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Operation
and
Maintenance
Manual
Cummins
Automotive
Diesel
Engines
Ma
intenance
Operations
2-19
'C'MaintenanGe
Check
At
each
"C"
Mainrenance
Check, f
irst
perform
all
,,A,,,
and
"B"
Checks
in
addition
to
those
following
-
Steam
Clean
Engine
Steam
is
the
most
satisfactory
method
of
cleaning
a
dirty
engine
or
piece
of
equipment.
lf
steam
is
not
available,
use
mineral
spirits
or
some
other
solvent
to
wásh
the
engine.
Al
I electrical
,components
and
wiring
should
be
protected
from
the
full
force
of
the
cleaner.,prJy
nozzle.
Check
Alternator
And
Cranking
Motor
Brushes
And
Commutators
Failure
of
an
alternator.
or
cranking
motor
may
cause
unit
downtime
and
nearly
always
"
,u.rii
¡n
.*p.nriuu
rep
lacement.
'l
.
lnspect
terminals.
for
corrosion
and
loose
connections
and
wiring
for
frayed
insuration.
cnecr
mtunting
borts
for
tightness
and
check
belt
for
alignment,
propu,
tension
and
wear.
2.
Slrp
rings
and
brushes
can
be
inspected
through
alternator
end
frame,assglblV.
lf
slip ring;are
d¡rty,
they
should
be
cleaned
with
400
grain
or
f
iner
pf,lishing cloth.
Note:
Never
use
emery
cloth
to
clean
slip rings.
Hold
polishing
cloth
against
sr
ip
rings
with
alternator
in
operation
and
blow
away
all
dust
alter
cleaning
operation.
3.
Check
alternator
bearings
for
wear.
Shaft
will
be
excessively
loose
if
bearings
are
worn.
4.
lf
brushes
are
worn
close
to
the
holder,
the
alternator
must
be
removed
and
sent
to
manufaciurer,s
rebuild
stat
ion.
6*
Adjust
Injectors
And
Valves
It is
essential
in
jectors
and
valves
be in
correct adjustment
at
all
times
for
engine
to
operate
properly.
One-controls
engine
breathing;
the
other
controls
iuel'delivery
to
the
cyl
i nders.
Final
operating
adjustments
must
be
made
using
correct
values
as
stated.
Temperature
Settings
The
following
temperature
conditions
provide
the
necessary
Definition
of
"Cold
Set,,
Engine
must
have
reached
a
stabilized
temperature
to
be
with¡n
10
deg.
F
temperature).
Definition
of
"Hot
Set',
1.
Set
injectors
and
valves
immediately
after
the
engine
has
reached
normal
stabilized
operat¡ng
oil'tempeüture.
2.
,lf
oil
temperature
gauge
is unavailable,
set injectors
and
valves
immediately
after
engine
has
op.rui"á-ut
rated
speed
and
load
or
at h¡gh
idle for
Jperiod
oi
ZO,rutu,
Valve
Set
Mark
Alignment
(V-gO3
Series)
Bar
crankshaft
in
d¡rection
of
rotation
until
No.
1
,,VS,,
mark
¿pp6¿¡5
on
the vibration
damper
cránksf¡att
pulley
or
accessory
drive
puiley
as used.
See Fig.
2-26for
location
of
valve
set
marks.
ln
this
position,
bot-h
intaks
and
exhaustvalves
must be
closed
for
cylinder
No
l;-it-not,
advance
crankshaft
one
revolution.
See
Fig.
221
ai¿Table
2-5.
Note:
Once
familiar
with
injector
start
at
any
cylinder
and follow
ad
iu
stments.
stabilization
of
engine
components
to
assure
accurate
sett
i
n
gs.
temperature
(oil
of
ambient
air
and
valve
adjustment,
firing
order
to
make
f
ig,2-26,
(V514115)
Valve
set marks
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2-20
1-5-4-8-6-3-7 -2
1-4-2-5-3-6
Fig,2-27,
(V'11462't
V8 F¡r¡ng order diagram
Before adjustments tighten injector, hold down
capscrew to
30
to
35
ft-lbs
[4.1
to 4.8
kg
m]
torque.
