Volvo G780VHP Motor Grader Service and Repair Manual PDF

Volvo G780VHP Motor Grader Service and Repair Manual PDF

Size: 90.62 MB
Language: English
Make: Volvo
Machine: Motor Grader
Document: Service and Repair Manual, Hydraulic and Electric Diagrams
Model: Volvo G780VHP

List of Files:
Engine Cummins-M11-Workshop-Manual.pdf (585 Pages)
MAIN MENU
COVER PAGE
TABLE OF CONTENTS
INTRODUCTION
ABOUT THE MANUAL
DEFINITION OF TERMS
GENERAL CLEANING INSTRUCTIONS
GLASS OR PLASTIC BEAD CLEANING
SOLVENT OR ACID CLEANING
STEAM CLEANING
GENERAL REPAIR INSTRUCTIONS
WELDING ON A CELECT CONTROLLED VEHICLE
GENERAL SAFETY INSTRUCTIONS
IMPORTANT SAFETY NOTICE
HOW TO USE THE MANUAL
ILLUSTRATIONS
SIMBOLOS
SYMBOLE
SYMBOLES
SYMBOLS
ENGINE IDENTIFICATION
ENGINE DIAGRAMS
ENGINE INDENTIFICATION
ELECTRONIC CONTROL MODULE (ECM) DATAPLATE
ENGINE DATAPLATE
ENGINE SPECIFICATIONS
AIR INTAKE SYSTEM
BATTERIES (SPECIFIC GRAVITY)
COOLING SYSTEM
ELECTRICAL SYSTEM
EXHAUST SYSTEM
FUEL SYSTEM
GENERAL ENGINE DATA
LUBRICATING OIL SYSTEM
ENGINE DISASSEMBLY AND ASSEMBLY – GROUP 00
ENGINE ASSEMBLY
ACCESSORY DRIVE ASSEMBLY – INSTALLATION
ACCESSORY DRIVE OIL SEAL – INSTALLATION
ACCESSORY DRIVE PULLEY – INSTALLATION
ACTUATOR HARNESS – INSTALLATION
AIR COMPRESSOR – INSTALLATION
AIR COMPRESSOR AIR SUPPLY TUBE – INSTALLATION
AIR COMPRESSOR COOLANT INLET TUBE FITTING – INSTALLATION
AIR COMPRESSOR COOLANT OUTLET TUBE – INSTALLATION
AIR INTAKE MANIFOLD – INSTALLATION
ALTERNATOR – INSTALLATION
ALTERNATOR AND BRACKET (BUS APPLICATIONS) – INSTALLATION
ALTERNATOR BELT (NON BUS APPLICATIONS) – INSTALLATION
ALTERNATOR DRIVE BELT (BUS APPLICATIONS) – INSTALLATION
ALTERNATOR DRIVE PULLEY – INSTALLATION
ALTERNATOR DRIVE SEAL – INSTALLATION
AUTOMATIC BELT TENSIONER – INSTALLATION
CAM FOLLOWER ASSEMBLIES – INSTALLATION
CAMSHAFT AND GEAR ASSEMBLY – INSTALLATION
CONNECTING ROD SIDE CLEARANCE MEASUREMENT
COOLANT FILTER – INTSTALLATION
CRANKSHAFT – INSTALLATION
CROSSHEADS – INSTALLATION
CYLINDER BLOCK – INSTALLATION ON REBUILD STAND
CYLINDER HEAD – INSTALLATION
CYLINDER LINERS – INSTALLATION
DIPSTICK TUBE BRACKET – INSTALLATION
DRAIN PLUGS – INSPECTION
ELECTRIC FAN CLUTCH (CUMMINS) – INSTALLATION
ELECTRONIC CONTROL COOLING PLATE – INSTALLATION
ELECTRONIC CONTROL MODULE – INSTALLATION
ENGINE – REMOVAL FROM THE REBUILD STAND
EXHAUST MANIFOLD – INSTALLATION
FAN BELT – INSTALLATION
FAN HUB (BELT DRIVEN) – INSTALLATION
FAN HUB SUPPORT – INSTALLATION
FAN IDLER PULLEY – INSTALLATION
FAN PULLEY AND FAN – INSTALLATION
FLYWHEEL – INSTALLATION
FLYWHEEL BORE RUNOUT – MEASUREMENT
FLYWHEEL FACE RUNOUT – MEASUREMENT
FLYWHEEL HOUSING – INSTALLATION
FLYWHEEL HOUSING BORE ALIGNMENT – MEASUREMENT
FLYWHEEL HOUSING FACE ALIGNMENT – MEASUREMENT
FLYWHEEL HOUSING, REPTO – INSTALLATION
FRONT CRANKSHAFT OIL SEAL – INSTALLATION
FUEL FILTER – INSTALLATION
FUEL FILTER HEAD AND BRACKET – INSTALLATION
FUEL PUMP PLUMBING – INSTALLATION
FUEL PUMP SUPPORT BRACKET – INSTALLATION
FUEL PUMP (WITH AIR COMPRESSOR) – INSTALLATION
FUEL PUMP (WITHOUT AIR COMPRESSOR) – INSTALLATION
GEAR COVER – INSTALLATION
GEAR HOUSING – INSTALLATION
HAND HOLE COVER (EXHAUST SIDE OF ENGINE ) – INSTALLATION
HAND HOLE COVER (FUEL PUMP SIDE OF ENGINE ) – INSTALLATION
HIGH OIL PRESSURE REGULATOR – INSTALLATION
HYDRAULIC PUMP DRIVE – INSTALLATION
IDLER GEAR ASSEMBLIES – INSTALLATION
IDLER GEAR (REPTO) – INSTALLATION
INJECTORS – INSTALLATION
JACOBS BRAKE HOUSING SPACER – INSTALLATION
JACOBS BRAKE OIL SUPPLY HOSE – INSTALLATION
JACOBS ENGINE BRAKE – INSTALLATION
LUBRICATING OIL COOLER – INSTALLATION
LUBRICATING OIL FILTER – INSTALLATION
LUBRICATING OIL FILTER HEAD – INSTALLATION
LUBRICATING OIL PAN – INSTALLATION
LUBRICATING OIL PUMP – INSTALLATION
MAIN OIL PRESSURE REGULATOR – INSTALLATION
OVERHEAD – ADJUSTMENT
PISTON AND CONNECTING ROD – ASSEMBLY
PISTON AND CONNECTING ROD – INSTALLATION
PISTON COOLING NOOZLE – INSTALLATION
PUSH RODS AND TUBES – INSTALLATION
REAR CRANKSHAFT OIL SEAL – INSTALLATION
ROCKER LEVER ASSEMBLIES – INSTALLATION
ROCKER LEVER COVER – INSTALLATION
ROCKER LEVER HOUSING – INSTALLATION
ROCKER LEVER SIDE CLEARANCE – ADJUSTMENT
SENSOR HARNESS – INSTALLATION
STARTING MOTOR – INSTALLATION
STATIC INJECTION TIMING – CHECKING
STATIC INJECTION TIMING – GENERAL INFORMATION
THERMOSTAT HOUSING – INSTALLATION
THERMOSTAT HOUSING SUPPORT – INSTALLATION
THRUST BEARING, LOWER BEARING SHELLS AND MAIN BEARING CAPS – INSTALLATION
TORQUE CONVERTER COOLER DISC – INSTALLATION
TURBOCHARGER – INSTALLATION
TURBOCHARGER DRAIN FITTING – INSTALLATION
UPPER MAIN BEARING SHELLS – INFORMATION
VIBRATION DAMPER AND CRANKSHAFT PULLEY – INSTALLATION
VIBRATION DAMPER ECCENTRICITY – MEASUREMENT
VIBRATION DAMPER FACE – RUNOUT MEASUREMENT
VISCOSITY SENSOR – INSTALLATION
WATER FILTER HEAD – INSTALLATION
WATER HEADER PLATE – INSTALLATION
WATER HEATER HOUSING – INSTALLATION
WATER PUMP – INSTALLATION
ENGINE DISASSEMBLY
ACCESSORY DRIVE ASSEMBLY – REMOVAL
ACCESSORY DRIVE OIL SEAL – REMOVAL
ACCESSORY DRIVE PULLEY – REMOVAL
AIR COMPRESSOR – REMOVAL
AIR COMPRESSOR AIR SUPPLY TUBE – REMOVAL
AIR COMPRESSOR COOLANT TUBES – REMOVAL
AIR INTAKE MANIFOLD – REMOVAL
ALTERNATOR ADJUSTING LINK (NON BUS APPLICATIONS) – REMOVAL
ALTERNATOR AND BRACKET (NON BUS APPLICATIONS) – REMOVAL
ALTERNATOR AND BRACKETS (BUS APPLICATIONS)
ALTERNATOR BELT (BUS APPLICATIONS) – REMOVAL
ALTERNATOR BELT (NON BUS APPLICATIONS) – REMOVAL
ALTERNATOR DRIVE OIL SEAL – REMOVAL
ALTERNATOR DRIVE PULLEY – REMOVAL
BLOCK MOUNTED FRONT SUMP SUCTION TUBE – REMOVAL
CAM FOLLOWER ASSEMBLIES – REMOVAL
CAMSHAFT – REMOVAL
COOLANT – DRAINING
COOLANT FILTER – REMOVAL
CRANKSHAFT AND UPPER MAIN BEARING SHELLS – REMOVAL
CRANKSHAFT FRONT OIL SEAL – REMOVAL
CRANKSHAFT PULLEY AND VIBRATION DAMPER – REMOVAL
CRANKSHAFT REAR OIL SEAL – REMOVAL
CROSSHEADS – REMOVAL
CYLINDER HEAD – REMOVAL
CYLINDER LINERS – REMOVAL
ELECTRONIC CONTROL COOLING PLATE – REMOVAL
ELECTRONIC CONTROL MODULE – REMOVAL
ENGINE – CLEANING
ENGINE – INSTALLATION ON REBUILD STAND
ENGINE – PREPARATION FOR CLEANING
ENGINE BARRING TOOL – INSTALLATION
EXHAUST MANIFOLD – REMOVAL
FAN AND FAN HUB – REMOVAL
FAN DRIVE BELT – REMOVAL
FAN HUB SUPPORT – REMOVAL
FLYWHEEL – REMOVAL
FLYWHEEL HOUSING – REMOVAL
FLYWHEEL HOUSING, REPTO – REMOVAL
FRONT ENGINE SUPPORT BRACKET – REMOVAL
FUEL FILTER – REMOVAL
FUEL LINES – REMOVAL
FUEL PUMP – REMOVAL
FUEL SUPPLY HOSE AND FILTER HEAD – REMOVAL
