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CUMMINS "K" SERIES 6-CYLINDER Article Text

For cyph8r pacific la ca 92101


1996 Mitchell International, All Rights Reserved. Tuesday, September 25, 2012 11:03PM

ARTICLE BEGINNING DIESEL ENGINES Cummins K Series 6-Cylinder ENGINE IDENTIFICATION Engine model, serial number and Control Parts List (CPL) number is listed on engine data plate. Engine data plate is mounted on right side of cylinder block below cylinder head surface. ENGINE IDENTIFICATION CODE

Engine

Code

1150" (18.7L) ........................... K

INTAKE & EXHAUST MANIFOLDS EXHAUST MANIFOLD Removal 1) Remove retainer straps and cap screws from air crossover tube. Remove air crossover tube. Cover inlet openings on turbocharger and aftercooler. Remove and plug oil supply and drain line from turbocharger. Remove turbocharger mounting nuts. Remove turbocharger. 2) Bend tabs on lock plate away from exhaust manifold cap screws (if used). Remove 4 cap screws. Install guide studs. Remove remaining cap screws. Remove exhaust manifold. Installation 1) There are two types of gaskets being used, metal and composition. Each gasket requires different torque value on cap screws. Two types of locks are used, external lockplates with cap screws or self-locking flange cap screws with hardened washer. Install new gaskets onto cylinder head. Sides marked "OUT" face away from cylinder head. 2) Install the exhaust manifold onto the guide studs. Coat the cap screws with anti-seize. Install the cap screws and lock plates (if used). Remove the guide studs. Install remaining cap screws. Check that the exhaust manifold sets flat against the cylinder heads. Cap screws must be tightened in sequence. See Fig. 1. Tighten cap screws. Refer to TORQUE SPECIFICATIONS table. Bend lock plates down on cap screw (if used).

Fig. 1: Exhaust Manifold Tightening Sequence Courtesy of Cummins Engine Co., Inc.

3) Install new mounting gasket for turbocharger with raised bead toward turbocharger. Install turbocharger. Tighten cap screws. See TORQUE SPECIFICATIONS table. Install new gasket and oil drain line. Install oil drain and supply lines. See TORQUE SPECIFICATIONS table. Center of oil drain line must be located within 35 vertical position when turbocharger is installed. 4) Turbocharger bearing housing must be rotated if drain line is not correct. On through bolt type turbochargers, bend over lock plates. Remove bearing housing-to-turbine housing cap screws. Rotate bearing housing to proper angle. Install and tighten cap screws to 105 INCH lbs. (12 N.m). Bend over lock plates. Check that turbocharger spins freely. 5) On clamping plate style turbochargers, bend over lock plates. Loosen cap screws in all clamping plates. Rotate bearing housing until proper angle. Tighten cap screws to 105 INCH lbs. (12 N.m). Bend over lock plates. Check that turbocharger spins freely. 6) Install new "O" rings on air crossover tube. Coat "O" rings with vegetable oil. Install air crossover tube. Check alignment of air crossover tube at turbocharger. Rotate turbocharger housing if alignment is not sealing properly. Install retainer straps and cap screws. See TORQUE SPECIFICATIONS table. INTAKE MANIFOLD Removal Remove air crossover tube. Remove air line from aftercooler to fuel pump. If engine contains crankcase breather in cam follower cover, remove cam follower cover. Remove HVT oil connection. Remove mounting cap screws. Remove intake manifold. Installation 1) Check that gasket surfaces are clean. Install guide studs in upper row of cap screw holes. Install gaskets with raised bead on gasket against cylinder head. Install grommets in upper row of cap screw holes of manifold. Grommets are used to prevent dirt entry. 2) Install the manifold onto the guide studs. Install washers and cap screws in bottom cap screw holes. Tighten the cap screws enough to hold manifold in place. Remove guide studs. Install washers and cap screws. Tighten cap screws in same sequence used for aftercooler installations. See Fig. 2. Tighten cap screws. Refer to the TORQUE SPECIFICATIONS table.

Fig. 2: Aftercooler Tightening Sequence Courtesy of Cummins Engine Co., Inc.

3) Install air tube from manifold to fuel pump. Install cam follower cover (if removed). Install HVT oil connection. Install new CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 2)For cyph8r pacific la ca 92101 "O" rings on air crossover tube. Install air crossover tube and

retaining straps. AFTERCOOLER Removal 1) Remove air crossover tube from turbocharger to aftercooler. Loosen hose clamps on water inlet and outlet hoses. Slide hoses back on water tubes. Remove air tube from aftercooler to fuel pump. Remove HVT oil connection from rear of aftercooler. 2) If engine contains crankcase breather in cam follower cover, remove cam follower cover. Remove two mounting cap screws from aftercooler. Install two guide studs. Use hoist to support assembly. Remove remaining cap screws. Remove aftercooler. Disassembly Remove cap screws from gasket cover plate at water inlet and outlet connections. Remove cover plate, gasket and seal from each connection. Remove cap screws from aftercooler cover. Remove cover, gasket and element from housing. Checking 1) Check housing for cracks or bad threads in cap screw holes. Check plate around element for cracking. Aftercooler element should be pressure tested for leaks. Clamp hose on outlet connection. Plug and clamp hose with solid plug. Clamp hose on inlet connection. Install pressure gauge with air fitting into hose on inlet connection. Check that all hose clamps are tight before applying air pressure. 2) Submerge element in tank of water. Check that entire element is covered. Use air pressure regulator. Adjust air pressure to 30 psi (210 kPa). Apply air pressure to element. Check for air bubbles. Replace element if leaks appear. Remove air pressure. Remove element and disassemble testing equipment. Dry element with compressed air. Reassembly 1) Check that all gasket surfaces are clean. Install lower gasket on housing. Install element in housing. Install upper gasket and cover. Install cap screws. DO NOT tighten cap screws at this time. 2) Lubricate water connection seals and sealing areas of aftercooler element with oil. Install seals on retainers. Install gasket on retainers. Install seal and retainer on tube of element. Install cap screws in retainer. Tighten retainer cap screws first, then tighten cover cap screws. See TORQUE SPECIFICATIONS table. Installation 1) Install guide studs in upper row of cap screw holes of cylinder heads. Install gaskets on cylinder heads with raised bead of gasket against cylinder head. Install grommets in upper row of cap screw holes on aftercooler. Grommets are installed to prevent dirt entry. 2) Install the aftercooler assembly onto the guide studs. Install washers and cap screws in bottom row of cap screw holes. Tighten cap screws lightly to hold assembly in position. Remove guide studs. Install remaining washers and caps screws. Cap screws must be tightened in sequence. See Fig. 2. Tighten cap screws. Refer to the TORQUE SPECIFICATIONS table. 3) Install new "O" rings on air crossover tube. Coat "O" rings with vegetable oil. Install air crossover tube and retaining straps. Install cam follower cover (if removed). Install air line from

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

aftercooler to fuel pump. Install HVT oil connection at rear of aftercooler. Install water hoses on aftercooler. CYLINDER HEAD (REPLACEMENT) Removal 1) Remove exhaust manifold. See INTAKE & EXHAUST MANIFOLDS. Remove aftercooler or intake manifold. See INTAKE & EXHAUST MANIFOLDS in this article. Remove fuel lines from fuel manifold. Remove cap screws from fuel manifold. Remove fuel manifold. Plug fuel passages in cylinder head and fuel manifold to keep areas clean. 2) On engines equipped with Hydraulic Variable Timing (HVT), remove oil line from rear of oil manifold mounted to rocker lever housings. Remove cap screws from oil manifold. Remove manifold. Plug all oil passages. Note location of rocker lever cover with crankcase breather. Remove cap screws. Remove rocker lever covers. Disconnect wiring connection from cover for Jacobs Brake (if equipped). Loosen adjusting screw lock nut on rocker levers. On HVT equipped engines, hold injector link when loosening lock nut. Remove HVT injector link. CAUTION: When loosening adjusting screw lock nut on HVT equipped engines, hold injector link. Injector link can fall into engine. 3) Remove cap screws from rocker lever assemblies. Mark each rocker lever assembly as to location. Remove rocker lever assemblies. DO NOT drop rocker levers from shaft during removal. Remove cap screws from Jacobs Brake housing (if equipped). Mark each housing as to location. Remove Jacobs Brake housing. Remove rocker lever assemblies. 4) Mark push rods as to location. Remove push rods. Loosen adjusting screw lock nut on crossheads. Mark each crosshead as to location. Remove crossheads. On engines equipped with Jacobs Brake, note location of special crosshead. 5) Remove water outlet line from air compressor. Remove cap screws from thermostat housing. Remove thermostat housing and water transfer tube. Remove retaining clips from water manifold. See Fig. 3. Using Water Tube Driver (ST-1319), push water tube toward front of cylinder block. Water tube must slide forward until rear of tube clears rocker lever housing.

Fig. 3: Removing Water Rail Courtesy of Cummins Engine Co., Inc.

6) On engines equipped with HVT, remove banjo connector cap screw. See Fig. 4. Remove connector and "O" ring from tappet. Remove cap screws from rocker lever housing. DO NOT drop washers into engine. Remove rocker lever housing and gasket. Remove injector hold-down. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 4)For

Fig. 4: Removing Banjo Connector Courtesy of Cummins Engine Co., Inc. 7) Injectors are removed to prevent damage during cylinder head removal. Use Injector Puller (3376000) for standard injectors. Use Injector Puller (3376497) for top stop injectors. All engines equipped with HVT use top stop injectors. DO NOT let tappet fall out of injector when removing injector from HVT equipped engines. Remove injectors and place in clean material. Keep injector sealing ring with injector which it was located. Place in proper rack to prevent damage. 8) Remove air compressor water outlet line. Remove cap screws from cylinder head. Remove cylinder head. Installation 1) Clean sealing surface of both cylinder head and cylinder block. Special attention should be given to ensure surface around cylinder liner flange is clean. Check that small sealing ridge on top of cylinder liner is not damaged. Clean cap screw holes in cylinder block. CAUTION: Cylinder head cap screw holes in cylinder block must be clean and dry before installation. Failure to clean will cause breakage of cylinder block when tightened to specifications. 2) Clean cylinder head cap screw threads using wire brush. Check cap screws for pitting or cracking of threads. Replace if damaged. Two different lengths have been used. Engines with serial number greater than 31103629 and service blocks use 8" (203 mm) cap screws. Engines with serial number less than 31103629 use 6 3/4" (171 mm) cap screw. 3) To check for proper length cap screw to be used, measure distance from top of cylinder block to first thread in cap screw hole. If distance is 1 3/4" (44 mm) 8" (203 mm) cap screw is used. Install new gasket with "TOP" facing upward. Gasket must slide easily over pins in cylinder block. Install all grommets and cylinder head. Ensure head sets on pins in cylinder block. Current production head cap screws are Black, early production are Silver. DO NOT mix cap screws. NOTE: Oversize head gasket must be used on cylinder blocks that have had .010-.030" (.25-.76 mm) removed from deck surface.

4) Coat the cap screws with 140W oil. Allow excess oil to drain from the cap screws. Install cap screws and washers. Tighten the cap screw in sequence. Refer to the TORQUE SPECIFICATIONS table. Also, see Fig. 5. Install rocker lever housing gasket. Check that water tube CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 5

sealing areas are clean in rocker lever housings. Install new "O" rings on water tubes. Lubricate "O" rings with vegetable oil. Install water tubes in rocker lever housings. Water tube with two grooves must be installed in rear cylinder head.

Fig. 5: Cylinder Head Tightening Sequence Courtesy of Cummins Engine Co., Inc. 5) Install rocker lever housings. Housing with only one "O" ring bore must be installed on No. 6 cylinder head. Check that housing sets properly on pins in cylinder head. Install cap screws in proper location. One cap screw is shorter than the others. Tighten cap screws in sequence. See Fig. 6. On engines equipped with Jacobs Brake, cap screw must be installed when Jacobs Brake housing is installed.

Fig. 6: Rocker Lever Tightening Sequence Courtesy of Cummins Engine Co., Inc. 6) Using Water Tube Driver (ST-1319), drive water tubes into adjacent housing. Install retaining clips. Install thermostat housing and water transfer tube. 7) Check that injector sleeves in cylinder head are clean. Install new "O" rings on injector. Check that proper size "O" rings are used. Coat "O" rings with oil. Position inlet screen toward holddown cap screw hole on intake side of cylinder block. Place blunt instrument on body of injector. Push injector into bore. 8) A snap will be heard and felt when injector is seated. Install hold-down and cap screws. Tighten the cap screws. Refer to the TORQUE SPECIFICATIONS table. Check that injector plunger mover freely. If plunger does not move freely, loosen hold-down and retighten. 9) On HVT equipped engines, position injector in bore so that oil passage in top stop screw faces oil supply hole in rocker lever housing. Rotate injector using jumper tube to align injector. Install injector in bore. A snap will be heard and felt when injector is seated. Install hold down. See TORQUE SPECIFICATIONS table. Install new "O" ring on jumper tube. Lubricate "O" ring with oil. Install jumper tube and sealing washers. Install connector screw. Tighten

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

connector screw. See TORQUE SPECIFICATIONS table. 10) Lubricate crosshead guides and valve stems with oil. Install crossheads in original location. Adjust crossheads. Refer to CROSSHEAD ADJUSTMENTS in this article. Install push rods in original locations. Injector push rods are thinner in the middle. Valve push rods are the same. Install injector links. DO NOT install injector link on HVT engines until rocker lever assembly is installed. 11) Check that dowel for rocker lever assembly is installed in rocker lever housing. Install rocker lever assembly. Check that assembly sets on dowels in rocker lever housings. Install cap screws. On engines with Jacobs Brake, housing must be installed while installing rocker lever assembly. Align push rods and injector link. On HVT engines, install injector link. Turn adjusting screw far enough to hold injector link. Tighten cap screws. See TORQUE SPECIFICATIONS. 12) Check that push rods are seated in cam followers. Adjust valves and injectors. See INJECTOR & VALVE CLEARANCE ADJUSTMENTS in this article. Install rocker lever covers and gaskets in original location. On engines with Jacobs Brake, connect wiring connection inside rocker lever housing. See TORQUE SPECIFICATIONS table. 13) Install air compressor water outlet line. Install new "O" rings on fuel manifold. Lubricate "O" rings with vegetable oil. Install fuel manifold. Tighten cap screws from center working toward outer edges. See TORQUE SPECIFICATIONS table. Install fuel lines to fuel manifold. Install new "O" rings on HVT oil manifold (if equipped). Lubricate "O" rings with vegetable oil. Install oil manifold. Tighten cap screws from center working toward outer edges. See TORQUE SPECIFICATIONS table. Install HVT oil line on manifold. 14) Install exhaust manifold. See INTAKE & EXHAUST MANIFOLDS in this article. Install the aftercooler or intake manifold. Refer to INTAKE & EXHAUST MANIFOLDS in this article. VALVE ARRANGEMENT 2E-2I-2E-2I-2E-2I-2E-2I-2E-2I-2E-2I (Front-to-rear). INJECTOR & VALVE CLEARANCE ADJUSTMENTS NOTE: When checking injector clearance, ensure tool is tight. Injector plunger is under spring tension and can cause injury and damage tool, if released quickly. If equipped with Jacobs brake model K-1150, adjust slave piston before adjusting valves. See JACOBS BRAKE ADJUSTMENT in this article. 1) Push barring shaft in and turn counterclockwise, to rotate engine. Align timing mark, located on pulley, to pointer on front gear cover. See Fig. 7. On engines with 2 piece front cover, remove clip, push shaft in, and turn shaft counterclockwise.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 7)Fo

Fig. 7: Barring Shaft & Timing Mark Location Courtesy of Cummins Engine Co., Inc. 2) Align mark "A" ("1-6 VS" on older engines) with pointer. Check valves on cylinder No. 5 are closed and can be moved easily. If valves are not open and cannot be moved easily, rotate engine 1 complete revolution and recheck valves. Check valve clearance between rocker arm and crosshead. See VALVE CLEARANCE SPECIFICATIONS table. 3) Adjust intake and exhaust valves clearance. See Fig. 8. Tighten lock nut to 45 ft. lbs. (60 N.m). If using torque wrench with Adapter (ST-669), tighten lock nut to 35 ft. lbs. (45 N.m). Install Injector Adjuster (3375004) on cylinder No. 3. Adjust dial indicator so tip is touching top of injector plunger.