Note':
Remove
key,
and
using
either
3/8
inch
hex drive for
female
type
barring
device
or
5/8
inch
six-point
socket
for
male
type
barring device,
press
inward
until
barring
gear
engages
drive
gear;
then
advance.
FiS.2-28.
After
completion
of
adjustment,
be sure drive
retracts
and install
key
into safety lock
groove.
V-903 And
VT-903
lnjector Adjustment,
Using Dial
lnd¡cator Method
This method involves
adjusting injector
plunger
travel
with
an accurate
dial
indicator
rather
than tightening the
adjusting
screw
to
a
specified torque.
The
"indicator method"
eliminates
errors
in
adjustment
caused
by
friction
in the
screw
threads
and
distortion
from
overt¡ghtening
the
adjusting screw locknut.
A check can be
made
of the
adjustment
without
disturbing
the
locknut or
screw
setting.
The
valves can
also
be
checked
or
set
while
adjusting
the
injectors
by this method.
See
Table 2-6
for
specif icat io ns.
Note: Values
listed in Table
2-6
are to be used
for
either
"Cold
Set"
or
"Hot
Set".
The timing mark
locations
(Fig's.
2-29
and
2-30) are used
with
the
dial indicator
method of setting injectors
and
Operation
and Maintenance
Manual
Cummins
Automotive
Diesel
Engines
Ma
intena nce
Oper¿ti ons
Fig.2-29,
(V514126'l
Location
of
t¡ming
marks
on
front
cover and
vrbrat¡on damper
F¡9,
2-30,
1V514127J
Locat¡on
of t¡ming marks on
accessory
drive
support
Table
2-5
Engine "V"
Series
Firing
Order
Right
Hand
Right
Hand
VB
V6
F
ig. 2-2a,
(
V5
1 486)
Eng¡ne barrin
g
arrangement
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r.1*
Table
2-6
Adiu$trnent
L¡mits
Llsing
lndicator
Method
Of
Adiustment
-
nch
[mm]
Operation and
Maintenance
Manual
Cummins
Automotive
Diesel
Engines
Ma
intenance
Operations
2-2
4. Allow
the injector
plunger
to rise and
then bottom
ag
and set
indicator
af
zero
(0).
We
recommend
lever
released
and
plunger
bottomed
again
to check
setting.
5.
Release
the
lever
completely,
indicator should
show
total
readinq as
indicated
in
Table
2-6.
(Use
proper
va
depending
if
new adjustment
or
reset check.)
Adjust
correct
tolerance
as
necessarY.
6.
Tighten
the
adiusting
screw
locknut
to
30
to
40
ft
[a.1
io 5.5
kg
m]
and
actuate
the
injector
plunger
sev
iim.r
ur a
check
of the
adjustment'
Tighten
to
25
to
ft-lbs
[3.5
to
4.8
kg
m]
when
using
5T-669 Adapter
torque
wrench.
Crosshead
Adjustment
1.
Loosen
valve
crosshead
adiusting
screw
locknut
and
b
off
screw
one turn.
lnjector
Plunger Travel
Adjustment
Value
Reset
Limit
Valve
Clearance
lntake
Exhaust
0.180
to 0.181
[4.57
to
4.60]
0.179
tó
0.182
0.012
0.025
[4.55
to
4.62]
10.301
t0.641
valv'es.
Alignment,
ln
either location,
should
be
held
to
one-half
inch
[12.7
mm]
of
pointer.
Using
regular
engine barring
device
(Fig.
2-281
,
rofafe
engine in dlrection
of rotation
untii
"VS"
mark
for cylinder
2-8
is
aligned
with
pointer.
ln this
position
both
the intake
and
exhaust
valve
rocker levers
for
number
2
cylinder
should
be
free and
can
be
moved up and
down.
lf
not,
bar
engine
another
360 deg.
in direction
of
rotation
and
realign
the 2-8
"VS"
mark.
