PDF Shop Manual Cummins L10 Series Engines External Damper - 3 MB
This specialized shop manual from Cummins focuses on the external damper for the L10 series engines.
It provides detailed procedures for inspection, removal, and installation of this critical component.
Following the correct procedures is vital for preventing engine-damaging vibrations.
This guide is an essential resource for any technician performing engine work on a Cummins L10.
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--- Page 3 ---
Section i - Introduction Illustrations
L10 Page i-7
Illustrations
The illustrations used in the ″Repair Sections″ of this
manual are intended to give an example of a problem,
and to show what to look for and where the problem can
be found. Some of the illustrations are ‘‘generic’’ and
might not look exactly like the engine or parts used in
your application. The illustrations can contain symbols
to indicate an action required, and an acceptable or not
acceptable condition.
The illustrations are intended to show repair or replace-
ment procedures. The illustration can differ from your
application, but the procedure given will be the same.
--- Page 4 ---
Section E - Engine Identification
L10 Page E-1
Section E - Engine Identification
Section Contents
Page
Engine Diagrams ............................................................................................................................................... E-7
Engine Identification ......................................................................................................................................... E-2
Engine Dataplate ........................................................................................................................................... E-2
Fuel Pump Dataplate (Nameplate) ................................................................................................................. E-3
Engine Specifications ....................................................................................................................................... E-4
Air Induction System ..................................................................................................................................... E-5
Batteries (Specific Gravity).............................................................................................................................. E-6
Cooling System ............................................................................................................................................. E-5
Electrical System ........................................................................................................................................... E-6
Exhaust System ............................................................................................................................................ E-5
Fuel System .................................................................................................................................................. E-6
General Engine Data ..................................................................................................................................... E-4
Lubricating Oil System .................................................................................................................................. E-5
--- Page 5 ---
Section 0 - Engine Disassembly and Assembly - Group 00
L10 Page 0-3
Page
Cylinder Liner Carbon Deposits - Removal .................................................................................................... 0-44
Cylinder Liners - Removal ............................................................................................................................. 0-49
Electronic Control Cooling Plate (CELECT™ Engines Only) - Removal........................................................... 0-25
Electronic Control Module (CELECT™ Engines Only) - Removal .................................................................... 0-25
Engine - Cleaning ......................................................................................................................................... 0-14
Engine - Installation On Rebuild Stand.......................................................................................................... 0-23
Engine - Preparation for Cleaning ................................................................................................................. 0-14
Engine Barring Tool - Installation .................................................................................................................. 0-44
Exhaust Manifold - Removal.......................................................................................................................... 0-19
Fan and Fan Hub - Removal ......................................................................................................................... 0-16
Fan Drive Belt - Removal .............................................................................................................................. 0-15
Fan Hub Support - Removal.......................................................................................................................... 0-28
Flywheel - Removal....................................................................................................................................... 0-36
Flywheel Housing - Removal ......................................................................................................................... 0-37
Flywheel Housing, REPTO — Removal ......................................................................................................... 0-37
Front Engine Support Bracket - Removal ...................................................................................................... 0-40
Fuel and Air Lines - Removal ........................................................................................................................ 0-26
Fuel Filter - Removal..................................................................................................................................... 0-15
Fuel Pump - Removal.................................................................................................................................... 0-26
Fuel Supply Hose and Filter Head - Removal................................................................................................ 0-24
Gear Cover - Removal................................................................................................................................... 0-41
Gear Housing - Removal ............................................................................................................................... 0-43
Hand Hole Cover and Dipstick Tube Bracket - Removal................................................................................ 0-23
Hand Hole Cover (Fuel Pump Side) - Removal.............................................................................................. 0-27
