-
2
Foreword
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3
Table of Contents
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4
Cummins 22-Group System Exploded Diagram
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5
How to Use the Manual
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6
Generic Symbols
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8
Introduction
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8
Section Contents
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9
About the Manual
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10
General Safety Instructions
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11
General Repair Instructions
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12
General Cleaning Instructions
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13
Glossary of Terms
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15
Engine and Component Identification
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16
Engine Identification
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17
Industrial Engine Nomenclature
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17
Automotive Engine Nomenclature
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18
Injection Pump Dataplate
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20
General Engine Specifications
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23
Engine Diagram-Automotive Engine
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23
Inlet Side
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23
Rear View
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24
Turbocharger Side View
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24
Front View
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25
Engine Disassembly and Assembly
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29
Engine Disassembly and Assembly-Service Tools
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31
Engine Disassembly Check List
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32
Engine Disassembly
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32
Steam Cleaning the Engine
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32
Engine Weight
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32
Rollover Stand-Engine Mounting
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33
Oil-Draining
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33
Lifting Bracket Removal-Rear
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33
Drive Beit-Removal
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34
Fan Pulley-Removal
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34
Vibration Damper/Crankshaft Pulley-Removal
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34
Belt Tensioner-Removal
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35
Fan Hub-Removal
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35
Alternator-Removal
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36
Thermostat-Removal
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36
Turbocharger-Removal
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38
Exhaust Manifold-Removal
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38
Fuel Filter-Removal
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39
Fuel Filter Head-Removal
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39
KSB (Remote Mounted)-Removal
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40
Fuel Lines-Removal
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40
High Pressure Fuel Line-Removal
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41
Fuel Drain Manifold-Removal
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42
Low Pressure Fuel Lines-Removal
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43
Dipstick-Removal
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43
Manifold Cover-Removal
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43
Aftercooler-Removal
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44
Valve Covers-Removal
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44
Injector Nozzles-Removal
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45
Rocker Levers-Removal
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45
Push Rods-Removal
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46
Cylinder Head-Removal
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46
Front Cover-Removal
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47
Water Pump-Removal
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47
Flywheel-Removal
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47
Flywheel Housing-Removal
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48
Accessories-Removal
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48
Injection Pump-Removal (Rotary Type Pumps)
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48
Gear Lash-Check
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49
Locking the Pump
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50
Drive Gear-Removal
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50
Injection Pump-Removal (In-Line)
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52
Fuel Transfer Pump-Removal
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52
Tappet Cover-Removal
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53
Side Oil Fill-Removal
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53
Oil Cooler-Removal
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53
Water Inlet Connection-Removal
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54
Oil Pan-Removal
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54
Suction Tube-Removal
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54
Rear Seal Housing-Removal
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55
Camshaft-Removal
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55
Measuring Gear Lash
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56
Valve Tappets-Removal
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56
Lube Pump-Removal
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56
Measuring Backlash
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58
Timing Pin Housing-Removal
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58
Gear Housing-Removal
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59
Balancer-Removal
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59
Measuring the End Play
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59
Locking the Balancer
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60
Removing the Balancer
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61
Piston and Rod Assemblies-Removal
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63
Crankshaft-Removal
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65
Turbocharger Drain Tube-Removal
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65
Cylinder Block-Removing from the Rollover Stand
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65
Engine Assembly
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65
Cylinder Block-Prepare for Assembly
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66
Valve Tappets-Installation
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66
Crankshaft-Installation
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71
Piston and Rod Assemblies-Installation
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71
Piston Grading for 1994 Automotive Applications Only
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72
Dial Indicator
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74
Piston Protrusion
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74
Piston and Connecting Rod Assemblies-Installation
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78
Gear Housing-Installation
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79
Lube Pump-Installation
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80
Camshaft-Installation
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82
Camshaft End Play-Measuring
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83
Camshaft Gear Backlash-Measuring
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83
Timing Pin-Installation
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90
