for obstruction, gauge hand for hanging up
and correct or replace as necessary.

485
 TRUCK SERVICE MANUAL FUEL SYSTEM

Check 8 - Air Pressure Regulator Correction

Cause Drain regulator bowl each day by releasing spring loaded
Excessive moisture. valve.
Clean filter by removing bowl, wash in solvent and air
Regulated pressure "creeps." dry.
Remove the top housing, valve seat and valve assembly.
Check 9 - Hydraulic Clamping Inspect the disc and seating surface of valve seat.
Cause Inspect the valve guide and valve guide recess for
Leaks-(hydraulic clamping system). foreign particles. Clean all parts thoroughly.
This may be verified by the following check: While the top housing is removed for the preceding step,
check the diaphragm and slip ring and replace faulty
(1) Clamp the load-cell in the stand. parts.
(2) If after 3 minutes the load-cell reading should
change position by more than 20 lbs [9.07 kg]. Correction
(3) Dry all plumbing connections and watch for
seepage with (See below for specific corrections.)
air valve closed and with it open.
(4) If no external seepage is indicated and the Check for leaks at bleed plug and correct as required.
condition still
persists, one of the following exists. Correct as required.

If 1/32 inch clearance has been affected because of loose set screw or
any other condition, the following steps should be taken to obtain
proper clearance.
1. Loosen set screw so that shaft slides freely in housing.

2. Manually engage clutch by fully depressing solenoid (inside

main housing). With clutch held in this position, the cross pin in the Fig. 6-1-123, F60159. Hydraulic loading cylinder
clutch shaft should be positioned to clear the end of the "U" slot in
clutch driver by approximately 1/32 inch.

3. Tighten set screw against flat on clutch shaft.

4. Check operation, if solenoid is noisy (loud hum or chatter)

recheck Step No. 2.

Fig. 6-1-122, F601060. Position of collar and drive clutch

486
 TRUCK SERVICE MANUAL FUEL SYSTEM

(a) Leakage past the piston sealing rings. (This is Replace sealing rings as required. (See Fig. 6-1-122 for
accompanied with loss of fluid from the reservoir assembly instructions.)
and appearance of oil out the cylinder vent when
the piston is actuated to top travel.) Repair or replace as required.

(b) Hydraulic lock-up valve leaking. (This may be Correction

checked by placing valve in closed position and
applying air pressure. Indicated travel of piston Check the load cell on a valve spring tester at 380 lbs
rod verifies leaking hydraulic lock-up valve.) [172 kg] load. The load cell should read 380 lbs [172 kg]
.
Check 10 - Load Test Cell
Correct the gauge with the recalibration screw on the
Cause gauge face.

Gauge on load cell has become miscalibrated as a result Correction

of mis-handling such as dropping or excessive loading.
Use correct link for injector being calibrated.
Check 11 - Plunger Actuating Link
Align link guide bracket so that it does not contact link at
Cause any point. Inspect link visually and during running of
stand and
Use of wrong injector model link causing hydraulic piston replace if necessary.
return spring to be worked at a height other than that
when checking the load cell. Plunger actuating link Correction
binding on link guide bracket.
Replace O-ring with new one. If an O-ring of a larger
Plunger actuating link distorted or cracked on socket and crosscut diameter is used, the injector may bounce on
causing cocking during operation of stand. the cup seat and thus affect transfer groove and
metering orifice timing. Any bouncing of the injector on
Check 12 - Test Oil Leaks the cup seat must be corrected.

Cause Correct as necessary, remove rear panel.

Cup seat O-ring leaking. (Leak may appear as mist.) Correction

Cup seat block-to-solenoid line (line H in Fig. 6-.1-121) Keep tank 3/4 full of Cummins 99011-68 test oil or Shell
leaking in between tank and front panel. (To check this, Injector Oil No. 66631. Use of oil not meeting these
route line H temporarily in front of panel and operate test specifications or diluted until viscosity or specific gravity
stand.) values are affected will cause improper calibration.

Visual leaks.

Check 13 - Test Oil Condition

Cause

Improper fuel or dilution.

487
 TRUCK SERVICE MANUAL FUEL SYSTEM

Fuel brown in appearance. New oil is clear in appearance and becomes amber
during use, never use when brown,
Dirty fuel.
Based on 8 hours per day, clean filter and change oil
Fuel Aerated. monthly or after 160 hours operation.

Low oil level in tank. It is normal for the drain on flange-type injectors to
appear "milky."
Air not completely expelled from system after filter
change or after having lines disconnected for other The PT (type B) (type C) and PT (type D) drain should
reasons. normally be clear. Fuel in the cup seat block-to-solenoid
line (line H, in Fig. 6-1-121)must always appear clear
Air leak between supply tank and gear pump suction. with all injector models.

(a) Strainer cap loose or cap gasket missing. It must be possible to disconnect the injector inlet lines
immediately after shutting off the test stand without
(b) Air leaks in strainer-to-gear pump section line or at evidence of any compressed air in the system.
connections.
Fill tank to 3/4 or above.
Check 14 - Solenoid Valve
Without breaking fuel line connections, remove the filter
Cause assembly from its mounting bracket. ’With the filter
assembly in inverted position and the test stand running
Solenoid leaking fuel into by-pass line during test cycle. at low pressure, bleed the filter at the drain cock until oil
is free of air.
Improperly installed solenoid valve (incoming fuel line
connected to discharge port and vial line connected to Correct as required.
inlet port) causing excessive restriction on metered fuel.
Correction
Solenoid valve sticks and fails to divert fuel to vials at
instant counter actuating switch is depressed. The 0.035 Check for foreign particles and pitted valve or seat and
inch (.89 mm) orifice below the solenoid is partially clean, repair or replace as necessary.
clogged with foreign particles causing excessive
restriction which expands injector-to-solenoid line (line H, Check identification on solenoid valve inlet port to which
Fig. 6-1-121) while fuel is being by-passed but regains line from injector cup tip must be connected is stamped
normal size and empties excess fuel into vial when test IN. Directly opposite is discharge port which must be
connected to vial line. Correct if necessary.

Clean valve until it operates freely or replace.

Clean as required.

488
 TRUCK SERVICE MANUAL FUEL SYSTEM

Check 1 - Master Injector Correction

This can be substantiated or disproved by calibrating a
Cause set of injectors at 132 cc and engine testing them. If the
fuel rate vs. manifold pressure relationship is not within
Master injector out of calibration. specifications, a miscalibrated master injector is verified.
During this check the utmost accuracy is required in
Check 2 - Test Oil Temperature weighing the fuel and recording the manifold pressure.
The correct camshaft and pistons as listed on the CPL
Cause must be used during this test.
Replace the faulty master with a new master ordered
Test oil at excessively high or low temperature. from the Factory. Clean and correct the faulty master,
and use it in an engine. Never use an injector as a
master after it has been taken apart or changed in any
way.
Correction
Setting up test stand or calibrating injectors while test oil
is at excessively low or excessively high temperatures.
Check test oil temperature indicator against master
thermometer and compensate as necessary for any
existing differential. It may be necessary to connect cold
or hot water lines to heat exchanger at back of tank to
maintain test oil temperature at the required 90 deg. to
95 deg. F [32 to 35 deg. C]. If temperature exceeds 95
deg. F [35 deg. C] increase cold water flow. If
temperature exceeds135 deg. F[57 deg. C] drain and
replace with new test oil.

Check 1 - Restrictor Orifice Threads Correction

Torque resistor orifice into check-valve body at 6 inch-lbs
Cause [.7 N. m].

Leakage around restrictor orifice threads. Correction

Check 2 - Check Valve Body Threads Use gasket (0.030 inch [.76 mm] throttle adjusting shim)
under check-valve body. Torque check-valve body into
Cause cup seat block at 10 to 12 inch-lbs [1.1 to 1.4 N. m}.

Leakage around check-valve body threads.

489
 TRUCK SERVICE MANUAL FUEL SYSTEM

Check 3 - Check Ball Travel Correction

Cause Orifice must be replaced if threads are damaged, Orifice

torque is 6 in-lbs [.7 No ml. Ball travel is 0.020 to 0.030
Loss of ball-travel caused by over-tightening of restrictor inch [.51 to .76 mm] with orifice torqued in position (for
orifice and consequent stripping of orifice threads. assembly diagram refer to Fig. 6-1-84).
Caution: Never try to attain the proper ball travel by
loosening the orifice as this will cause leakage around
the threads and defeat the purpose of the restrictor
orifice and check valve.

Check 1 - Soft Lines Correction

Cause Install lines of material and length shown in Fig. 6-1-121.

Use of filter-to-injector and injector-to-regulator lines Correction

(lines L and E in Fig. 6-1-121 ) which are softer and
more resilient than those supplied with test stand. Replace with standard filter per Fig. 6-1-121.

Check 2 - Filter Can Note: Be sure that filter is installed in correct location in
the circuit.
Cause
Correction
Original filter has been replaced with one which is larger
or has a softer can, such as Cummins throwaway filter. See Causes and Corrections under Check 13 of "Test
Stand will not repeat consistently on any given injector.”
Check 3 - Aerated Fuel

Cause

Aerated fuel.

490
 TRUCK SERVICE MANUAL FUEL SYSTEM

Check 1 - Drain Flow Lines Correction

Cause Replace per line K in Fig. 6-1-121.

Use of a line with less than 5/16 inch [7.95 mm] I.D. or
crimp caused by sharp bend in drain line.

Check 1 - Filter Installation Correction

Cause Install filter.

Removal of the filter assembly from the circuit. Filter assembly must be in specified location as shown.

Installation of the filter assembly in the suction side of the Correction

gear pump.
Filter must be of specified type.
Check 2 - Filter Can
Correction
Cause
With the pressure regulator by-pass line (line G, in Fig.
Installation of a smaller or more rigid than standard filter 6-1-121) completely blocked, check the gear pump
can. against a 0.045 inch [11.1 43 mm] orifice installed in line
L.
Check 3 - Gear Pump The gear pump is acceptable if it delivers 80 to 120 psi
[552 to 827 kPal during this check.
Cause If the gear pump delivers less than 80 psi [552 kPa],
check the fuel strainer for clogging end consequent
Low gear pump delivery. pump suction restriction and clean if necessary; the gear
pump must be replaced.
Check 4 - Cam Eccentricity
Correction
Cause
Check as follows:
Cam base circle eccentricity.
(a) Align timing wheel mark and pointer.

(b) Install ST-790-5111 load cell with regulated air

pressure to give 380 lbs. [172 kg] load. Repeat the
clamping several times to assure that the setting of the
clamping load is correct.