GEAR COVER – REMOVAL
GEAR HOUSING – REMOVAL
HAND HOLE COVER AND DIPSTICK TUBE BRACKET – REMOVAL
HAND HOLE COVER (FUEL PUMP SIDE) – REMOVAL
HIGH OIL PRESSURE REGULATOR – REMOVAL
HYDRAULIC PUMP DRIVE – REMOVAL
HYDRAULIC PUMP OR COVER – REMOVAL
IDLER GEAR ASSEMBLIES – REMOVAL
INJECTORS – REMOVAL
INTERNAL ACTUATOR HARNESS – REMOVAL
JACOBS ENGINE BRAKE – REMOVAL
LIFTING BRACKETS – REMOVAL
LUBRICATING OIL – DRAINING
LUBRICATING OIL COOLER – REMOVAL
LUBRICATING OIL FILTER HEAD – REMOVAL
LUBRICATING OIL FILTERS – REMOVAL
LUBRICATING OIL PAN – REMOVAL
LUBRICATING OIL PUMP – REMOVAL
LUBRICATING OIL TRANSFER TUBE – REMOVAL
MAIN BEARING CAPS, LOWER BEARING SHELLS AND THRUST BEARINGS – REMOVAL
MAIN OIL PRESSURE REGULATOR – REMOVAL
PISTON COOLING NOZZLES – REMOVAL
PISTONS AND CONNECTING ROD – DISASSEMBLY
PISTONS AND CONNECTING RODS – REMOVAL
PUSH RODS – REMOVAL
ROCKER LEVER ASSEMBLIES – REMOVAL
ROCKER LEVER COVER – REMOVAL
ROCKER LEVER HOUSING – REMOVAL
ROCKER LEVER HOUSING SPACER – REMOVAL
SENSOR HARNESS AND SENSORS REMOVAL
STARTING MOTOR – REMOVAL
THERMOSTAT HOUSING – REMOVAL
THERMOSTAT HOUSING SUPPORT – REMOVAL
TORQUE CONVERTER COOLER DISC – REMOVAL
TURBOCHARGER – REMOVAL
TURBOCHARGER OIL DRAIN CONNECTION – REMOVAL
VISCOSITY SENSOR – REMOVAL
WATER FILTER HEAD – REMOVAL
WATER HEADER PLATE – REMOVAL
WATER HEATER HOUSING – REMOVAL
WATER PUMP – REMOVAL
ENGINE DISASSEMBLY AND ASSEMBLY – GENERAL INFORMATION
ASSEMBLY
DISASSEMBLY
ENGINE LIFTING BRACKETS
SERVICE TOOLS – DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK – GROUP 01
CAMSHAFT – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
CAMSHAFT – MAGNETIC CRACK INSPECTION
BEARING JOURNAL – LIMITS OF ACCEPTANCE
DEFINITIONS OF INDICATIONS
VALVE AND INJECTOR LOBE – LIMITS OF ACCEPTANCE
CAMSHAFT BUSHING – REPLACEMENT
CLEANING
INSPECTION
INSTALLATION
REMOVAL
CAMSHAFT GEAR – REPLACEMENT
CLEANING
INSPECTION
INSTALLATION
REMOVAL
CAMSHAFT OR IDLER GEAR – MAGNETIC CRACK INSPECTION
CAMSHAFT OR IDLER GEAR – LIMITS OF ACCEPTANCE
DEFINITIONS OF INDICATION
CONNECTING ROD – BEND AND TWIST INSPECTION
ALIGNMENT INSPECTION
FIXTURE CALIBRATION
TWIST INSPECTION
CONNECTING ROD – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
CONNECTING ROD – MAGNETIC CRACK INSPECTION
CONNECTING ROD – LIMITS OF ACCEPTANCE
CONNECTING ROD BEARINGS – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
CRANKSHAFT – CLEANING AND INSPECTIONS FOR REUSE
CLEANING
INSPECTION
CRANKSHAFT GEAR – REPLACEMENT
INSPECTION
INSTALLATION
REMOVAL
CRANKSHAFT MAGNETIC CRACK INSPECTION
COIL SHOT (CIRCUMFERENTAL MAGNETIZATION)
HEAD SHOT (LONGITUDINAL MAGNETIZATION)
MAGNETIC INSPECTION – LIMITS OF ACCEPTANCE
CRANKSHAFT PULLEY – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
CYLINDER BLOCK – EXPLODED VIEW
CYLINDER BLOCK – GENERAL INFORMATION
CYLINDER BLOCK – INSPECTION FOR REUSE
CAMSHAFT BUSHING INSIDE DIAMETER
CYLINDER LINER BORES – INSPECTION
HIGH OIL PRESSURE REGULATOR SEAT DEPTH – MEASUREMENT
IDLER GEAR RING DOWEL BORE – MEASUREMENT
MAIN BEARING BORE ALIGNMENT – INSPECTION
MAIN BEARING BORE INSIDE DIAMETER – MEASUREMENT
MAIN OIL PRESSURE REGULATOR VALVE BORE – MEASUREMENT
THRUST BEARING SURFACE WIDTH – MEASUREMENT
CYLINDER BLOCK
ASSEMBLY
CAM FOLLOWER STUDS – INSTALLATION
DOWEL PINS – INSTALLATION
PIPE PLUGS – INSTALLATION
CLEANING
DISASSEMBLY
CAM FOLLOWER STUDS – REMOVAL
DOWEL PINS – REMOVAL
IDLER SHAFT RING DOWELS – REMOVAL
PIPE PLUGS – REMOVAL
CYLINDER LINER – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
DIPSTICK TUBE BRACKET – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
GEAR COVER – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
GEAR HOUSING – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
NEEDLE BEARING INSTALLATION
HAND HOLE COVER – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
IDLER GEAR ASSEMBLY – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
MAIN BEARINGS – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
PISTON – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
PISTION RINGS – REMOVAL
SERVICE TOOLS – CYLINDER BLOCK
VIBRATION DAMPER (VISCOUS) – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
CYLINDER HEAD – GROUP 02
CYLINDER HEAD – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
CYLINDER HEAD – EXPLODED VIEW
CYLINDER HEAD – GENERAL INFORMATION
CYLINDER HEAD – PRESSURE TEST FOR REUSE
CYLINDER HEAD – REBUILD
ASSEMBLY
DISASSEMBLY
INSPECTION
VALVE SEATS – GRINDING
CYLINDER HEAD – VACUUM TEST VALVE SEATING
CYLINDER HEAD – VALVE GRINDING
INSPECTION
CYLINDER HEAD INJECTOR SLEEVE – REPLACEMENT
ASSEMBLY
DISASSEMBLY
INSPECTION
CYLINDER HEAD OVERSIZE VALVE SEAT INSERT – INSTALLATION
CYLINDER HEAD VALVE GUIDE – REPLACEMENT
ASSEMBLY
DISASSEMBLY
ASSEMBLY
CYLINDER HEAD VALVE SEAT INSERT – REPLACEMENT
ASSEMBLY
DISASSEMBLY
INSPECTION
CYLINDER HEAD VALVES – MAGNETIC CRACK INSPECTION
SERVICE TOOLS – CYLINDER HEAD
VALVE CROSSHEAD – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
VALVE CROSSHEAD – MAGNETIC CRACK INSPECTION
ROCKER LEVERS – GROUP 03
CRANKCASE BREATHER (INTERNAL) – CLEANING AND INSPECTION
ROCKER HOUSING AND COVER (AUTOMOTIVE) – EXPLODED VIEW
ROCKER LEVER – MAGNETIC CRACK INSPECTION
ROCKER LEVER ASSEMBLY – CLEANING AND INSPECTION FOR REUSE
ASSEMBLY
DISASSEMBLY
INSPECTION
ROCKER LEVER ASSEMBLY – REBUILD
ASSEMBLY
DISASSEMBLY
INSPECTION
ROCKER LEVER BUSHING – REPLACEMENT
ASSEMBLY
DISASSEMBLY
INSPECTION
ROCKER LEVER COVER – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
ROCKER LEVER HOUSING – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
ROCKER LEVERS – EXPLODED VIEW
ROCKER LEVERS – GENERAL INFORMATION
SERVICE TOOLS – ROCKER LEVERS
CAM FOLLOWERS – GROUP 04
CAM FOLLOWER ASSEMBLY – CLEANING AND INSPECTION FOR REUSE
ASSEMBLY
DISASSEMBLY
INSPECTION
CAM FOLLOWER ASSEMBLY – EXPLODED VIEW
CAM FOLLOWER ASSEMBLY – GENERAL INFORMATION
CAM FOLLOWER ASSEMBLY – REBUILD
ASSEMBLY
DISASSEMBLY
INSPECTION
CAM FOLLOWER LEVER – MAGNETIC CRACK INSPECTION (ROLLER REMOVED)
CAM FOLLOWER LEVER – ROLLER REPLACEMENT
ASSEMBLY
DISASSEMBLY
INSPECTION
CAM FOLLOWER LEVER SOCKET – REPLACEMENT (ROLLER REMOVED)
ASSEMBLY
DISASSEMBLY
INSPECTION
PUSH RODS AND TUBES – CLEANING AND INSPECTION FOR REUSE
INSPECTION
SERVICE TOOLS – CAM FOLLOWER ASSEMBLY
FUEL SYSTEM – GROUP 05
FUEL PUMP – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
FUEL PUMP – GENERAL INFORMATION
FUEL PUMP – REBUILD
ASSEMBLY