High Oil Pressure Regulator - Removal ......................................................................................................... 0-49
Hydraulic Pump Drive - Removal................................................................................................................... 0-43
Hydraulic Pump (If Equipped) - Removal ....................................................................................................... 0-28
Idler Gear Assemblies - Removal .................................................................................................................. 0-41
Injectors (Fixed Time Engines) - Removal ..................................................................................................... 0-33
Injectors (STC and CELECT™ Engines) - Removal ........................................................................................ 0-32
Lifting Brackets - Removal ............................................................................................................................ 0-24
Lubricating Oil - Draining .............................................................................................................................. 0-14
Lubricating Oil Cooler - Removal................................................................................................................... 0-20
Lubricating Oil Filter Head - Removal............................................................................................................ 0-20
Lubricating Oil Filters - Removal ................................................................................................................... 0-15
Lubricating Oil Pan - Removal....................................................................................................................... 0-35
Lubricating Oil Pump - Removal.................................................................................................................... 0-42
Main Bearing Caps, Lower Bearing Shells and Thrust Bearings - Removal ................................................... 0-47
Main Oil Pressure Regulator - Removal......................................................................................................... 0-48
Piston Cooling Nozzles - Removal................................................................................................................. 0-44
Pistons and Connecting Rods - Disassembly................................................................................................. 0-51
Pistons and Connecting Rods - Removal....................................................................................................... 0-45
Push Rods - Removal ................................................................................................................................... 0-30
Rocker Lever Assemblies - Removal ............................................................................................................. 0-31
Rocker Lever Assemblies (If Equipped with a JacobsW Brake) - Removal..................................................... 0-31
Rocker Lever Cover - Removal...................................................................................................................... 0-29
Rocker Lever Housing - Removal .................................................................................................................. 0-33
Rocker Lever Housing Spacer (If Equipped with a JacobsW Brake) - Removal ............................................. 0-29
Sensor Harness and Sensors (CELECT™ Engines Only) - Removal............................................................... 0-28
Starting Motor - Removal .............................................................................................................................. 0-26
STC Oil Control Valve - Removal .................................................................................................................. 0-33
STC Oil Manifold - Removal .......................................................................................................................... 0-32
Thermostat Housing - Removal ..................................................................................................................... 0-19
Thermostat Housing Support - Removal ........................................................................................................ 0-21
Torque Converter Cooler Disc - Removal ...................................................................................................... 0-19
Turbocharger - Removal................................................................................................................................ 0-17
Turbocharger Oil Drain Connection - Removal .............................................................................................. 0-23
Viscosity Sensor - Removal........................................................................................................................... 0-49
Water Filter Head - Removal ......................................................................................................................... 0-22
Water Header Plate - Removal ...................................................................................................................... 0-22
Water Heater Housing - Removal .................................................................................................................. 0-22
Water Pump - Removal ................................................................................................................................. 0-21
--- Page 6 ---
Section 0 - Engine Disassembly and Assembly - Group 00 General Information
L10 Page 0-13
Engine Lifting Brackets
Warning: The engine lifting equipment must be designed
to safely lift the engine as an assembly.
Use a properly rated hoist and engine lifting fixture, Part
No. 3822512, attached to the engine mounted lifting
brackets to lift the engine.
Refer to Section E for the weight of the engine you are
working on.
Install the engine on two engine support stands, Part No.
3376057.
--- Page 7 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
L10 Page 0-23
Hand Hole Cover and Dipstick Tube Bracket -
Removal
Remove the four capscrews (1), the dipstick tube bracket
and gasket.
Remove the four capscrews (2), the hand hole cover and
gasket.
Turbocharger Oil Drain Connection - Removal
Remove the turbocharger oil drain tube connection fitting
from the side of the cylinder block.
Engine - Installation On Rebuild Stand
Use the engine rebuild stand, Part No. 3375194, and
adapter plate, Part No. 3376432.
Use five capscrews (5/8—11 X 2 inch) grade 5 capscrews
to install the adapter plate to the rebuild stand.
Torque Value: 180 N•m [135 ft-lb]
Install two guide pins, Part No. 3376488, in the water
header plate mounting capscrew holes at points (1) and
(2).