Fig. 8: Adjusting Valve & Injector Clearance Courtesy of Cummins Engine Co., Inc. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 8)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reserve 4) On engines with HVT (Hydraulic Variable Timing) tip must touch tappet between ends of retainer rings. See Fig. 9. Tip must not touch rocker lever. Lower dial indicator to .50" (12.7 mm) and lock in position. Using Rocker Lever Actuator (3376869), depress lever 2 or 3 times until injector bottoms, to remove fuel and oil from cup.

Fig. 9: Checking Injector Clearance Courtesy of Cummins Engine Co., Inc. 5) Loosen lock nut and tighten adjusting screw until injector plunger bottoms in cup. Zero dial indicator. Turn adjusting screw both directions 2 or 3 times to confirm zero reading on dial indicator. Adjust injector clearance. See VALVE CLEARANCE SPECIFICATIONS table. 6) While holding adjusting screw, tighten lock nut to 45 ft. lbs. (60 N.m). If using torque wrench with Adapter (ST-669), tighten to 35 ft. lbs. (45 N.m). Using rocker arm actuator, bottom injector plunger and allow rocker lever to slowly return. 7) Confirm dial indicator reads zero. Recheck clearance and readjust if necessary. Remove injector adjuster and rotate engine to next mark. See VALVE & INJECTOR SEQUENCE table. Adjust valves and injectors. VALVE CLEARANCE SPECIFICATIONS

Application

In. (mm)

Exhaust ....................................... .027 (.69) Intake ........................................ .014 (.36) Injector With HVT ................................... .304 (7.72) Without HVT ............................... .403 (10.24)

VALVE & INJECTOR SEQUENCE

Mark On Pulley A (1) B (2) C (3) A (1) B (2) C (3)

Adjust No. Valves 5 3 6 2 4 1

Adjust No. Injector 3 6 2 4 1 5

.................... .................... .................... .................... .................... ....................

......................... ......................... ......................... ......................... ......................... .........................

(1) - "1-6 VS" on older engines. (2) - "2-5 VS" on older engines. (3) - "3-4 VS" on older engines. JACOBS BRAKE ADJUSTMENT NOTE: Sequence for each Jacobs brake adjustment is the same as valve adjustment. See VALVE & INJECTOR SEQUENCE table

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 9)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reserve

for proper cylinder adjustment. K-1150 Models 1) With engine set to adjust cylinder No. 5 valves, loosen exhaust valve adjusting screw. Check clearance between slave piston and Jacobs brake crosshead. Clearance should be .018" (.46 mm). If clearance is as specified, no adjustment is needed. If clearance is not as specified, loosen lock nut. 2) Starting with adjusting screw, nearest to water manifold side, turn screw 1/8 turn then adjust screw under rocker lever 1/8 turn. Adjust screws evenly until proper clearance is obtained. Using Adapter (3840) and a torque wrench, tighten lock nut to 48 ft. lbs. (65 N.m). Adjust exhaust valve and rotate engine to adjust next cylinder. K-1200 Models 1) With engine set to adjust cylinder No. 5 valves, check clearance between the slave piston and crosshead. Clearance should be .018" (.46 mm). If clearance is as specified, no adjustment is necessary. If clearance is not as specified, loosen lock nut. 2) Adjust screw until proper clearance is obtained. Tighten adjusting screw to 30-40 ft. lbs. (41-54 N.m). Rotate engine to adjust next cylinder. To bleed brake unit, if necessary, start engine and accelerate to 1800 RPM. Release throttle and manually depress solenoid armature 5-6 times. CROSSHEAD ADJUSTMENTS NOTE: Adjusting screw must always be toward exhaust side of engine.

1) While pushing crossheads down, loosen lock nut and turn adjusting screw until it touches valve stem but does not raise crosshead. Tighten the lock nut to 30 ft. lbs. (40 N.m) without Jacobs brake. 2) Using torque wrench and Adapter (ST-669), tighten to 25 ft. lbs. (35 N.m). If equipped with Jacobs brake, tighten to 35 ft. lbs. (45 N.m) without adapter or 30 ft. lbs. (40 N.m) with adapter. CYLINDER HEAD (OVERHAUL) VALVES Disassembly Clean cylinder head. Mark each valve as to location. Using Valve Spring Compressor (ST-448) with Spring Compressor Plate (ST-3375043), compress valve spring. Remove valve spring collets, retainers, valve spring guides and valve springs. Cleaning & Inspection 1) Clean valves and polish with crocus cloth. Check thickness of the valve head rim thickness using Gauge Block (ST-547). Refer to the VALVE HEAD THICKNESS SPECIFICATIONS table. Check diameter of valve stem in 3 areas. Refer to the VALVES table at end of article. Replace worn valves. 2) Check that collets fit tightly in valve stem grooves. Check valve for cracks. Replace damaged valves. When replacing valves, check that proper valve is installed. See Fig. 10.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 10

Fig. 10: Valve Identification Courtesy of Cummins Engine Co., Inc. VALVE HEAD THICKNESS SPECIFICATIONS

Application

(1) In. (mm)

Exhaust ...................................... .120 (3.00) Intake ....................................... .085 (2.16) (1) - Minimum thickness.

Valve Grinding Using Valve Facing Machine (3376256), grind valve to proper angle. See VALVES table at end of article. Measure valve head thickness. Replace valve if not within specification. Reassembly 1) Clean and inspect cylinder head. Inspect, repair or replace the following components: valve seats, valve guides, valve springs, crosshead guides and crossheads. See appropriate section within this article. 2) Apply oil to valve stem. Install valve in original locations. Install valve spring guide, spring and retainer. Compress valve spring. Install new collets. Slowly release valve spring compressor. Check that collets are seated in valve stem groove. CAUTION: New valve spring collets must always be used. CYLINDER HEAD Checking Cylinder head should be clean. Cylinder head should be tested for cracks using the magnetic method before performing other tests. Using straightedge, check flatness of head gasket surface in several areas. See CYLINDER HEAD SPECIFICATIONS table. Cylinder head thickness must be checked before resurfacing. Replace cylinder head if beyond limits. CYLINDER HEAD SPECIFICATIONS

Application

In. (mm)

Flatness ................................. (1) .003 (.076) Thickness ............................. (2) 4.715 (119.76) (1) - Maximum clearance.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 11)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser

(2) - Minimum thickness.

Testing (Air Pressure) NOTE: Valves and valve springs must be removed before pressure testing. 1) Use Water Test Adapter Plate (3375070) and Adapter Plate "O" Rings (3375071). Install lower adapter plate on cylinder head. Plate guide pins must fit in water passages. Install "O" rings on upper adapter plate. Install upper plate on cylinder head. Install clamping assembly over adapter plates. Guide pins on clamping assembly must fit in holes on lower adapter plate. 2) Install air hose with pressure regulator on upper adapter plate. Install lifting arm over clamping assembly. Adjust air pressure to 80 psi (552 kPa). Install cylinder head in tank of water. Check for air bubbles. Repair or replace cylinder head if leaks appear. Remove testing equipment. VALVE GUIDE SERVICING Inspection Inspect guide for damage. Using dial bore gauge, measure bore at 3 areas 90 apart. See VALVE GUIDE SPECIFICATIONS table. Replace worn guides. VALVE GUIDE SPECIFICATIONS

Application

In. (mm)

Installed Bore I.D. .......... .4961-.4987 (12.600-12.667) Cylinder Head Guide Bore ....... .8435-.8445 (21.43-21.45) Installed Height Style 3 & 4 .................. 1.375-1.390 (34.93-35.31) Style 5 ...................... 1.175-1.190 (29.85-30.23)

Removal Install cylinder head in hydraulic press. Press valve guide from cylinder head. Measure bore of cylinder head at two areas 90 apart. See VALVE GUIDE SPECIFICATIONS table. Valve guide bore must be reamed for oversized valve guide if beyond limit. CAUTION: Valve seat must be ground if valve guide is replaced. Installation Valve guide must be identified before installing. Proper valve guide driver must be used with different guides. See Fig. 11. Using hydraulic press and proper valve guide driver, install valve guide. Valve guide must be installed to proper height. Measure distance from top of valve guide to surface of cylinder head. See VALVE GUIDE SPECIFICATIONS table.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 12)For cyph8r pacific la ca 92101 1996 Mitche

Fig. 11: Valve Guide Identification Courtesy of Cummins Engine Co., Inc. VALVE SEAT INSERTS Inspection Carefully tap the head of the valve seat with a rubber hammer. Note any movement of the valve seat. Replace the valve seat if loose. Measure the valve seat width area. See Fig. 12. Refer to the VALVES table at end of article. Replace valve seat if worn.

Fig. 12: Measuring Valve Seat Courtesy of Cummins Engine Co., Inc. Removal 1) Different valve seat extractors are used for intake and exhaust valves. Use Valve Seat Extractor (ST-1323-1) for exhaust valves and (3376799) for intake valves. Install valve seat extractor in valve seat. Using slide hammer, remove valve seat. Remove antiswirl plate from intake ports. Small groove may be machined in valve seat insert to allow valve seat extractor to be used. 2) Check for cracks around the valve seat area. Measure the inside diameter and depth of insert bore of cylinder head. Refer to the VALVE SEAT BORE SPECIFICATIONS table. Cylinder head must be machined for oversized valve seat if not within specifications. VALVE SEAT BORE SPECIFICATIONS

Application

In. (mm)

Diameter CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 13)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser Intake ....................... 2.377-2.378 (60.37-60.40) Exhaust ...................... 2.377-2.378 (60.37-60.40) Depth Intake ......................... .512-.517 (13.00-13.13) Exhaust ........................ .492-.497 (12.50-12.62)

CAUTION: Intake valve seat insert has wider valve seat area than exhaust valve seat inserts. DO NOT install improper valve seat insert. Installation 1) Check that proper valve seat insert is used. Both valve seat inserts must be installed with 30 angle upward. Exhaust seats are color coded to identify 30 angle side of seat. Some engines do not require anti-swirl plate. Insert spacer plate must be used if anti-swirl plate is not used. 2) Install anti-swirl plate (if used). Use arbor press and mandrel. Install valve insert. Check that valve seat bottoms in counterbore. Valve Seat Grinding Check valve seat width. Using Valve Seat Grinding Machine (ST-685), grind valve seat insert to angle and seat width. See VALVES table at end of this article. Valve Seat Testing 1) Assemble valve and springs in cylinder head. Valve and valve seats must be clean and dry. Use Valve Vacuum Tester (ST-1257). Place the vacuum cup over the valve. Turn shutoff valve to the open position. Operate the vacuum pump until a reading of 18 in. Hg is reached. Turn valve off. Stop vacuum pump. 2) Check amount of time it requires for vacuum reading to drop from 18 to 8 in. Hg. Total time should not be less than 10 seconds. If time is less than 10 seconds, lightly tap on valve stem with a soft hammer. Check connections of vacuum tester. Hold cup against a flat surface. Operate vacuum pump. The gauge must not show a decrease. Perform vacuum test again. 3) Apply a light coat of grease to outside diameter of valve seat insert. This makes a seal between the insert and counterbore. Vacuum test and recheck grease seal. Break in seal indicates a leak between insert and counterbore. 4) If no leak appears at insert and counterbore, grind valve face or valve seat insert. CROSSHEAD GUIDES Inspection Use micrometer to measure outside diameter of crosshead guide. See CROSSHEAD SPECIFICATIONS table. Check that guide is straight. Guide must be at right angle to surface of cylinder head. Replace any worn or bent guide. Removal & Inspection Using Dowel Pin Extractor (ST-1134), remove damaged guide. Measure inside diameter of guide bore in cylinder head. Refer to the CROSSHEAD SPECIFICATIONS table. Bore may be reamed for oversized guides if not within specifications.

Installation Use Crosshead Guide Spacer (ST-1264) and hydraulic press. Install new guide. Measure distance from top of guide to cylinder head surface. See CROSSHEAD SPECIFICATIONS table. Guide must be installed to proper height. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 14)For cyph8r pacific

CROSSHEAD SPECIFICATIONS

Application

In. (mm)

Crosshead Bore I.D. .............. .434-.440 (11.02-11.17) Guide O.D. ..................... .4320-.4335 (10.97-11.01) Guide Bore I.D. ................ .4314-.4325 (10.96-10.99) Guide Installed Height ............... 2.35-2.37 (59.69-60

CROSSHEADS Inspection 1) Use magnetic method to check crossheads for cracks. Check inside diameter of crosshead bore. Check bore measurement at 4 areas 90s apart. Replace crosshead if bore is out-of-round. Refer to the CROSSHEAD SPECIFICATIONS table. 2) Inspect rocker lever contact surface and valve stem contact surface for wear. Check adjusting screw and threads in crosshead for wear or damage. Replace crosshead if damaged. INJECTOR BORE Inspection 1) Inspect injector bore for cracks or damage. Install sealing ring on injector. Coat sealing ring with Prussian blue. Support cylinder head. Install injector. Tighten hold-down cap screws to 145 INCH lbs. (16 N.m). Using Gauge Block (ST-547), measure injector tip protrusion. See INJECTOR PROTRUSION SPECIFICATIONS table. If protrusion is not within specifications, oversize sealing rings are available. INJECTOR PROTRUSION SPECIFICATIONS

Application

In. (mm)

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

2) Remove injector. Check contact pattern in injector bore. Contact area must be at least .060" (1.52 mm) wide and 360 circumference. If contact area is not correct, check for damage or dirt in injector bore. ROCKER LEVER ASSEMBLY & PUSH RODS

Disassembly & Inspection 1) Remove cap screws. Mark rocker lever as to location. Remove rocker levers. Inspect shaft for scoring or roughness. Check socket area of rocker lever for excessive wear. If excessive wear is apparent, check push rods for damage. Inspect bushing bore area of rocker levers for wear or damage. Inspect for wear in crosshead contact area. Inspect push rods for damage or cracks. 2) Check threads in rocker lever and on adjusting screw. Adjusting screw must turn freely in rocker lever. Using dial bore gauge, measure inside diameter of rocker lever at two areas 90 apart. Measure rocker lever shaft in two areas 90 apart where rocker levers fit on shaft. See ROCKER LEVER SPECIFICATIONS table. Replace worn(p. or 15)For cyph8r pacific la ca 92101 1996 Mitchell Internatio CUMMINS "K" SERIES 6-CYLINDERArticle Text

damaged parts. 3) Replace bushing if worn. Using hydraulic press and Rocker Lever Bushing Mandrel (ST-1284), press bushing from rocker lever. Check that bore area is free of burrs. Using dial bore gauge, measure inside diameter of rocker lever at two areas 90 apart. Refer to the ROCKER LEVER SPECIFICATIONS table. ROCKER LEVER SPECIFICATIONS

Application

In. (mm)

Bushing Bore I.D. .......... 1.3735-1.3776 (34.890-34.990) Lever Bore I.D. ................ 1.436-1.437 (36.47-36.50) Shaft O.D. ................. 1.3710-1.3725 (34.820-34.860)

Reassembly 1) Align oil hole in bushing and rocker lever. Using hydraulic press and bushing mandrel, install bushing. Check that oil holes are aligned. 2) Lubricate shaft with oil. Install rocker levers in original locations. Rocker lever oil passages must align with oil passages in rocker lever shaft. Rocker levers must be installed in sequence. See Fig. 13. Install cap screws in shaft.