DISASSEMBLY
FUEL DAMPER – ASSEMBLY
FUEL DAMPER – DISASSEMBLY AND INSPECTION
FUEL SHUTOFF VALVE – ASSEMBLY
FUEL SHUTOFF VALVE – CLEANING AND INSPECTION
FUEL SHUTOFF VALVE – DISASSEMBLY
FUEL SUPPLY PUMP – TEST
INSPECTION
INJECTORS AND FUEL LINES – GROUP 06
FUEL TUBES, FITTINGS AND MOUNTING PARTS – CLEANING AND INSPECTION FOR REUSE
INSPECTION
INJECTOR – CELECT – EXPLODED VIEW
INJECTORS – CALIBRATION
INJECTORS – CLEANING AND INSPECTION FOR REUSE
INSPECTION
INJECTORS – GENERAL INFORMATION
INJECTORS – REBUILD
LUBRICATING OIL SYSTEM – GROUP 07
LUBRICATING OIL COOLER – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
PRESSURE TEST THE OIL COOLER ELEMENT
LUBRICATING OIL DIPSTICK – CALIBRATION
LUBRICATING OIL DIPSTICK AND DIPSTICK TUBE – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
LUBRICATING OIL FILTER HEAD – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
LUBRICATING OIL FILTER HEAD – REBUILD
ASSEMBLY
DISASSEMBLY
LUBRICATING OIL PAN – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
LUBRICATING OIL PAN TRANSFER TUBE – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
LUBRICATING OIL PUMP – CLEANING AND INSPECTION FOR REUSE
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
LUBRICATING OIL PUMP – REBUILD
LUBRICATING OIL SYSTEM – EXPLODED VIEW
LUBRICATING OIL SYSTEM – GENERAL INFORMATION
SERVICE TOOLS – LUBRICATING OIL SYSTEM
COOLING SYSTEM – GROUP 08
FAN HUB – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
FAN HUB – EXPLODED VIEW
FAN HUB AND FAN IDLER PULLEY – GENERAL INFORMATION
FAN HUB (BELT DRIVEN) – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
FAN IDLER PULLEY – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
FAN IDLER PULLEY – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
FAN IDLER PULLEY AND BRACKET – EXPLODED VIEW
HEATER HOUSING, THERMOSTAT SUPPORT AND WATER HEADER COVER – CLEANING AND INSPECTION
CLEANING
INSPECTION
SERVICE TOOLS – COOLING SYSTEM
THERMOSTAT – OPERATING TEMPERATURE INSPECTION
TEST
THERMOSTAT HOUSING ASSEMBLY – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
WATER FILTER HEAD ASSEMBLY – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
WATER FILTER HEAD ASSEMBLY – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
WATER PUMP – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
WATER PUMP – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
WATER PUMP ASSEMBLY – EXPLODED VIEW
WATER PUMP ASSEMBLY – GENERAL INFORMATION
DRIVE UNITS – GROUP 09
ACCESSORY DRIVE PULLEY – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
DRIVE UNITS – GENERAL INFORMATION
FUEL PUMP AND COMPRESSOR DRIVE
HYDRAULIC PUMP DRIVE
FUEL PUMP AND COMPRESSOR DRIVE – CLEANING INSPECTION FOR REUSE
CLEANING
INSPECTION
FUEL PUMP AND COMPRESSOR DRIVE – EXPLODED VIEW
FUEL PUMP AND COMPRESSOR DRIVE – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
HYDRAULIC PUMP DRIVE – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
HYDRAULIC PUMP DRIVE – EXPLODED VIEW
HYDRAULIC PUMP DRIVE – REBUILD
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
SERVICE TOOLS – DRIVE UNITS
AIR INTAKE SYSTEM – GROUP 10
AIR INTAKE SYSTEM – GENERAL INFORMATION
CAC AIR INTAKE SYSTEM EXPODED VIEW
INTAKE MANIFOLD – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
SERVICE TOOLS – AIR INTAKE SYSTEM
TURBOCHARGER – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
EXHAUST SYSTEM – GROUP 11
EXHAUST MANIFOLD – CLEANING INSPECTION FOR REUSE
CLEANING
DISASSEMBLY
INSPECTION
EXHAUST SYSTEM – EXPLODED VIEW
EXHAUST SYSTEM – GENERAL INFORMATION
AIR EQUIPMENT – GROUP 12
AIR COMPRESSOR – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
AIR EQUIPMENT – GENERAL INFORMATION
COMPRESSED AIR SYSTEMS FLOW DIAGRAMS
ELECTRICAL EQUIPMENT – GROUP 13
ALTERNATOR ADJUSTING LINK – CLEANING AND INSPECTION FOR REUSE
INSPECTION
ALTERNATOR BRACKET – CLEANING AND INSPECTION FOR REUSE
INSPECTION
ALTERNATOR BRACKET (BUS APPLICATIONS) – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
AUTOMATIC BELT TENSIONER BRACKET (BUS APPLICATIONS) – CLEANING AND INSPECTION FOR REUSE
CLEANING
AUTOMATIC BELT TENSIONER (BUS APPLICATIONS) – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
ELECTRICAL EQUIPMENT – GENERAL INFORMATION
STARTING MOTOR – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
WIRING DIAGRAMS
ENGINE TESTING – GROUP 14
CHASSIS DYNAMOMETER
GENERAL TEST PROCEDURE
CHARGE AIR COOLER RESTRICTION
COOLANT PRESSURE
ENGINE BLOWBY
ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER
EXHAUST AIR RESTRICTION
FUEL DRAIN LINE RESTRICTION
FUEL INLET RESTRICTION
FUEL RATE
INTAKE AIR RESTRICTION
INTAKE AIR TEMPERATURE CONTROL – CHASSIS DYNAMOMETER TEST
INTAKE MANIFOLD PRESSURE
LUBRICATING OIL PRESSURE
OPERATION
DYNAMOMETER WORKSHEET
ENGINE DYNAMOMETER – INSTALL ENGINE
AIR COMPRESSOR
AIR INLET RESTRICTION
COOLANT PLUMBING
ENGINE BLOWBY
ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER
ENGINE THROTTLE CONTROL
EXHAUST RESTRICTION
FUEL DRAIN LINE RESTRICTION
FUEL INLET RESTRICTION
FUEL PRESSURE
FUEL RATE
INTAKE AIR TEMPERATURE CONTROL
INTAKE MANIFOLD PRESSURE
LUBRICATING OIL PRESSURE
LUBRICATING OIL TEMPERATURE
STARTING MOTOR
ENGINE PAINTING
ENGINE RUN-IN PROCEDURE -CHASSIS DYNAMOMETER
ENGINE RUN-IN PROCEDURE – ENGINE DYNAMOMETER
ENGINE RUN-IN PROCEDURE – WITHOUT DYNAMOMETER
ON-HIGHWAY
ENGINE STORAGE – LONG TERM
REMOVE THE ENGINE FROM LONG TERM STORAGE
ENGINE STORAGE – SHORT TERM
REMOVE THE ENGINE FROM SHORT TERM STORAGE
ENGINE TESTING – GENERAL INFORMATION
CHASSIS DYNAMOMETER, PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN
DEFINITION OF TERMS ON ENGINE PERFORMANCE CURVE
ENGINE DYNAMOMETER RUN-IN
FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER
INSTALLATION
OPERATION
GENERAL RUN-IN PROCEDURES
IN-SERVICE RUN-IN
INTAKE MANIFOLD BOOST PRESSURE CORRECTION FACTORS
ENGINE TESTING – SPECIFICATIONS
SERVICE TOOLS – ENGINE TESTING
INSTRUMENTS AND CONTROLS – GROUP 15
INSTRUMENTS AND CONTROLS – GENERAL INFORMATION
AIR HEATERS
COOLANT HEATERS
FUEL WARMERS
GAUGES
OIL HEATERS
SAFETY CONTROLS
MOUNTING ADAPTATIONS – GROUP 16
FLYWHEEL – CLEANING AND INSPECTION FOR REUSE
ASSEMBLY
DISASSEMBLY
INSPECTION
FLYWHEEL HOUSING – CLEANING AND INSPECTION FOR REUSE
CLEANING
INSPECTION
FLYWHEEL RING GEAR – REPLACEMENT
ASSEMBLY
DISASSEMBLY
INSPECTION
FRONT ENGINE SUPPORT – CLEANING AND INSPECTIONS
MOUNTING ADAPTATIONS – EXPLODED VIEW