491
 TRUCK SERVICE MANUAL FUEL SYSTEM

PT (type D) Injector Trouble Shooting The following list (c) Close the hydraulic valve while the load cell is
of problems is of importance when trouble shooting PT clamped in position and turn the timing wheel
(type D) injectors: slowly by hand.
(d) If the load cell indicates more than 50 lbs. [22.7
Check 1 - Unable To Get Correct Plunger To Cup kg] increase above the clamping load, the cam
Alignment and/or shaft and/or cam follower must be
replaced.
Cause
Correction
Defective or dirty cup. Test cup spray pattern on ST-668. Clean, inspect and
repair. Assemble with correct tools and procedure.
Improper assembly techniques. Clean and inspect.
Defective plunger. Clean, inspect and repair.
Defective barrel face surfaces. If damaged areas cannot be cleaned up, replace part.
Damaged retainer cup seating shoulder or threads. Check cup to plunger alignment.
Improper interpretation of cup alignment.
Correction
Check 2 - Defective Barrel To Adapter Seal Install new gasket each time barrel is removed from
adapter on 5/16 inch [7.94 mm] type injectors. All 3/8
Cause inch [9.52 mm] type injectors built after January, 1969 do
not require gasket. Lap surface.
Gasket, when required, torn or creased at time of Inspect and replace if interference occurs.
assembly.
Correction
Adapter or barrel face damaged. Inspect and replace with barrel plunger assembly.
Roll pins or spiral pins damaged, preventing barrel and Stake plugs with punch.
gasket from seating properly. Lap surface.

Check 3 - Fuel Leaking Around Retainer Correction

Assemble correctly.
Cause
Barrel cracked.
Leaking barrel plugs.
Defective barrel to cup seal.

Check 4 - Plunger Sticks Or Scuffed

Cause

Cup to plunger misalignment.

492
 TRUCK SERVICE MANUAL FUEL SYSTEM

Check 5 - Loose Or Broken Plunger, Coupling Swage Correction

Joint
Attempt to rotate by hand-replace if defective.
Cause
J and C injector springs could be mixed with PT (type D)
Coupling not swaged deep enough into plunger. springs. PT (type D) springs are 1/16 inch [1.59 mm]
longer, have 0.187 inch [4.75 mm] diameter wire with a
Wrong spring used. slightly larger O.D.

Check 6 - Excessive Link Wear Correction

Cause Mark links when removed.

New link placed in old socket. Part number should be installed in up position.

5/16 inch [7.94 mm] link turned end for end at time of Correction
assembly.
This is normal wear. Unless metal is displaced or wear
Check 7 - Bright Polished Spots At Top And Bottom is measurable, plunger may be reused.
Of Plunger 180 deg. Apart

Cause

Bearing pattern on plunger.

493
 TRUCK SERVICE MANUAL FUEL SYSTEM

FUEL PUMP
PT REBUILDING

TABLE OF CONTENTS

Subject Page

OPERATING PRINCIPLES................................................................................................................ 495

GOVERNORS .................................................................................................................................... 497

REMOVAL OF FUEL PUMP UNIT..................................................................................................... 497

FUEL PUMP FILTER SCREEN ......................................................................................................... 499

FUEL PUMP HOUSING ..................................................................................................................... 499

GOVERNOR BARREL, PLUNGER AND SPRING PACK HOUSING................................................ 500

GOVERNOR PLUNGER .................................................................................................................... 501

AIR FUEL CONTROL......................................................................................................................... 502

TACHOMETER DRIVE - MECHANICAL ........................................................................................... 503

GEAR PUMP AND PULSATION DAMPER ....................................................................................... 504

INTEGRAL TYPE PT FUEL PUMP COOLING .................................................................................. 505

SHUT-DOWN VALVES ...................................................................................................................... 506

FRONT COVER ASSEMBLIES ......................................................................................................... 508

GOVERNOR WEIGHT CARRIER...................................................................................................... 509

DRIVE SHAFT.................................................................................................................................... 509

DRIVE COVER................................................................................................................................... 510

GOVERNOR SPRING PACK............................................................................................................. 512

FUEL PUMP ASSEMBLY................................................................................................................... 512

FUEL PUMP COOLING KIT............................................................................................................... 516

CALIBRATION ................................................................................................................................... 516

TACHOMETER CABLE ..................................................................................................................... 517

INDEX................................................................................................................................................. 518

494
 TRUCK SERVICE MANUAL FUEL SYSTEM

PT Fuel Pump Group The PT fuel system is used exclusively on Cummins

Diesels. The identifying letters, "PT" are an abbreviation
OPERATING PRINCIPLES for "pressure-time."

The operation os the Cummins PT Fuel System is based pump via the main shaft passage and main housing to
on the principle that the volume of liquid flow is gear pump by-pass passage.
proportionate to the fluid pressure, the time allowed to
flow and the size of passage the liquid flows through. To 2. The governor which controls the flow of the fuel from
apply this simple principle to the Cummins PT Fuel the gear pump, as well as the maximum and idle
System, it is necessary to provide: engine speeds.

1. A fuel pump to draw fuel from the supply tank and 3. The throttle which provides a manual control of the
deliver it to individual injectors for each cylinder. Fig. fuel flow to the injectors under all conditions in the
5-1. operating range. The location of the fuel pump
components is indicated in Fig. 5-3.
2. A means of controlling the pressure of the fuel being
delivered by the fuel pump to the injectors so the
individual cylinders will receive the right amount of
fuel for the power required of the engine.

3. Fuel passages of the proper size and type so that

the fuel will be distributed to all injectors and
cylinders with equal pressure under all speed and
load conditions.

4. Injectors to receive low-pressure fuel from the fuel

pump and deliver it into the individual combustion
chambers at the right time, in equal quantity and
proper condition to burn.

Fuel Pump
The fuel pump is coupled to the compressor or fuel Fig. 1, F5295. PT (type G) AFC fuel pump
pump drive which is driven from the engine gear train.
The fuel pump main shaft turns at engine crankshaft
speed on most engines. The main shaft turns about
78% of engine RPM in V555 series engines. The main
shaft drives the gear pump, governor and tachometer
shaft.

PT (type G) Fuel Pump

The PT (type G) fuel pump can be identified by the
absence of the return line at the top of the fuel pump.
The pump assembly is made up of three main units.

1. The gear pump which draws fuel from the supply

tank and forces it through the pump filter screen to
the governor.

NOTE : The fuel pump inlet on V6140, V8185, V504

and V555 series engines may be through a fitting Fig. 3, F5235. PT (type G) fuel pump
into the top of the fuel pump in line with the
tachometer drive. Fuel flows from the main housing
to the gear

495
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 5.1, FWC-33. Fuel flow in PT fuel system

Fig. 5-3, FWC-37. PT (type G) fuel pump cross-section and fuel flow

496
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Gear Pump And Pulsation Damper Governors

The gear pump is driven by the pump main shaft and Idling And High-Speed Mechanical Governor
contains a single set of gears to pick-up and deliver fuel The mechanical governor, sometimes called "automotive
throughout the fuel system. A pulsation damper governor," is actuated by a system of springs and
mounted to the gear pump contains a steel diaphragm weights, and has two functions. First, the governor
which absorbs pulsations and smooths fuel flow through maintains sufficient fuel for idling with the throttle control
the fuel system. in idle position; second, it cuts off fuel to the injectors
From the gear pump, fuel flows through the filter screen above maximum rated rpm. The idle springs in the
and. governor spring pack positions the governor plunger so
In the PT (type G) fuel pump, to the governor the idle fuel port is opened enough to permit passage of
assembly as shown in Fig. 5-3. fuel to maintain engine idle speed.
Currently, PT (type G) gear pumps are equipped with a During operation between idle and maximum speeds,
bleed line (to the engine injector return line or to tank) fuel flows through the governor to the injectors in accord
which prevents excessive fuel temperatures within the with the engine requirements as controlled by the throttle
fuel pump. The bleed line functions primarily when the and limited by the size of the idle spring plunger
pump throttle is set at Idle speed but when gear pump counterbore on PT (type G) fuel pumps. When the
output is high, due to engine rotative speed, as occurs engine reaches governed speed, the governor weights
during down hill operation. A special check valve and/or have moved the governor plunger to close the fuel
fitting is used In the gear pump to accomplish the bleed passages to injectors. At the same time another
action. passage is opened and fuel is dumped back into the
Pressure Valve main pump body. In this manner engine speed is
The pressure valve is used only In PT (type G) VS controlled and limited by the governor regardless of
governor fuel pump. The valve is located near gear throttle position. Fuel leaving the pump flows through the
pump drive shaft. It restricts return fuel coming from shut-down valve, supply lines and cylinder head drillings
governor barrel thereby creating low fuel pressure in into the injectors.
housing.
Removal Of Fuel Pump Units
Throttle Clean And Mount
In both fuel pumps, the throttle provides a means for the 1. Clean outside of fuel pump thoroughly with an
operator to manually control engine speed above Idle as approved solvent. Remove lockwires and seals if used.
required by varying operating conditions of speed and Note: Many solvent cleaners are injurious to aluminum.
load. Make sure your cleaner is suitable before using it on
In the PT (type G) fuel pump, fuel flows through the aluminum.
governor to the throttle shaft. At idle speed, fuel flows 2. Remove pulsation damper from gear pump and
through the idle port in the governor barrel, past the discard "0" ring. Older style dampers are fitting mounted
throttle shaft. To operate above idle speed, fuel flows and are removed by screwing damper from fitting on
through the main governor barrel port to the throttling gear pump,
hole in the throttle shaft. 3. To remove gear pump from main housing, tap sides
of gear pump with a plastic hammer to loosen from
Shut-Down Valve dowel. Remove gear pump discard gasket.
Either a manual or an electric shut-down valve is used on PT (type G) Fuel Pump Service Cooling Kit
Cummins fuel pumps. 1. Remove check valve and orifice elbow assembly
from bottom or back side of fuel pump.
With a manual valve, the control lever must be fully Note: Current pumps have the check valve located at
clockwise or open to permit fuel flow through the valve. the gear pump and older pumps should be changed over
at any time a new gear pump is used.
With the electric valve, the manual control knob must be 2. Clean parts in clean fuel oil and dry with compressed
fully counterclockwise to permit the solenoid to open the air blown through both ends.
valve when the "switch key" is turned on. For emergency
operation in case of electrical failure, turn manual knob Shut-Down Valve, Pulsation Damper And Gear Pump
clockwise to permit fuel to flow through the valve. 1. Remove shut-down valve from top of main housing
and discard "O" ring.