Fig. 13: Rocker Lever Sequence Courtesy of Cummins Engine Co., Inc. CAUTION: Oil passages in rocker lever shaft and rocker levers must be aligned. ACCESSORY DRIVE & PULLEY FUEL PUMP Removal Remove wire to shutoff solenoid. Remove throttle linkage. Remove wires to micro switch for Jacobs Brake (if equipped). Remove tachometer cable. Remove all lines connected to fuel pump. Remove cap screws. Remove fuel pump. Installation Install new gasket on fuel pump. Install new fuel pump drive spider. Install fuel pump. Install and tighten cap screws. Install all lines to fuel pump. Install throttle linkage, tachometer cable and wire to shutoff solenoid. Install wiring to micro switch for Jacobs Brake (if equipped). Ensure accelerator linkage goes into full fuel when operated.

CUMMINS "K" SERIES 6-CYLINDERArticle Tex

AIR COMPRESSOR Removal Remove fuel pump. Remove air intake to air compressor. Remove air line to air governor. Remove air compressor output line. Remove water supply lines. Remove cap screws from lower support bracket (if equipped). Remove mounting cap screws from air compressor. Remove air compressor and drive coupling. Installation 1) Install new gasket on air compressor. Install air compressor on splined coupling. Install cap screws and nuts. DO NOT tighten at this time. Install cap screws for rear support bracket. Rear support bracket must fit flat against the cylinder block. Tighten air compressor mounting cap screws. Tighten the rear support-to-block cap screws. Tighten the rear support-to-pump cap screw. Refer to the TORQUE SPECIFICATIONS table. Cap screws must be tightened in this sequence to prevent failure. 2) Install air line for air governor. Install air compressor intake and output line. Install water lines. Install fuel pump. ACCESSORY DRIVE PULLEY Removal Install Puller (ST-647) on accessory drive pulley using two long cap screws. Remove accessory drive pulley using puller. Replace oil seal if needed. CAUTION: DO NOT use cap screws that extend past rear face of accessory drive pulley. Long cap screws damage gear cover. Installation 1) Install oil slinger. Install new accessory drive seal. Replace wear ring on accessory drive pulley. Apply film of Lubriplate 105 to accessory drive shaft. Check that drive key is in accessory drive shaft. Align keyway in pulley with key. Push pulley on by hand as far as possible. 2) Install Pulley Installer (3376326) on accessory drive shaft. Press pulley on until it contacts step on shaft. Remove pulley installer. ACCESSORY DRIVE SEAL Removal & Installation 1) Remove accessory drive pulley. Drill two 1/8" holes 180 apart in seal casing. Install two No. 10 sheet metal screws. Use slide hammer puller to remove seal. 2) Clean seal mounting surface. Use crocus cloth to remove rough edges. Install seal on proper mandrel. Part number on seal faces the mandrel. Check that accessory drive shaft is clean and dry. NOTE: DO NOT use lubricant on accessory drive shaft or seal. Seal must be installed dry. 3) Push seal into seal bore until seal casing is below chamfer edge of front engine cover. Install accessory drive pulley.

PULLEY WEAR SLEEVE CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 17)For cyph8r pacific la ca 92101 1996 Mitchell Internation

Removal Secure pulley in soft-jawed vise. Using chisel lightly strike wear sleeve in four different positions. This relieves press fit. Remove wear sleeve. Clean surface with crocus cloth. Inspect for cracks in pulley keyway. Installation Place pulley in arbor press. Install wear sleeve on pulley with chamfer facing away from pulley. Place flat steel on wear sleeve. Press wear sleeve on until steel plate contacts pulley. Check wear sleeve for burrs. ACCESSORY DRIVE Removal 1) Remove fuel pump and air compressor. See FUEL PUMP and AIR COMPRESSOR in this article. Rotate engine until "A" mark on accessory drive aligns with pointer on gear cover. Remove accessory drive pulley. See ACCESSORY DRIVE PULLEY in this article. Remove inspection plugs from upper and lower timing plug holes in front of gear cover. Plugs are located just below accessory drive seal area. 2) Check that timing mark on camshaft idler gear and accessory drive are aligned. See Fig. 14.

Fig. 14: Accessory Drive Timing Marks Use with following legend. Courtesy of Cummins Engine Co., Inc. LEGEND FOR FIGURE 14

Number

Description

1 .................................... Key 2 ................................. Pulley 3 ............................ Wear Sleeve 4 ................................... Seal 5 ............................ Oil Slinger 6 ................................... Gear 7 .......................... Thrust Washer 8 .................................... Key 9 .................................. Shaft 10 ................................. Gasket 11 ................................ Housing 12 ................................ Bushing 13 .......................... Thrust Washer 14 ........................ Clamping Washer CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 18)For cyph8r pacific la ca 92101 1996 15 ............................... Coupling

16 ...................... Special Cap Screw 17 ................................. Washer

CAUTION: DO NOT use "A" marks on camshaft idler gear for accessory drive alignment unless "X" marks on camshaft and camshaft idler are aligned and centered in upper timing plug hole. 3) Remove drive key from accessory drive shaft. Remove mounting cap screws. Remove accessory drive assembly. Disassembly Remove cap screw, washer from rear of drive shaft. Place cap screw back in drive shaft after washer is removed. Install Coupling Puller (3376663) on coupling. Remove coupling. Remove clamping washer. Remove inner and outer thrust bearings. Remove drive shaft and gear from housing. Place gear and shaft in press. Press shaft from gear. See Fig. 15.

Fig. 15: Accessory Drive Courtesy of Cummins Engine Co., Inc. Inspection 1) Check inside diameter of bushings. Check drive shaft for cracks around keyways. Check for wear in bushing areas. Replace drive gear if any teeth are chipped, cracked or flaking. 2) Measure outside diameter of drive shaft. See Fig. 16. Measure inside diameter of drive gear bore. Measure thrust bearing thickness. Measure drive pulley bore inside diameter. See DRIVE UNIT SPECIFICATIONS table.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 19)For cyph8r pacific la ca 92101 19

Fig. 16: Measuring Accessory Drive Shaft Courtesy of Cummins Engine Co., Inc. LEGEND FOR FIGURE 16

Number 1 2 3 4

Description

....... 1.3765-1.3770" (34.963-34.976 mm) ....... 1.5616-1.5620" (34.662-39.674 mm) ........... 1.311-1.312" (33.30-33.33 mm) ....... 1.0030-1.0035" (25.476-25.489 mm)

DRIVE UNIT SPECIFICATIONS

Application

In. (mm)

Bushing I.D. ................... 1.316-1.319 (33.43-33.50) Drive Gear Bore I.D. ........... 1.564-1.565 (39.73-39.75) Shaft End Play ....................... .002-.012 (.05-.30) Shaft Gear Fit Area O.D. ... 1.5665-1.5670 (39.789-39.802) Pulley Bore I.D. ........... 1.3745-1.3755 (34.912-34.938)

Reassembly 1) Coat shaft with oil. Install key in shaft. Using hydraulic press, install shaft into gear. Using feeler gauge, check clearance between shoulder of shaft and surface of gear. Clearance must not be more than .002" (.05 mm). 2) Install thrust bearing on housing. Grooved side of thrust bearing goes"K" away from housing. Coat thrust bearing with Lubriplate CUMMINS SERIES 6-CYLINDERArticle Text (p. 20)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser 105. Install shaft and gear assembly in housing. Install rear thrust bearing with grooved side away from housing. Install clamping washer with bevelled edge toward housing. Using arbor press, press coupling on shaft. Clamping washer must be positioned tightly between coupling and shoulder of shaft. 3) Install washer and cap screw. Cap screw must contain oil drilling if air compressor is mounted on engine. Tighten 3/8" cap screw to 35 ft. lbs. (45 N.m). Tighten 1/2" cap screw to 75 ft. lbs. (100 N.m). Check drive shaft end play. See DRIVE UNIT SPECIFICATIONS table. Oversize thrust bearings are available to adjust end play. Installation 1) Install new gasket. Rotate accessory drive so that "A"

mark on accessory drive gear aligns with "A" mark on camshaft idler gear. Install mounting cap screws. See TORQUE SPECIFICATIONS table. Check that timing marks are aligned. CAUTION: DO NOT use "A" marks on camshaft idler gear for accessory drive alignment unless "X" marks on camshaft and camshaft idler are aligned and centered in upper timing plug hole. 2) Install oil slinger. Install key in drive shaft. Install accessory drive seal. Install plugs in inspection holes. Tighten plugs to 20 ft. lbs. (25 N.m). Install accessory drive pulley. Install fuel pump. Install air compressor. CAMSHAFT & TIMING GEARS VIBRATION DAMPER NOTE: Cummins engines use two types of vibration dampers: rubber element and viscous. Vibration damper cannot be repaired. Replace if defective. Checking Vibration Damper Eccentricity Install dial indicator to front gear cover. Place indicator tip on outside diameter of damper. Check that indicator tip does not fall into balance hole of damper. Rotate crankshaft 360. Replace vibration damper if reading exceeds limits. See VIBRATION DAMPER SPECIFICATIONS table. Checking Vibration Damper Wobble Install dial indicator to front gear cover. Place indicator tip on front of vibration damper 1/2" from outer edge of damper. Indicator tip must be located on smooth area of inertia member. Push crankshaft to front of engine. Zero dial indicator. Rotate engine 360. Replace the vibration damper if reading exceeds limits. See VIBRATION DAMPER SPECIFICATIONS table. VIBRATION DAMPER SPECIFICATIONS

Application

(1) In. (mm)

Eccentricity Rubber Damper .............................. .055 (1.40) Viscous Damper ............................. .040 (1.02) Wobble ....................................... .040 (1.02) (1) - Maximum reading.

Removal Remove cap screws. Using rubber hammer tap on vibration damper. DO NOT allow vibration damper to fall during removal. CAUTION: DO NOT use metal hammer or screwdriver to remove damper.

Inspection (Rubber Element Damper) 1) Check mounting hub for cracks. Check for deterioration or missing chunks of elastic member. Elastic member should not be more than 1/8" (3 mm) below metal surface. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 21)For cy 2) Check alignment marks on vibration damper. Outer member

and inner member have alignment marks. See Fig. 17. Replace vibration damper if marks are more than 1/16" (1.5 mm) out of alignment. Check that outer member is not sliding out of alignment with hub.

Fig. 17: Vibration Damper Alignment Marks Courtesy of Cummins Engine Co., Inc. 3) Outer member must not be higher or lower than hub area. Replace if outer member is more than .050" (1.3 mm) out of alignment. Inspection (Viscous Damper) 1) Check mounting hub for cracks. Check for dents, or raised surfaces. Remove paint from vibration damper on both sides in four locations. Measure thickness 1/8" (3 mm) from outside of vibration damper. Measure in four locations. Replace vibration damper if thickness varies more than .010" (.25 mm). 2) Spray vibration damper with Spotcheck Developer Type SKD-NF. Place vibration damper in 200F (93C) oven for two hours. Remove and check for leaks. Replace if any leaks appear. Installation Place vibration damper on crankshaft adapter. Rubber member damper does not require a crankshaft adapter. Install cap screws. See TORQUE SPECIFICATIONS table. Install vibration damper and adapter on crankshaft. Check that pilot on adapter is aligned with crankshaft. Install cap screws. See TORQUE SPECIFICATIONS table. ENGINE FRONT COVER Removal 1) Remove cap screws from gear driven fan hub (if equipped). On one piece covers, clamping plate fits on rear of cover in front of cylinder head. Remove fan hub assembly. 2) Remove plastic plug from end of alternator drive shaft. Use Pulley Installer (3376326). Install adapter in the end of shaft. Install puller on pulley. Remove pulley. Remove adapter from shaft. 3) Remove vibration damper. Remove front engine support. On one piece covers, master dowel must be removed. See Fig. 18. Remove accessory drive pulley. Remove key from accessory drive shaft.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 22

Fig. 18: Removing Master Dowel Courtesy of Cummins Engine Co., Inc. 4) One piece covers have five cap screws on the bottom and three on rear of cover. Two piece covers have only two cap screws on rear of cover. Remove cap screws. Note length and location of cap screws. Remove front engine cover and gasket. Inspection 1) Inspect barring mechanism bushing for wear. Inspect shaft and worm gear for wear. Check for movement of shaft in bushing. Inspect front engine cover for cracks or damage in seal areas. 2) Measure inside diameter of all drive bushings at two areas 90 apart. See FRONT COVER BUSHING SPECIFICATIONS table. Inspect for signs of bushings moving in housing. Check that all oil feed holes are aligned. Replace worn or damaged bushings. FRONT COVER BUSHING SPECIFICATIONS

Application

In. (mm)

Accessory Drive Bushing ...................... 1.696-1.697 (43.078-43.104) Hydraulic Pump Drive Bushing ................. 1.625-1.626 (41.275-41.301) Water Pump Drive Bushing ..................... 1.696-1.697 (43.078-43.104)

Bushing Replacement (Barring Mechanism) 1) Remove retaining ring from barring mechanism. Remove shaft, spring and worm gear. Remove "O" ring from shaft. Inspect barring mechanism thrust washer for damage. Remove bushing using small roll pin. DO NOT damage housing while removing bushing. Install new bushing assembly in bore. Use barring mechanism shaft as a mandrel. Drive new bushing in bore. 2) Install new "O" ring on shaft. Lubricate "O" ring with vegetable oil. Install spring, worm gear and shaft in cover. Install retaining clip. CUMMINS "K" Check SERIES for freedom 6-CYLINDERArticle of rotation. Text (p. 23)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser Bushing Replacement (Drive Bushing) 1) Using Mandrel (ST-598), remove accessory drive and water pump drive bushings from cover. Using appropriate mandrel, remove hydraulic pump drive bushing. Measure inside diameter of bushing bore in front engine cover. See FRONT COVER BUSHING BORE SPECIFICATIONS table. Replace cover if beyond limits. 2) Align oil hole in bushing with that of cover. Using proper

mandrel, install bushing in cover. Use an 1/8" (3 mm) Allen wrench to check oil hole alignment. FRONT COVER BUSHING BORE SPECIFICATIONS

Application

In. (mm)

Accessory Drive .............. 1.696-1.697 (43.078-43.104) Hydraulic Pump Drive ......... 1.625-1.626 (41.275-41.301) Water Pump Drive ............. 1.696-1.697 (43.078-43.104)

Installation 1) Check that gasket surfaces are clean. Install guide studs in cylinder block. Install new gasket. Install front engine cover. On one piece covers, clamping plate must be installed. 2) DO NOT tighten clamping plate cap screws until fan hub or cover plate is installed. Install cap screws in proper location. Install master dowel. Drive dowel in until it bottoms in cylinder block. 3) Check that all cap screws are installed. Cap screws must be tightened in sequence. See Fig. 19. Tighten cap screws. See the TORQUE SPECIFICATIONS table. Install front engine support.