MOUNTING ADAPTATIONS – GENERAL INFORMATION
REAR ENGINE POWER TAKEOFF – EXPLODED VIEW
REAR ENGINE POWER TAKEOFF (REPTO) REBUILDING
ASSEMBLY
CLEANING
DISASSEMBLY
INSPECTION
SERVICE TOOLS – MOUNTING ADAPTATIONS
SPECIFICATIONS – GROUP 18
CAPSCREW MARKINGS AND TORQUE VALUES
CAPSCREW MARKINGS AND TORQUE VALUES – METRIC
CAPSCREW MARKINGS AND TORQUE VALUES – U.S. CUSTOMARY
COMPONENT SPECIFICATIONS AND TORQUE VALUES
AIR EQUIPMENT – INSPECTION SPECIFICATIONS
AIR INTAKE SYSTEM – INSPECTION SPECIFICATIONS
CAM FOLLOWER ASSEMBLY – REBUILD SPECIFICATIONS
COOLING SYSTEM – REBUILD SPECIFICATIONS
COOLING SYSTEMS – TORQUE VALUES
CYLINDER BLOCK – REBUILD SPECIFICATIONS
CYLINDER BLOCK – TORQUE VALUES
CYLINDER HEAD – REBUILD SPECIFICATIONS
CYLINDER HEAD – TORQUE VALUES
DRIVE UNITS – REBUILD SPECIFICATIONS
ELECTRICAL EQUIPMENT – INSPECTION SPECIFICATIONS
ENGINE ASSEMBLY – CAPSCREW TORQUE VALUES
ENGINE ASSEMBLY – SPECIFICATIONS
ENGINE TESTING – TEST SPECIFICATIONS
EXHAUST SYSTEM – TORQUE VALUES
FUEL PUMP – REBUILD SPECIFICATIONS
FUEL PUMP – TORQUE VALUES
INJECTORS – REBUILD SPECIFICATIONS
LUBRICATING OIL SYSTEMS – SPECIFICATIONS
LUBRICATING OIL SYSTEMS – TORQUE VALUES
MOUNTING ADAPTATIONS – REBUILD SPECIFICATIONS
ROCKER LEVER ASSEMBLY – REBUILD SPECIFICATIONS
VEHICLE BRAKING – REBUILD SPECIFICATIONS
DRIVE BELT TENSION
INJECTIONS TIMING CODES
NEWTON-METER TO FOOT-POUND CONVERSTION CHART
PIPE PLUG TORQUE VALUES
SPECIFICATIONS – GENERAL INFORMATION
TAP-DRILL CHART – U.S. CUSTOMARY & METRIC
WEIGHT AND MEASURES – CONVERSION FACTORS
VEHICLE BRAKING – GROUP 20
VEHICLE BRAKING – GENERAL INFORMATION
SERVICE LITERATURE
ADDITIONAL SERVICE LITERATURE
SERVICE LITERATURE ORDERING LOCATION
COMPONENT MANUFACTURERS: NAMES AND ADDRESSES
COMPONENT MANUFACTURERS’ ADDRESSES
AIR COMPRESSORS
AIR CYLINDERS
AIR HEATERS
AIR STARTING MOTORS
ALTERNATORS
AUXILIARY BRAKES
BELTS
CATALYTIC CONVERTERS
CLUTCHES
COOLANT HEATERS
DRIVE PLATES
ELECTRIC STARTING MOTORS
ENGINE PROTECTION CONTROLS
FAN CLUTCHES
FANS
FILTERS
FLEXPLATES
FUEL WARMERS
GAUGES
GOVERNORS
HEAT SLEEVES
HYDRAULIC AND POWER STEERING PUMPS
OIL HEATERS
TORQUE CONVERTERS
INDEX
Troubleshooting Engine-M11-Repair-Manual.pdf (926 Pages)
MAIN MENU
COVER PAGE
TABLE OF CONTENTS
INTRODUCTION
ABOUT THIS MANUAL
ACRONYMS AND ABBREVIATIONS
GENERAL CLEANING INSTRUCTIONS
GLASS OR PLASTIC BEAD CLEANING
SOLVENT AND ACID CLEANING
STEAM CLEANING
GENERAL REPAIR INSTRUCTIONS
WELDING ON A VEHICLE WITH AND ELECTRONIC CONTROLLED FUEL SYSTEM
GENERAL SAFETY INSTRUCTIONS
IMPORTANT SAFETY NOTICE
HOW TO USE THE MANUAL
ILLUSTRATIONS
SYMBOLS
ENGINE IDENTIFICATION
ENGINE DIAGRAMS
ENGINE IDENTIFICATION
CUMMINS ENGINE NOMENCLATURE
ECM DATAPLATE
ENGINE DATAPLATE
FUEL PUMP DATAPLATE
SPECIFICATIONS
AIR INTAKE SYSTEM
BATTERIES (SPECIFIC GRAVITY)
COOLING SYSTEM
ELECTRICAL SYSTEM
EXHAUST SYSTEM
FUEL SYSTEM
GENERAL SPECIFICATIONS
LUBRICATING OIL SYSTEM
TROUBLESHOOTING SYMPTOMS
PROCEDURES AND TECHNIQUES
TROUBLESHOOTING SYMPTOMS CHARTS
AIR COMPRESSOR AIR PRESSURE RISES SLOWLY
AIR COMPRESSOR CYCLES FREQUENTLY
AIR COMPRESSOR NOISE IS EXCESSIVE
AIR COMPRESSOR PUMPING EXCESS LUBRICATING OIL INTO THE AIR SYSTEM
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)
AIR COMPRESSOR WILL NOT PUMP AIR
AIR COMPRESSOR WILL NOT STOP PUMPING
ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING
ALTERNATOR OVERCHARGING
COMMUNICATION ERROR – ELECTRONIC SERVICE TOOL OR CONTROL DEVICE
CONNECTING ROD BEARING NOISE
COOLANT IN THE LUBRICATING OIL
COOLANT LOSS (EXTERNAL)
COOLANT LOSS – INTERNAL
COOLANT TEMPERATURE ABOVE NORMAL – GRADUAL OVERHEAT
COOLANT TEMPERATURE IS ABOVE NORMAL – SUDDEN OVERHEAT
COOLANT TEMPERATURE IS BELOW NORMAL
CRANKCASE GASES (BLOWBY) EXCESSIVE
CRANKING FUEL PRESSURE IS LOW
DRIVEABLITY – GENERAL INFORMATION
DRIVEABLITY /LOW POWER – CUSTOMER COMPLAINT FORM
DRIVEABILITY/LOW POWER/EXCESSIVE FUEL CONSUMPTION – CHECKLIST
ENGINE ACCELERATION OR RESPONSE POOR
ENGINE BRAKE DOES NOT OPERATE (CELECT OR CELECT PLUS)
ENGINE BRAKE – LOW RETARDING POWER OR SLOW TO ACTIVATE (CELECT OR CELECT PLUS)
ENGINE BRAKE – ONE OR MORE CYLINDERS BRAKING WITH POWER SWITCH OFF (CELECT OR CELECT PLUS)
ENGINE DECELERATES SLOWLY (CELECT AND CELECT PLUS)
ENGINE DECELERATES SLOWLY (PT)
ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE)
ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE)
ENGINE NOISE DIAGNOSTIC PROCEDURES – GENERAL INFORMATION
ENGINE NOISE EXCESSIVE
ENGINE NOISE EXCESSIVE – COMBUSTION KNOCKS
ENGINE NOISE EXCESSIVE – CONNECTING ROD
ENGINE NOISE EXCESSIVE – MAIN BEARING
ENGINE NOISE EXCESSIVE – PISTON
ENGINE NOISE EXCESSIVE – TURBOCHARGER
ENGINE POWER OUTPUT LOW (CELECT OR CELECT PLUS)
ENGINE POWER OUTPUT LOW (PT)
ENGINE RUNS ROUGH AT IDLE
ENGINE RUNS ROUGH OR MISFIRES
ENGINE SHUTS OFF UNEXPECTEDLY OR DIES DURING DECELERATION
ENGINE SPEED SURGES AT LOW OR HIGH IDLE
ENGINE SPEED SURGES UNDER LOAD OR IN OPERATING RANGE
ENGINE STARTS BUT WILL NOT KEEP RUNNING
ENGINE VIBRATION EXCESSIVE
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)
ENGINE WILL NOT SHUT OFF
FUEL CONSUMPTION EXCESSIVE (CELECT AND CELECT PLUS)
FUEL CONSUMPTION EXCESSIVE (PT)
FUEL CONSUMPTION – CUSTOMER COMPLAINT FORM
FUEL CONSUMPTION – GENERAL INFORMATION
FUEL IN THE COOLANT
FUEL IN THE LUBRICATING OIL
INTAKE MANIFOLD AIR TEMPERATURE ABOVE SPECIFICATION
INTAKE MANIFOLD PRESSURE (BOOST) IS BELOW NORMAL
LOW IDLE ADJUST SWITCH DOES NOT WORK
LUBRICATING OIL CONSUMPTION EXCESSIVE
LUBRICATING OIL CONTAMINATED
LUBRICATING OIL IN THE FUEL
LUBRICATING OIL PRESSURE HIGH
LUBRICATING OIL PRESSURE LOW
LUBRICATING OIL SLUDGE IN THE CRANKCASE EXCESSIVE
LUBRICATING OIL TEMPERATURE ABOVE SPECIFICATION
LUBRICATING OR TRANSMISSION OIL IN THE COOLANT
MAIN BEARING NOISE
OIL CONSUMPTION
OPERATING FUEL PRESSURE IS LOW
PISTON NOISE
RESPONSE TEST – CELECT AND CELECT PLUS
SMOKE, BLACK – EXCESSIVE (CELECT AND CELECT PLUS)
SMOKE, BLACK – EXCESSIVE (PT)
SMOKE, WHITE – EXCESSIVE (CELECT AND CELECT PLUS)
SMOKE, WHITE – EXCESSIVE (PT)
STEP TIMING CONTROL (STC) VALVE IS NOT SHIFTING CORRECTLY
TURBOCHARGER LEAKS ENGINE OIL OR FUELBVARIABLE SPEED (VS) GOVERNOR – FUEL LEAK AT THE THROTTLE SHAFT
VARIABLE SPEED (VS) GOVERNOR – FUEL LEAK AT THE THROTTLE SHAFT
VARIABLE SPEED (VS) GOVERNOR – SPEED IS NOT SET CORRECTLY
VARIABLE SPEED (VS) GOVERNOR – SURGE WITH ENGINE UNDER LOAD
COMPLETE ENGINE – GROUP 00
COMPLETE ENGINE – GENERAL INFORMATION