Warning: To avoid personal injury, use a properly rated
hoist to lift the engine. The engine weighs approximately
902 kg [1990 lb].
Use the engine lifting fixture, Part No. 3822512, to lift the
engine.
Install the exhaust side of the engine to the adapter plate
of the rebuild stand.
--- Page 8 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
L10 Page 0-33
Injectors (Fixed Time Engines) - Removal
Remove the injector plunger links (1).
Number each link with the cylinder number as it is re-
moved.
Remove the injector clamp capscrews and clamps.
Use injector puller, Part No. 3823024, to remove the
injectors.
Number each injector with the cylinder number as it is
removed.
Rocker Lever Housing - Removal
NOTE: Do not drop the capscrew washers into the engine.
Remove the capscrews, washers and rocker lever
housing.
STC Oil Control Valve - Removal
Remove the oil vent line from the gear housing (1) and
STC valve (2).
Remove the STC fuel pressure sensing line (3) from the
cylinder head and the STC control valve.
Remove the two STC control valve mounting capscrews,
oil control valve and o-ring seal.
Remove the two adapter block capscrews, adapter block
and seal.
--- Page 9 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Disassembly (0-01)
L10 Page 0-43
Use one hand to slowly rotate and pull the camshaft from
the cylinder block and the other hand to balance the
camshaft as it is removed.
Remove the camshaft pilot tool.
Hydraulic Pump Drive - Removal
Remove the three drive adapter mounting capscrews.
Install engine barring tool, Part No. 3824270, and dowel
pin extractor, Part No. ST-1134, to the hydraulic drive
adapter. Use two (M10-1.50 x 30) capscrews, Part No.
3335003, for SAE ‘‘A’’ drives. Use two (M12-1.75 x 40)
capscrews, Part No. 3018671, for SAE ‘‘B’’ drives.
Caution: Do not allow the hydraulic drive gear to slide
out of the adapter or the gear housing during removal.
Damage to the gear will result.
Remove the hydraulic drive adapter, o-ring and hydraulic
drive gear.
Gear Housing - Removal
Remove the gear housing mounting capscrews and the
housing.
Remove the rectangular seal from the back side of the
housing.
--- Page 10 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-53
• A lathe cut o-ring which has a straight outside with
sharp corners and the inside which has two 45
degree chamfers, so there are no sharp corners
next to the liner. This o-ring must be installed with
the straight side facing the block, and the chamfered
side next to the liner. If the o-ring is not installed this
way, liner bore distortion can occur.
Caution: Do not let the oil remain on the liner o-rings for
more than 12 hours before the liners are installed. The
o-ring can be damaged when installing the liner.
Make sure the cylinder block and all parts are clean.
Install the liner o-ring on the liner then use clean 15W-40
oil to coat the o-ring.
Install the liner into the cylinder block.
NOTE: When acceptable reused liners are installed, rotate
the liner 90 degrees from their original position in the engine.
The thrust and anti-thrust surfaces must face the front and
back of the cylinder block.
Use the cylinder liner driver, Part No. 3376056, and a
leather mallet to drive the liner into the cylinder block
bore.
If the liner does not seat properly, remove the liner.
Inspect the counterbore seat and liner for nicks, burrs, or
dirt. Install the liner again.
Use cylinder liner clamping tool, Part No. 3824272, to
seat the liner into the cylinder block.
Place the force plate (3) across the top of the liner with
the step inside the liner bore.
--- Page 11 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-63
Use dial indicator, Part No. 3376050, to measure the
crankshaft end clearance.
Crankshaft End Clearance
mm in
0.10 MIN 0.004
0.56 MAX 0.022
If the end clearance is not within specifications, complete
the following steps:
• Remove the number ‘‘4’’ main bearing cap and
thrust bearings.
• Inspect for burrs, dirt or damage.
If nicks or burrs cannot be removed with fine crocus cloth,
the cap and bearings must be replaced.
Measure the thrust bearing thickness and replace the
bearings if they are not within specifications.