Fig. 19: Front Cover Tightening Sequence Courtesy of Cummins Engine Co., Inc.

4) See TORQUE SPECIFICATIONS table. Install front crankshaft seal. Install vibration damper. Install key in accessory drive shaft. Install accessory drive oil slinger and seal. Install accessory drive pulley. 5) Install alternator drive seal. Check that alternator drive shaft is clean and dry. Place installation sleeve provided with seal, over shaft. Push seal onto shaft. Push seal into bore until it is . CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 24)For

125" (3.18 mm) below surface of engine front cover. Using Pulley Installation Kit (3376326), install alternator drive pulley on shaft. Check that pulley touches step on shaft. Install plastic cap in end of shaft. 6) Install new gasket for fan hub on front engine cover. Oil passage hole in gasket must be aligned with oil hole in the cover. Install fan hub. See TORQUE SPECIFICATIONS table. Rotate fan backward and forward to check fan hub backlash. See FAN HUB SPECIFICATIONS. Remove and check gears for wear if not within specifications. FAN HUB SPECIFICATIONS

Application

In. (mm)

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

FRONT CRANKSHAFT SEAL Removal Remove vibration damper. Using Seal Remover and Installer (ST-1131), remove seal. Installation 1) Check that seal surfaces are clean and dry. Place installation sleeve provided with seal on crankshaft. Push seal on crankshaft until it touches front engine cover. Install seal installer on crankshaft. Install cap screws into crankshaft. 2) Tighten cap screws in an alternately and evenly until tool bottoms on crankshaft. Check that both seal lips are clear of repair sleeve (if used). Seal should be approximately .140" (3.56 mm) below surface of engine front cover. Install vibration damper. IDLER GEARS Removal (Bolt-in Design) 1) Remove vibration damper. See VIBRATION DAMPER in this article. Remove engine front cover. See ENGINE FRONT COVER in this article. Note timing marks before removing idler gears. Remove retaining cap screw from idler gear. Bolt in idler shaft has a flange which requires idler gear and thrust washers to be removed as an assembly. 2) Slide hammer assembly must be threaded into idler gear shaft. Remove idler gear assembly. See Fig. 20. Mark each idler gear and thrust washer as to location.

Fig. 20: Removing Idler Gears Courtesy of Cummins Engine Co., Inc.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 25)For c

Removal (Press Fit Design) 1) Remove vibration damper. See VIBRATION DAMPER in this article. Remove engine front cover. See ENGINE FRONT COVER in this article. Note timing marks before removing idler gears. 2) Remove retaining cap screw from idler gear. Idler gear shafts are a press fit into cylinder block. Shaft does not have to be removed to remove idler gear assembly. Remove idler gear and thrust washers from shaft. Inspection 1) Inspect gears for broken, chipped or flaking teeth. Inspect thrust washers for damage. Measure inside diameter of idler gear bushings. Measure outside diameter of gear shafts at gear area and pilot area. 2) Pilot area is the area that fits into cylinder block. Measure thickness of thrust washers. See IDLER GEAR SPECIFICATIONS table. Replace if worn or damaged. IDLER GEAR SPECIFICATIONS

Application

In. (mm)

Camshaft Idler Gear Bushing I.D. ......... 1.8755-1.8785 (47.638-47.714) Gear Backlash ........................ .003-.012 (.07-.30) Gear End Play ........................ .004-.014 (.10-.36) Hydraulic Pump Idler Gear .. 1.7517-1.7535 (44.488-44.539) Hydraulic Pump Idler Shaft Pilot Area O.D. .......... 1.4390-1.4395 (36.551-36.563) Gear Area O.D. ........... 1.7470-1.7490 (44.370-44.425) Idler Shaft (Bolt-In) Pilot Area O.D. ............ .9995-1.000 (25.397-25.400) Gear Area O.D. ........... 1.8720-1.8740 (47.549-47.600) Thrust Washer Thickness ............ .088-.095 (2.24-2.41) Water Pump Idler Gear Bushing I.D. ......... 1.8755-1.8785 (47.638-47.714) Water Pump Idler Shaft (Press Fit) Pilot Area O.D. ......... 1.5600-1.5605 (39.624-39.627) Gear Area O.D. .......... 1.8720-1.8740 (47.549-47.600)

Installation (Bolt-in Design) 1) Coat thrust washers and gear bushings with Lubriplate 105. On bolt-in design assemblies, install shaft and thrust washer into gear. Grooves on thrust washers must face the gear. Install thrust washer on rear side of idler gear. Coat cap screw with oil. 2) Start idler gear cap screw into cylinder block. Rotate gear to align timing marks. See Fig. 21. Camshaft idler gear is only idler gear with timing marks. DO NOT allow inner thrust washer to fall from shaft.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 26)For cyph8r pacific la ca 9210

Fig. 21: Aligning Timing Marks Courtesy of Cummins Engine Co., Inc. 3) Tighten cap screw to install shaft in bore of cylinder block. See TORQUE SPECIFICATIONS table. Check that timing marks are aligned. If no hydraulic pump drive is used, install cap screw and plain washer in place of shaft. Washer must be larger than bore in cylinder block. Tighten cap screw to 50 ft. lbs. (65 N.m). CAUTION: Engines that do not have hydraulic pump idler must have plug installed in place of idler shaft. Low oil pressure will result is plug is left out. 4) Check that the cap screw does not protrude beyond the cylinder block and hit the crankshaft. Install a dial indicator on the front of the cylinder block. Check end play of each idler gear. Refer to the IDLER GEAR SPECIFICATIONS table. If end play is not within specifications, remove gear and check thrust washers. Oversized thrust washers are available. 5) When all gear assemblies are installed, check gear backlash on all idler gears. Install dial indicator on front of cylinder block. Position tip against tooth of gear. Rotate gear clockwise. Adjust dial indicator to "O" (zero). Rotate gear counterclockwise and note reading. See IDLER GEAR SPECIFICATIONS table. 6) If backlash in not within limits, gear must be replaced. Oil pump gear backlash can be adjusted by rotating oil pump. Install front engine cover. Install vibration damper. CAUTION: Engines with press fit idler assemblies must have hydraulic pump idler gear installed even if no hydraulic pump is used. No plug is available to block oil drillings.

Installation (Press Fit Design) 1) Check that small plugs are installed in ends of shafts. If shafts are to be installed in cylinder block, put shafts in freezer at 32F (0C) for eight hours. Heat cylinder block bores using heat lamps for two hours before installing shafts. Install shafts in bores. Allow parts to warm to room temperature before installing gears. 2) Coat gears and thrust washers with Lubriplate 105. Install rear thrust washer on shaft. Grooves in thrust washer must face gear. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. gear. 27)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser Install gear. Align timing marks on idler gear with crankshaft See Fig. 21. Camshaft idler gear is only gear with timing marks. Install front thrust washer and retaining washer. Install cap screw. See TORQUE SPECIFICATIONS table. Check that timing marks are aligned. 3) Install dial indicator on front of cylinder block. Check end play of each idler gear. See IDLER GEAR SPECIFICATIONS table. If end play is not within specifications, remove gear and check thrust

washers. Oversized thrust washers are available. 4) When all gear assemblies are installed check gear backlash on all idler gears. Install dial indicator on front of cylinder block. Position tip against tooth of gear. Rotate gear clockwise. Adjust dial indicator to "O" (zero). Rotate gear counterclockwise and note reading. See IDLER GEAR SPECIFICATIONS table. 5) If backlash in not within limits, gear must be replaced. Oil pump gear backlash can be adjusted by rotating oil pump. Install front engine cover. Install vibration damper. CRANKSHAFT GEAR Removal Remove front engine cover. See ENGINE FRONT COVER in this article. Remove oil pump and camshaft idler gears. Install Crankshaft Gear Puller Kit (3375840) on crankshaft gear. Turn pressure screw to remove crankshaft gear. Slight heat may be applied to gear during removal. Remove key from crankshaft. Inspection Inspect gear teeth for cracking, broken or chipped teeth. Inspect keyway in gear and crankshaft for cracks or burrs. Check key for burrs. Replace damaged parts. Measure crankshaft gear journal outside diameter in two areas 90 apart. See CRANKSHAFT GEAR SPECIFICATIONS table. CRANKSHAFT GEAR SPECIFICATIONS

Application

In. (mm)

Gear Journal Area O.D. ....... 4.380-4.381 (111.25-111.28)

Installation Install key in crankshaft. Heat gear in oven at 450F (230C) for one hour. Lubricate crankshaft with Lubriplate 105. Install gear on crankshaft with timing mark facing away from crankshaft. Align key and keyway. Install gear on crankshaft. Install camshaft and oil pump idler gears. Install front engine cover. CAM FOLLOWERS Removal Remove the rocker lever covers. Remove push rods. Refer to CYLINDER HEAD (REPLACEMENT) in this article. Remove cam follower covers. Note location of cam follower cover with crankcase vent. Remove cap screws from cam followers. Special cap screws are used. Mark these cap screws as to location. Remove cam follower assemblies. Mark cam follower assemblies as to location. Disassembly Mark each cam follower lever as location. Remove retaining clip from shaft. Remove levers from shaft. Inspection 1) Check that shaft rotates freely in cam followers. Inspect rollers for flat spots or flaking. Check that rollers rotate freely. Inspect shaft for scoring or wear. Inspect for wear in push rod sockets. If wear is excessive check push rods for damage. Check cam

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 28)F

followers for cracks using magnetic method. 2) Check for clearance between roller and pin. Measure shaft bore area of each cam follower lever. Measure shaft outside diameter in each cam follower lever area. See CAM FOLLOWER SPECIFICATIONS. Replace worn or damaged parts. CAM FOLLOWER SPECIFICATIONS

Application

In. (mm)

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

Reassembly Lubricate shaft and cam follower bores with oil. Install cam follower levers on shaft in original location. Install retaining clip. Check that cam followers move freely on shaft. Installation 1) Lubricate rollers with oil. Install cam follower assembly in original location. Check that cam follower shaft fits properly on ring dowels in cylinder block. Install special cap screws. 2) Cap screws have slot which allows oil to flow to cam follower assembly. See TORQUE SPECIFICATIONS table. Check injection timing if cam followers are replaced. See INJECTION TIMING in this article. 3) Two types of cam follower cover gaskets are used. One style gasket has bead of sealant which must be against cam follower cover. Another style of gasket is used, which must be installed dry. 4) Gasket material expands when exposed to engine oil. Install gaskets. Install cam follower covers in original positions. Cam follower cover with crankcase vent must be installed on No. 4 cylinder. Install cap screws. See TORQUE SPECIFICATIONS table. Install push rods. Install rocker lever covers. Adjust valves and injectors. CAMSHAFT Removal 1) Remove the front engine cover. See ENGINE FRONT COVER in this article. Remove the rocker lever covers and push rods. Refer to CYLINDER HEAD (REPLACEMENT) in this article. Remove cam follower assemblies. 2) Bend lock plates on cap screws on camshaft thrust plate. Remove cap screws. Install Camshaft Installation Pilots (3376280) on inner base circle of valve lobes of last two cylinders. See Fig. 22. Rotate camshaft while removing.

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

Fig. 22: Installing Camshaft Pilots Courtesy of Cummins Engine Co., Inc. Inspection Remove camshaft pilots. Inspect camshaft for flaking or flat lobes. Use magnetic method to check camshaft for cracks. Using micrometer, measure each journal. See CAMSHAFT table at the end of this article. Replace camshaft if worn. Measure camshaft nose and thrust plate. See CAMSHAFT GEAR in this article. Installation 1) Install camshaft pilots on valve lobes for last two cylinders. Lubricate camshaft and camshaft bushings with Lubriplate 105. Install camshaft. Rotate camshaft backward and forward while installing. 2) Align timing mark on camshaft gear with mark on camshaft idler gear. See Fig. 21. Check that gear spacer plate gasket is not preventing thrust plate from fitting flat against cylinder block. Install cap screws in thrust plate. See TORQUE SPECIFICATIONS table. Bend locks over cap screws. 3) Check camshaft end clearance. Install dial indicator on front of cylinder block. Place tip of indicator against face of camshaft gear. Push camshaft toward rear of engine. Adjust dial indicator to "O" (zero). Pull camshaft forward and note reading. See CAMSHAFT CLEARANCE SPECIFICATIONS table. If end clearance is not within specifications, check for foreign material or gasket under thrust plate. CAMSHAFT CLEARANCE SPECIFICATIONS

Application

In. (mm)

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

For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 30) article. Check injection timing if camshaft gear, camshaft gear key or camshaft is replaced. See INJECTION TIMING in this article. Install front engine cover. CAMSHAFT GEAR Removal Place camshaft in hydraulic press. Place "V" blocks under camshaft gear. Place wooden block under camshaft to prevent damage when camshaft drops from camshaft gear. Press camshaft from gear. Mark direction of key in camshaft.