ENGINE INSTALLATION
INSTALL
ENGINE REMOVAL
REMOVE
SERVICE TOOLS
ENGINE REMOVAL AND INSTALLATION
CYLINDER BLOCK – GROUP 01
ACCESSORY DRIVE SEAL
CLEAN
INSTALL
REMOVE
ALTERNATOR DRIVE SEAL
CLEAN
INSTALL
REMOVE
BEARINGS, CONNECTING ROD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
BEARINGS, MAIN
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
BEARINGS, THRUST
INSTALL
REMOVE
CAMSHAFT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CAMSHAFT BUSHINGS
CLEAN
INSPECT FOR REUSE
INSTALL
NUMBER ONE BUSHING – INSTALLATION
NUMBER SEVEN BUSHING – INSTALLATION
NUMBER SIX THROUGH NUMBER TWO BUSHING – INSTALLATION
REMOVE
CAMSHAFT END CLEARNACE
MEASURE
CAMSHAFT GEAR (CAMSHAFT INSTALLED)
INSPECT FOR REUSE
INSTALL
REMOVE
CAMSHAFT GEAR (CAMSHAFT REMOVED)
INSTALL
REMOVE
CONNECTING ROD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CRANKSHAFT
ROTATION CHECK
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CRANKSHAFT PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
CRANKSHAFT SEAL, FRONT
CLEAN
INSTALL
REMOVE
CRANKSHAFT SEAL, REAR
CLEAN
INSTALL
REMOVE
CYLINDER BLOCK AND LINER SEATS
LEAK TEST
CYLINDER LINER
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CYLINDER LINER PROTRUSION
MEASURE
PREPARATORY
GEAR COVER, FRONT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
GEAR HOUSING, FRONT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
IDLER GEAR, CAMSHAFT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
IDLER GEAR, HYDRAULIC PUMP
CLEAN
INSPECT
INSTALL
REMOVE
IDLER GEAR, WATER PUMP
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
PISTON
ASSEMBLE
CLEAN
DISASSEMBLE
GENERAL INFORMATION
INSPECT FOR REUSE
ARTICULATED PISTON
INSTALL
REMOVE
PISTON AND CONNECTING ROD ASSEMBLY
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
PISTON COOLING NOZZLE
INSPECT FOR REUSE
INSTALL
REMOVE
PISTON RINGS
INSPECT FOR REUSE
SERVICE TOOLS
CYLINDER BLOCK
VIBRATION DAMPER
CLEAN
ECCENTRICITY CHECK
INSPECT FOR REUSE
INSTALL
REMOVE
WOBBLE CHECK
WATER HEADER PLATE, CYLINDER BLOCK
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CYLINDER HEAD – GROUP 02
CYLINDER HEAD
CLEAN
INSPECT FOR REUSE
INSTALL
LEAK TEST
PRESSURE TEST
REMOVE
SERVICE TOOLS
CYLINDER HEAD
ROCKER LEVERS – GROUP 03
CRANKCASE BREATHER (INTERNAL)
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
OVERHEAD SET
ADJUST
ENGINE BRAKE – ADJUST
GENERAL INFORMATION
INJECTOR ADJUSTMENT – CELECT AND CELECT PLUS ENGINES
INJECTOR ADJUSTMENT -STC ENGINES
VALVE ADJUSTMENT – CELECT AND CELECT PLUS ENGINES
VALVE ADJUSTMENT – STC ENGINES
MEASURE
GENERAL INFORMATION
VALVE AND INJECTOR LASH – CELECT AND CELECT PLUS ENGINES
VALVE LASH – STC ENGINES
ROCKER LEVER ASSEMBLY
ASSEMBLE
ALUMINUM SUPPORTS
CAST IRON SUPPORTS
CLEAN
DISASSEMBLE
GENERAL INFORMATION
INSPECT FOR REUSE
INSTALL
REMOVE
ROCKER LEVER COVER
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
ROCKER LEVER HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
ROCKER LEVERS
CAM FOLLOWERS/TAPPETS – GROUP 04
CAM FOLLOWER ASSEMBLY
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
PUSH RODS OR TUBES
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
CAM/FOLLOWER/TAPPETS
FUEL SYSTEM – GROUP 05
FLOW DIAGRAM, FUEL SYSTEM
FUEL CONSUMPTION
MEASURE
FUEL FLOW
INITIAL CHECK
LEAK TEST
PRESSURE TEST
MINIMUM CRANKING PRESSURE
MINIMUM OPERATING PRESSURE
FUEL PUMP
CLEAN
INSPECT FOR REUSE
INSTALL
CELECT OR CELECT PLUS
STC
PRIME
CELECT OR CELECT PLUS
GENERAL INFORMATION
STC
REMOVE
CELECT OR CELECT PLUS
STC
ROTATION CHECK
FUEL PUMP GEAR PUMP CHECK VALVE
INSTALL
REMOVE
FUEL PUMP HIGH IDLE SPEED (VS GOVERNOR)
ADJUST
HIGH SPEED
IDLE SPEED
FUEL PUMP IDLE SPEED
ADJUSTMENT
FUEL PUMP PRESSURE REGULATOR
INITIAL CHECK
FUEL PUMP PULSATION DAMPER
INSPECTION FOR REUSE
FUEL PUMP THROTTLE LEVER
ADJUST
FUEL PUMP THROTTLE LINKAGE
ADJUST
FUEL PUMP VS THROTTLE SHAFT HOUSING
INSTALL
REMOVE
FUEL SHUTOFF VALVE (FSOV)
INSPECT FOR REUSE
FUEL SYSTEM – GENERAL INFORMATION
INSTALLATION RECOMMENDATIONS
INSTALLATION PUBLICATIONS
OVERHEAD FUEL TANK REQUIREMENTS
PROPER USE OF FUEL SYSTEM GAUGES
SERVICE TOOLS
FUEL SYSTEM
SPECIFICATIONS
FUEL RECOMMENDATIONS
FUEL OIL RECOMMENDED PROPERTIES
FUEL SYSTEM
STALL SPEED CHECK LIST
IF THE STALL SPEED IS TOO HIGH, CHECK THE FOLLOWING:
IF THE STALL SPEED IS TOO LOW, CHECK THE FOLLOWING:
STALL SPEED TEST
STALL SPEED CHECK
CONVERTER TRANSMISSIONS STALL SPEED
TIME SPEED CHECK
VS GOVERNER ADJUSTING SCREW SEALING WASHERS
INSTALL
REMOVE
VS GOVERNER IDLE SPRING
INSTALL
REMOVE
INJECTORS AND FUEL LINES – GROUP 06
AFC NO AIR CHECK
MEASURE
AIR IN FUEL
TEST
GEAR PUMP DRAIN METHOD
SIGHTGLASS METHOD
CYLINDER MISFIRES OR SMOKES
AUTOMATED CYLINDER PERFORMANCE TEST
CELECT OR CELECT PLUS
CYLINDER CUTOUT TEST
CELECT OR CELECT PLUS
STC
EXHAUST MANIFOLD TEMPERATURE TEST
EXHAUST MANIFOLD TILT-BACK METHOD
GENERAL INFORMATION
ECM COOLING PLATE
INSTALL
REMOVE
FUEL DRAIN LINE RESTRICTION
MEASURE
FUEL FILTER (SPIN-ON TYPE)
INSTALL
REMOVE
FUEL INLET RESTRICTION
MEASURE
FUEL SUPPLY LINES
INSPECT FOR REUSE
REMOVE
INJECTOR
INSTALL
CELECT OR CELECT PLUS
STC
REMOVE
CELECT OR CELECT PLUS
STC
INJECTORS AND FUEL LINES – GENERAL INFORMATION
THEORY OF OPERATION – CELECT AND CELECT PLUS FUEL SYSTEM
HYDROMECHANICAL SUBSYSTEM
INJECTION CYCLE
THEORY OF OPERATION – PT FUEL SYSTEM
THEORY OF OPERATION – STC FUEL SYSTEM
SERVICE TOOLS
INJECTORS AND FUEL LINES
STATIC INJECTION TIMING
MEASURE
SETUP
STC OIL CONTROL VALVE (MECHANICAL)
INITIAL CHECK
INSTALL
REMOVE
STC OIL DELIVERY SYSTEM BLOCKAGE
INITIAL CHECK
LEAK TEST
STC OIL DELIVERY SYSTEM DIAGNOSTICS
TEST
LUBRICATING OIL SYSTEM – GROUP 07
FLOW DIAGRAM, LUBRICATING OIL SYSTEM
LUBRICATING OIL AND FILTERS
INSPECT
LUBRICATING OIL CONTAMINATION
FLUORESCENT DYE TRACER
FUEL PRESSURE TEST
LUBRICATING OIL COOLER
CLEAN
INSTALL
PRESSURE TEST
REMOVE
LUBRICATING OIL DIPSTICK
CALIBRATE
LUBRICATING OIL DIPSTICK HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL FILTER (CANISTER-TYPE)
LEAK TEST
LUBRICATING OIL FILTER HEAD
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL FILTER (SPIN ON)
GENERAL INFORMATION
INSTALL
REMOVE
LUBRICATING OIL HIGH PRESSURE RELIEF VALVE
INTIAL CHECK
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL LEAKS
MAINTENANCE CHECK
EXTERNAL
LUBRICATING OIL PAN
CLEAN
DRAIN
FILL
INSPECT FOR REUSE
INSTALL
FRONT SUMP PAN
REAR SUMP PAN
REMOVE
FRONT SUMP PAN
REAR SUMP PAN
LUBRICATING OIL PRESSURE GAUGE