Note:
No.
2 cylinder
is
selected
for
purpose
of
illustration
only. Any
other cylinder could
be
used,
if
so
desired.
1. Set up the ST-1170
lndicator Support
with the indicator
extension atop the
in
jector
plunger f
lange
at
No.
2 cyllnder.
Fis.2-31
.
Fig.2-31,
(V5141'l4l
D¡al
¡nd¡cator
¡n
place
-
extension
in contact
with
plunger
2.
Make sure
that
the
indicator
extension
is secure
in
indicator
stem
and
not against
the
rocker
fever.
3.
Using
ST-125,1
Acluator,
Fig 232,
bar
the
lever
icr''vard
until
inlector
plunger
is boiiomed
rn
cuo
to
sQUeez3
crl
filn-r
from
between
plunger
and
cuP.
2.
Use
light
finger
pressure
at
rocker
lever
contact
sur
to
hold trosshead
in
contact
with valve
stem
(with
adiusting
screw).
&
3.
Turn
down
crosshead
adjusting
screw
until
it touc
valve
stem.
4.
Hold adjusting
screw
in this
position
and
torque
lock
to
25
to 30
ft'-lbs
[3.5
to
4.1
kg m] .
Note:
lnsure that
crosshead
retainers
on
exhaust
valve
used) are
positioned
equally
on both
sides
of
spring
crossheads
and
valve
springs
properly
5.
Check
clearance
between
crosshead
and
valve sp
retainer
with
wire
gauge.
There
must be
a
minimum
0.025
inch
[0.64
mm]
clearance
at
this
point.
Fig,2-32,
(v51412A1.
Bottoming
injector
plunger
¡n
cup
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-22
Valve
Adjustment
The same
engine
position
used
in adjusting
injectors is used
for
setting intake
and
exhaust
valves.
1.
Loosen
locknut
and back
off adjusting screw.
lnseri
feeler
gauge
between
rocker
lever
and top
of
crosshead.
Valve
clearances
are
shown in Table
2-6.
Turn screw
down
until lever
just
touches
gauge
and
lock adjusting screw
in
this
position
with
locknut.
Torque
adjusting screw
locknuts
to 30 to 40
ft-lbs
14.1
to 5.5
kg
ml
or
25
to
35
ft-lbs
13"5
to
4.8
kg
ml
when
using
a
ST
669
Adapter.
2.
Always
make
f
inal
valve
adjustment after injectors
are
ad
j
usted
.
lnjector
Plunger, Valve
Adjustment
Using
Torque
Method, V-378,
V-504,
V-555, VT-555
Ensines
Valve
Set Mark
Alignment
Turn
crankshaft
in direction of rotation
unt¡l
a
"VS"
mark
appears
on the
vibration
damper, crankshaft
pulley
or
accessory
drive
pulley.
See
Fig.
2-33
for
location
of
valve
set
marks. In
this
position
both intake
and exhaust
valves
must
be
closed
for
that
cylinder; if not,
advance
crankshaft
one revolution.
See
Fig.
2-34,
Fig.2-27
and Table2-5 for
firing
order.
Fig.
2-33,
(V11913)
Valve
set
marks
Before
adiusting
injector,
tighten
injector
hold-down
capscrew
to 30
to
35
ft-lbs
[4.1
to 4.8
kg
m]
torque.
The
injector
plungers
must be
adjusted
with an
inch-pound
torque
wrench
to
a
definite
torque
setting.
A
torque
wrench
and
a screwdriver
adapter
can
be
used
for
this
adiustment.
Fig.
2 35.
Operation
and
Malntenance
Manual
Cummins
Automotive
Diesel
Engines
Ma intenance
Operations
Fig.
?-34,
(V11461)
V6 Firing
order
1
.
Turn
adiusting
screw
down
unt¡l
plunger
contacts
cup'
Advance
an additional
'1
5
degrees
to squeeze
oil
from
cup.