Crankshaft Thrust Bearing Thickness
mm in
4.83 MIN 0.1902
4.89 MAX 0.1925
--- Page 12 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-73
Apply LubriplateW 105 under the head of the idler shaft
capscrew. Insert the capscrew through the idler shaft.
Tighten the installation capscrew with a torque wrench.
NOTE: The torque needed to draw the idler shaft in place
must not exceed 88 N•m [65 ft-lb]. If installation torque
exceeds this amount, it indicates misalignment between the
bore and the shaft. Remove the idler shaft and install it
again.
After the idler shaft has been seated, remove the cap-
screw.
Apply pipe sealant, Part No. 3375066, to the threads of
the idler shaft capscrew. Apply LubriplateW 105 under the
head of the capscrew. Install the capscrew and tighten to
its final torque value.
Torque Value: 102 N•m [75 ft-lb]
Apply a film of cup plug sealant, Part No. 3375068, to the
outside diameter of the cup plug.
Use driver, Part No. 3823710, to install the cup plug into
the housing as shown.
Install two guide pins, Part No. 3822784, into the crank-
shaft flywheel mounting flange 180 degrees apart.
Make sure the crankshaft and crankshaft gear are clean.
Install the crankshaft gear on the guide pins.
--- Page 13 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-83
Complete the following steps to tighten the capscrews in
alternating sequence:
Torque Value: Step 1 - 68 N•m [ 50 ft-lb]
2 - 142 N•m [105 ft-lb]
3 - 210 N•m [155 ft-lb]
4 - Loosen Completely
5 - 68 N•m [ 50 ft-lb]
6 - 142 N•m [105 ft-lb]
7 - 210 N•m [155 ft-lb]
Connecting Rod Side Clearance Measure-
ment
Use a feeler gauge to measure the connecting rod side
clearance.
Connecting Rod Side Clearance
mm in.
0.10 MIN 0.004
0.30 MAX 0.012
The rod must move freely from side-to-side.
Piston Cooling Nozzles - Installation
Two kinds of piston cooling nozzles are used. Engines
with articulated pistons use a longer spray nozzle than
engines with aluminum pistons. Make sure the correct
nozzles are used.
Piston Cooling Nozzle Length
mm in
Articulated Pistons 44.5 1.752
Aluminum Pistons 15.9 0.626
The piston and connecting rod assemblies must be in-
stalled before the piston cooling nozzles are installed.
Rotate the crankshaft to position the connecting rod jour-
nal toward the exhaust side of the engine.
Install the nozzles and the special capscrews.
Torque Value: 27 N•m [18 ft-lb]
--- Page 14 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-93
NOTE: On SAE ‘‘B’’ drives, install a new rectangular seal on
the rear surface of the gear retainer (4) before installation.
Install the gear retainer (4).
Install the three capscrews (M10-1.50x60) and tighten.
Torque Value: 61 N•m [45 ft-lb] plus 60 degrees
Water Pump/Lube Pump Idler - Installation
Caution: The grooved side of the rear thrust bearing
must be facing toward the gear to prevent damage to the
gear and engine during engine operation.
Use LubriplateW 105, or equivalent, to lubricate the thrust
bearings and idler gear shaft.
Install the rear thrust bearing.
Install the idler gear without the shaft.
Align the inside diameter of the rear thrust bearing with
the inside diameter of the idler gear.
The shaft must pass through the gear and pilot into the
rear thrust bearing. After installation, the shaft must pro-
trude only slightly less than the thickness of the front
thrust bearing. Shaft protrusion beyond the thickness of
the front thrust bearing indicates that the shaft is not
properly piloted into the rear thrust bearing.
Install the shaft into the gear bore.
--- Page 15 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-103
Use the alignment tool (6) to align the push rod plunger
rod (7).
Tighten the clamp handle (8) after the plunger rod is
aligned, and remove the alignment tool.
Install the injector push rod (9) between the injector cam-
shaft follower and the plunger rod.