497
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Front Drive Cover And Governor Plunger Governor Spring-Pack Cover

1. To remove drive cover from main housing, tap edge of 1. Remove spring-pack cover from main housing, lift off
cover lightly with a plastic hammer to loosen. Lift cover off cover and discard gasket.
dowels and discard gasket. 2. For disassembly of spring-pack, see Spring-Pack
Note: Never use a steel hammer on aluminum, or on a section.
finished surface, it can cause extensive damage. General
3. Remove weight assist plunger, spring and shims from
weight carrier assembly. Slide governor plunger from Fuel pump sub-assembly repair, cleaning, inspection and
barrel. rebuild instructions are listed in the following sections.
Worn replacement limits are given to help the mechanic
Caution: Place plunger where it will not be damaged, a decide when to replace parts or to use parts that have
slight nick can cause extensive damage. many hours or miles of useful life.
However, parts that are worn beyond replacement limits
Throttle Assembly - Drive Screw Cover Plate Type must not be re-used.
1. Remove snap ring from inside housing. Remove drive
screws securing cover plate. Pull throttle assembly from Cleaning
housing. Remove "O" ring and discard. A clean shop, clean tools and good cleaning practices are
essential to good quality fuel pump repair. Special care
Filter Screen must be taken when cleaning aluminum alloy parts since
1. Screw off screen cover on top of main housing. Lift some cleaning solvents will attack and corrode aluminum.
cap, spring and filter screen assembly from main housing; However, cleaning time is always well spent. Most fuel
discard "O" ring. pump failures occur because of dirt. Clean all parts before
rebuild or assembly.
Tachometer Drive
1. Remove tachometer drive cover screws. Inspection
2. Lift drive cover from main housing or front cover. Time spent on inspection is profitable. It can save many
Discard gaskets, when used. dollars worth of parts and also prevent failure of the rebuilt
3. Carefully drive tachometer drive assembly from pump, pump.
using a brass punch and hammer or use ST-667-10 collet Too often inspection is performed too lightly or not
with ST-667 Dowel Puller or use ST-1326 to pull performed at all. Proper tools are essential to do a
tachometer seal, shaft and bushing. Fig. 5-15. satisfactory job of inspection.
4. Remove oil seal and dust seal, when used, from shaft
and discard. Tools
Using proper tools has many advantages. The fuel pump
Throttle Assembly-Retaining Ring Type consists of several aluminum parts, which makes it light;
Compress throttle plate retaining ring and remove from but the parts may be easily damaged if the right tool is not
groove. Pull throttle assembly from pump. The throttle used to perform the job being done.
shaft is a select fit in its sleeve and sizes are identified by Note: Aluminum parts must be handled carefully.
color code.
Service tools may be purchased from your Cummins
Note: Handle throttle shaft with care. Distributor if you perform your own rebuild work.
An arbor press should be used for all pressing operations to
control pressure and alignment. Always make sure that the
part is properly supported when pressing in another part,
the parts can easily be damaged beyond repair if not
properly supported.

Pressing Lubricant

A high pressure lubricant should be used on mating

surfaces In all pressing or driving operations. The lubricant
prevents galling or scoring during assembly. Be sure to
remove all burrs from mating parts before pressing
Fig. 5-15, F5300. Removing tachometer drive assembly together.
with ST- 1326

498
 TRUCK SERVICE MANUAL
FUEL SYSTEM
Capscrews And Washers Filter Screen Optional Replacements
Capscrews used in connecting a part to aluminum
should have an engaging thread length two times the Two new fuel filter screens, both with a 40 micron mesh
diameter. Observance of this rule will prevent stripping rating, are available for use in the PT fuel pumps. Filter
threads with a capscrew that is too short or breaking a screen, Part No. 200004, is used to replace screen, Part
part from using a capscrew that is too long. No. 146483, when additional protection is desired in
single screen type fuel pumps.
Lockwashers must never be used next to aluminum.
Always use a flat washer between the lockwasher and Use of the new screen also provides a good check on
aluminum part. the primary fuel filter to see If the filter is performing its
proper filtration functions. Tests with a good primary
FUEL PUMP FILTER SCREEN filter indicated the 200004 Screen should be cleaned at
Cummins engines are equipped with single or double 50,000 mile or 1600 hour intervals. However, when a
fuel screens, located in fuel pump housing. questionable primary filter was used, the screen cleaning
periods had to be moved up to much closer intervals to
Disassembly And Inspection prevent clogging.
Two types of screens are used on PT Fuel Pumps.
FUEL PUMP HOUSING
1. The standard automotive screen assembly mounts in
top of fuel pump housing. Fig. 5-16. The fuel pump housing is the largest part of the fuel
pump and contains the governor barrel, throttle shaft
a. Remove upper retainer, the top retainer contains a
magnet to pick up any iron particles that may have The drive shaft bushing, throttle sleeve, governor barrel
entered the fuel pump. Some screens are one piece. and spring pack housing still remain in the fuel pump
b. The lower retainer and screen has hole In center to main housing.
permit fuel flow.
c. Clean retainer in fuel oil and blow dry with The drive shaft bushing and governor barrel can be
compressed air. Visually inspect retainer and magnet for removed if damaged. The throttle sleeve was honed to
damage or excessive wear. size after assembly to the housing, and due to the close
d. Proper cleaning of the filter screens can best be tolerances must be returned to a Cummins Distributor for
accomplished by soaking In a carbon-dissolving agent, repair or replacement. Exchange housings are available
followed by flushing in a sonic cleaner unit, or clean the to reduce downtime to a minimum, as this is a
screen and retainer portion in fuel oil and dry with specialized repair and only performed by Factory Repair
compressed air. Stations.
e. Visually Inspect screen for holes or imbedded metal
particles in mesh. Drive Shaft Bushing
f. Discard damaged or worn parts and replace with
new parts. 1. Check drive shaft bushing for sign of seizure or
burrs.
2. Check drive shaft bushing 1.D. with inside
micrometers; If worn beyond 0.7525 Inch [19.11 mm]
replace bushing.
3. Remove worn bushing using a gouge chisel or half
Inch pipe tap, After tapping bushing, screw a half inch
pipe cap on a close nipple and screw the half inch nipple
into the bushing. Insert a punch through the rear of the
housing and drive out the bushing.
4. Apply a thin coat of high pressure lubricant to a new
front drive shaft bushing; press bushing into housing
flush with housing bore using an arbor press.
Fig. 5-16, F5183. Fuel filter screens 5. Line ream bushing to 0.7495 to 0.7505 inch [19.04 to
19.06 mm] with ST-490 Ream Fixture, and a well oiled
0.750 inch (3/4 inch [19.05 mm] ) reamer, Fig. 5-17.
Check bushing I.D.

499
 TRUCK SERVICE MANAUL
FUEL SYSTEM

Note: Check through plug hole In bottom of PT (type G)

pump for spring dowel which secures barrel In fuel
pumps built after May 1963, before attempting to remove
governor barrel. Sometimes a wire hook, Inserted into
the hole provided, will pull the spring dowel. Fig. 5-18.

2. Check barrel bore in housing to determine whether

standard (1.5020 to 1 5025 inch [38.15 to 38 16 mm]
O.D.) barrel, 0.010 inch [0.25 mm] or 0.020 Inch [0.51
mm] oversize must be used. Minimum 0002 inch [0.05
mm] interference fit is required. Check bore for score
marks, remove If found.

Fig. 5-17, F514. Reaming drive shaft bushing with ST- Assembly And Fitting
490 1. To locate a new governor barrel in the housing,
scribe a center line on barrel and housing, lining up the
Governor Barrel, Plunger And Spring Pack Housing fuel passages so fuel flow will not be restricted. Fig. 5.19
and 5-20.
Inspection

1. Check governor barrel and plunger visually for wear.

2. If worn, replace governor plunger with a new plunger

of same class size as etched on face of governor barrel

Note: Due to hardness of governor barrel sleeve, it

wears very little. If worn excessively or if plunger shows
signs of scoring, barrel should be replaced.

Standard Governor Barrel Replacement

1. If governor barrel is worn or shows signs of scoring,

it will be necessary to heat housing in oven to 30° deg. F Fig. 5-19, F516. Scribe center line on governor barrel
[149 deg. C) and press out governor barrel. Heat will
expand the aluminum housing and permit the steel barrel
to be pressed out with less chance of damaging housing
bore.

Fig. 5-20, F5136. Scribe center line on fuel pump

housing

2. Heat housing in oven to 300 deg. F [149 deg C].

Fig. 5-18, F5135. Removing locking pin from bottom of
barrel
3. Coat new governor barrel with high pressure
lubricant. Drop spring pack housing In place.

500
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Table 5-1: Current PT (type G) Governor Plungers

Note: The chamfer on small diameter of thrust washer is
Code Red provided as a relief for fillets of plunger driver.
Size 0

Part No. 182530 4. If It is necessary to remove stop sleeve, press stop

sleeve off shaft.
4. Place governor barrel In housing bore with
chamfered end first and location pin hole on bottom side, Assembly
lining up scribe marks, then press barrel In housing with 1. If stop sleeve was removed, press stop sleeve on
arbor press until It bottoms against spring pack housing. plunger with notched end going on plunger first (notches
This is Important to align barrel retaining pin holes. toward governor barrel).
5. Select a new Class 2 (green color code) plunger and 2. Assemble plunger driver through thrust washer and
attempt to fit it in barrel, if plunger enters, try a Class 3 drive into plunger. Driver must have interference fit In
(yellow). Keep trying larger sizes until one will not enter plunger.
barrel, then select plunger two sizes smaller than last
plunger which did enter for use. Plunger must drop into Note: The plunger has a lubrite finish. Protect it by
bore of its own weight. Remark governor barrel with laying the plunger on a copper jawed vise or V-block to
class size of plunger used. See Tables 51 or 52 for prevent damage to the finish when installing pin.
class sizes and color codes. 3. Drive retainer pin through the plunger and plunger
6. Install spring dowel into bottom of barrel with ST-853 driver.
driver with slot of pin to front of housing.
Note: The chamfered side of thrust washer must be
installed next to driver. There must be at least 0.002 to
0.005 inch [0.05 to 0.13 mm] clearance between washer
face and driver so washer will ’float."

4. Install torque spring and shims as required, put the

small end of the spring on the shoulder end of the
plunger with a twisting motion to avoid distorting the
spring.
5. If torque spring is replaced with new one, select from
specification sheets pertinent to the fuel pump being
rebuilt, see fuel pump calibration data In Bulletin No.
3379068, 3379077 or 983533, "PT (type G) Fuel Pump
Calibration," and Table 53 following.
Fig, 5-23, F5139. Removing torque spring 6. One type of plunger failure is caused by excessive
Governor Plunger heat from contact of the stop collar and sleeve during
long periods of overspeeding. Plunger stop collars
1. If necessary, remove torque spring (torque spring machined from glass filled teflon eliminate this type of
used on PT (type G) governor plungers only) by twisting failure.
spring off shoulder. Do not use a straight pull which will
stretch spring beyond its elastic limit so it has to be Because of the large outside diameter of the teflon stop
replaced. Fig. 5-23. collar it is Impossible to use a torque control spring if it is
2. If governor plunger outside diameter is worn, replace required, therefore, the teflon stop collar is to be used
with new plunger of same class size as etched on barrel only In PTG. fuel pumps that do not require a torque
face. See "Governor Barrel and Plunger" control
3. If only thrust washer is worn, drive retainer pin from
plunger and pull governor plunger drive from plunger.