TEST
LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE)
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL PUMP
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL SYSTEM
PRIME
LUBRICATING OIL SYSTEM – GENERAL INFORMATION
LUBRICATING OIL TEMPERATURE GAUGE
TEST
LUBRICATING OIL THERMOSTAT
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL TRANSFER TUBE
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL VISCOSITY SENSOR
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
LUBRICATING OIL SYSTEM
SPECIFICATIONS
CUMMINS/FLEETGUARD FILTER SPECIFICATIONS
LUBRICATING OIL FILTERS
LUBRICATING OIL SYSTEM
COOLING SYSTEM – GROUP 08
COOLANT FILTER
INSTALL
REMOVE
COOLANT FILTER HEAD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT HEATER HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT TEMPERATURE GAUGE
INITIAL CHECK
COOLANT THERMOSTAT
INSPECT FOR REUSE
INSTALL
LEAK TEST
REMOVE
COOLANT THERMOSTAT HOUSING SUPPORT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT THERMOSTAT SEAL
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT VENT LINES
INITIAL CHECK
COOLING SYSTEM
CLEAN
DRAIN
FILL
PRESSURE TEST
COOLING SYSTEM – AIR OR COMBUSTION GAS TEST
INITIAL TEST
AIR COOLING SYSTEM
LEAK TEST
AIR COMPRESSOR
COMBUSTION GAS LEAK
FAN, SHUTTER, OR HEATER AIR CONTROL VALVE
COOLING SYSTEM – GENERAL INFORMATION
COOLING SYSTEM DIAGNOSTICS
ANALYZING THE DATA
GENERAL INFORMATION
SETUP
TEST
OPERATIONAL WORKSHEET
COOLING SYSTEM PRECHARGE
CUSTOMER PRECHARGE METHOD
FACTORY PRECHARGE METHOD
GENERAL INFORMATION
DRIVE BELT, COOLING FAN
INSPECT FOR REUSE
INSTALL
REMOVE
FAN CLUTCH, AIR-DISENGAGED
GENERAL INFORMATION
MAINTENANCE CHECK
FAN CLUTCH, AIR-ENGAGED
GENERAL INFORMATION
MAINTENANCE CHECK
FAN CLUTCH, ELECTRIC
INSPECT FOR REUSE
INSTALL
REMOVE
FAN CLUTCH, ON-OFF
GENERAL INFORMATION
INITIAL CHECK
FAN CLUTCH, VISCOUS
GENERAL INFORMATION
INITIAL CHECK
INSTALL
REMOVE
FAN, COOLING
INSPECT FOR REUSE
INSTALL
REMOVE
FAN DRIVE IDLER PULLEY ASSEMBLY
INITIAL CHECK
INSTALL
REMOVE
FAN HUB, BELT DRIVEN
INITIAL CHECK
INSTALL
REMOVE
FAN SHROUD ASSEMBLY
INITIAL CHECK
FAN SPACER AND PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
FLOW DIAGRAM, COOLING SYSTEM
RADIATOR
INITIAL CHECK
RADIATOR HOSES
INSPECT FOR REUSE
RADIATOR PRESSURE CAP
INSPECT FOR REUSE
RADIATOR SHUTTER ASSEMBLY
INITIAL CHECK
SERVICE TOOLS
COOLING SYSTEM
SPECIFICATIONS
COOLANT REPLACEMENT REQUIREMENTS
COOLING SYSTEM
COOLING SYSTEM SEALING ADDITIVES
COOLING SYSTEM SOLUBLE OILS
FLEETGUARD DCA4 SERVICE FILTERS AND LIQUID PRECHARGE
FULLY FORMULATED COOLANT/ANTIFREEZE
GENERAL INFORMATION
SUPPLEMENTAL COOLANT ADDITIVE (SCA)
TEST INTERVALS
TESTING SCA CONCENTRATION LEVEL CC-2602 TEST KIT
PRECAUTIONS AND INSTRUCTIONS FOR PROPER KIT USE
THERMO CONTROL SETTINGS
TORQUE CONVERTER COOLER
GENERAL INFORMATION
WATER PUMP
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
WIRING HARNESS, CUMMINS ELECTRIC FAN CLUTCH
GENERAL INFORMATION
INITIAL CONNECTIONS
INSTALL
REMOVE
DRIVE UNITS – GROUP 09
ACCESSORY DRIVE
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
ACCESSORY DRIVE PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
ALTERNATOR DRIVE PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
HYDRAULIC PUMP DRIVE
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
DRIVE UNITS
AIR INTAKE SYSTEM – GROUP 10
AFTERCOOLER
CLEAN
INSPECT FOR REUSE
INSTALL
PRESSURE TEST
REMOVE
AIR INTAKE MANIFOLD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
AIR INTAKE RESTRICTION
MEASURE
AIR INTAKE SYSTEM – GENERAL INFORMATION
GENERAL INFORMATION
AIR LEAKS, AIR INTAKE AND EXHAUST SYSTEMS
MAINTENANCE CHECK
CHARGE AIR COOLER (CAC)
CLEAN
INSPECT FOR REUSE
LEAK TEST
PRESSURE DIFFERENTIAL TEST
TEMPERATURE DIFFERENTIAL TEST
FLOW DIAGRAM, AIR INTAKE SYSTEM
SERVICE TOOLS
AIR INTAKE SYSTEM
SPECIFICATIONS
AIR INTAKE SYSTEM
TURBOCHARGER
CHECK FOR CORRECT COMPONENT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
TURBOCHARGER AXIAL CLEARANCE
MEASURE
TURBOCHARGER BLADE DAMAGE
INSPECT FOR REUSE
TURBOCHARGER COMPRESSOR SEAL LEAKS
LEAK TEST
TURBOCHARGER RADIAL BEARING CLEARANCE
MEASURE
TURBOCHARGER TURBINE SEAL LEAKS
LEAK TEST
EXHAUST SYSTEM – GROUP 11
EXHAUST MANIFOLD, DRY
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
EXHAUST RESTRICTION
MEASURE
FLOW DIAGRAM, EXHAUST SYSTEM
SPECIFICATIONS
EXHAUST SYSTEM
COMPRESSED AIR SYSTEM – GROUP 12
AIR COMPRESSOR
INSPECT FOR REUSE
INSTALL
REMOVE
AIR COMPRESSOR CARBON BUILDUP
INITIAL CHECK
AIR COMPRESSOR CYLINDER HEAD (HOLSET QE MODELS)
ASSEMBLE
QE, EUROPEAN
QE, NON-EUROPEAN
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
AIR COMPRESSOR CYLINDER HEAD (HOLSET SS AND E-TYPE MODELS)
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
AIR COMPRESSOR CYLINDER HEAD (HOLSET ST MODELS)
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
AIR COMPRESSOR PIN BORE WEAR
INITIAL CHECK
AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY
CLEAN
INITIAL CHECK
INSPECT FOR REUSE
INSTALL
HOLSET QE MODELS
HOLSET SS, E-TYPE, AND ST MODELS
REMOVE
HOLSET QE MODELS
HOLSET SS, E-TYPE, AND ST MODELS
AIR GOVERNER (AIR COMPRESSOR PUMPS CONTINUOUSLY)
INITIAL CHECK
AIR GOVERNOR (AIR COMPRESSOR WILL NOT PUMP)
INITIAL CHECK
AIR LEAKS, COMPRESSED AIR SYSTEM
INITIAL CHECK
COMPRESSED AIR SYSTEM – GENERAL INFORMATION
SERVICE TOOLS
COMPRESSED AIR SYSTEMS
SPECIFICATIONS
COMPRESSED AIR SYSTEM
HOLSET SS296/SS296E/QE296A/C MODELS
HOLSET SS338/QE338 A/C MODELS
HOLSET ST676 A/C MODEL
ELECTRICAL EQUIPMENT – GROUP 13
ALTERNATOR
INITIAL CHECK
INSTALL
REMOVE
BATTERIES
INITIAL CHECK
BATTERY CABLES AND CONNECTIONS
INITIAL CHECK
DRIVE BELT, ALTERNATOR
ADJUST
ADJUSTMENT LINK TYPE
AUTOMATIC BELT TENSIONER
INSTALL
ADJUSTMENT LINK TYPE
AUTOMATIC BELT TENSIONER
REMOVE
ADJUSTMENT LINK TYPE
AUTOMATIC BELT TENSIONER
ELECTRICAL EQUIPMENT – GENERAL INFORMATION
SERVICE TOOLS
ELECTRICAL EQUIPMENT
SPECIFICATIONS
ELECTRICAL SYSTEM
STARTER MAGNETIC SWITCH
CURRENT CHECK
STARTER SOLENOID
VOLTAGE CHECK
STARTER SWITCH
VOLTAGE
STARTING MOTOR
INSTALL
REMOVE
ENGINE TESTING – GROUP 14
DYNAMOMETER WORKSHEET
ENGINE RUN-IN (CHASSIS DYNAMOMETER)
RUN-IN INSTRUCTIONS
ENGINE RUN-IN (ENGINE DYNAMOMETER)
RUN-IN INSTRUCTIONS
ENGINE RUN-IN (WITHOUT DYNAMOMETER)
RUN-IN INSTRUCTIONS
OFF-HIGHWAY APPLICATIONS
ON-HIGHWAY APPLICATIONS
ENGINE TESTING – GENERAL INFORMATION
FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER
ENGINE TESTING (CHASSIS DYNAMOMETER)
SETUP
TEST
ENGINE TESTING (ENGINE DYNAMOMETER)
SETUP
ENGINE TESTING (PORTABLE DYNAMOMETER OR LOAD BANK)
GENERAL INFORMATION
SERVICE TOOLS
ENGINE TESTING
SPECIFICATIONS
ENGINE TESTING
MOUNTING ADAPTATIONS – GROUP 16
ENGINE LIFTING BRACKETS
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
ENGINE SUPPORT BRACKET, FRONT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
FLYWHEEL
CLEAN
INSPECT FOR REUSE
INSTALL
MEASURE
BORE RUN OUT
FACE RUN OUT
REMOVE
FLYWHEEL HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
MEASURE
FACE ALIGNMENT
BORE ALIGNMENT
REMOVE
FLYWHEEL HOUSING, REPTO
CLEAN
INSPECT FOR REUSE
INSTALL
MEASURE
BORE ALIGNMENT
FACE ALIGNMENT
REMOVE
FLYWHEEL RING GEAR
INSTALL
REMOVE
SERVICE TOOLS
MOUNTING ADAPTATIONS
MISCELLANEOUS HARDWARE – GROUP 17
CUP PLUG
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
PIPE PLUG
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
STRAIGHT THREAD PLUG
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
VEHICLE BRAKING – GROUP 209
ENGINE BRAKE
ADJUST
CLEAN
INITIAL CHECK
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE LITERATURE
ADDITIONAL SERVICE LITERATURE
LITERATURE ORDER FORM
SERVICE LITERATURE ORDERING LOCATION
COMPONENT MANUFACTURERS
COMPONENT MANUFACTURERS’ ADDRESSES
AIR COMPRESSORS
AIR CYLINDERS
AIR HEATERS
AIR STARTING MOTORS
ALTERNATORS
AUXILIARY BRAKES
BELTS
CATALYTIC CONVERTORS
CLUTCHES
COOLANT HEATERS
COOLANT LEVEL SWITCHES
DRIVE PLATES
ELECTRIC STARTING MOTORS
ELECTRONIC SWITCHES
ENGINE PROTECTION SWITCHES
FAN CLUTCHES
FANS
FAULT LAMPS
FILTERS
FLEXPLATES
FUEL COOLERS
FUEL WARMERS
GAUGES
GOVERNORS
HEAT SLEEVES
HYDRAULIC AND POWER STEERING PUMPS
IN-LINE CONNECTORS
OIL HEATERS
PRELUBRICATION SYSTEMS
READIATORS
THROTTLE ASSEMBLIES
TORQUE CONVERTERS
SPECIFICATIONS
AIR INTAKE SYSTEM – SPECIFICATIONS
AIR INTAKE RESTRICTION
TURBOCHARGER AXIAL CLEARANCE
TURBOCHARGER RADIAL BEARING CLEARANCE
AIR INTAKE SYSTEM – TORQUE VALUES
AFTERCOOLER
AIR INTAKE MANIFOLD
AIR LEAKS, AIR INTAKE AND EXHAUST SYSTEMS
TURBOCHARGER
CAM FOLLOWERS/TAPPETS – SPECIFICATIONS
CAM FOLLOWER ASSEMBLY
CAM FOLLOWERS/TAPPETS – TORQUE VALUES
CAM FOLLOWER ASSEMBLY
CAPSCREW MARKINGS AND TORQUE VALUES
CAPSCREW MARKINGS AND TORQUE VALUES – METRIC
CAPSCREW MARKINGS AND TORQUE VALUES – U.S. CUSTOMARY
COMPRESSED AIR SYSTEM – TORQUE VALUES
AIR COMPRESSOR
AIR COMPRESSOR CYLINDER HEAD (HOLSET QE MODELS)
AIR COMPRESSOR CYLINDER HEAD (HOLSET SS AND E-TYPE MODELS)
AIR COMPRESSOR CYLINDER HEAD (HOLSET ST MODELS)
AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY
COOLING SYSTEM – SPECIFICATIONS
COOLANT THERMOSTAT
FAN DRIVE IDLER PULLEY ASSEMBLY
FAN HUB, BELT DRIVEN
WATER PUMP
COOLING SYSTEM – TORQUE VALUES
COOLANT FILTER HEAD
COOLANT HEATER HOUSING
COOLANT THERMOSTAT
COOLANT THERMOSTAT HOUSING SUPPORT
DRIVE BELT, COOLING FAN
FAN CLUTCH, ELECTRIC
FAN CLUTCH, VISCOUS
FAN, COOLING
FAN HUB, BELT DRIVEN
FAN SPACER AND PULLEY
WATER PUMP
CYLINDER BLOCK – SPECIFICATIONS
BEARINGS, CONNECTING ROD
BEARINGS, MAIN
BEARINGS, THRUST
CAMSHAFT
CAMSHAFT BUSHINGS
CAMSHAFT GEAR (CAMSHAFT INSTALLED)
CONNECTING ROD
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)
CYLINDER LINER PROTRUSTION
GEAR HOUSING, FRONT
IDLER GEAR, CAMSHAFT
IDLER GEAR, HYDRAULIC PUMP
IDLER GEAR, WATER PUMP
PISTON COOLING NOZZLE
PISTON RINGS
CYLINDER BLOCK – TORQUE VALUES
ACCESSORY DRIVE SEAL
ALTERNATOR DRIVE SEAL
BEARINGS, MAIN
CAMSHAFT
CRANKSHAFT PULLEY
CRANKSHAFT SEAL, FRONT
CRANKSHAFT SEAL, REAR
CYLINDER LINER PROTRUSION
GEAR COVER, FRONT
GEAR HOUSING, FRONT
IDLER GEAR, CAMSHAFT
IDLER GEAR, HYDRAULIC PUMP
IDLER GEAR, WATER PUMP
PISTON AND CONNECTING ROD ASSEMBLY
PISTON COOLING NOZZLE
WATER HEADER PLATE, CYLINDER BLOCK
CLYINDER HEAD – SPECIFICATIONS
CYLINDER HEAD
CYLINDER HEAD – TORQUE VALUES
CYLINDER HEAD
DRIVE BELT TENSION
DRIVE UNITS – SPECIFICATIONS
ACCESSORY DRIVE
HYDRAULIC PUMP DRIVE
DRIVE UNITS – TORQUE VALUES
ACCESSORY DRIVE
ACCESSORY DRIVE PULLEY
ALTERNATOR DRIVE PULLEY
HYDRUALIC PUMP DRIVE
ELECTRICAL EQUIPMENT – TORQUE VALUES
ALTERNATOR
DRIVE BELT, ALTERNATOR
STARTING MOTOR
EXHAUST SYSTEM – SPECIFICATIONS
EXHAUST RESTRICTION
EXHAUST SYSTEM – TORQUE VALUES
EXHAUST MANIFOLD, DRY
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
FUEL SYSTEM – SPECIFICATIONS
FUEL FLOW
FUEL SYSTEM – TORQUE VALUES
FUEL PUMP
FUEL PUMP GEAR PUMP CHECK VALVE
FUEL PUMP PULSATION DAMPER
FUEL PUMP VS THROTTLE SHAFT HOUSING
FUEL SHUTOFF VALVE
INJECTION TIMING CODES
INJECTORS AND FUEL LINES – SPECIFICATIONS
FUEL DRAIN LINE RESTRICTION
FUEL INLET RESTRICTION
INJECTORS AND FUEL LINES – TORQUE VALUES
ECM COOLING PLATES
INJECTOR
STC OIL CONTROL VALVE (MECHANICAL)
LUBRICATING OIL SYSTEM – SPECIFICATION
LUBRICATING OIL HIGH PRESSURE RELIEF VALVE
LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE)
LUBRICATING OIL PUMP
LUBRICATING OIL SYSTEM – TORQUE VALUES
LUBRICATING OIL COOLER
LUBRICATING OIL DIPSTICK HOUSING
LUBRICATING OIL FILTER HEAD
LUBRICATING OIL PAN
LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE)
LUBRICATING OIL PUMP
LUBRICATING TRANSFER TUBE
LUBRICATING OIL VISCOSITY SENSOR
MISCELLANEOUS – SPECIFICATIONS
MOUNTING ADAPTATIONS – SPECIFICATIONS
FLYWHEEL HOUSING
MOUNTING ADAPTATIONS – TORQUE VALUES
ENGINE LIFTING BRACKETS
ENGINE SUPPORT BRACKET, FRONT
FLYWHEEL
FLYWHEEL HOUSING
FLYWHEEL HOUSING, REPTO
NEWTON-METER TO FOOT-POUND CONVERSION CHART
PIPE PLUG TORQUE VALUES
ROCKER LEVERS – SPECIFICATIONS
OVERHEAD SET
ROCKER LEVER ASSEMBLY
ROCKER LEVERS – TORQUE VALUES
CRANKCASE BREATHER (INTERNAL
ROCKER LEVER ASSEMBLY
ROCKER LEVER COVER
ROCKER LEVER HOUSING
TAP-DRILL CHART – U.S. CUSTOMARY AND METRIC
VEHICLE BRAKING – TORQUE VALUES
ENGINE BRAKE
WEIGHT AND MEASURES – CONVERSION FACTORE
INDEX
Volvo G780 VHP Serive and Repair Manual.pdf (4238 Pages)
1 G780 VHP
Diagrams
5 amp converter option
All Wheel Drive system
Auxiliary and EEC lights
Beacons and heated mirrors
Blade and front float modules
Blade float module
Blade lift options Sheet 3
Brakes and supplemental steering
Differential lock, horn, and back-up circuits
Double lock valve fig 2
Double lock valve
Engine shutdown systems
Flood and dome lights
Front float module
Heater and air conditioning
Index and symbology
Main hydraulic schematic – ECC Sheet 2
Main hydraulic schematic Sheet 1
Main lights
Main power and ignition
Monitoring module (page 1)
Monitoring module (page 2)
