Chapter 3

7/17/2019 Chapter 3

http://slidepdf.com/reader/full/chapter-3-568f853f9c06b 1/12

CHAPTER : 3

Technical Description

7/17/2019 Chapter 3


LIST OF CONTENTS

SECTION NO. DESCRIPTIONCHAPTER NO.

3.1 G.A. and Sectional Drawing of D/G Set

3.2 Cylinder Block

3.3 Cylinder Head

3.4 Valve Train

3.5 Lubrication

3.6 Cooling System (Engine)

3.7 Fuel System and Governor

3.8 Engine Breathing and Turbocharger

3.9 Specifications and Wear Limits

7/17/2019 Chapter 3


LIST OF ILLUSTRATIONS

S. No. Description Page No.

3-1 Cylinder block - exploded view 3.2.1

3-2 Measuring camshaft bushing 3.2.3

3-3 Cylinder liner counterbore dimension 3.2.3

3-4 Checking counterbore depth 3.2.3

3-5 Location of cylinder liner flange thickness 3.2.3

3-6 Measuing cylinder liner flange 3.2.4

3-7 Checking cylinder liner protrusion 3.2.4

3-8 Checking cylinder liner to block clearance 3.2.5

3-9 Checking cylinder liner out-of-round 3.2.53-10 Cylinder liner check points 3.2.5

