Cummins Manuals Pdf

Online Cummins Manuals

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

Cummins Onan Manuals Pdf

Cummins Engine Manuals Pdf

Cummins qsm11 engine service manual pdf contains help for troubleshooting and will support you how to fix your problems immediately. Perfect for all DIY persons! Your Do-It-Yourself specialist for service manuals, workshop manuals, factory manuals, owner manuals, spare parts catalog and user manuals. Cummins Engines PDF manuals. If you want to download Cummins engines service repair manuals – visit the official site of Cummins. The links from this web site to Cummins web sites are for informational purposes only. Our web site is not affiliated with Cummins, and Cummins is not responsible for the content of this web site or the accuracy of. Other types of manuals include: Factory service manual – These are usually found in PDF format and available online. They contain factory recommended details regarding maintenance and repairs, usually only available to factory certified specialists. Workshop manual – A less detailed manual meant for light repairs and maintenance.