Table 5-3: Torque Springs and Specifications

Part Color Wire Dia. Number Pounds Inches [mm] Free Length
Number Code Inches [mm] Coils Load [kg] @ Length Inches [mm]
138782 Red/Blue .047 [1.19] 5.2 5.40/5.76 [2.5/2.6] @ .340 [8.64J .640/.660 [16.26/16.76]

501
 TRUCK SERVICE MANUAL
FUEL SYSTEM

spring. Use thrust washer, Part No. 188713, with teflon

stop collar, Part No. 188714.
Air Fuel Control
Fuel pumps with Air Fuel Control (AFC) must be
mounted to Swivel Vise, ST-302, with front cover
Mounting Plate, No. 3375133. Fig. 5-10.
Disassembly
1. Remove AFC cover plate. Fig. 5-24.
2. Carefully lift bellows away from sealing surface
around AFC cavity and pull bellows, piston and plunger
assembly from AFC barrel. Fig. 5-25.
3. Remove AFC bellows spring and steel shim between
spring and fuel pump housing. Fig. 5-26.
4. Remove AFC barrel retaining ring. Fig. 5-27.
5. Remove AFC barrel, discard barrel "O" rings.
6. Remove plunger jam nut and unscrew plunger from
center bolt. Fig. 5-24, F5301. Removing AFC side cover plate
7. Remove center bolt jam nut, washer, and gasket;
remove bellows from piston. Fig. 5-9.
8. Slide "Glyd" ring and "O" ring seal assembly from the
AFC throttle plunger.
AFC Assembly Installation
1. Lubricate barrel "O" rings and Install in grooves in
barrel, press barrel Into housing and secure with snap
ring.
Note: Lightly coat all "O" rings with a 50-50 mixture of a
lubricating oil additive (such as STP) and clean
lubricating oil just before installation. Fig. 5-27.
2. Place steel shim in bellows spring seat groove.
3. Install spring with small end in housing. Fig. 5-26.
4. Lubricate "O" ring and install over throttle plunger
using installation tool No. 3375146 then install "Glyd"
ring over tool and plunger on top of "O" ring. Install
plunger assembly in seal-ring forming tool No. 3375147,
leave in tool and complete Steps 5 through 7. Fig. 5-25, F5302. Removing AFC bellows and piston
5. Assemble center bolt, gasket, washer (rounded edge assembly
toward bellows), bellows (with part number toward
piston), piston, washer and jam nut.
6. Hold assembly by hex on center bolt and center
bellows piston and washers, without twisting bellows
tighten jam nut to 30 to 40 in-lbs [3.4 to 4.5 N•m] torque.
Make sure parts are centered.
7. Wrap plunger threads with teflon tape and screw
plunger into center bolt until threaded end of plunger is
flush with center bolt surface. Install jam nut, leave
loose.

Fig. 5-26, F5303. Removing AFC bellows spring and

washer

502
 TRUCK SERVICE MANUAL
FUEL SYSTEM

1. Remove felt seal, when used, and oil seal from

tachometer drive shaft.

2. Press tachometer drive shaft from drive gear and

bushing, if the gear is badly worn or shaft and bushing
are galling or scoring. Check shaft outside diameter and
bushing inside diameter. Replace if necessary. Table 5-
4.

Assembly

Place bushing on tachometer shaft with chamfered end

Fig. 5-27, F5304. Removing AFC barrel retaining ring. of bushing toward gear end. Press gear onto shaft until
flush
8. Slide plunger and piston/bellows assembly from tool
and into barrel. Insert very carefully to avoid damage to
the "Glyd" ring. Fig. 5-25.

Caution: Make sure plunger and "Glyd" ring

assembly have been in forming tool for a minimum
of thirty minutes to establish a contoured form.

9. Cup bellows downward between piston and housing

to insure bellows does not wrinkle when cover is
installed.

10. Line up bellows holes with housing and cover plate

holes, install capscrews and washers. Capscrews are to
be tightened to 30 to 35 in-lbs [3.4 to 4.0 N•m] torque
after setting AFC on test stand. Fig. 5-24.

11. Install lubricated "O" ring on needle valve using

assembly tool No. 3375148 and screw into housing Fig. 5-29, F537. Pressing tachometer gear on shaft
above throttle shaft until it bottoms in housing; install jam
nut loosely until set on test stand. Table 5-4: Tachometer Drive Parts Specifications
Part Description In. [mm]
Front Cover
Mounted
Tachometer Shaft .3950/.3955 [10.033/10.046]
Shaft Bushing .3963/.3970 [10.066/10.084]
Housing Mounted
Tachometer Shaft .3100/.3105 [7.874/7.887]
Shaft Bushing .3120/.3130 [7.925/7.950]

with end of shaft. Fig. 5-29. Check to see that shaft

turns freely in bushing. Maximum clearance between
gear and bushing is 0.005 Inch [0.127 mm].
Fig. 5-28, F5214. Tachometer drive parts in housing
Note: Check gear to make sure it matches with
Tachometer Drive - Mechanical tachometer drive gear. Fig. 5-30.

Disassembly

503
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 5-31, F5141. Gear pump with integral cooling

Cleaning And Inspection

Fig. 5-30, F5140. Tachometer and matching drive gears 1. Check pump shafts for wear or scoring, discard if
damaged. Replace shaft If worn smaller than 0.4998 to
0.5001 inch [12.695 to 12.703 mm] diameter.
Right Hand And Left Hand Rotation Housings
2. Check gear width. See Table 5-5. If gears are
Do not use a right hand rotation fuel pump housing with a
scored or worn badly, the gears must be replaced.
left hand rotation gear pump. The fuel passage from the
gear pump to the fuel filter is located up and to the right
3. Check gear body and cover for scoring or wear,
of the main shaft in a right hand rotation housing.
replace parts as needed. Check gear pocket depth. See
(Looking at gear pump end of housing.)
Table 5-5. Fig. 5-32.
The fuel passage is located up and to the left of the main
4. Shaft bore in cover and body should be 0 5013 to
shaft In a left hand rotation housing.
0.5016 Inch [12.733 to 12.740 mm] I.D. In 3/4 inch
[19.05 mm] current cast Iron bearing gear pumps. If
GEAR PUMP AND PULSATION DAMPER
gears are removed from shaft, press
The gear pump draws fuel from the tank through a filter
and supplies the fuel to the fuel pump. Fuel at a given
pressure is then routed to the injectors. Table 5-5: Gear Width And Pocket Depth - Fig. 5-32.
Pump Size Gear Width Gear Pocket
Gear Pump Inch [mm] Inch [mm] Depth In. [mm]
PT (type G) fuel pumps currently have gear pumps with 3/4 0.7483/0.7486 0.7478/0.7483
hollow idle shafts and the gear pump cover is drilled for [19.05} [19.006/19.014] [18.994/19.006]
cooling as described under "Gear Pump"

Note: Special C.I.T.E. fuel gear pumps will have the BM

or AR number stamped on the side of the gear pump.

Caution: Engines with integral cooling gear pumps

(Fig. 5-31) must not be run with the fuel bleed hole
plugged.
Disassembly
1. Remove capscrews securing gear cover to gear
body.

2. Drive against dowels with flat end punch to remove

gear over from dowels In gear body. Discard gasket
Fig. 5-32, F523. Gear pump pocket depth
3. Lift drive and driven gears and shafts from gear
pump body.
504
 TRUCK SERVICE MANUAL
FUEL SYSTEM

gears on shaft 0.680 to 0.690 Inch [17.27 to 17.53 mm] check for error in assembly which must be corrected to
from body end of shaft. Oil shaft before assembly. prevent early pump failure.

5. Check lubrication holes in cover and body; they must 5. If cooling feature is used, install elbow and/or check
be clean. valve. If 1/8 inch [3.17 mm] pipe plugs is used, torque to
10 to 13 foot pounds [14 to 18 No m].
6. Clean cooling kit components, if used, and dry with
compressed air. Integral Type PT (type G) Fuel Pump Cooling
The small amount of fuel which is routed back to fuel
Assembly 1. Lubricate and slide shafts and gears into tank, previously was recirculated internally, Therefore,
cover. Make sure parts are clean. this method of cooling does not use any of normal
delivery of gear pump and present fuel pump calibration
2. Position new gasket and install body to cover. Align specifications will still apply.
locating notches together. Fig. 5-33.
This bleed fuel is that fuel which flows through and
lubricates gear pump bearing bores. Previously, this fuel
was dumped back into suction side of gear pump. With
integral bleed gear pump, the lubricating fuel flow through
three gear pump bearings is bled off through an external
tapped drain hole. The former internal pump drillings
which permitted this fuel to return to the suction side,
have been eliminated. Fig. 5-34.

Fig. 5-33, F524. Locating notches for right hand pump.

Note: Location of notches and drive shaft determines
pump rotation.
1. TO INJECTOR DRAIN LINE OR FUEL TANK
2.TO FUEL PUMP HOUSING
3. When a right hand rotation pump is being assembled,
Fig. 5-34, F5157. Gear pump fuel flow
place the driven gear shaft of the gear pump in the
pocket nearest the locating notches. Place the driving
The inboard main shaft bearing bore still returns its fuel
gear shaft in the other pocket. The ring dowel is always
to the gear pump suction. The inboard idler shaft bearing
located around drive shaft.
fuel flows through the hollow idler shaft to the external
4. Secure cover and body with dowels, tighten
drain line. As can be seen from the sketch, both
capscrews to 11 to 13 foot pounds [15 to 18 N. m].
outboard gear pump bearings drain externally.
Check to see that pump turns freely with finger pressure.
Note: Total gear backlash must be 0.001 to 0.004 inch
Since three of the bearing bores drain externally, it is
[0.025 to 0.102 mm] The drive shaft must protrude 2.370
apparent that both tapped holes in the gear pump
to 2.412 inch [60.2 to 61.3 mm] from the body. End
housing cannot be plugged. Plugging both tapped
clearance should not exceed 0.0015 inch [0.0377 mm]
openings will prevent lubricating and cooling fuel flow
nor be less than 0.0009 inch [0.0228 mm]. Gaskets are
through the three bearing bores and gear pump seizure
available in .0020 inch [.051 mm] (red) and .0015 inch
will occur.
[.038 mm] (purple). If pump binds or has excessive play,

505
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Both ends of through drain drillings are tapped so that SHUT-DOWN VALVES
gear pumps can be converted from R.H. to L.H. In
normal manner. The shut-down valve, electric or manually operated,
Caution: Under no circumstances should the pump controls flow of fuel from the pump to the injectors. The
be operated with cooling return flow plugged. This electric valve is equipped with a knob which will open the
fuel flow is necessary to lubricate the bearing valve. In case of electrical power failure, keep in
surfaces within the gear pump. counterclockwise position to operate electrically.
1. Fuel pumps with the integral cooling feature may be
identified by a 1/8 inch N.P.T.F. hole In top of gear Electric Shut-Down Valve
pump. The electric shut-down valve is held open while current is
2. Install elbow-check valve, Part No. 175836, in 1/8 flowing through the electric coil, or solenoid. When
inch drain hole in gear pump. A 1/8 inch N.P.T.F. brass current is not flowing, valve will shut unless the shut-
street elbow and a check valve, Part No. 179037, may down valve is locked open manually.
be used as a substitute for valve combination. Disassembly
Note: The spring-loaded check valve is necessary to Remove coil housing from valve housing. Remove coil
prevent fuel in pump from draining away and causing housing, fuel shield and discard "O" ring. Remove spring
hard starting. washer and plate-type valve. Remove manual override
Pulsation Damper knob, and unscrew override shaft from coil end. Discard
shaft and "O" ring. See Fig. 5-37.
Disassembly And Inspection
1. Remove housing from cover. Remove spring steel
diaphragm. Discard "O" rings and nylon washer.