Optional converter systems
Radio and tire pump
Supplemental steering circuit – Sheet 4
Table 1 – Wire codes
Table 2 – Wire codes (continued)
Table 3 – Connectors (numerical)
Table 3 Wire codes (continued)
Table 4 Connectors (alphabetical)
Transmission and VHP controls
Windshield washers and wipers
G700B LabourTimeGuide Old version
G700B Labour Time Guide Foreword.pdf
Foreword, Labour Time Guide
The standard times are issued for the purpose of:
The following is not included in the listed times:
Repair
Accumulator precharge adjustment chart
Adjustment checks
Air conditioner service
Air conditioning system
Articulation hinge – Assembly
Articulation hinge – Disassembly
Articulation hinge fig 1
Articulation hinge Preparation for disassembly
Articulation hinge
Articulation hydraulics
Axle disassembly and assembly
Brake housing pre-assembly
Brake master cylinder and power booster
Cab air distribution
Charging batteries
Charging the Accumulator
Checking the precharge pressure
Circle adjustment
Circle operation
Circle setup and timing
Circle turn mechanism, all models
Circle turn valve overhaul procedure
Cleaning and inspection
Cleanliness, brake and hydraulic systems
Climate control unit electrical schematic fig1
Climate control unit electrical schematic
Clutch assembly – Removal and installation
Clutch slave cylinder and pedal free play
Component specification and identification
Components hydraulic
Components steering
Converter installation 75 amp
Converter installation 24V to 12V 10 amp
Cylinder cycle time in seconds
Description circle turn fig 1
Description circle
Description Electrical system
Description gerbox
Description hydralic brake system
Description hydraulic equipment
Description interior eq
Description miling fig 1
Description miling
Description parking brake
Description steering
Description transmission
Description wheel brake
Drawbar ball stud, all models
Electric welding
Electrical Schematic Legend
Engine diagrams M11-pdf
Engine Install Instructions
Engine Installation
Engine parts catalog
Engine Removal
Flow rates
Function
Fuses, circuit breakers and relays
G710 to G740 Circle and drawbar
G780 circle and drawbar
General description – Wheels
General Engine
General parking brake
Glossary of Abbreviations
Hand brake and caliper
HVAC routine maintenance
HVAC system components
Hydraulic components, location fig1
Hydraulic components, location
Hydraulic cylinder overhaul procedure
Hydraulic cylinder specifications fig 1
Hydraulic cylinder specifications
Hydraulic swivel joint overhaul procedure
Hydraulic system bleeding procedure
Hydraulic system pressure tests
Hydraulic system troubleshooting guide
Installing final drive assembly onto grader
Installing the final drive assembly onto the grader
Key switch
Load sense module
Lock unlock function
Low power complaint troubleshooting guide
Main control valve overhaul procedure
Main control valve section
Main control valve spool flow rates
Main control valve troubleshooting
Main hydraulic circuit fig 1
Main hydraulic circuit
Main hydraulic pump overhaul procedure
Main hydraulic pump troubleshooting guide
Main hydraulic pump, components
MBCS disassembly and assembly
Oil disc brake assembly -Removal
Oil disc brake installation
Oil disc brakes -Assembly
Oil disc brakes -Bench adjustment
Operating principle hvac
Operating principle
Overview brakes
Pedestal disassembly and assembly
Pedestal locking strut
Pictorial torque guide
Pinion wear
Priority flow valve operation
Recommended lubricants
Removing final drive assembly from grader
Removing the final drive assembly from the grader
Repairing hydraulic system
Seal installation Procedure
Self-adjusting caliper
Special instructions for working on the electrical system
Specific hydraulic circuit problems
Specifications circle dowbar
Specifications hydraulic equipment
Specifications parking brake
Standard torque guide
Steering axle – Disassembly
Steering axle -Assembly
Steering column disassembly and assembly
Steering control unit overhaul procedure
Steering control unit troubleshooting
Steering hydraulic circuit components
Steering system troubleshooting guide
Tandem assembly
Tandem axle oil seal installation
Tandem removal
Tightening torques stering
Tire Pressure Tables
Tire troubleshooting guide
Torque Guide
Towing
Transmission installation
Transmission removal
Transmission troubleshooting
Transporting
Troubleshooting gearbox
Troubleshooting guide circle dowbar
Troubleshooting guide hvac
Variable Horsepower (VHP)
VHP parts not supplied by Cummins
Service Bulletins
Accumulator Maintenance and Pressure Verification
CareTrack, new software version 2008w6
Circle Turn and Moldboard Slide Circuit Performance Improvement
Defroster Fan
Diagnosing Oil Transfer Between the Engine and Transmission
Engine Oil Pressure Gauge Hose Routing
Front Float Operation
Fuel sampling, method
G700 Powertrain Service Manual
G700, G700B Circle Tooth Template
Hydraulic oil cleanliness
Hydraulic oil dye
Improved Wheel Bolt Retention in Heavy Applications
Information On the A and L Transmission Coil Polarity
Installation, Maintenance and Operation of Moldboard Carbide Bit Blades
Lap Seat Belts
Main & AWD Hydraulic System Oil Specifications
Main Hydraulic System Cooling Improvement
New Wheel Rims
Parts & Service Training Material
Pedestal gas spring adjustment
Pedestal gas spring improvement
Pedestal travel limiting spacer
Recirculation Vents – Description and Operation
Recommendations for Oil Sampling Intervals
Reporting of product misuse near-miss report
Reports
Secondary Steering Pump and Motor
Service Manual – HVAC Section
Service Material
Severe Service Cab Mounts
Special tools
Tandem Bolt Torque Maintenance
Tandem Sprocket
Transmission Solenoid Nut
Unauthorized modifications of Roll Over Protective Structure (ROPS)
UV Dye Added to Air Conditioning Receiver Dryer
Volvo Makeing
Volvo Product incident accident report & Interview Form
Special tool catalog
General
Index
Hooks
1. Enviroment and Safety equipment
2. Measuring equipment
3. Tightening and Loosening tools
4. Lifting equipment
5. Pullers and Pressing equipment
6. Drifts
7. Guide pins and Guide sleeves
8. Pliers
9. Fixtures
10. Tech Tool
11. Spare parts
Time Guide Currrent generation
Time Guide Old generation
Time Guide Previous generation

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