NOTE: The push tube must be aligned properly to attain a
correct reading.
Caution: Always use the accessory drive shaft to rotate
(bar) the crankshaft for injection timing. Using any other
method will cause an error in the injection timing or can
damage the engine.
Determine the piston top dead center (TDC) on the com-
pression stroke by rotating the accessory drive shaft in
the direction of engine rotation clockwise. The acces-
sory drive pulley capscrew will need to be installed to
rotate the crankshaft.
The piston is on the compression stroke when both plung-
ers move in an upward direction at the same time. TDC
is indicated by the maximum clockwise indicator posi-
tion of the piston travel indicator pointer.
Caution: Both indicators must have a travel range of at
least 6.35 mm [0.250 inch] or the indicators will be dam-
aged.
Position the gauge contact tip in the center of the plunger
rod and lower the gauge to within 0.63 mm [0.025 inch]
of the fully compressed position.
--- Page 16 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-113
Vibration Damper Face Alignment
(‘‘Wobble’’) - Measurement
Install the dial indicator gauge against the face of the
vibration damper to measure the ‘‘wobble’’.
Push the crankshaft toward the front or the rear of the
engine.
Rotate the crankshaft with the accessory drive shaft one
complete revolution (360 degrees) while maintaining the
position of the crankshaft either toward the front or the
rear of the engine.
Record the total indicator movement.
Replace the damper if wobble exceeds 0.28 mm [0.011
inch].
Accessory Drive Oil Seal - Installation
Install a new gasket on the gear cover.
Do not use lubricant to install the seal. The oil seal must
be installed with the lip of the seal and the shaft clean and
dry to provide a proper oil sealing surface and provide
maximum engine life.
The dust lip of the seal must be facing out to prevent an
oil leak.
Use the installation sleeve provided with the new seal or
oil seal guide, Part No. 3376099, to install the seal.
Install the clamping ring and five capscrews (M8-1.25 X
20) and washers.
Tighten the capscrews in a star pattern in two steps.
Torque Value: Step 1 - 7 N•m [ 60 in-lb]
2 - 19 N•m [170 in-lb]
--- Page 17 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-123
Use clean 15W-40 oil to lubricate the oil connector o-rings.
Press the oil connector all the way into the front housing
by hand.
NOTE: When installing the front housing, be sure the oil
connector and o-ring is in position to be pushed into the rear
housing.
Install the front JacobsW Brake housing on the front rocker
lever supports.
Center the oil connector between the front and rear hous-
ings before tightening the capscrews. Snug the capscrews.
Torque Value: 5 N•m [45 in-lb]
Adjust the rocker lever side clearance. Refer to the pre-
ceding procedure (‘‘Rocker Lever Side Clearance -
Adjustment’’).
After adjusting the side clearance for each rocker lever
assembly, torque the support capscrews in the sequence
shown as the rocker lever side clearance is adjusted.
Torque Value: 122 N•m [90 ft-lb]
Slave Piston Clearance Adjustment
To achieve maximum brake operating efficiency and pre-
vent engine damage by piston-to-valve contact, complete
the following instructions carefully.
Install an 0.38 mm [0.015 inch] feeler gauge between the
slave piston and the actuating pin in the crosshead.
--- Page 18 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-133
Adjust the appropriate injector and valves following the
Injector and Valve Adjustment Sequence Chart.
Repeat the process to adjust all injectors and valves.
Injector Adjustment - CELECT™ Engines
This procedure describes the valve and injector adjust-
ment procedures for CELECT™ engines.
All valve and injector adjustments must be made when
the engine is cold, any stabilized coolant temperature at
60°C [140°F] or below.
The crankshaft rotation is clockwise when viewed from
the front of the engine.
The cylinders are numbered from the front gear housing
end of the engine.
The engine firing order is 1-5-3-6-2-4.
The valve set marks are located on the accessory drive
pulley. The marks align with a pointer on the gear cover.
Use the accessory drive shaft to rotate the crankshaft.