Note: Diaphragm must be kept clean prior to assembly.

1 CONNECTION 6 ’0’ RING

2 KNOB 7 VALVE
3 SEALING RING 8 SPRING
4 HOUSING 9 SHIELD
5 SHAFT 10 COIL
1 SEAL 5 ’0’ RING
2 BODY 6 NYLON WASHER Fig. 5-37, F5143. Electric shut-down valve - exploded
3 ’O’ RING 7 PLATE
view
4 DIAPHRAGM
Fig. 5-36, F5132. Pulsation damper - exploded view Cleaning And Inspection
1. Clean all parts except the coil assembly in mineral
spirits.
2. Check for corrosion, excessive wear or cracks In
cover or diaphragm. Replace if necessary. Fig. 5-36. Note: Do not wet the coil with solvent; instead, wipe it
clean with a lint free cloth.
2. Visually check valve and valve seat for wear, bonding
Assembly
failure or corrosion. Replace if necessary. Valve seat
1. Install new "0" rings In grooves and new nylon
should have a minimum seat 0.015 inch [0.38 mm] wide.
washer.
Fig. 5-38.
2. Coat the diaphragm with a good grade of 10W or
3. Check coil assembly with an Ohm meter, replace if
20W oil and lay in cover.
below values given in Table 5-6.
3. Assemble cover to housing, torque capscrews to 11 to
13 foot pounds [15 to 18 No m]. Caution: Be sure starting switch is in off position
when checking coil.

506
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 5-38, F528. Inspecting plate type valve

Fig. 5-40, F530, Checking shaft tip depth
Table 5-6: Coil Resistances
Coil 4. Apply lubricant to housing "O" ring and seat in groove.
Coil Voltage Resistance
5. Drop spring washer on valve with concave side up
Part No. And Type (Ohms)
and piloted around valve locator. Fig. 5-41.
134072 12 V.D.C. Single Terminal 7.5 ± 0.5
6. Place fuel shield on valve housing and tighten screws
to 25 to 30 inch pound [2.8 to 3.4 N- ml torque.
Assembly 7. Energize valve and pump fluid through valve at 300
1. Install a new "O" ring on new override shaft and coat with psi [2068 kPa]. De-energize valve and valve should
lubricant. Fig. 5-39. withstand the 300 psi [2068 kPa] load with no leakage
2. Screw shaft into housing until it reaches bottom of its through valve.
bore. Use depth micrometer set at 0.118 Inch [2.997 mm] 8. Should leakage exist, check the main body for nicks
and check distance from face of valve housing to tip or depressions where body and plate come in contact.
Check the rubber seal in the plate for swelling or other
defects.

Fig. 5-39, F529. Installing override shaft

of shaft. If necessary, screw shaft out until it is 0.118 inch Fig. 5-41, F531. Assembling shut-down valve
[2.997 mm] below housing face. Do not move shaft and
press on knob until it contacts valve housing which will act High Pressure Fuel Shut-Down Valve
as a stop. Fig. 5-40. Some applications and/or approval tests require that
3. Place valve into valve housing with rubber side toward, rapid successive engine starts be made. Starts are
housing. attempted as soon as the flywheel stops. Rapid starting
in this manner places an overload on the solenoid valve,
since it must open against pressure that has not
dissipated from the previous operating cycle. Fire engine
applications are an example of this requirement.

507
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Kit, Part No. AR-05592, enables valve to operate against

the higher fuel pressure plus the spring load. Disassembly And Inspection Of Standard Cover
The orifice disc, with the center hole, restricts the fuel 1. Check governor weight carrier shaft in Its bushing
pressure loading on the spring loaded disc. This allows before removal. Excessive wear can be felt by moving
the spring loaded disc to operate like the standard disc shaft from side to side in the bushing.
without the fuel pressure effect. 2. Observe gear backlash between weight shaft gear
The high pressure valve will be valuable In applications and
having shut-down controls where immediate starts are
required after a control has broken the electrical circuit.
The engine may be started with this kit as soon as the
operator desires.
Arrangement of AR-05592 kit in the shut-off valve is
shown in Fig. 5-44.

Fig. 5-47, F538. Using ST-709 to pull governor weight

assembly
drive gear. Normal backlash is 0.005 to 0.009 Inch [0.13
to 0.23 mm] .
Note: Remove weight assist plunger If not previously
removed.
3. To remove governor weight carrier assembly from
drive cover use ST-709 Puller to pull weight shaft
1 HOUSING ASSEMBLY 5 S607 LOCKWASHER 8 129768 SPRING assembly and bushing from front cover. Fig. 5-47. The
2 19888 ”O” RING 4 RED 9 196056 DISC, ORIFICE
3 OIL ASSEMBLY 6 19605 5 SPACER 10 19605117 DISC PILOTING
bushing is locked on shaft with a snap ring and will
4 S1215 CAPSCREWS 7 129839FUELSHIELD usually come out of cover with weight shaft assembly,
(10-24X3/4)4 - REQD.
however, if snap ring pulls off shaft leaving bushing In
Fig. 5-44, F5232. High pressure fuel shut-down valve
front cover, use an internal engaging puller of ST-709 to
Assembly
pull bushing. If shaft pulls off of cast carrer, use ST-667
1. Remove solenoid from valve body. Discard standard
to remove shaft and bushing.
disc in valve body. Retain wave spring and stainless
4. Remove fuel pump drive coupling retainer capscrew
steel plate.
and washers. If cover contains tachonmeter drive, pull
2. Place spacer block on valve body with "O" ring groove
coupling with ST-709 puller or pull spline drive coupling
toward solenoid. Make sure "O" rings are in grooves In
with ST-1249.
valve body and spacer block.
5. If cover contains tachometer shaft, remove drive
3. Insert orifice disc, with hole In center, in valve body.
cover retaining screw and lift off drive cover.
Insert piloting disc, with no center hole, In spacer block.
6. Use ST-667 dowel puller or brass punch to remove
4. Place wave spring on raised portion of top disc fuel
tachometer shaft, seal and bushing from front cover;
shield. Place stainless steel plate on wave spring and
discard seal.
attach solenoid with 10-24 x 3/4 Inch [19 mm] screws
7. Remove large snap ring from. pump end of drive
supplied.
shaft between drive cover and drive gear with hose
Front Cover Assemblies clamp pliers or grind a small groove in a pair of needle
Front cover assemblies consist of the cover, main shaft nose pliers. Fig. 5-48.
and bearing, and the governor weight carrier assembly. 8. If cover does not contain tachometer drive, Install a
Most front covers built after Jan. 1975 will contain the longer capscrew In place of drive coupling retainer
tachometer drive. The cover may be flange mounted to capscrew, press on capscrew to remove drive shaft
the compressor or fuel pump drive, or the pump bracket bearing and shaft assembly from front cover. Fig. 5-49.
mounted to the engine. 9. Press drive shaft oil seals from drive cover.
508
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 5-48, F539. Removing snap ring from groove

Fig. 5-50, F5285. Removing gear from weight carrier
with ST-1231

3: Slip governor carrier bushing on the carrier shaft with

flanged end of bushing next to gear and secure bushing
withsnap ring.

Drive Shaft
Disassembly

1. Press gear pump drive coupling or tachometer drive

gear, when used, and governor drive gear from drive
shaft. Fig. 5-52.
2. Remove front cover tachometer drive gear with small
gear puller, remove key.
Fig. 5-49, F5144. Press drive gear assembly from front
cover Note: Press away from bearing because shaft has a
shoulder under bearing.
10. Governor assembly can be disassembled to change
gear and bushing. The governor qarrier, weights and
shaft can only be replaced as an assembly. If bushing is
worn larcer than 0.504 onlych [1280 mm],be replace
bushing.
Governor Weight Carrier
Welded and cast governor weight carrier assemblies
must be purchased as a complete unit. These pins
cannot be replaced.
1. If cast carrier shaft has pulled off in removal from
cover, press shaft into carrier until end of shaft is flush to
0.005 inch [0.13 mm] below carrier surface (weight side).
Note: Do .not reuse parts unless there is a minimum of
0.0005 Inch [0.013 mm] interference fit between shaft
and carrier.
2. If removed, press on gear Do not press against carrier
as it may be damaged. Press against inside end of the Fig. 5-52, F5146. Press shaft from gears
carrier
shaft, If possible. The rough edge of gear goes toward
carrier weight.

509
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 5-53, F541. Pressing drive bearing on shaft Fig. 5-55, F543, Installing drive cover oil seal

3. Press drive bearing from shaft only If bearing is rough Note: Check gear to make sure it matches with
or shaft has worn grooves. tachometer gear to give proper rotation. Fig. 5-30.
Assembly 4. Check to see if parts are firmly seated. Insert snap
ring between ball bearing and governor drive gear.
1. If bearing or shaft is replaced, lubricate shaft with high
pressure lubricant and press bearing over shaft, pressing Drive Cover Assembly Of Standard Cover and Cover
against Inner race of bearing. Fig. 5-53. With Tachometer Drive
2. Press governor drive gear to drive shaft bearing over 1. Clean all parts thoroughly with mineral spirits or
shaft. equivalent.
3. Lubricate shaft and bore before pressing gear pump 2. Press first oil seal into drive cover with lip toward
drive coupling or rear tachometer drive gear, when used, outside of pump, and press second oil seal into drive
on shaft; press against governor drive gear. Fig. 5-54. cover with sealing lip toward inside of fuel pump. Seals
must be spaced so the "telltale" hole is not covered, Fig.
555.
Note: Field installation of front cover tachometer drive
fuel pumps to engines not previously equipped, may
require air compressor modifications 011 must be
allowed to splash from the air compressor housing into
the fuel pump front cover cavity to lubricate the tach drive
gears. If an oil seal is used on the fuel pump side of the
compressor drive shaft, the seal must be removed, and
any oil drain holes plugged prior to fuel pump
installation. If interference exists between Cummins
single cylinder compressor air outlet plumbing and
the tachometer cable, use an air compressor head with
offset air outlet port.

3. Lubricate ST-419 Assembly Tool and install tool over

Fig. 5-54, F542. Pressing tachometer gear on shaft main shaft. Place snap ring between drive gear and
bearing. Press main shaft assembly into front cover and
through seals. Secure snap ring in cover groove. Fig, 5-
57.