4) Check camshaft gear backlash. See IDLER GEARS in this

Inspection 1) Check camshaft gear for cracks, chipped or broken teeth. Inspect bore for fretting, burrs or cracking in keyway. Replace camshaft gear if fretting cannot be removed with a fine crocus cloth. 2) Measure inside bore diameter of camshaft gear. See CAMSHAFT GEAR SPECIFICATIONS table. Replace camshaft gear if beyond limits. Measure thickness of thrust plate. See THRUST PLATE SPECIFICATIONS table. 3) Check camshaft keyway for cracks, fretting or burrs. Measure camshaft gear area in two areas 90 apart. See CAMSHAFT GEAR SPECIFICATIONS table. Replace camshaft if beyond limits or if keyway is cracked. CAMSHAFT GEAR SPECIFICATIONS

Application

In. (mm)

Gear Journal O.D. .......... 2.2520-2.2525 (57.200-57.210) Gear Bore I.D. ............. 2.2490-2.2500 (57.124-57.150)

THRUST PLATE SPECIFICATIONS

Application

In. (mm)

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

Installation 1) Using a soft hammer, install key in camshaft. Check that key is installed in original position. If using new key, check that same part number key is used. Install thrust plate on camshaft. Grooved side must be against the camshaft gear. 2) Heat gear in over at 450F (235C) for at least one hour. Install camshaft in hydraulic press. Install heated gear on camshaft aligning key and keyway. Timing mark on camshaft gear must face away from camshaft. Press gear onto camshaft. 3) Keep camshaft in vertical position until gear has cooled. Using feeler gauge, check clearance between gear and thrust plate. See THRUST PLATE SPECIFICATIONS table. Check injection timing when key or camshaft gear is replaced. See INJECTION TIMING in this article. CAMSHAFT BEARINGS Inspection 1) Inspect bearings for turning in cylinder block. Check alignment of oil passage holes. If bearings have turned, measure camshaft bearing bore in cylinder block. See CYLINDER BLOCK in this article. 2) Using dial bore gauge, measure inside diameter of camshaft bearings. Replace bearings if worn larger than specification. See CAMSHAFT BEARING SPECIFICATIONS table. CAMSHAFT BEARING SPECIFICATIONS

Application

In. (mm)

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

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 31)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser

Removal 1) Camshaft bearing bore in cylinder block must be determined before removing camshaft bearings. Engines serial numbers greater than 31103629 have 3.354" (8.26 mm) bores. Engines serial numbers less than 33103629 have 3.188" (8.10 mm) bores. Use Camshaft Bearing Driver (3376637) and Mandrel (3376634) for 3.188" (8.10 mm) bores. Use Mandrel (3376635) for 3.254" (8.26 mm) bores. 2) Install tool assembly through camshaft bore until driver is against No. 1 camshaft bearing. Hit slide hammer against shaft assembly until camshaft bearing is removed. Remove remaining camshaft bearings. Installation 1) Different styles of camshaft bearings are used on 3.188" (8.10 mm) bores. Some camshaft bearings have a 131 groove on the outside diameter of camshaft bearing. This type camshaft bearing must be used if engine is equipped with Jacobs Brake. Camshaft bearings without groove can be used if not equipped with Jacobs Brake. 2) Camshaft bearings for the 3.254" (8.26 mm) bores have a 360 groove around outside diameter of bearing. Notch in bearing must be positioned toward front of cylinder block. 3) Align oil holes of camshaft bearings. Using driver and proper mandrel, install camshaft bearings. Bearing must be installed until groove on the back is even with edge of cylinder block. Front camshaft bearing must be installed until it is even or below surface of cylinder block. 4) Each bearing contains four oil holes. All oil holes must be aligned except on front camshaft bearing. There are no oil holes to align with upper oil holes of front camshaft bearings. Using 1/4" (7 mm) Allen wrench, check alignment of all oil holes. INJECTION TIMING 1) Remove valve cover. Remove rocker arms and crossheads assembly from cylinder No. 3. Remove injector from cylinder No. 3. Install Injector Timing Set (3375522) to cylinder head. See Fig. 23. Install push rod plunger support in outside slot in piston plunger support.

Fig. 23: Injector Timing Set Installed Courtesy of Cummins Engine Co., Inc.

2) Align push rod plunger support with mark and tighten CUMMINS retaining bolts. Ensure rods are straight. Slowly rotate engine, using"K" SERIES 6-CYLINDERArticle Text (p. 32)For cyph8r p

crankshaft, clockwise (viewed from front of engine). When both plungers start moving upward, cylinder is on compression stroke. 3) When piston plunger dial indicator goes upward and then stops, piston is at TDC. Rotate engine until dial indicator starts to move downward. Rotate engine in opposite direction until dial indicator starts to move downward. 4) Cylinder should be slightly BTDC. Slowly move crankshaft counterclockwise (viewed from front of engine) until dial indicator has moved downward a minimum of .50" (12.7 mm). Lock dial indicator in place. Slowly rotate engine clockwise (viewed from front of engine) until dial indicator stops turning clockwise. Engine should be at TDC. 5) Move dial indicator down until there is only .10" (2.5 mm) movement on dial indicator. Zero dial indicator. Slowly rotate engine clockwise and counterclockwise. Dial indicator should always stop at zero before reversing direction. 6) If so, dial indicator is adjusted correctly. If not, readjust dial indicator. Turn push rod dial indicator so stem touches plunger. Carefully lower dial indicator until it bottoms out. Raise dial indicator when reading is a minimum of .30" (7.6 mm). 7) Slowly turn crankshaft clockwise (viewed from front of engine) until push rod dial indicator stops, and then reverses direction and stops. Momentarily reverse movement is the crush of the camshaft lobe. 8) Carefully lower push rod travel dial indicator until it bottoms out. Raise dial indicator until it reads .050" (1.27 mm) and lock in place. Zero dial indicator. Slowly rotate engine counterclockwise (viewed from front of engine) until dial indicator reads zero. 9) Continue to rotate engine counterclockwise (viewed from front of engine) until dial indicator reads .250" (6.35 mm). Slowly rotate engine until dial indicator reads .2032" (5.16 mm). If engine was rotated past .2032" (5.16 mm), rotate engine in opposite direction to .250" (6.35 mm). 10) Rotate engine clockwise (viewed from front of engine) to .2032" (5.16 mm). Dial indicator reading should be more than 1 revolution. Read push rod dial indicator counterclockwise from zero. This reading is the injection timing specification. See INJECTION TIMING SPECIFICATIONS table for correct reading. 11) If injection timing is as specified and a slip-fit gear is being used, replace gear with a standard gear. Recheck injection timing after camshaft gear has cooled. If injection timing is not as specified, recheck injection timing. 12) If injection timing is still not as specified, adjust timing by replacing camshaft key with an offset key. See OFFSET KEY SPECIFICATION table in this article. Place offset key in camshaft and recheck timing. INJECTION TIMING SPECIFICATIONS

Timing Code

(1) (2) Injection Timing

AE ............................... .106-.110" (2.7-2.8 mm) AM ............................... .116-.120" (2.9-3.0 mm) BL ............................... .161-.165" (4.1-4.2 mm) CI ............................... .112-.116" (2.8-2.9 mm) CL ............................... .142-.146" (3.6-3.7 mm) CU ............................... .126-.130" (3.2-3.3 mm) (1) - Push rod travel at .2032" (5.161 mm).

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 33)

(2) - All injection timing readings are negative measurements.

OFFSET KEY SPECIFICATIONS

Offset Key Part No.

Offset In. (mm)

216294 ...................................... .0035 (.089) 200711 ...................................... .0070 (.179) 216782 ...................................... .0110 (.279) 200709 ...................................... .0150 (.381) 200704 ...................................... .0197 (.500) 200708 ...................................... .0230 (.584) 3000491 ..................................... .0270 (.686) 200706 ...................................... .0328 (.833) 3000492 ..................................... .0360 (.914) 200714 ...................................... .0390 (.991) 3000493 .................................... .0430 (1.092) 3000494 .................................... .0470 (1.194) 3000495 .................................... .0510 (1.295)

OIL PAN & SUCTION TUBE Removal Remove cap screws from oil pan sump. Remove oil cover plate. See Fig. 24. Remove cap screws from suction tube mounting bracket. Remove suction tube.

Fig. 24: Removing Oil Pan Courtesy of Cummins Engine Co., Inc. Installation Install suction tube and gasket on cylinder block. Tighten cap screws to cylinder block, then tighten mounting bracket cap screws. See TORQUE SPECIFICATIONS table. Install guide studs in adapter. Install gasket. Install oil sump and oil cover plate. Cap screws must be tightened in sequence. See Fig. 25. Tighten cap screws. See TORQUE SPECIFICATIONS table.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 34)For cyph8r pacific la ca 9

Fig. 25: Oil Pan Tightening Sequence Courtesy of Cummins Engine Co., Inc. OIL PAN ADAPTER Removal Remove cap screws from rear of adapter-to-flywheel housing. Remove remaining cap screws from adapter. Remove adapter and gaskets. Installation 1) Check that all gasket surfaces are clean. Install four cap screw seals in rear of adapter. Contact adhesive can be used to hold cap screw seals. Install two rectangular seals on rear of adapter. Rectangular seals have adhesive on one side. Install gasket on adapter using contact adhesive. 2) Apply Sealant (Part No. 3377132) to areas between adapter gasket and rectangular seals. Apply sealant to rear of rectangular seals. Install guide studs in cylinder block. Install adapter. Install cap screws to support adapter. DO NOT tighten cap screws. 3) Install cap screws in rear corners of adapter. Install upper cap screws into flywheel housing. See Fig. 26. Tighten cap screws to 10, 20 and 35 ft. lbs. (15, 25, and 45 N.m).

Fig. 26: Install Adapter Cap Screws Courtesy of Cummins Engine Co., Inc.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 35)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser
4) Install lower cap screws from adapter into flywheel housing. Tighten cap screws to 35 ft. lbs. (45 N.m). Remaining cap screws must be tightened in sequence. See Fig. 27. Tighten cap screws to 35 ft. lbs. (45 N.m).

Fig. 27: Adapter Tightening Sequence Courtesy of Cummins Engine Co., Inc. PISTON, CONNECTING ROD & CYLINDER LINER PISTONS & ROD ASSEMBLY Removal 1) Remove cylinder head. See CYLINDER HEAD (REPLACEMENT) in this article. Remove oil pan. See OIL PAN in this article. Use 240 grit emery cloth to remove carbon deposits from cylinder liner. Remove loose carbon from cylinder liner. 2) Loosen connecting rod cap screws. Using rubber hammer, hit connecting rod cap screws to loosen from dowel rings. Connecting rod assemblies are numbered for cylinder location. Numbers must face camshaft side of engine. Remove connecting rod cap screws and rod cap. Mark bearings for location if bearings are to be reused. 3) Install Connecting Rod Pins (3375098) in connecting rod. Push assembly from cylinder block. Place assembly in container to prevent damage. Disassembly Using Piston Ring Expander (ST-1269), remove piston rings. Remove piston pin snap rings. To remove piston pin, heat piston in boiling water for 15 minutes. Using blunt tool, push pin from piston and rod assembly. Cleaning & Inspection (Piston) 1) Soak pistons in aluminum cleaner. Clean pistons with a soapy solution and non-metallic brush. Steam clean pistons and dry with compressed air. CAUTION: DO NOT clean pistons with wire brush or glass beads. This causes damage to grooves and pin bores.

2) Inspect piston for skirt or pin bore cracks. Insert Piston Ring Groove Wear Gauge (ST-560) into top and second ring grooves. Widest part of tool must not come in touch with piston. Replace if shoulder touches piston. Measure width of oil ring groove. Refer to the PISTON SPECIFICATIONS table. 3) Using a dial bore gauge, measure the piston pin bore at two areas 90 apart. Also measure the piston skirt diameter at two locations 90 apart. Refer to the PISTON SPECIFICATIONS table. Also, see Fig. 28. Measure piston pin outside diameter at two areas 90 apart. See PISTON PIN SPECIFICATIONS table. Replace parts not within specifications. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 36)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser

Fig. 28: Measuring Piston Skirt Diameter Courtesy of Cummins Engine Co., Inc. PISTON SPECIFICATIONS

Application

In. (mm)

Measurement 1 ............ 6.2380-6.2390 (158.445-158.471) Measurement 2 ............ 6.2389-6.2409 (158.468-158.518) Oil Ring Groove Width .......... .1855-.1895 (4.788-4.813) Pin Bore ................... 2.3985-2.3989 (60.922-60.932)

PISTON PIN SPECIFICATIONS

Application

In. (mm)

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

Cleaning & Inspection (Connecting Rod) 1) Steam clean connecting rod. Clean oil passages with bristle brush. Dry with compressed air. Check connecting rod for nick or damage. Connecting rod should be checked for cracks using magnetic method. Replace rod if damaged. Check rod pin bushing for cracking or misalignment of oil passage hole. Replace bushing if damaged. 2) Install connecting rod cap and cap screws. Tighten cap screws. Refer to the TORQUE SPECIFICATIONS table. Using a dial bore gauge, measure connecting rod journal bore at two areas 90 apart. Refer to the CONNECTING ROD SPECIFICATIONS table. Using a dial bore gauge, measure the piston pin bushing at two locations 90 apart. See the CONNECTING ROD SPECIFICATIONS table. Replace parts not within specifications. CONNECTING ROD SPECIFICATIONS

Application

In. (mm)

Rod Journal Bore I.D. .... 4.2518-4.2522 (107.995-108.005) CUMMINS "K" SERIES Text (p. 37)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser Piston Pin Bushing I.D. .... 6-CYLINDERArticle 2.4010-2.4025 (60.990-61.020)

Reassembly 1) Check piston ring end gap. See FITTING PISTON RINGS in this article. Install new snap ring in piston pin bore of each piston. Heat pistons in oven heated to 200F (93C) for 15 minutes. Coat connecting rod pin bushing and piston pin with 15W-40 oil. 2) Remove piston from oven. Install piston pin through connecting rod. DO NOT drive piston pin through piston. Damage will result if piston pin will not slide freely. Install new snap ring in piston pin bore. Check that snap rings are properly seated in grooves. Installation 1) Install piston rings. See FITTING PISTON RINGS in this article. Install piston and ring assembly in container of 15W-40 oil. Remove piston assembly. Position piston rings in proper location. See Fig. 29. Install Connecting Rod Guide Pins (3375098) on connecting rod. Using Piston Ring Compressor (3375342), compress piston rings.

Fig. 29: Alignment of Piston Rings Courtesy of Cummins Engine Co., Inc. 2) Install upper connecting rod bearing in connecting rod. Tang of bearing shell must be in slot of connecting rod. Connecting rod bearing must be placed in original position if used bearing shells are installed. Coat bearing surface with 15W-40 oil. 3) Rotate crankshaft until connecting rod journal is at bottom dead center. Position piston assembly so that number on connecting rod is toward camshaft side of engine. Place piston on top of cylinder liner. 4) Push piston assembly into cylinder liner. DO NOT use metal object to install piston. Push piston until top piston ring enters cylinder liner. Piston must move freely from ring compressor into cylinder liner. If piston does not move freely, remove piston and check for damage to rings. 5) Using guide studs, pull connecting rod against crankshaft. Remove guide studs. Install bearing shell in connecting rod cap. Coat bearing surface with 15W-40 oil. Install cap so that bearing slot side of cap is against slot side of connecting rod. Number on connecting rod and cap must be on same side. CAUTION: Check that number on connecting rod and cap are on camshaft side of engine. Numbers on connecting rod and cap must match.