--- Page 19 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-143
Fuel Pump (With Air Compressor) - Installa-
tion
Install the spider coupling to the end of the air compressor
crankshaft.
Use a new gasket to install the fuel pump.
Install the four 12 point capscrews (7/16-14 x 1-1/4) and
tighten.
Torque Value: 47 N•m [35 ft-lb]
Install the support bracket to the cylinder block with two
capscrews (M10-1.50 x 25) and washers. Do not tighten
the capscrews.
Install two support capscrews (1/4-20 x 7/8) with washers
into the fuel pump housing.
Torque Value: 11 N•m [95 in-lb]
Tighten the two capscrews (M10-1.50 x 25) into the cyl-
inder block.
Torque Value: 47 N•m [35 ft-lb]
Fuel Pump (Without Air Compressor) -
Installation
Install the spider coupling to the end of the accessory
drive shaft.
Install the new o-ring on the accessory drive oil drain plug
and install the plug into the accessory drive.
Use a new gasket and install the fuel pump on the ac-
cessory drive.
Install four capscrews (M10-1.50 x 45) and four nuts (M10-
1.50).
Torque Value: 47 N•m [35 ft-lb]
--- Page 20 ---
Section 0 - Engine Disassembly and Assembly - Group 00 Engine Assembly (0-02)
L10 Page 0-153
Hand Hole Cover (Exhaust Side of Engine) -
Installation
Use a new gasket and install the cover with four cap-
screws (M10-1.50 X 20).
Torque Value: 47 N•m [35 ft-lb]
Dipstick Tube Bracket - Installation
Use a new gasket and install the tube bracket with four
capscrews (M10-1.50 X 20).
Torque Value: 47 N•m [35 ft-lb]
Exhaust Manifold - Installation
Install two guide pins, Part No. 3376488, into the cylinder
head.
The gaskets can be installed with either side facing out.
Do not use an adhesive to hold the gaskets in place on
the cylinder head.
Use high temperature anti-seize compound, Part No.
3823097 or equivalent, to coat the capscrew threads, this
will aid future capscrew removal.
Install the exhaust manifold with twelve capscrews (M10-
1.50 X 100) and tubular spacers.
--- Page 21 ---
Section 1 - Cylinder Block - Group 01
L10 Page 1-1
Section 1 - Cylinder Block - Group 01
Section Contents
Page
Camshaft - Cleaning and Inspection for Reuse .............................................................................................. 1-50
Camshaft - Cleaning ..................................................................................................................................... 1-50
Camshaft - Inspection ................................................................................................................................... 1-51
Camshaft - Magnetic Crack Inspection ........................................................................................................... 1-56
Bearing Journal - Limits of Acceptance ......................................................................................................... 1-57
Indications Below the Surface - Limits of Acceptance.................................................................................... 1-58
Open Indications - Limits of Acceptance ....................................................................................................... 1-57
Camshaft Bushings - Replacement................................................................................................................. 1-23
Camshaft Bushing Bores - Cleaning.............................................................................................................. 1-23
Camshaft Bushing Bores - Inspection............................................................................................................ 1-23
Camshaft Bushings - Installation ................................................................................................................... 1-24
Camshaft Bushings - Removal ...................................................................................................................... 1-23
Camshaft Gear - Replacement ........................................................................................................................ 1-52
Camshaft Gear - Cleaning............................................................................................................................. 1-52
Camshaft Gear - Installation.......................................................................................................................... 1-54
Camshaft Nose and Gear - Inspection........................................................................................................... 1-53
Camshaft or Idler Gear - Magnetic Crack Inspection ..................................................................................... 1-58
Forged Surfaces - Limits of Acceptance ........................................................................................................ 1-60
Machined Surfaces - Limits of Acceptance.................................................................................................... 1-60
Connecting Rod Bearings - Cleaning and Inspection for Reuse.................................................................... 1-39
Connecting Rod Bearings - Cleaning............................................................................................................. 1-39