3-11 Checking main bearing bore 3.2.6

3-12 Checking tappet bore 3.2.7

3-13 Oil control valve 3.2.8

3-14 Drilling main bearing cap dowel hole 3.2.10

3-15 Exploded view of ST-1177 boring tool 3.2.11

3-16 Reaming eroded water hole 3.2.13

3-17 Location to check cylinder block height 3.2.14

3-18 Sleeve and block boring dimensions 3.2.15

3-19 Adjusting tool bit with set block 3.2.16

3-20 Installing dentering ring 3.2.17

3-21 Installing o-ring into groove 3.2.17

3-22 Centering ring and o-ring installed 3.2.17

3-23 Tool bit installed 3.2.18

3-24 ST-1318 chamfer tool 3.2.19

3-25 ST-1272 Repair kit 3.2.20

3-26 Adjusting stop collar 3.2.20

3-27 Removing shavings 3.2.21

3-28 Installing thread insert 3.2.21

3-29 ST-1168 boring tool 3.2.22

3-30 Blind oil drilling in crankshaft 3.2.23

3-31 Measuring crankshaft connecting rod journal 3.2.24

3-32 Undersize main and connecting rod markings 3.2.25

7/17/2019 Chapter 3



3-33 Oversize thrust bearing marking 3.2.25

3-34 Measuring bearing shell 3.2.25

3-35 Checking crankshaft end clearance 3.2.26

3-36 Rubber cavity depth of vibration damper 3.2.27

3-37 Vibration damper alignment marks 3.2.27

3-38 Connecting rod specifications 3.2.28

3-39 Checking connecting rod piston pin bushing 3.2.28

3-40 Checking rod bore alignment 3.2.29

3-41 Checking rod twist 3.2.30

3-42 Areas of flatness 3.2.30

3-43 Connecting rod bore check points 3.2.31

3-44 Connecting rod radius specifications 3.2.31

3-45 Installing piston pin bushing 3.2.32

3-46 Boring piston pin bushing 3.2.32

3-47 Measuring piston ring gap in liner 3.2.33

3-48 Piston check points 3.2.34

3-49 Measuring camshaft journal 3.2.35

3-50 Fuel pump/accessory drive bushing location 3.2.38

3-51 Auxiliary/generator drive bushing location 3.2.38

3-52 Gear case cover and trunnion 3.2.39

3-53 Cylinder head - exploded view 3.3.1

3-54 Compressing valve spring with ST-448 3.3.2

3-55 Restrictor plug installed 3.3.3

3-56 Cylinder head instajled in ST-1012 3.3.3

3-57 Magnetic crack detection with ST-1166 3.3.4

3-58 Valve seat insert - cross, section 3.3.4

3-59 Injector sleeve sealing width 3.3.5

3-60 Check injector tip protrusion with ST-547 3.3.5

3-61 Measure crosshead guide 3.3.5

3-62 Crosshead dimensions 3.3.6

3-63 Measure valve guide I.D. 3.3.6

3-64 Valve head thickness 3.3.6

3-65 Measure valve stem 3.3.7

3-66 Magnetic indications area of Magnaglo 3.3.7

3-67 Drive bushing into hole 3.3.8

7/17/2019 Chapter 3



3-68 Check cylinder head height 3.3.9

3-69 Installing valve guide 3.3.9

3-70 Removing crosshead guide with ST-1134 3.3.10

3-71 Installing crosshead guide 3.3.10

3-72 Removing valve seat insert 3.3.10

3-73 Counterbore for valve seat insert 3.3.11

3-74 Grind valve seat 3.3.12

3-75 Valve seat insert - cross section 3.3.12

3-76 Indicate valve seat 3.3.12

3-77 Pencil marks on valve 3.3.13

3-78 Testing valve spring tension 3.3.13

3-79 Removing injector sleeve with ST-1244 3.3.14

3-80 Installing bead cutting tool 3.3.15

3-81 Rolling upper injector sleeve with ST-880 3.3.15

3-82 Cutting injector seat with ST-884 3.3.16

3-83 Vacuum test for leaks 3.3.16

3-84 Vent hole 3.3.17

3-85 Rocker levers, shaft and housing 3.4.1

3-86 Removing shaft retaining plug 3.4.2

3-87 Crack indications of magnetic inspection 3.4.3

3-88 Checking ball end of rocker lever adjusting screw 3.4.3

3-89 Checking rocker lever bushing for wear 3.4.3

3-90 Installing rocker lever bushing 3.4.3

3-91 Breather vent hole (bottom view) 3.4.4

3-92 Rocker lever assembly position 3.4.4

3-93 Breather vent hole (top view) 3.4.5

3-94 Rocker lever cover assembly (breather type) 3.4.5

3-95 Crankcase breather - mesh element 3.4.6

3-96 Tappets and pushtubes 3.4.7

3-97 Removing tappet roller pin with ST-1198 3.4.7

3-98 Tappet assembly - exploded view 3.4.7

3-99 Installing tappet roller pin 3.4.8

3-100 Installing sleeve into tappet body with 3375315 3.4.8

3-101 Checking tappet roller concentricity 3.4.8

3-102 Toruqe tool for 108156 tappet sleeve 3.4.9

7/17/2019 Chapter 3



3-103 Torque tool for 195066 tappet sleeve 3.4.9

3-104 Torque tool for 111689 tappet sleeve 3.4.9

3-105 Checking push tube ball end with radius gauge 3.4.10

3-106 Push tube comparison 3.4.10

3-107 Checking push tube socket with adjusting screw 3.4.10

3-108 Lubricating oil pump - exploded view 3.5.1

3-109 Right hand rotation lubricating oil pump 3.5.2

3-110 Left hand rotation lubricatfng oil pump 3.5.3

3-111 Scavenger oil pump - exploded view 3.5.6

3-112 Inspecting filter element 3.5.7

3-113 By-pass valves - full flow filter 3.5.7

3-114 Cross-section by-pass filter 3.5.8

3-115 Installing hose into socket 3.5.9

3-116 Oil flow - engine end view 3.5.11

3-117 Oil flow - engine side view 3.5.12

3-118 Oil flow - schematic diagram 3.5.12

3-119 Water pump and idler assembly (Typical) 3.6.1

3-120 Removing water pump pulley 3.6.1

3-121 Removing water pump bushing and seal assembly 3.6.23-122 Removing inner race/cone and bearing assembly 3.6.2

3-123 Removing bearing races 3.6.2

3-124 Removing idler pulley cover and gasket 3.6.2

3-125 Removing idler pulley bearing races 3.6.3

3-126 Installing retaining ring 3.6.3

3-127 Installing front bearing race/cup. 3.6.3

3-128 Installing race cup spacer 3.6.3

3-129 Installing rear bearing racecup. 3.6.4

3-130 Installing inner bearing race 3.6.4

3-131 Installing bearing cone spacer 3.6.4

3-132 Installing upper inner race 3.6.5

3-133 Checking water pump shaft end play 3.6.5

3-134 Installing front oil seal 3.6.5

3-135 Installing rear oil seal 3.6.5

3-136 Installing gasket and bushing 3.6.6

3-137 Installing water pump pulley 3.6.6

7/17/2019 Chapter 3



3-138 Checking idler pulley assembly end play 3.6.7

3-139 Water pump (old style) - exploded view 3.6.7

3-140 Removing pulley 3.6.8

3-141 Press shaft assembly from housing 3.6.8

3-142 Drive seal from housing 3.6.8

3-143 Press shaft from bearing 3.6.9

3-144 Measuring housing bore 3.6.9

3-145 Installing retaining ring 3.6.9

3-146 Pressing shaft into inner bearing 3.6.10

3-147 Assemble shaft, spacer & outer bearing 3.6.10

3-148 Packing bearings 3.6.10

3-149 Applying pipe sealant to seal 3.6.11

3-150 Pressing carbon face seal into housing 3.6.11

3-151 Installing cup seal 3.6.11

3-152 Checking impeller clearance 3.6.12

3-153 Thermostat housing and seal 3.6.12

3-154 Testing thermostat 3.6.12

3-155 Coolant flow - schematic diagram 3.6.14

3-156 Cummins corrosion resistor 3.6.153-157 Corrosion Resistor arrangement 3.6.15