6) Coat cap screws with 15W-40 oil. Install cap screws. Tighten cap screws in alternating sequence. See TORQUE SPECIFICATIONS table. Connecting rod must move freely from side to side. IfCUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 38)For cyph

connecting rod will not move freely, check bearing for damage and proper size. 7) Check connecting rod side clearance. Push the connecting rod to one side as far as possible. Using a feeler gauge, measure clearance between the connecting rod and the crankshaft. Refer to the CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table. 8) If side clearance is not within specifications, remove rod caps. Check bearings for damage, dirt or proper size. Install oil pan. Install cylinder head. CYLINDER LINER Removal 1) Install Liner Puller (3376015) on top of cylinder block. Adjust feet of puller to extend below bottom of the cylinder liner. Center puller on cylinder block. CAUTION: When installing and using liner puller use care not to damage piston spray nozzles (if equipped). 2) Rotate liner puller clockwise. Remove liner from cylinder block. Check for shims or counterbore ring used in liner counterbore. Mark shims or ring and cylinder liners as to cylinder location. Cleaning & Inspection 1) Clean liner seating flange using high quality wire brush. Steam clean liners. Dry with compressed air. Check for cracks inside and outside cylinder liners. Inspect or cracks under liner flange. Check outside of liner for excessive pitting or corrosion. Pits must not be deeper than 1/16" (1.58 mm). Replace if corrosion cannot be removed using fine emery paper. Replace if pitting exceeds limit. 2) Replace is signs of scoring exist. Check for a bright mirror finish inside cylinder liner. Replace if mirror finish exists over 20% of piston travel area. With dial bore gauge, measure inside diameter in three places 90 apart. 3) Compare readings to those in CYLINDER LINER SPECIFICATIONS table. Replace cylinder liner if not within specifications. CYLINDER LINER SPECIFICATIONS

Application

Minimum Reading In. (mm)

Maximum Reading In. (mm)

Inside Diameter (1) .. 6.2495 (158.74) .. 6.2550 (158.88) Liner Protrusion (2) ... .003 (.08) ......... .006 (.15) (1) - New cylinder liner dimensions at 60-70F (16-21C) may be .0002-.0006" (.005-.015 mm) smaller than indicated due to lubrite coating. (2) - Liner installed.

Installation 1) Install shims or counterbore ring on liner. Curved edge of counterbore ring must face cylinder block. Install crevice seal in top groove of clean cylinder liner. Chamfer on crevice seal goes toward bottom of cylinder liner. Install Black "O" ring in second groove. Place Red "O" ring in lower groove. Ensure "O" rings are not twisted.

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

CAUTION: Cylinder block counterbore must be checked before installing cylinder liner. 2) Check counterbore. See CYLINDER BLOCK in this article. Ensure counterbore and cylinder liner flange are clean. Apply a bead of Sealant (3801048) on cylinder liner flange. If counterbore ring is used, apply sealant to bottom of ring. Diameter of bead must be at least 3/64" (1.1 mm) and not more than 1/16" (1.6 mm). 3) Lubricate crevice seal and "O" rings with vegetable oil. Place liner in cylinder block. DO NOT allow oil to touch sealant. Push liner in with a quick push. Install liner against counterbore ledge using Cylinder Liner Driver (3375422). See Fig. 30.

Fig. 30: Installing Cylinder Liner Courtesy of Cummins Engine Co., Inc. 4) Install Cylinder Liner Hold-Down (3376944). Tighten cap screws to 50 ft. lbs. (65 N.m). Use Gauge Block (3376220) to check liner protrusion. Refer to the CYLINDER LINER SPECIFICATIONS table. See Fig. 31. If not within specifications, liner shims or oversize liners may be required.

Fig. 31: Checking Cylinder Liner Protrusion Courtesy of Cummins Engine Co., Inc. 5) Measure inside diameter of cylinder liner at three areas 90 apart. See CYLINDER LINER SPECIFICATIONS table. Check liner bore for out-of-round. See Fig. 32.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 40

Fig. 32: Cylinder Liner Bore Check Points Courtesy of Cummins Engine Co., Inc. 6) If measurements are not within specifications, remove liner. Check for twisted "O" rings. Check liner flange and counterbore for burrs. Remove burrs. Replace damaged parts. Install cylinder liner. Check liner measurements. FITTING PISTON RINGS 1) Check new piston rings in the new cylinder liner to which they are to be installed. Make sure ends have correct gap by positioning each ring in cylinder liner. Use top of piston to even rings in cylinder liner. Measure end gap with a feeler gauge. See PISTONS, PINS & RINGS table at the end of this article. If ring gap is incorrect, check part numbers to make sure rings are correct. 2) Use Piston Ring Expander (ST-763) to install piston rings. Install oil control ring first. Install expander ring gap 180 from oil ring gap. Piston shipping package identifies location of each piston ring by part number. Install piston rings with the part number, mark or the word TOP toward the top of piston. CRANKSHAFT & ROD BEARINGS MAIN BEARINGS

Removal 1) Remove main bearing cap screws, starting at each end and moving toward center of crankshaft. Main bearing caps are marked as to cylinder location. Mark bearing caps if they are not marked. Use two pry bars. Place pry bars in notches at sides of the caps. Remove main bearing caps. Care must be taken when removing No. 6 bearing cap to avoid damage to dowels. 2) Mark all bearings to location. Remove thrust bearings from No. 6 bearing cap. Carefully remove upper thrust bearings using blunt object. Lift crankshaft from cylinder block. Remove upper main bearing shells. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 41)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser Cleaning & Inspection 1) Clean main bearing caps and cap screws. Clean cap screw holes in cylinder block. Inspect cap screws and main bearing caps for cracks. Clean bearing and inspect them for scoring, pitting, flaking, etching, loss of babbitt or signs of overheating. 2) Inspect backs of main bearing shells for bright spots

which indicate they have been moving in the bearing caps. Replace bearing if any of these signs are present. Installation 1) Check that main bearing cap screw holes are clean and dry. Check that crankshaft journals and oil passages are clean. Main bearing shells are marked on back side for upper and lower location. Install upper bearing shells. Used bearing shells must be installed in original position. Tang on bearing shell must fit in slot of cylinder block. Coat bearing shells with 15W-40 oil. Install crankshaft. 2) Push crankshaft toward rear of engine. Coat thrust bearings with 15W-40 oil. Install rear upper thrust bearing. Grooves on thrust bearings go toward crankshaft. Push crankshaft toward front of engine. Install front upper thrust bearing. 3) Install lower bearing shells in main bearing caps. Coat main bearings with 15W-40 oil. Install thrust bearings on No. 6 main bearing cap. Grooves of thrust bearings go toward crankshaft. Install main bearing caps in proper location. 4) Two different types of main bearing cap screws are used. Cap screws marked "x34" on top have a small radius between shank and the head. Cap screws marked with other markings on top have a large radius between shank and the head. DO NOT mix different cap screws. Engines with serial number 31118624 and above have been chamfered at cap screw holes for large radius cap screws. 5) Use large radius cap screw with chamfered main bearing caps. On chamfered main bearing caps, washer is not required with cap screw. If cap is not chamfered, washer must be used with cap screw. Small radius cap screws may be used on all main bearing caps. 6) Coat cap screws with 140W oil. Install cap screws. Cap screws must be tightened in sequence. See Fig. 33. Tighten cap screws. See TORQUE SPECIFICATIONS table. Check that crankshaft rotates freely by hand. Check for wrong bearings or improper installation if crankshaft will not rotate freely.

Fig. 33: Main Bearing Tightening Sequence Courtesy of Cummins Engine Co., Inc. THRUST BEARING

1) Install Dial Indicator (3376050) with magnetic base to rear of cylinder block. Position tip of indicator against crankshaft flywheel flange. Push crankshaft toward front of cylinder block. Adjust dial indicator to "O" (zero). 2) Push crankshaft toward rear of cylinder block and note reading. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table at the end of article. If reading is not within specifications, remove No. 4 main bearing cap. Check thrust bearing for burrs or damage. Replace if damaged. If bearings are not damaged, measure outside diameter of CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 42)For cyp

thrust bearings. Select proper size thrust bearing to reach specification. Install thrust bearing and recheck end play. NOTE: When an engine is being rebuilt, it may be necessary to bring crankshaft end play to specifications by using a reconditioned crankshaft and oversize thrust bearings. CONNECTION ROD BEARING Removal 1) Remove oil pan. See OIL PAN in this article. Rotate engine until connecting rod is at bottom dead center. Loosen cap screws. Hit connecting rod cap screws with soft hammer. This loosens rod caps from dowel rings. 2) Remove cap screws and connecting rod cap. Remove lower bearing shell and mark as to location. Push connecting rod up far enough to remove upper bearing shell. Remove bearing shell and mark location. Cleaning & Inspection Clean cap screws and connecting rod cap. Inspect bearing for flaking, pitting or lock tang damage. Installation 1) Install upper bearing shell in connecting rod. Tang on bearing shell must align with slot of connecting rod. Install bearing in original location if used bearings are used. Coat bearing shells with 15W-40 oil. Pull connecting rod down to crankshaft journal. 2) Install lower bearing shell in connecting rod cap. Check that number on connecting rod and rod cap are on same side. Install connecting rod cap on connecting rod. Slot side of rod cap must be on slot side of connecting rod. Coat cap screws with 15W-40 oil. Install cap screws. Tighten cap screws in alternating sequence. See TORQUE SPECIFICATIONStable. 3) The connecting rod must slide freely from side to side. Move the connecting rod to one side as far as possible. Install a feeler gauge between the connecting rod and the crankshaft. Refer to the CRANKSHAFT MAIN & CONNECTING ROD BEARING table at the end of this article. If not within specifications, remove connecting rod cap. Check for burrs, damage or wrong bearing size. CRANKSHAFT Cleaning & Inspection 1) Use bristle brush to clean oil passages. Steam clean crankshaft. Dry with compressed air. Use special attention to clean oil passages and thread holes in crankshaft. 2) Check crankshaft for cracks using magnetic method. Inspect rear seal area for wear. Measure connecting rod and main bearing journals. Measure journals at two areas 90 apart. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table. Measure thrust face width. See CRANKSHAFT THRUST SPECIFICATIONS table. Repair or replace crankshaft if not within specifications. CRANKSHAFT THRUST SPECIFICATIONS

Application

In. (mm)

Face Width ..................... 2.374-2.374 (60.30-60.33)

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 43

REAR CRANKSHAFT SEAL Removal Remove flywheel. See FLYWHEEL in this article. Remove rear seal cap screws. Remove seal and "O" ring. Installation Check that seal areas are dry and clean. Lubricate "O" ring with vegetable oil. Install "O" ring on seal housing. Install installation sleeve provided with seal on crankshaft. Push seal onto crankshaft. Check that the directional arrow on seal matches engine rotation. Install cap screws. Tighten cap screws to 95 INCH lbs. (11 N.m). Install flywheel. CYLINDER BLOCK INSPECTION Cylinder block should be cleaned before checking. Inspect for crack around cylinder head cap screw holes. Inspect liner bore areas for cracks or damage. Inspect water holes for erosion or pitting. If pitting is more than .003" (.08 mm) deep or extends more than .095" (2.41 mm) from edge of hole, water hole must be repaired. Liner Bore Packing Ring Area Use dial bore gauge. Measure packing ring bore at two areas 90 apart. See CYLINDER BLOCK SPECIFICATIONS table. Main Bearing Bore Alignment 1) Check main bearing bores. Install centering rings (ST1177-54) in Nos. 2 and 6 main bearings. Install main bearing caps in proper location. Bearing slot in cap and slot in cylinder block must be on same side. Tighten cap screws in sequence. See Fig. 33. Also, refer to the TORQUE SPECIFICATIONS table. 2) Lubricate inside diameter of centering ring with oil. Install Alignment Bar (ST-117-16) into centering rings. Alignment bar must rotate freely. If bar does not rotate easily, check that main bearing caps are in proper location. If caps are installed correctly, move centering ring to another bearing location. Check rotation of alignment bar. 3) Install checking ring in main bearing bore. If checking ring binds, check for burrs. If ring still binds, repair is needed. Cylinder block must be repaired. Use .003" (.075 mm) feeler gauge which in not more than 0.5" (13 mm) wide. Try to install feeler gauge between checking ring and the bore while rotating alignment bar. 4) Main bearing bore is correct if feeler gauge does not enter at any location. If feeler gauge will slide through or around checking ring. Alignment bar must still rotate freely. If feeler gauge will enter and slides around the bore, bore is oversized. If feeler gauge will fit on one side and not on the other side of checking ring, bore is tapered. If bore is oversized or tapered, cylinder block must be repaired.

Main Bearing Bores Check bores for out-of-roundness. Install main bearing caps in proper location. Tighten cap screws in sequence. See Fig. 33. See CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 44)For cyph8r pac TORQUE SPECIFICATIONS table. Using dial bore gauge, measure bore

diameter in three areas 90 apart. See CYLINDER BLOCK SPECIFICATIONS table. Cylinder Liner Counterbore 1) Measure counterbore depth a 4 equally spaced points at edge of bore. Measurements must not exceed a total of .001" (.03 mm) difference around circumference of counterbore. Ledge must be flush with top of block to within .0014" (.036 mm). Check counterbore diameter for out-of-roundness. See CYLINDER BLOCK SPECIFICATIONS table. Repair cylinder block if not within specifications. 2) Install liner in cylinder block without "O" rings. Use Cylinder Liner Hold-Down Clamps (3376944) to hold liner in block. Ensure clamps are installed so there is equal pressure on liner. Tighten clamps to 50 ft. lbs. (68 N.m). 3) Use Gauge Block (3376220) to measure liner protrusion. Shims can be used under flange of liner to obtain correct protrusion. Liner protrusion should be .003-.006" (.08-.15 mm). 4) Another method of measuring liner protrusion is to measure thickness of liner flange. DO NOT include bead on top of flange when measuring. Measure depth of counterbore with gauge block. 5) Subtract depth of counterbore form thickness of outer flange. Remainder is liner protrusion when installed in cylinder block. Measurement must be within .003-.006" (.08-.15 mm). Add shims under flange of liner to obtain proper liner protrusion. Counterbore must be repaired if proper liner protrusion is not obtained. Camshaft Bearing Bore I.D. With camshaft bearings removed, measure bore at two areas 90 apart. See CYLINDER BLOCK SPECIFICATIONS table. Repair cylinder block if not within specifications. Idler Shaft Bore I.D. Using dial bore gauge, measure bore diameter of all idler shaft bores. Measure bore at two areas 90 apart. See CYLINDER BLOCK SPECIFICATIONS table. CYLINDER BLOCK SPECIFICATIONS

Application

In. (mm)

Camshaft Bearing Bore After Serial Number 31103629 ............. 3.2535-3.2545 (82.639-82.665) Before Serial Number 33103629 ............ 3.1875-3.1885 (80.963-80.988) Camshaft Idler Shaft Bore .................... 1.558-1.559 (39.57-39.60) Counterbore Out-Of-Round ..................... .001 (.025) Hydraulic Pump Idler Shaft Bore .............. 1.437-1.438 (36.50-36.53) Idler Shaft Bore ............................. 1.558-1.559 (39.57-39.60) Liner Bore Packing Area ...................... 6.982-6.984 (177.34-177.39) Main Bearing Bore Out-Of-Round ............................... .0005 (.013) Water Pump Idler Shaft ....................... 1.558-1.559 (39.57-39.60)

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p

MAIN, CONNECTING & THRUST BEARING THICKNESS

Bearing Application

Maximum Thickness In. (mm)

Minimum Thickness In. (mm)

Main ................ .1712 (4.348) ...... .1690 (4.293) Connecting Rod ...... .1250 (3.175) ...... .1230 (3.124) Thrust ............... .1535 (3.899) ...... .1505 (3.823)

FLYWHEEL & FLYWHEEL HOUSING FLYWHEEL FACE RUNOUT Checking 1) Using a dial indicator, measure flywheel face runout. Place tip of dial indicator against flywheel face. Place tip as close to outside of face as possible. Measure radius of flywheel. 2) Push flywheel forward to remove crankshaft end clearance and zero dial indicator. Rotate engine 360. Check dial indicator reading at four different points of flywheel. See Fig. 34. Total reading must not exceed that listed. See FLYWHEEL FACE RUNOUT SPECIFICATIONS table. FLYWHEEL FACE RUNOUT SPECIFICATIONS

Flywheel Radius In. (mm)

Indicator Reading In. (mm)

8 (203) ...................................... .008 (.203) 10 (254) ..................................... .010 (.254) 12 (035) ..................................... .012 (.305) 14 (356) ..................................... .014 (.356) 16 (406) ..................................... .016 (.406)

3) If reading exceeds specifications, remove flywheel. Check crankshaft flange or flywheel mounting area for nicks, burrs or foreign material.