510
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Fig. 5-57, F544. Securing snap ring in groove

4. Line up oil groove in top of tachometer drive bushing Fig. 5-58, F5305. Installing weight assist plunger in cast
with fuel pump drive shaft. Press bushing, shaft and weight carrier.
gear
assembly into cover until bushing bottoms.
5. Install spacer on top of bushing with slotted edge
down. Install new oil seal, with spring side down. Spacer
must bottom on bushing.

Caution: Do not overpress spacer. It can be

flattened eliminating its effectiveness.
6. Cover top of seal with a thin coat of lubricating oil.
Secure tachometer housing to cover.
7. ’Install key, press coupling and front tachometer drive
gear into position on drive shaft. Press slow and straight.
Be certain tachometer gear teeth are aligned. Fig. 5-67, F546. Measuring assist plunger protrusion
8. Install coupling retainer flatwasher, lockwasher and
capscrew to shaft and tighten in place. Hold coupling or CHECKING PROTRUSION WITH DEPTH MIKE
main shaft in a copper-jawed vise while tightening. 1. Place one leg of the depth mike base of pedestal
9. Coat governor-carrier bushing with high pressure across the carrier walls and measure down to the front
lubricant and press welded carrier assembly into front cover gasket surface (no gasket). Fig. 5-67. Move the
cover with ST-1231. Press cast carrier assembly into depth mike to the opposite side of the carrier and again
front cover using a driver contacting carrier and shaft measure to the front cover gasket surface directly across
between weights. Mesh gears to avoid gear tooth the cover from the previous measurement (do not turn
damage. The bushing must seat against housing. carrier or cover). Average these two measurements.
Rotate weight assembly, with weights opened out, to be This procedure is necessary to eliminate any possible
sure it will turn completely in housing. influence of uneven carrier wall heights.
10. Install shims, when required, spring and governor 2. Position the depth mike across the carrier directly
assist plunger between governor weights and into bore of over the weight assist plunger. Measure down to the
governor weight carrier shaft. Fig. 5-58. plunger. Do not depress spring.
Note: Always check and assemble weight assist plunger 3. Subtract "Step 2" from the average determined under
with smallest end of plunger to weights. This will prevent "Step 1". The result is the weight assist protrusion. If
weights from sticking. Governor assist plunger is used weight assist protrusion is below specifications, (see Fuel
only on PT (type G) fuel pumps. Pump Calibration Data) add shims. If the weight assist
11. Use enough shims back of spring to make governor protrusion is above specifications, remove shims or grind
assist plunger protrude above gasket face of front cover. the exposed end of the weight plunger (grind only if no
Gauge protrusion with a dial depth gauge having a base shims are being used).
approximately 4 inches long or use ST-1120 or ST-1241.
Note: Refer to calibration data for weight assist
protrusion pertinent to pump being rebuilt.

511
 TRUCK SERVICE MANUAL
FUEL SYSTEM

GOVERNOR SPRING PACK

The governor spring pack consists of the idle and
maximum or high-speed springs, plungers, adjusting
screw and shims. The springs control engine speed and
adjustments are made by the shims or adjusting screw.
Fig. 5-68

Standard Automotive Spring Pack

Disassembly

1. Remove snap ring which holds governor spring pack

in sleeve with a pair of snap ring pliers.

Fig. 5-70, F510. Removing standard spring pack

assembly
2. Remove high-speed spring, spring retainer and shims
from spring-pack housing.
3. Remove idle-spring plunger guide (adapter when
used), idle spring or springs, idle spring plunger and
1 ADOPTER 6 ADJUSTING SCREW 11 GASKET spring rest washer. Fig. 5-70.
2 IDLE SPRING PLUNGER 7 HI-SPEED SPRING 12 COYER
3 IDLE SPRING 8 SHIM 13 PLUG
See Fuel Pump Assembly section for assembly of
4 WASHER 9 RETAINER 14 SEAL governor spring pack to fuel pump.
5 GUIDE AN CLIP 10 SNAP RING
Fig. 5-68, F5148. Standard governor - exploded view

Table 5-10: Governor Springs

Inches Free
Part Color Wire Dia Number Pounds Length Length
Number Code Replaces Inch [mm] Coils Load [kg] @ [mm] Inch[mm]

Maximum or High Speed Springs and Specifications

*143251 Blue/Purple 70711B 086[2.18] 8.4 11.65/10.75[5.28/4.89] @ 1.06[25] 1.487[37.8]
*Formerly color coded - 143251 Red/Black and Blue/Brown
Weight Assist Springs and Specifications
143847 Blue 028[.711] 9.7 3.30/3.70[1.50/1.68] @ .325[8.2] 584114.8]
Idle Springs and Specifications
144195 None (Idle) Std. Auto 032[.813] 12 0.69/0.85[.31/.38] @ .955[24] 1.025[26.0]

FUEL PUMP ASSEMBLY

Vise And Holding Fixture
The pump assembly requires all parts to be dirt free, and
the actual operations performed with the utmost care, to Mount the fuel pump on Holding Fixture ST-546 or
insure proper and trouble-free performance. 3375133 and Swivel Vise ST-302.

512
 TRUCK SERVICE MANUAL
FUEL SYSTEM

Tachometer Drive In Housing The life of tachometer

drive seal can be significantly improved by keeping
maximum clearance between gear and bushing to .005
inch [0.127 mm] and by correctly installing drive
assembly into fuel pump housing.
1. Line up oil groove in top of bushing with fuel pump
drive shaft. Press bushing, shaft and gear assembly into
housing with ST-1032 Driver until bushing bottoms.
Note: Using any tool but ST-1032 Driver may cause
indentations In oil seal which leads to premature seal
failure.
2. Install spacer on top of bushing with slotted edge
down. Install new oil seal, with spring side down, with
ST-1032 Driver. Spacer must bottom on bushing.
Fig. 5-95, F557. Installing fuel screen in standard
Caution: Do not overpress spacer. It can be
housing
flattened eliminating its effectiveness.
Double Screen
3. Cover top of seal with a thin coat of lubricating oil.
1. Install lower screen (one with holes in each end),
Install new felt dust seal with white side up. Secure
install screen retainer and new "0" ring.
tachometer cover with new gasket to housing.
2. Install upper screen, hole down; install spring.
3. Lubricate new "O" ring and plate on cap, torque cap 8
to 12 foot pounds [11 to 16 N. ml.
Governor Spring Pack
Automotive Governor
PT (type G) Fuel Pump

1. Assemble idle screw into plunger guide, place small

washer over screw point inside guide. Fig. 5-97. Place
small idle spring into guide and place idle plunger
(button) against spring in guide. Fig. 5-98.

Note: When assembling governor spring pack, the new

improved plunger should be used. Fig. 5-99.
2. The size of counterbore changes with different engine
Fig. 5-94, F556. Installing tachometer drive models. See pump calibration data for correct plunger to
use. The plunger controls maximum fuel pressure
Filter Screen produced by the fuel pump.
Single Screen Types Spring Pack Notes
1. Assemble the filter screen assembly into top of Note: There are different maximum-speed springs
standard housing, hole in retainer goes down. Fig. 5-95. available and each is identified by color stripes. See
Governor Spring Pack section, Table 5-10, for tabulation
2. Install "O" ring using grease to hold in place. and specifications.
Note: Shims are available In 0.005, 0.010 and 0.020 inch
3. Position spring and tighten cover in place. Torque [0.13, 0.25 and 0.51 mm] thickness. The final number of
cap to 8 to 12 foot pounds [11 to 16 No m]. shims must be determined during fuel pump calibration.
Overtightening is not necessary or desirable.
Install the spring pack cover and new gasket. Secure
cover to housing, torque capscrews to 9 to 11 foot
pounds [12 to 15 N•m]

513
 TRUCK SERVICE MANUAL
FUEL SYSTEM
Throttle Shaft

Fuel Adjusting Screw Type

1. Lubricate "O" ring and slide on fuel adjusting screw.

2. Insert fuel adjusting screw into throttle shaft about 6
turns. Do not- restrict throttle shaft fuel port. Fig. 5-101.
3. Lubricate "O" ring and slide on throttle shaft.

Fig. 5-97, F558. Installing washer over idle screw

Fig. 5-101, F5307. Installing fuel adjusting screw in

throttle shaft

4. Insert throttle shaft in housing with counterbored port

down and throttle stop slanted down in standard
automotive pump.
5, Instali snap ring on end of throttle shaft. Fig. 5-102.

Fig. 5-98, F559. Installing idle plunger button Restriction Plunger Type
Throttle shafts vary with applications. Replace with same
type throttle shaft, if needed. Table 5-12 and 5-13.

1. Install new "0" ring on throttle shaft using ST-835

Sleeve for 1/2 inch [12.7 mm] (ST-422 for larger) shaft to
avoid damage to "0" ring. Lubricate before assembly.

Fig. 5-99, F5149. Old and new design idle plunger

buttons

Fig. 5-102, F5299. Installing snap ring in throttle shaft

514
 FUEL SYSTEM
TRUCK SERVICE MANUAL

Note: The throttle lever stop in the vehicle chassis

Note: Install enough shims to bring the plunger flush with should be adjusted so there will be a minimum or
the fuel passage leaving it completely open for pump negligible amount of collapsing of the throttle lever.
calibration, Fig. 5-103. Some throttle shafts do not have Otherwise, the purpose of the spring loaded lever will be
a restriction plunger. defeated as the lever can collapse only so far. When the
throttle linkage stop is not properly adjusted, the spring
2. Install restriction plunger in the throttle shaft, if loaded lever may permit the bell crank in the linkage
used. Torque plug to 40 to 55 inch pounds [4.5 to 6.2 No mechanism to go "over center," locking the throttle in full
m]. fuel position.
Governor Plunger
3. Install washer over shaft. Insert the throttle shaft
In sleeve so the "ears" of the stop are curved downward
or if pin is used so open side of pin is down, lubricate 1. Lubricate with engine oil and install the plunger
with fuel oil. into barrel. Fig. 107. Make sure plunger is correct fit
and change
Note: Counterbored port on PT (type G) throttle must go
4. Install the snap ring and lock in the groove in front of
the throttle shaft cover plate.