3-158 .Fuel flow schematic - V-1710 Engines (Typical) 3.7.1

3-159 PT fuel system mechanical linkage 3.7.2

3-160 Flow diagram - PT fuel system 3.7.3

3-161 Pressure regulator 3.7.4

3-162 Pressure regulator by-pass valve 3.7.5

3-163 Fuel adjustment plunger 3.7.5

3-164 PTR Fuel Pump with Standard Automotive Governor 3.7.5

3-165 Cross Section of PTR Pump with Standard Automotive Governor 3.7.6

3-166 Idling and high speed mechanical governor 3.7.6

3-167 Overspeed position 3.7.7

3-168 Exploded view of Fuel Pump Shutdown Valve 3.7.7

3-169 PTD Injectors 3.7.8

3-170 Fuel flow 3.7.9

3-171 Downstroke (Fuel injection) 3.7.10

3-172 Upstroke complete (Fuel enters injector cup) 3.7.10

7/17/2019 Chapter 3



3-173 Flange type injector 3.7.11

3-174 Cup 3.7.11

3-175 Cylindrical type injector 3.7.11

3-176 Cup 3.7.11

3-177 PSG Hydraulic Governor 3.7.15

3-178 Hydraulic Governor Upper Mechanism 3.7.16

3-179 Schematic Diagram, PSG with External Return Spring 3.7.18

3-180 Outline Drawing with Externally Adjusted Speed Droops & 3.7.19PM Speed Adjusting Motor (Do not use for construction)

3-181 Externally mounted air cleaners with flap valves 3.8.2

3-182 Dry type air cteaner 3.8.43-183 Composite dry type air cleaner - dual element 3.8.4

3-184 Wire-reinforced hose 3.8.5

3-185 Connecting hose 3.8.6

3-186 Moulded rubber elbows 3.8.6

3-187 Hose clamps 3.8.6

3-188 Pressure checking air leaks - turbocharged engine 3.8.7

3-189 Low profile intake manifold watercooler 3.8.9

3-190 HC 3-1 Turbocharger cutaway 3.8.10

3-191 Checking the air inlet restriction 3.8.12

3-192 Checking the exhaust back pressure 3.8.12

3-193 Turbocharger mounting 3.8.14

3-194 Removing rotor nut from rotor shaft 3.8.16

3-195 Removing “V” band clamps 3.8.16

3-196 Removing compressor wheel, housing & diffuser plate 3.8.16

3-197 Removing the diffuser plate from the compressor housing 3.8.17

3-198 Removing the turbocharger bearing insert 3.8.17

3-199 Installing the turbochargers sleeve 3.8.17

3-200 Pressing the bearing housing assembly from the turbine housing 3.8.17

3-201 Removing the wheel and shaft from the bearing housing 3.8.17

3-202 Installing the insulation material 3.8.18

3-203 Installing the heat shield 3.8.18

3-204 Installing the sealing rings onto the turbine wheel and uhaft 3.8.19

3-205 Installing the turbine wheel and shaft into the bearing housing 3.8.19

7/17/2019 Chapter 3



3-206 Installing the turbocharger bearing 3.8.19

3-207 Installing the turbocharger bearing insert 3.8.19

3-208 Installing the O-ring onto the bearing housing 3.8.19

3-209 Installing the oil sleeve into the diffuser plate 3.8.20

3-210 Installing the O-ring on the ST diffuser plate 3.8.20

3-211 Installing the O-ring on the VT diffuser plate 3.8.20

3-212 Installing the diffuser plate onto the bearing housing 3.8.20

3-213 Torquing the rotor nut 3.8.21

3-214 Position the compressor housing onto the rotor assembly 3.8.21

3-215 Torquing the diffuser plate and capscrews 3.8.22

3-216 Torque the V-band clamps to 32 to 36 in-lb (3.6 to 4,1 N.m) 3.8.22

3-217 Check the turbine end radial clearance 3.8.22

3-218 Check the total end clearance 3.8.22

3-219 HC3-1 Specifications 3.8.24

3-220 VT-50, HC3-1 Turbocharger - exploded view 3.8.25

3-221 Smooth - welded steel tubing 3.8.31

3-222 Measuring back pressure 3.8.32

3-223 Cylinder Block and Vibration Damper Torque sequence 3.9.20

3-224 Cylinder Head Torque Sequence 3.9.21

3-225 Torque Sequence of flywheel housing, 3.9.22Accessory drive pulley, con rod 7 flywheel cap screws

3-226 Torque - Valves 3.9.25

7/17/2019 Chapter 3


CHAPTER : 3

SECTION : 3.1

GA and Sectional drawing of D/G. Set

7/17/2019 Chapter 3


7/17/2019 Chapter 3


Documents

Chapter 3