Fig. 34: Checking Flywheel Face Runout Courtesy of Cummins Engine Co., Inc. CHECKING FLYWHEEL BORE RUNOUT

CUMMINS "K" SERIES 6-CYLINDER

1) Using a dial indicator, measure flywheel bore runout. Place tip of dial indicator against inside bore of flywheel and zero dial indicator. See Fig. 35. 2) Rotate engine 360. Note dial indicator readings. Total indicator reading must not exceed .005" (.127 mm). If reading exceeds specification remove flywheel. Check flywheel mounting surface for dirt or damage. Check for burrs in mounting area of flywheel and crankshaft. 3) Install flywheel. Check flywheel bore runout. Replace flywheel if not within specifications.

Fig. 35: Checking Flywheel Bore Runout Courtesy of Cummins Engine Co., Inc. FLYWHEEL Removal 1) Remove one cap screw. Install one 5/8" x 18 guide stud. Remove remaining cap screws. Install two "T" handles in flywheel cap screw holes. 2) Attach hoist with lifting sling to "T" handles and apply tension to sling. Remove remaining cap screws. If necessary, use a mallet to lightly tap flywheel while pulling and remove flywheel. Inspection Check flywheel for cracks using Crack Detector Kit (3375432). Replaced if cracked. Drive pilot bearing from flywheel. Check for cracks in pilot bearing bore. Check for bad threads in face of flywheel where clutch assembly attaches to flywheel. Check for cracked or chipped ring gear teeth. Replace ring gear teeth if cracked. See FLYWHEEL RING GEAR in this article. Installation 1) Clean pilot bearing bore with emery paper. Install new pilot bearing. Pilot bearing must be flush with pilot bore surface. Install guide stud in crankshaft. 2) Using hoist and "T" handles mounted to flywheel, lift flywheel onto guide stud. Lubricate flywheel cap screws with motor oil. Install cap screws. Remove guide stud. Install remaining cap screw. Tighten cap screws in star pattern to specification. See TORQUE SPECIFICATIONS table. Safety wire cap screws if used. FLYWHEEL RING GEAR

Removal Heat outside diameter of ring gear. Using a blunt chisel, drive ring gear from flywheel. Clean area from burrs or corrosion. CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 47)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser

Installation 1) Heat ring gear in oven for one hour at 450F (235C). If oven is not available use heating torch. Heat inside diameter of ring gear. Use Tempilstik crayon to check ring gear temperature. CAUTION: DO NOT overheat ring gear. Overheating of ring gear can change metal hardness. 2) Install heated ring gear on flywheel. Tap ring gear onto flywheel using soft material. FLYWHEEL HOUSING Removal Remove flywheel. See FLYWHEEL this article. Remove two flywheel housing retaining cap screws. Install two guide studs. Remove remaining cap screws. Tap on flywheel housing using rubber hammer to loosen from engine block. On wet type flywheel housings remove rectangular seals from mounting cap screw and dowel pin counterbores. Remove "O" ring from rear cover. Inspection Check flywheel housing for cracks. Carefully check all threaded cap screw holes. Check for burrs in rear seal area. Check dowel pin holes for burrs or damage. Replace flywheel housing if cracked or cap screw holes cannot be repaired. CAUTION: If installing new flywheel housing, dowels must be removed before installation. Flywheel housing must be doweled with over-size dowel after being aligned. See FLYWHEEL HOUSING REDOWEL. Installation 1) Check that rear of cylinder block is clean. Check that oil passage plugs are in rear of cylinder block. Install two guide studs in cylinder block. On wet type flywheel housings install new "O" rings in counterbores. Lube "O" ring with 15W-40 oil. Install new sealing ring in groove of flywheel housing. 2) Install flywheel housing over guide studs. Install cap screws. Check that flywheel housing is seated on dowels. Tighten cap screws in sequence. See Fig. 36. Tighten the cap screws. Refer to the TORQUE SPECIFICATIONS table. 3) Flywheel housing must be checked for bore alignment and face alignment correctness. Refer to FLYWHEEL HOUSING BORE ALIGNMENT and FLYWHEEL HOUSING FACE ALIGNMENT in this article. If flywheel housing is within specifications install flywheel. See FLYWHEEL section.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 48)Fo

Fig. 36: Flywheel Housing Cap Screw Tightening Sequence Courtesy of Cummins Engine Co., Inc. CAUTION: Flywheel housing bore alignment and face alignment must be checked any time flywheel housing is removed or replaced. FLYWHEEL HOUSING BORE ALIGNMENT Checking 1) Check that inside bore of flywheel housing is clean and free of burrs. Install dial indicator on crankshaft. Position dial indicator tip so that it rests on the bore of flywheel housing. Indicator tip should be positioned just inside flywheel housing opening. Place dial indicator at the 12 o'clock position. Adjust dial indicator to read "O" (zero). 2) Slowly rotate engine clockwise until dial indicator is at 3 o'clock position. Record dial indicator reading at this location. Rotate engine and take readings at 6 o'clock and 9 o'clock positions. 3) Continue rotating engine to the 12 o'clock position. Check that dial indicator is still at "O" (zero). Total all dial indicator "Plus" readings. Total all indicator "Minus" readings. 4) Subtract the smaller of the two readings from the larger reading. The final reading will have the sign of the larger of the two numbers. For example, if +.003" is subtracted from -.006", the result will be -.003". If -.002" is subtracted from +.004", the result is +. 002". 5) This measurement is the "runout". Maximum allowable total runout is determined by the flywheel housing diameter. Refer to the FLYWHEEL HOUSING RUNOUT SPECIFICATIONS table. FLYWHEEL HOUSING RUNOUT SPECIFICATIONS

Bore Diameter In. (mm) (1)

Runout In. (mm)

16.130 (409.70) ............................... .008 (.20) 17.630 (447.80) ............................... .008 (.20) CUMMINS "K"............................... SERIES 6-CYLINDERArticle Text (p. 49)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser 20.130 (534.40) .008 (.20) 23.008 (584.20) ............................... .010 (.25) 25.510 (647.95) ............................... .010 (.25) 31.010 (787.65) ............................... .012 (.30) (1) - Figures have been rounded off.

6) If bore alignment exceeds specifications, loosen cap screws. Tighten cap screws again. Check bore alignment again. If not within specifications and bore is round, flywheel housing can be

shifted. See FLYWHEEL HOUSING REDOWEL. If bore is not round, replace flywheel housing. FLYWHEEL HOUSING FACE ALIGNMENT Checking 1) Check that face of flywheel housing is clean and free of burrs. Install dial indicator on flywheel. Position dial indicator tip so it rides on the outside face of flywheel housing. 2) Check that dial indicator tip does not hit cap screw holes when engine is rotated. Place dial indicator at the 12:00 o'clock position. Push crankshaft toward front of engine. Adjust dial indicator to read zero. NOTE: Crankshaft must be pushed toward front of engine each time dial indicator reading is taken. 3) Slowly rotate engine clockwise until dial indicator is at the 3 o'clock, 6 o'clock and 9 o'clock positions. Record dial indicator readings at all locations. Continue rotating engine to the 12 o'clock position. 4) Check that dial indicator is still at zero. Total all dial indicator "Plus" readings. Subtract "Minus" readings. This is the runout. Maximum total indicator runout is determined by flywheel housing diameter. See FLYWHEEL HOUSING RUNOUT SPECIFICATIONS table. 5) If face alignment exceeds specifications remove flywheel housing. Check for nicks, burrs or foreign material between cylinder block and flywheel housing. Install flywheel housing. Check face alignment again. If reading exceeds specification cylinder block or flywheel housing is not machined correctly. FLYWHEEL HOUSING REDOWEL 1) Remove flywheel housing. See FLYWHEEL HOUSING article. Using Dowel Pin Extractor (ST-1134), remove dowel pins from cylinder block. Measure diameter of each dowel pin. Install flywheel housing. DO NOT tighten cap screws to final torque at this time. Install dial indicator to crankshaft. Position dial indicator tip so that it rests on the bore of flywheel housing. Dial indicator tip should be positioned just inside flywheel housing opening. 2) Rotate engine until dial indicator is at the 3 o'clock position. Adjust dial indicator to read "O" (zero). Rotate engine to the 9 o'clock position. Check total dial indicator reading. If dial indicator reading exceeds limits move flywheel housing using soft mallet. Move flywheel housing horizontally 1/2 of total dial indicator reading. 3) Rotate engine until dial indicator is at the 12 o'clock position. Adjust dial indicator to read "O" (zero). Rotate engine to the 6 o'clock position. Check total dial indicator reading. If dial indicator reading exceeds limits move flywheel housing using soft mallet. Move flywheel housing vertically 1/2 of total dial indicator reading. 4) Check flywheel housing alignment again. When flywheel housing is in alignment, tighten cap screws in sequence. See Fig. 36. Tighten cap screws to specifications. See TORQUE SPECIFICATIONS table. Check flywheel housing alignment after cap screws are tightened. 5) Use Drill Ream Fixture (ST-1232). Attach Plate (ST-1232-1) to rear of crankshaft flange. DO NOT tighten cap screws so that plate will not move. Use locator pin to align plate with dowel pin hole.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 50)For

Tighten plate retainer cap screws. Locator pin must rotate freely after tightening cap screws. 6) Measure dowel pins to be used. Use reamer that is .0005-.0010" (.013-.02 mm) smaller than dowel pin. Dowel pin must be long enough to protrude from cylinder block one-half of the flywheel housing wall thickness. Dowel pin must not protrude past flywheel housing wall. 7) Three oversize dowel pins are available. For dowel pin sizes, see the OVERSIZE DOWEL PIN table. Install appropriate drill bushings. See DOWEL DRILL BUSHING SPECIFICATIONS table. Drill bushings must be same size as the reamer or drill used. 8) If new dowel pins are more than .015" (.38 mm) larger than old dowel pins. Drill hole to a size slightly smaller than the reamer. Ream hole until reamer touches bottom of hole in cylinder block. Turn plate and align so that second dowel pin hole can be reamed. 9) Ream second dowel pin. Remove plate from crankshaft. Clean metal shavings from each dowel pin hole. Use square nose drift. Drive new dowel pins into each hole. Measure face alignment and bore alignment of flywheel housing bore after dowels are installed. Install flywheel. See FLYWHEEL in this article. OVERSIZE DOWEL PIN SPECIFICATIONS

Pin Dimension In. (mm)

Pin Oversize In. (mm)

.515 (13.08) .................................. .015 (.38) .530 (13.46) .................................. .030 (.76) .545 (13.84) ................................. .045 (1.14)

DOWEL DRILL BUSHING SPECIFICATIONS

Oversize In. (mm) Standard .................................. .015 (.380) ............................... .030 (.760) ............................... .045 (1.1.40) ............................

Bushing Size In. (mm) .5000 (12.700) .5156 (13.096) .5312 (13.494) 1.5464 (13.879)

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 51)For

Fig. 37: Exploded View of Oil Pump Assembly Refer to the following legend. Courtesy of Cummins Engine Co., Inc. LEGEND FOR FIGURE 37

Figure Number

Description

1 .............................. Cap Screw 2 ................................... Gear 3 ................................ Bushing 4 ................................... Body 5 ............................... "O" Ring 6 .................................. Shaft 7 .................................. Shaft 8 ................................... Gear 9 ................................. Gasket 10 .................................. Dowel 11 .................................. Dowel 12 ...................... Cover and Bushing 13 .............................. Seal Ring 14 .............................. Cap Screw 15 .................................... Pin 16 ............................... Retainer CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 52)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser 17 ................................. Spring 18 ................................ Plunger

ENGINE OILING ENGINE OILING SYSTEM Engine oiling system uses a gear pump driven by an idler gear. Pressure regulator is built into the oil pump assembly. OIL PUMP Removal Remove front engine cover. See ENGINE FRONT COVER in this article. Remove bolts securing pump body to block. Remove pump. Discard sealing and "O" rings.