Fig. 5-107 F566. Installing governor plunger

Fig. 5-103, F564. Installing throttle restriction plunger number if replaced. Remark governor barrel if oversize
plunger is used, so size of barrel and plunger
correspond.
Table 5-12: Throttle Shafts 1/2" PT (type G)
Drive Cover Assembly
Code Red
Size 0 1. Place a new gasket over the pump housing
Part No. 149030 dowel pins.
2. Place the assist plunger In the weight shaft bore
Throttle Lever with spring and shims, when required.
Install the throttle lever on throttle shaft and tighten 3. Hold the governor weights in to hold the assist
securely. Throttle levers are available in lengths of about plunger while assembling cover to housing,
1-1/4 to 5 inches (31.7 to 127 mm]; use the correct meshing with tachometer gear.
length for the pump application. 4. Position plunger drive tang horizontally position
The spring loaded throttle lever is used to prevent throttle weight carrier horizontally.
shaft bushing wear and scoring that can occur when Note: The weights straddle the governor plunger driver.
excessive pressure is applied to the throttle lever In full
fuel position. The spring loaded lever is designed to 5. Torque capscrews 9 to 11 foot pounds [12 to 15
collapse under this excessive pressure and then spring No m], securing cover to housing.
back when the pressure is released. 6. Rotate drive shaft to be certain tachometer gear
This will also prevent the throttle lever from turning on meshes.
the shaft and mutilating the serrated shaft diameter.

515
 FUEL SYSTEM TRUCK SERVICE MANUAL

Gear Pump

1. Assemble the gear pump to the main housing using a

new gasket. Locate notch for right hand or left hand
rotation. For right hand rotation locate notch to upper
right hand corner (looking from behind the fuel pump);
for left hand rotation locate the notch to bottom left hand
corner.

6 175836 ELBOW-CHECK VALVE

Fig. 5-110, F5159. Fuel flow check valves

Assembly

1. Install orifice assembly, consisting of elbow and

orifice plug in 1/8 inch [3.17 mm] hole in bottom or back
side of fuel pump housing. See Table 5-14 for correct
orifice assembly.

Table 5-14: Cooling Kits

Pump Size Kit Part Check Orifice
Fig. 5-109, F562. Torquing gear pump capscrews Inch [mml Number Valve Assembly
Note: Use correct gasket and be sure it is positioned
correctly. Be certain housing fuel holes match gear 3/4 [19.0] BM-96293 177279 BM-93301
pump holes.
2. Torque capscrews in increments to 11 to 13 foot 2. Attach check valve, Part No. 177279, to elbow. End
pounds [15 to 18 N. m]. Fig. 5-109. Check gear pump of valve containing ball must be toward orifice assembly.
rotation freedom.
Note: Check valve will prevent fuel pump from being
3. Install fuel inlet connection with same type threads as drained at engine shutdown.
gear pump. Current gear pumps use a 3/4 inch-16 UNF
3. Assemble No. 4 hose or tubing to valve and run to
threaded connection with an "O" ring. Previous gear
fuel tank.
pumps had 3/8 inch NPTF inlet connection. Don’t let
pipe sealer, used on NPTF type, enter gear pump. Use Note: All engines using flanged type PT injectors, vented
sealer sparingly to keep out of pump. Cover connection or not vented, must have cooling kit drain line returned
to keep out dirt. directly to the fuel tank. Any engine with cylindrical
injectors may have cooling kit drain line connected to
4. Install cooling check valve and/or elbow into top of
injector drain line or be returned to fuel tank.
gear pump if used.
Shut-Down Valve And Pulsation Damper
1. Install the shut-down valve with new "0" ring on fuel CALIBRATION
pump housing. REFER TO FUEL PUMP CALIBRATION.
2. Install damper with new "0" ring to the gear pump.
Torque capscrews to 11/13 foot pounds [15 to 18 N. m].
Fuel Pump Cooling Kit PT (type G)
Cooling kit is used to prevent maximum fuel temperature
from exceeding 250 deg. F [121 deg. C] under any
operating conditions. Fig. 5-110
Note: This kit is required when long periods of down hill
operations are encountered.
516
 FUEL SYSTEM TRUCK SERVICE MANUAL

Tachometer Cable

The tachometer drive is a standard SAE size operating Governor Shaft And Linkage Adjustment
at 1/2 engine speed. Fill cavity with clean, heavy grease
before attaching cable. Do not force tang into slot. If fit 1. Governor-to-fuel-pump linkage must be connected
is incorrect, change tang to a new, standard SAE type. with both fuel pump throttle and governor terminal shaft
When tachometer cable outer casing is plastic, do not levers in fuel shut-off or Idle position. The fuel pump
route near exhaust manifold or other "hot" areas. throttle lever will be all the way down against stop (full
clockwise) and the governor terminal shaft away from the
Fuel Pump Throttle Travel engine will be in extreme clockwise position.

The most sensitive adjustment on units using a hydraulic 2. Adjust control linkage to a length (about 9-1/2 inches
governor is fuel pump throttle travel. Do not change the [241 mm] ) which will permit installation of unibals in
idle throttle stop screw setting (front). Using a protractor levers without any movement of levers.
or ST-1162, Fig. 5-126, set the fuel pump lever idle
position centerline at 55 deg. from vertical on centerline Caution: Be sure linkage and levers are not binding.
of fuel pump throttle shaft. Lock throttle lever screw. Set
the centerline of the fuel pump lever in the maximum 3. Start engine and adjust low speed stop screw (atop
position at 27 deg. from vertical. Lock rear adjusting governor head) for desired idling speed.
screw. Recheck throttle lever centerline travel, it must
be 28 deg., or as specified, between idle and full throttle.

Fig. 5-126, F-5187.ST-1162 fuel pump throttle

adjustment template

For PT Fuel Pump calibration and speed setting refer to

FUEL PUMP CALIBRATION.

517
 FUEL SYSTEM TRUCK SERVICE MANUAL

INDEX

Subject Page

ASSEMBLY OF FUEL PUMP............................................................................................................. 512

CALIBRATION ................................................................................................................................... 516
COOLING KIT INSTALLATION ......................................................................................................... 516
DISASSEMBLY, FUEL PUMP............................................................................................................ 497
DRIVE COVER ASSEMBLY .............................................................................................................. 515
DRIVE SHAFT ASSEMBLY AND DISASSEMBLY ............................................................................ 509
FILTER SCREEN INSTALLATION .................................................................................................... 513
FRONT DRIVE COVER DISASSEMBLY........................................................................................... 508
FRONT DRIVE COVER INSTALLATION .......................................................................................... 510
FUEL PUMP SCREEN....................................................................................................................... 499
GEAR PUMP COOLING .................................................................................................................... 505
GEAR PUMP DISASSEMBLY AND ASSEMBLY............................................................................... 504
GEAR PUMP INSTALLATION ........................................................................................................... 516
GOVERNOR BARREL AND PLUNGER ............................................................................................ 500
GOVERNOR BARREL REPLACEMENT ........................................................................................... 500
GOVERNOR OPERATIONS.............................................................................................................. 497
GOVERNOR PLUNGER INSTALLATION ......................................................................................... 515
GOVERNOR SPRING PACK DISASSEMBLY AND ASSEMBLY...................................................... 512
GOVERNOR SPRING PACK INSTALLATION .................................................................................. 513
GOVERNOR WEIGHT CARRIER...................................................................................................... 509
INTEGRAL COOLING FEATURE ...................................................................................................... 505
MAIN SHAFT BUSHING .................................................................................................................... 499
OPERATING PRINCIPLES................................................................................................................ 495
PULSATION DAMPER DISASSEMBLY AND ASSEMBLY ............................................................... 506
PULSATION DAMPER INSTALLATION ............................................................................................ 516
REMOVAL OF UNITS ........................................................................................................................ 497
SHUT-DOWN VALVE (ELECTRIC) ................................................................................................... 506
SHUT-DOWN VALVE INSTALLATION.............................................................................................. 516
SHUT-DOWN VALVE, HIGH PRESSURE ........................................................................................ 507
STANDARD AUTOMOTIVE SPRING PACK ..................................................................................... 512
TACHOMETER CABLE ..................................................................................................................... 517
TACHOMETER DRIVE INSTALLATION IN HOUSING ..................................................................... 513
TACHOMETER DRIVE REBUILD...................................................................................................... 503
THROTTLE LEVER INSTALLATION ................................................................................................. 515
THROTTLE SHAFT INSTALLATION ................................................................................................. 514
WEIGHT ASSIST PLUNGER CHECKING......................................................................................... 511

518
 FUEL SYSTEM TRUCK SERVICE MANUAL

FUEL PUMP PT (TYPE G) CALIBRATION INSTRUCTIONS

Table of Contents
Subject Page

CONTROL PARTS LIST .................................................................................................................... 520

CALIBRATION TABLE ....................................................................................................................... 520

CALIBRATION TEST EQUIPMENT................................................................................................... 521

Horsepower Conversions............................................................................................................. 522
Instruments .................................................................................................................................. 522
Test Oil......................................................................................................................................... 521
Test Stands.................................................................................................................................. 521

CALIBRATION INSTRUCTIONS ....................................................................................................... 523

Brake Horsepower Formula ......................................................................................................... 522
Calibration Procedure .................................................................................................................. 525
Check Point Pressures ................................................................................................................ 530
Fuel Manifold Adjustment on Pump ............................................................................................. 528
Gear Pump Test .......................................................................................................................... 533
Governed Cut-off Speed on Pump .............................................................................................. 525
Nameplate Stamping ................................................................................................................... 524
Pump Hookup on Test Stand....................................................................................................... 523
Pump Run In ................................................................................................................................ 525
Pump Seal Check ........................................................................................................................ 533
Recheck Specifications................................................................................................................ 531
Throttle Leakage Adjustment on Pump ....................................................................................... 527
Throttle Travel, Special ................................................................................................................ 529
Torque Modifying Device Adjustment on Pump........................................................................... 529
Trouble Shooting with Test Stand................................................................................................ 534
Weight Assist Pressure Check .................................................................................................... 530

FUEL PUMP TROUBLE SHOOTING................................................................................................. 534

ANEROID ........................................................................................................................................... 540

Aneroid Adjustments.................................................................................................................... 540
Aneroid Altitude Derating ............................................................................................................. 543
Aneroid Assembly, Disassembly and Repair............................................................................... 543
Aneroid Installed on Test Stand................................................................................................... 540
Aneroid Maintenance ................................................................................................................... 545
Aneroid Plumbing......................................................................................................................... 542
Aneroid Factory Settings.............................................................................................................. 542
Aneroid Testing and Adjusting ..................................................................................................... 541
Aneroid Trouble Shooting ............................................................................................................ 545
ADJUSTMENT ON ENGINE .............................................................................................................. 546
Adjustment on Engine.................................................................................................................. 546
Engine Hi-Idle Speed Adjustment ................................................................................................ 547
Engine Power Check ................................................................................................................... 549
Filter Restriction ........................................................................................................................... 550
Fuel Manifold Adjustment on Engine ........................................................................................... 547
Fuel Pump Adjustment on Engine ............................................................................................... 546
Fuel Rate Adjustment on Engine ................................................................................................. 548
Governor Cut-Off Speed on Engine............................................................................................. 547
High Idle Adjustment on Engine................................................................................................... 547
Sealing Fuel Pump....................................................................................................................... 550
Throttle Leakage Adjustment on Engine...................................................................................... 548