Crankshaft End Play-Measuring
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90
Rear Seal-Installation
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91
Suction Tube-Installation
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92
Oil Pan-Installation
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92
Oil Pan Sealing Surfaces-Sealants
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93
Oil Cooler-Installation
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93
Side Oil Fill-Installation
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93
Fuel Transfer Pump-Installation
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94
Tappet Cover-Installation
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95
Injection Pump-Installation
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96
Locked Timed Injection Pump-Installation
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98
Injection Pumps-Unlocking
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99
Chisel, Hammer
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100
Unlocked CAV Injection Pump-Installation
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101
Unlocked Stanadyne DB4 Injection Pump-Installation
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104
Unlocked Bosch VE and P7100 Injection Pump-Installation
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107
Disengage the TDC Pin
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107
Pump Gear Backlash Limit
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108
Injection Pump Installation
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112
Accessories-Installation
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113
Flywheel Housing-Installation
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113
Flywheel-Installation
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114
Water Pump-Installation
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115
Front Cover-Installation
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116
Cylinder Head-Installation
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117
Push Rods-Installation
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118
Rocker Levers-Installation
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119
Cylinder Head-Tightening
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121
Valve Clearance-Adjustment
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122
Valve Stem to Rocker Lever Clearance
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123
Injector Nozzles-Installation
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124
Valve Covers-Installation
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124
Manifold Cover-Installation
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125
Aftercooler-Installation
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125
Fuel Lines-Installation
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125
Infection Pump Supply Line-Installation
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126
Fuel Drain Manifold-Installation
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126
Injection Pump Vent Line-Installation
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127
High Pressure Fuel Lines-Installation
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128
KSB (Remote Mounted)-Installation
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128
Fuel Filter Head-Installation
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129
Exhaust Manifold-Installation
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130
Turbocharger-Installation
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133
Thermostat-Installation
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134
Vibration Damper-Installation
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134
Fan Hub-Installation
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135
Beit Tensioner-Installation
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135
Water Inlet Connection-Installation
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135
Alternator-Installation
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137
Drive Belt-Installation
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137
Oil Filter-Installation
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137
Rollover Stand-Engine Removal
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138
Starter-Installation
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139
Cylinder Block
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141
Cylinder Block-Exploded View
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144
Cylinder Block-General Information
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145
Cylinder Block-Service Tools
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146
Cylinder Block Group Inspection Checklist
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147
Cylinder Block-Precheck before Disassembly
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147
Cylinder Block-Disassembly
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149
Cylinder Block-Cleaning
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152
Cylinder Block-Inspection
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154
Cylinder Block-De-Glazing
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157
Expansion and Pipe Plug-Installation
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159
Camshaft Expansion Plug-Installation
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160
Camshaft Bushing-Installation
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162
Dipstick Tube-Replacement
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162
Cylinder Block-Storing
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163
Crankshaft-Cleaning
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163
Crankshaft-Inspection
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164
Crankshaft Gear-Replacement
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164
Determining Mam Bearing Clearance
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166
Camshaft-Cleaning
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166
Camshaft and Gear-Inspection
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167
Camshaft Lobe Pitting Reuse Criteria
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168
Camshaft Lobe Edge Deterioration (Breakdown) Criteria
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171
Camshaft Gear-Replacement
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171
Camshaft Gear-Removal
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171
Camshaft Gear-Installation (Heated Gear Method)
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173
Camshaft Gear-Installation (with Special Tool 3823589)
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175
Camshaft Capscrew-Installation
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176
Rubber Element Vibration Damper-Cleaning and Inspection
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178
Piston and Connecting Rod-Disassembly
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178
Piston, Pin and Connecting Rod-Cleaning
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179
Piston Inspection
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180
Piston Pin-Inspection
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181
Connecting Rod-Inspection
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181
Rod Bearing Clearance-Checking
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182
Piston and Connecting Rod-Assembly
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183
Piston Ring Gap-Checking
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184
Piston Rings-Installation
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185
Balancer-Disassembly
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188
Balancer-Assembly
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194
Gear Housing and Timing Pin Assembly-Inspection
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195
Gear Housing-Disassembly
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195
Fuel Pump Stud-Replacement
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196
Data Plate-Replacement
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198