2.
Loosen
adjusting
screw
one turn, then,
uslng a
torque
wrench
calibrated
in inch-pound
and
a
screwdriver
adapter,
tighten the
adjusting
screw
to
values
shown in Table
2--/
for
cold
setting
and
tighten
the
locknut.
Note:
Values
listed in f ar|e
2-1
and
2-9
are
to
be
used
for
either
"Cold
Set"
or
"Hot
Set".
3.
Hold-
iniector adjusting
screw
and
tighten injector
locknut
to
vi..rlues indicated in
Table 2-8.
When 5T-669
Adapter
is
used,
nut torque is
reduced
to
compensate
for
additional
torque arm
length.
Fig.
2-36.
Ad
just
crossheads
and
valves as
described in
Crosshead
and
Valve
Adjustment
Pages2-21
and
22 and Table
2-9.
dl
Fig. 2-35,
(V51488)
Adjusting
¡niector
plungers
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Operation
and
Maintenance
lVanual
Cummins
Automotive Diesel
Engines
Ma
in renance
Opera
lions
1-/
Engine
Model
Table2-7: lnjector
Plunger
Ad¡ustment Torque
lnjector
And
Valve
Adjustment
Using
ST-1170
Dial lndicator Method t\iH-NT Series
This method involves
adjusting
injector
plunger
travel wi
an accurate
dial
ind¡cator
rather
than
tightening th
adjusting
screw
to
a
specified torque.
A
check can
be mad
of
the adjustment
without
disturbing
the
locknut
or scre
settinq.
The valves can also be checked
or
set
wh
adjustin the
injectors
by
this method.
See
Table
2-10.
Temperature
conditions described as
"Cold
Set"
or
"H
Set"
must
be
observed when
recheck
is
being
performed.
travel
exceeds recheck values,
adjust
to
proper
value
show
in
"Adjustment
Value"
column.
Check
and/or
adjust
Valv
as
necessary.
Note:
lf
injectors
were removed
for
cleaning
or replaceme
t¡ghten injector, hold-down
capscrews
in
alternate steps
lOto 12
ft-lbs.
[1.4to
1.7 kg
m]
torque.
Table 2-10:lnjector and Valve
Set
Position
Set
v-378,
504, 555,
VT-555
60 inch-lb
[0.7
ks
m]
Table
2"8:
Injector
And
Valve
l-ocknut
Torque
(AllModels)
with sT-669
Without
ST-669
Bar
in
Direction
Pulley
Position
Set
Cylinder
lniector
Valv
Sta
rt
Adv. To
Adv. To
Adv. To
Adv. To
Adv.
To
A
or
1-6VS
B
or
2-5VS
C or 3-4VS
A or
1-6VS
B
or
2-5VS
C
or
3-4VS
3
6
2
4
1
5
5
3
b
2
4
1
25 to 35
ft-lbs
[3.5
to
4.8
kg ml
30
to
40
ft-lbs
[4.1
to
5.5
ks m]
Note:
lf
cylinder
head
gasket
or any components
of
actuating
train
have been
replaced,
engine must
be started
and brought
to operat¡ng
temperature,
then allowed
to cool
thoroughly. Cylinder
head capscrews
must be
retorqued.
See Shop
Manual.
lnjector
plungers
should
then
be
reset
to
values
listed
above.
Table
2.9:
Valve
Clearance
-
Inch
Imm]
lntake
Valves
Set
Exhaust
Valves
Set
V-378,
5M,
555, VT-555
Engines
0.012
[0.30]
Maintenance Adjustment
The
appropriate
check
values
in
Table 2-11
are applicab
to enqines which have
operated long
enough
to
warra
checking of injector setting
and
valve
clearance.
Fig.2-36,
(V51489)
T¡9hten¡ng
injector adjusting screw locknut
F
ig.
2-37,
(V5149O)
Adjust¡ng crossheads
0.022
[0.56]
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