519
 FUEL SYSTEM TRUCK SERVICE MANUAL

Test HP @ RPM CPL Code No. Torque Rise %

NTC-290

290 @ 2100 101 2764-A 15

520
 FUEL SYSTEM TRUCK SERVICE MANUAL

Calibration Test Equipment

Cummins ST-848, ST-775, and ST-445 (with ST-773 calibrating the PT fuel pump, but due to some older
conversion) fuel pump test stands have the following engines being built on special, "one time" orders cannot
features to provide accuracy: be applied to all engines which have been built with PT
fuel pumps.
1. Large dial, laboratory accurate gauges. However,
gauges are only accurate if properly maintained and Test Oil
should, therefore, be checked at regular intervals. Cummins fuel pump test stands must be filled with clean
Cummins Test Oil No. 99011-68 or equivalent since all
2. Accurate tachometers, either electric on ST-445, ST- calibration data has been established using this test oil.
775 and ST-848 or hand tachometer ST-774 for use with
ST-445. A digital tachometer is now In ST-848. Note: Hydraulic oils are not suitable to use as test oils in
Cummins test stands.
3. A flow-meter, which permits the tester to adjust each
fuel pump for total flow and correlate it with pressure Duplication of factory test methods and materials is the
calibration. The "fuel manifold pressure" thus obtained key to correct calibration and insures uniform results
on the test stand will duplicate fuel manifold pressure on wherever the fuel pump is adjusted.
the engine.
General Requirements
Test Stands
Cummins fuel pump test stands equipped with a flow- The material shall be a straight oil or a blend of oils
meter are ST-848,ST-775 and ST-445 (with ST-773 containing parafinic, aromatic or naphenic compounds,
conversion kit.) These test stands provide the most but not olefininc compounds, which show little or no
accurate method of change in physical properties during storage or use. The
use of various additives and/or inhibitors to stabilize the
oil is left

Fig. 5-1-1, F5100. Cummins ST-848 Fuel pump test stand

521
 FUEL SYSTEM TRUCK SERVICE MANUAL

to the discretion of the supplier. The additives must be Brake Horsepower = Lbs. (on Dyno. Scale) x Engine
antifoaming, anti corrosive antigumming. The fuel, RPM
additives, and color dye must be non-toxic and non- Dynamometer Constant
harmful to personnel.
Example: Dynamometer in operation has brake constant
Chemical And Physical Requirements of 500. Scales show a reading of 50 pounds and
Kinematic Viscosity at tachometer shows engine rpm of 1600.
100 deg F Centistokes, ASTM D445.................... 2.5 3.3 Brake Horsepower = 50 x 1600 = 160
Viscosity at 100 deg F [38 deg C] Saybolt Universal 500
(SUS), ASTM D2161 ........................................ 34.4 37.0 The above formulas apply to engine dynamometers only.
Specific Gravity at 60 deg. F, ASTM D287......... 820.830 Where chassis dynamometers are used, a factor of
approximately 25% must be used to compensate for
Gravity, Degrees API, 60 deg F, ASI M D287 ........ 41-39 gear ratios, tire size, etc.
Flash Point, P.M., Closed Cup, ASTM D93 160 deq F Min). Procedures of Converting Horsepower
Color, ASTM D1500 ............................................. 2 Max. 1. All horsepower ratings In fuel pump data are
Water ASSTM D01796............................................. .005 Cummins test ratings. Cummins test horsepower ratings
are made at 500 ft. [152 m] altitude and 80 deg, F [26.7
Corrosion, ASIM D130....................... Must Pass Class 1 deg. C] temperature, therefore, test horsepower is about
Galvanic Corrosion, ASTM-5322-1 ................ Must Pass 4% below the ratings made at sea level and 60 deg. F
Sulphur % Weight, ASTM-P129, D1552 .................... 0.4 [15.6 deg. C]. To convert sea level horsepower ratings
to your location (see Table 5-1-1) deduct 3% per 1000 ft.
Distillation at 20% point, ASTM-D86 ...... 440 deq. F Min, [305 m] above Sea Level and 1% per 10 deg. above 60
Sediment - Using a 10 Micron filter, 22,260 particles per deg. F [15.6 deg. C].
millileter are permissible. Using a 40 Micron filter, 195 Notes:
particles per millileter are permissible. Using a 50
Micron filter, 5 particles per millileter are permissible. a. Turbocharged engines develop the stated
horsepower from sea level to the altitude given in engine
Mobile Oil Company Type MC L-41 is one source that operators manuals.
meets the above requirements.
b. All engines derated in power only, or in power and
Instruments speed combined, need not be converted for any
A fuel pump cannot be calibrated with any greater difference between Cummins and Sea Level standards.
precision than that of instruments on the test stand. 2. Data given in Table 5-1-1 is Intended as a guide to be
Pressure, speed and flow measurements must be very used In the conversion of horsepower as expressed in
accurate, since these are the factors which determine one system to that of another system. Standard test
the pump characteristics. conditions vary from one system to another as noted.
The instruments on a fuel pump test stand and engine Note: The Din (German) horsepower ratings includes fan
test stand have the accuracy required for precision horsepower whereas the other systems listed do not
calibration and testing when new, but this accuracy must include the horsepower required to drive the engine
be periodically checked and maintained. cooling fan or the battery charging generator. In general,
General approximately 10 percent adjustment of horsepower
rating will make up the difference, When the horsepower
CAUTION required to drive the fan and the generator is known, the
Cummins Engine Company, inc. assumes no exact adjustment in net horsepower may be made.
responsibility of damage if fuel pump is calibrated to a 3. Including differences in altitude and temperature in
different specification than listed for a specific engine the standard test conditions, the following conversion
model and Pump Code. must also be made in addition to the conversion from the
Formula to Determining SAE Brake Horsepower difference in Ft. Lbs./Sec., so the total conversion
becomes
Evaluation of engine performance during testing is for
the most part, based on accurate horsepower readings. Cummins, SAE or British HP = Metric or Din
Therefore, it is imperative that the following formulas be (German) HP x .9863
used with test procedures. The basic formula to
determine brake horsepower is as follows: Metric or Din (German) HP = Cummins, SAE or
Brake Horsepower = Torque In (Ft. Lbs.) x Engine RPM British HP x 1.0139
5252 Note: The above conversion disregards the very slight
percent difference in relative humidity between Cummins
Most engine dynamometer manufacturers provide a and SAE or British systems.
figure known as a "brake constant" with each
dynamometer. The constant simplifies the process of 4. Units of measurement conversions from one system
computing brake horsepower since only engine rpm and to another.
the scale reading (in pounds) need be found by the test
mechanic. The formula used with a known constant Is
522
 FUEL SYSTEM TRUCK SERVICE MANUAL

a. Altitude or Elevation Conversion

100 feet = 30.48 meters
b. Barometric Pressure Conversion
1 inch Hg. = 25.4 millimeters Hg.
c. Temperature Conversion
°F = 9/5 x °C + 32
°C=F -32 x 5/9
d. Horsepower Conversion
Mkg./Sec. x 7.233 = Ft. Lb./Sec.
Ft. Lbs./Sec. -. .13825 = Mkg./Sec.

Fig. 5-1-2, F5163. Cummins ST-755 Fuel pump test

strand

Fig. 5-1-3, F5164. Cummins ST-445 Fuel pump test

strand

Table 5-1-1: Test Standards For Conversions

Altitude or Elevation Barometric Pressure Degrees Temperature and Humidity Horsepower

Measurement Relative
System Feet Meters In. Hg. Mm. Hg. Fahrenheit Centigrade Humidity Mkg./Sec Ft.Lb./Sec.

Cummins 500 152.4 29.38 746.25 85° 29.4° 30% 76.04 550.0
SAE 500 152.4 29.38 746.25 85° 29.4° 50% 76.04 550.0
British 500 152.4 29.38 746.25 85° 29.4° 50/% 76.04 550.0
Din (Germany) 984 300.0 28.88 733.55 68° 20.0° 60% 75.00 542.5
Metric 984 300.0 28.88 733.55 68° 20.0° 60% 75.00 542.5
Sea Level Sea Sea Level 29.92 759.97 60° 15.55° Dry Air *76.04 *550.0
Level
Horsepower for Metric or Din will be 75.00 Mkg/Second or 542.5 Ft.Lb./Sec.

Calibration Instructions Note: To obtain the 1/16 inch clearance, it may be

Pump Hookup necessary to adjust the test stand coupling.
1. Install the proper drive coupling to test stand, which 4. Squirt some clean test oil into the gear pump inlet
matches pump drive shaft coupling, so pump being hole, so pump will pick up faster, then connect suction
tested may be driven. See Fig. 5-1-4 and 5-1-5. line. Fig. 5-1-6.
2. Before mounting fuel pump, check the location of the 5. Fill fuel pump housing with clean test fuel through the
mounting holes; it may be 'necessary to change the test plug hole on top of pump (fuel inlet fitting on V6-140/V8-
stand adapter plate. 185 engines). Reinstall plug or fitting.
3. Mount fuel pump on the test stand mounting bracket 6. Connect line to fuel pump shut-down valve.
leaving about 1/16 inch [0.0625 mm] between fuel pump 7. Connect a No. 4 hose to the cooling bleed check
coupling and test stand drive coupling. valve on
523
 FUEL SYSTEM TRUCK SERVICE MANUAL

pump housing or on gear pump, if used. Drain into

splash tray under pump.

CAUTION
Never operate gear pump having cooling drain with the
drain plugged.

8. Never remove fuel pressure damper either during

testing or operation as it will cause erratic pump
performance and accelerate wear.
9. Use ST-774 Tachometer at the fuel pump tachometer
shaft connection to obtain most accurate speed readings
(unless using ST-775 or ST-848 stand).
10. The ST-848 test stands with 60-cycle current require
Fig 5-1-4, F5168. Mounting fuel pump with buffer type only that the reverse or forward start button be pressed
drive depending on right or left hand pumps. Fig. 5-1-7.
11. The ST-848 test stands with 50-cycle current
requires a change in motor brush location to reverse,
motor for left hand fuel pumps. Fig. 5-1-8. Rotate
cover shown to position required by loosening two cover
screws.
12. Remove fuel pump mounted fuel filter and replace
with Fuel Filter Adapter, Service Tool No. 3375014, and
gasket 3375015.

Fig. 5-1-5, F5169. Mounting fuel pump with spline drive

Fig. 5 1 7, F5170 60 cycle motor buttons

Check Pump Name Plate
1. The first item in top line is Control Pair Its List. 0101.
2. The next five spaces will be Shop Order Number.
0101-11521.
3. The next six or eight Spaces give fuel pump Serial
No. 0101-11521-846067 or 0101-11521-DP205361.
4. The first space on bottom line will be stamped "L"
when pump is left handed. Some "V" series right hand
rotation engines require left hand pumps. Right hand
Fig 5-1-6, F5102 Connect gear pump suction line fuel pumps will not be stamped.
5. The next seven spaces will be fuel pump BM or AR
number. 0101-11521-846067 L-BM-70486.
524