Cylinder Head
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199
Cylinder Head-Service Tools
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200
Cylinder Head Exploded View
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202
General Information
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203
Cylinder Head-Precheck before Disassembly
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203
Cylinder Head-Disassembly
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204
Cylinder Head-Cleaning
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206
Valve-Inspection
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208
Valve Guide Inspection
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208
Cylinder Head Combustion Face Inspection
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208
Valve Seat Inspection
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209
Cylinder Head Cracks-Reuse Guidelines
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209
Valve Spring Inspection
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210
Cup Plug Replacement
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212
Valves-Grinding
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213
Valve Seats-Grinding
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213
Calculating the Grinding Depth
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214
Valve Depth
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214
Seat Angle
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214
Gauge Block
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215
Seat Grinding Depth Limit
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216
Valve Seat Width Limit
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218
Cylinder Head-Assembly
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218
Valve Spring Compressor
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220
Rocker Levers
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221
Rocker Lever Assembly-Exploded View
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223
Rocker Lever Assembly-General Information
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224
Rocker Levers-Disassembly
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225
Rocker Levers and Pedestals-Cleaning
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225
Rocker Lever-Inspection
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226
Rocker Lever Pedestals-Inspection
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226
Rocker Levers-Assembly
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228
Tappets and Push Rods
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229
Tappets and Push Rods-Exploded View
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230
Tappets and Push Rods-General Information
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231
Valve Tappets-Inspection
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231
Push Rods-Inspection
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233
Fuel System
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234
Service Tools-Injection Pump
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235
Exploded View-Fuel System
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236
Injection Pump-General Information
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236
Injection Pump-Identification
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238
KSB Electrical Solenoid Style-General Information
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238
Cold Start Timing Advance System (KSB)-Electrical Solenoid Style
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239
VE Pump Timing Advance Principles (Without KSB)
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240
VE Pump Timing Advance Principles (with Electrical Solenoid KSB Installed)
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242
Warm Engine Operation (more than 90°F IMT), Retarded Timing
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244
KSB Electrical Solenoid Style-Inspection
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244
KSB Electrical Solenoid-Inspection
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246
KSB Electrical Solenoid Style Wiring Harness-Inspection
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247
Injection Pump Repairs-Bosch VE
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248
Delivery Valve Holder/Sealing Washer-Replacement
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249
Shutdown Solenoid-Replacement
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250
Shutdown Lever/Spring-Replacement
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251
Overflow Adapter/Sealing Ring-Replacement
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252
Fuel Inlet Adapter/Seal-Replacement
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253
Injection Pump Timing-Bosch VE
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257
Injection Pump Repairs-Lucas CAV DPA
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258
Back Leakage Valve-Replacement/Inspection
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260
Bleed Screws/Sealing Washers-Replacement
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261
Vent Fitting/Sealing Washer-Inspection/Replacement
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262
Fuel Inlet Fitting/Sealing Washer-Replacement
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262
Control Lever-Replacement
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263
Inspect the Lever Components
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265
Automatic Timing Advance-Disassembly
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266
Timing Advance Components-Inspection
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267
Timing Advance-Assembly
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271
Injection Pump Repairs
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271
Injection Pump Timing-Stanadyne DB4
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272
Return Connection Replacement, Stanadyne DB4
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273
Shutoff Solenoid Replacement, Stanadyne DB4
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275
Speed Droop Adjustment off Engine-Stanadyne DB4
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276
Injection Pump Timing-Nippondenso EP9
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278
Seals Replacement, Nippondenso EP9
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278
Shut down Lever or Spring Replacement, Nippondenso EP9
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280
Pressure Relief Valve and Sealing Washer Replacement, Bosch P7100
-
282
Seal Replacement, Bosch P7100
-
282
Fuel Inlet Banjo Connector Replacement, Bosch P7100
-
283
Fuel Shut off Solenoid Replacement, Bosch P7100
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283
Fuel Shut off Solenoid Adjustment, Bosch P7100
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284
Fuel Shut off Solenoid Bracket Replacement, Bosch P7100
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284
Fuel Pump Shut off Lever Replacement, Bosch P7100
-
285
Throttle Lever Replacement, Bosch P7100
-
286
Shutdown Solenoid Inspection, Bosch P7100
-
286
Wiring Guidelines
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286
Solenoid Resistance Check
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287
Solenoid Voltage Check
-
288
Injectors
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289
Injector-Service Tools
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290
Injector Group-Exploded View
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291
General Information-Injectors
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292
Fuel Transfer Pump-General Information
-
292
Fuel Transfer Pump-Identification
-
294
Injector-Disassembly
-
295
Injector-Clean and Inspect
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296
Nozzle Cleaning Kit
-
297
Injector-Assembly
-
299
Injector-Testing
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300
Chatter Test
Source: https://www.manualslib.com/manual/1201997/Cummins-5-9.html
Posted by: doreendoreeneleberea0252003.blogspot.com