Disassembly 1) Remove 4 cap screws and using a mallet, tap oil pump cover from oil pump housing. Lift idler gear and idler gear shaft from housing. Using a press, remove drive gear from oil pump housing. 2) On pumps fitted to engine Nos. 31117701 and earlier, remove retaining ring from oil pressure regulator bore. On pumps fitted to engine Nos. 31117702 and later, use a drift to remove retaining pin from oil pressure regulator bore. Remove spring retainer, spring and plunger from oil pressure regulator bore. Inspection Inspect shafts wear limits. See OIL PUMP ASSEMBLY WEAR LIMITS table. Replace gears if cracked, chipped, scored, show excessive wear or beyond gear to body clearance. Inspect bushing wear limits. Replace if necessary. Reassembly Use engine oil to lubricate all moving parts. Reassemble oil pressure regulator and oil pump drive and idler gears in reverse of disassembly procedure. Using a press, install drive gear of drive gear shaft making sure that part numbers face up. Installation To install, reverse removal procedure. Install new sealing and "O" rings. OIL PUMP ASSEMBLY WEAR LIMITS

Application

Maximum In. (mm)

Minimum In.(mm)

Bushing Inside Diameter ..... .8785 (22.324) ... .8765 (22.263) Drive Shaft End Clearance ........ .0065 (.165) ...... .0025 (.064) Idler & Drive Shaft Outside Diameter .... .8750 (22.225) ... .8745 (22.212)

Normal Oil Pressure Minimum oil pressure at idle is 15 psi. (1.1 kg/cm2) and 45-70 psi. (3.2-4.9 kg/cm2) at rated RPM.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 53)For cyph8r pacific la ca 92101 1996 M

Fig. 38: Exploded View of Oil Cooler Assembly Courtesy of Cummins Engine Co., Inc. OIL COOLER CAUTION: DO NOT reuse oil cooler element if engine has had a metal failure. Metal particles cannot be cleaned from oil cooler element. DO NOT attempt to repair oil cooler element. Element must be replaced. Removal Remove oil cooler cover retaining bolts. Remove cover. Remove oil cooler housing retaining bolts. Remove housing. Remove heater elements from housing and cover plate. Remove transfer tubes and discard "O" rings. Remove oil cooler straight back. Inspection Inspect housing and cover for cracks or damage. Inspect retainers for excessive wear. Use adapters to plug openings on oil cooler. Place oil cooler into water tank. Apply 60 psi (414 kPa) to oil cooler. Inspect for leaks.

Installation To install, reverse removal procedure. Install new "O" rings. For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser CUMMINS SERIESSee 6-CYLINDERArticle Text (p. 54) Tighten bolts"K" in sequence. Fig. 39. On aluminum housing, tighten cap screws 1 through 9 to 30 ft. lbs. (40 N.m). Tighten cap screws 10 through 39 to 35 ft. lbs. (45 N.m). On models with cast iron housings, tighten all cap screws to 35 ft. lbs. (45 N.m).

Fig. 39: Oil Cooler Tightening Sequence Courtesy of Cummins Engine Co., Inc. PISTON COOLING NOZZLES Some engine models are equipped with engine piston cooling nozzles. Piston spray nozzles receive oil from the oil galley. Piston spray nozzles seal in the engine block by an "O" ring. Spray nozzles direct oil to the lower section of the piston. Removal Removal of some piston oil cooling nozzles may require removal of coolant inlet transfer pipe, oil filters and starter motor on some applications. Remove retaining cap screw. Remove piston cooling nozzle from cylinder block. Cleaning & Inspection Clean piston cooling nozzle oil hole in cylinder block. Check for burrs which might cut sealing "O" ring. Remove "O" ring from piston cooling nozzle. Check that tip of piston cooling nozzle is not cracked or crushed shut. Replace is damaged. Installation Remove "O" ring from piston cooling nozzle. Lube new "O" ring with vegetable oil. Install new "O" rings to nozzles and install piston cooling nozzles in cylinder block with tip pointing upward. Install retaining cap screw. Tighten hexagon cap screw to 110 INCH lbs. (12.5 N.m).

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 55)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser

Fig. 40: Exploded View of Water Pump Assembly Refer to the following legend. Courtesy of Cummins Engine Co., Inc. LEGEND FOR FIGURE 40

Figure Number

Description

1 .................................. Shaft 2 ................................... Ring 3 ................................... Ring 4 ................................ Bearing 5 .................................. Shaft 6 ................................ Bearing 7 ................................... Seal CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 56)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser 8 ................................. Gasket 9 ................................... Body 10 ................................. Gasket 11 ............................. Connection 12 ............................... "O" Ring 13 ................................... Tube 14 ................................ Housing 15 ................................ Adapter 16 ................................ Element 17 .............................. Cap Screw 18 ............................. Connection 19 ................................. Gasket 20 ............................... "O" Ring 21 ............................... Impeller 22 ................................... Seal

ENGINE COOLING WATER PUMP Removal 1) Drain cooling system. Remove tube assembly connecting water pump to oil cooler housing. Remove oil cooler assembly. Refer to OIL COOLER in this article. Remove and discard water filter. 2) Remove attaching bolts and bracket. Remove pump straight back to clear from drive shaft and stud. Remove and discard gasket. Remove water pump drive shaft. Disassembly 1) Remove water inlet housing bolts and remove water inlet housing. Remove support bracket. Remove shutoff valve capscrew, shutoff valve, washer, "O" ring, transfer tube and transfer tube grommets. 2) Using Puller (ST-647), remove impeller from water pump housing. Using snap ring pliers, remove snap ring. Using a press, remove impeller bearing/shaft assembly from water pump housing. Remove and discard water seal and oil seal. Inspection 1) Check the impeller bearing shaft assembly for wear, scoring, or damage to the female splines. Inspect the drive shaft for wear of male splines. Using a cylinder gauge, measure the water housing at 4 points. Refer to the WATER PUMP SPECIFICATIONS table. Also, see Fig. 41. If not within specifications, replace housing.

Fig. 41: Measuring Points of Water Pump Housing Courtesy of Cummins Engine Co., Inc. WATER PUMP SPECIFICATIONS

Application

Minimum In. (mm)

Maximum In. (mm)

Water Seal "A" ...... 1.4350 (36.450) .. 1.4360 (36.470) Oil Seal "B" ........ 1.7490 (44.430) ... 1.751 (44.480) Rear Bearing "C" .... 2.0471 (51.996) .. 2.0557 (52.215) Front Bearing "D" ... 2.8345 (71.996) .. 2.8431 (72.215)

2) Using a cylinder gauge and micrometer, measure inside diameter of impeller and outside diameter of impeller shaft. Using these dimensions, determine the press fit clearance. Clearance should be between .001-.003" (.03-.07 mm). If not, replaceText impeller CUMMINS "K" SERIES 6-CYLINDERArticle (p. or 57)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser

impeller shaft as necessary. Reassembly 1) Using Oil Seal Installer (3375320), install oil seal with part number down. Install seal no more than .020" (.51 mm) below edge of step in housing. Using Mandrel (3375318), press bearing/shaft assembly into housing. Install snap ring. 2) Using Seal Driver (3376091), install water seal making sure that shoulder of seal contacts housing. Install impeller seat over seal and measure protrusion of seal/seat combination from housing. See Fig. 42. Protrusion should be between .414-.416" (10.52-10.57 mm). 3) Apply one drop of Loctite 290 to seat contact point on shaft. See Fig. 43. Apply a smooth coating of Loctite 609 to inside bore of impeller. Using a press, install impeller onto shaft. Using a feeler gauge, measure clearance of impeller-to-housing through water outlet port. 4) Clearance should be between .023-.034" (.58-.86 mm). Replace washer, shutoff valve and shutoff valve cap screw. Lubricate "O" ring with vegetable oil and install "O" ring, transfer tube and transfer tube grommets. Using a new gasket, install inlet housing and inlet housing cap screws. Install support bracket.

Fig. 42: Measuring Seat/Seal Protrusion Courtesy of Cummins Engine Co., Inc.

Fig. 43: Applying Loctite to Seat/Shaft DO NOT apply more than one drop. Courtesy of Cummins Engine Co., Inc. Installation To install, reverse removal procedure. Install new gaskets, "O" rings and filter. AFTERCOOLER See EXHAUST & INTAKE MANIFOLD in this article.

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 58)For c

Fig. 44: Exploded View of Thermostat Housing Refer to the following menu. Courtesy of Cummins Engine Co., Inc. LEGEND FOR FIGURE 44

Figure Number 1 2 3 4 5 6 7 8

Description

.............................. Connection .................................. Gasket ................................. Housing .................................. Gasket .................................... Tube ................................ "O" Ring ........................... Support Cover .................................. Gasket THERMOSTAT

Removal Remove water outlet hoses. Remove cap screws from thermostat housing. Remove housing and gasket. Remove thermostats. Remove thermostat seals. DO NOT damage housing when removing seals. Installation 1) Clean seal area inside thermostat housing. Check housing for cracks. Install seal in thermostat housing. Seal must be even with thermostat housing. 2) Temperature rating is stamped on the outside of thermostat body. Install thermostats in housing. Using new gasket, install thermostat housing mounting cap screws. Tighten cap screws to 35 ft. lbs. (45 N.m). Install water outlet hoses. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS

Application

Ft. Lbs. (N.m)

Aftercooler Cover Cap Screws ..................... 35 (45) Aftercooler Mounting Cap Screws .................. 35 (45) Aftercooler Seal Cap Screws ............. 25 Text (35) (p. 59)For cyph8r pacific la ca 92101 1996 Mitchell International, All Rights Reser CUMMINS "K"Retainer SERIES 6-CYLINDERArticle Air Compressor Cap Screws ........................ 35 (45)

Cam Follower Cap Screw ........................... 31 (42) Cam follower Cover Cap Screws .................... 20 (25) Camshaft Thrust Plate Cap Screws ................. 35 (45) Connecting Rod Cap Screws Step 1 ........................................ 75 (100) Step 2 ....................................... 150 (205) Step 3 ....................................... 215 (290) Step 4 .......................................... Loosen Step 5 ........................................ 75 (100) Step 6 ....................................... 150 (205) Step 7 ....................................... 215 (290) Cylinder Head Cap Screws (Black) Step 1 ......................................... 50 (65) Step 2 ....................................... 150 (200) Step 3 ....................................... 250 (340) Step 4 ....................................... 360 (490) Cylinder Head Cap Screw (Silver) Step 1 ......................................... 50 (65) Step 2 ....................................... 120 (160) Step 3 ....................................... 185 (250) Step 4 ....................................... 255 (345) Engine Front Cover Cap Screws .................... 35 (45) Engine Support Cap Screws ...................... 145 (195) Exhaust Manifold Cap Screw With Metal Gasket .............................. 35 (45) With Composite Gasket .......................... 40 (55) Fan Hub Cap Screws ............................... 35 (45) Flywheel Cap Screws Step 1 ....................................... 110 (150) Step 2 ...................................... 210 ( 285) Flywheel Housing Cap Screws Step 1 ........................................ 75 (100) Step 2 ....................................... 150 (205) Fuel Pump Cap Screws ............................. 35 (45) Idler Gear Shaft Cap Screws Press Fit ...................................... 35 (45) Bolt-In ...................................... 180 (245) Intake Manifold Cap Screws ....................... 35 (45) Main Bearing Cap Screws Step 1 ....................................... 195 (265) Step 2 ....................................... 445 (605) Step 3 .......................................... Loosen Step 4 ....................................... 195 (265) Step 5 ....................................... 445 (605) Oil Pan Adapter Cap Screws 3/8" x 16 ...................................... 35 (45) 7/16" x 14 ..................................... 45 (61) 9/16" x 12 .................................... 70 (95) Oil Pan Cap Screws ............................... 35 (45) Oil Pump Mounting Cap Screws ..................... 35 (45) Rocker Lever Housing Cap Screws .................. 65 (90) Rocker Lever Assembly Cap Screws ................. 65 (90) Rocker Lever Cover Cap Screws .................... 35 (45) Tappat Oil Tube Cap Screw ........................ 20 (25) Turbocharger Drain Line Cap Screws ............... 35 (45) Turbocharger Nuts ................................ 30 (45) Vibration Damper-to-Adapter Cap Screws ......... 105 (140) Vibration Damper Cap Screws Step 1 ....................................... 170 (230) CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 60)For cyph8r pa

Step 2 ....................................... 330 (445) Water Pump Cap Screws ............................ 35 (45) Water Support Bracket Screws ................... 150 (205) INCH Lbs. (N.m) Fuel Manifold Cap Screws ........................ 85 (9.5) HVT Oil Manifold Cap Screws ..................... 85 (9.5) Injector Hold-Down Cap Screws ................. 145 (16.2)

ENGINE SPECIFICATIONS GENERAL ENGINE SPECIFICATIONS (1977-86) GENERAL ENGINE SPECIFICATIONS (1977-86)

Application

Specification

KT-1150-450 Displacement .............. 1150 Cu. In. (18.848 Liters) Fuel System ............................. Pressure Timed HP @ RPM .................................... 450 @ 2100 Torque Ft. Lbs. @ RPM ...................... 1350 @ 1500 Compression Ratio ............................... 15.5:1 Bore And Stroke ...................... 6.25" (158.75 mm) KTA-1150-525 Displacement .............. 1150 Cu. In. (18.848 Liters) HP @ RPM .................................... 525 @ 2100 Torque Ft. Lbs. @ RPM ...................... 1650 @ 1300 Compression Ratio ............................... 15.5:1 Bore And Stroke ...................... 6.25" (158.75 mm) KTA-1150-600 Displacement .............. 1150 Cu. In. (18.848 Liters) HP @ RPM .................................... 600 @ 2100 Torque Ft. Lbs. @ RPM ...................... 1650 @ 1600 Compression Ratio ............................... 14.5:1 Bore And Stroke ...................... 6.25" (158.75 mm)

VALVES VALVES

Application

Specification In. (mm)

Intake & Exhaust Head Diameter ............. 2.3815-2.805 (60.490-60.465) Face Angle ......................................... 30 Seat Angle ......................................... 30 Seat Width ........................ .100-.60 (2.54-1.52) Stem Diameter .............. .4955-.4935 (12.586-12.535) Stem Clearance ................. .0031-.0035 (.078-.088)

PISTONS, PINS & RINGS

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 61)For cyph8r pacific la ca

PISTONS, PINS & RINGS

Application

Specification In. (mm)

Piston Clearance ..................... .012-.020 (.30-.50) Pins Piston Fit ..................... .0001-.0005 (.002-.012) Rod Fit ........................ .0025-.0045 (.063-.114) Rings Ring No. 1 End Gap .................... (1) .025-.040 (.64-1.02) Side Clearance ....................... (2) .006 (.15) Ring No. 2 End Gap .................... (1) .025-.040 (.64-1.02) Side Clearance ....................... (2) .006 (.15) Ring No. 3 End Gap ..................... (1) .012-.016 (.38-.76) (1) - Add .003" (.08 mm) ring gap to new maximum limit for each .001" (.03 mm) wear in cylinder liner wall. (2) - Ring-to-groove side clearance.

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

Application

Specification In. (mm)

Main Bearings Journal Diameter ....... 5.5000-5.4975 (139.700-139.636) Clearance ...................... .0065-.0085 (.165-.216) Thrust Bearing ................................... No. 6 Crankshaft End Play ................ .004-.016 (.10-.40) Connecting Rod Bearings Journal Diameter ......... 4.000-3.9970 (101.60-101.524) Clearance ....................... .005-.0075 (.191-.130) Side Play ......................... .008-.014. (.20-.36)

VALVE SPRINGS VALVE SPRINGS

Engine

Free Length In. (mm)

K-1150 ..................................... 3.349 (85.06)

CAMSHAFT CAMSHAFT

Specification

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 62)For cyph8r pacific la ca 92101 1996

Application

In. (mm)

Journal Diameter ............... 2.997-2.995 (76.12-76.07) Clearance ........................ .0045-.0075 (.114-.190)

END OF ARTICLE

CUMMINS "K" SERIES 6-CYLINDERArticle Text (p. 63)For cyph8r pacific la ca 9