Service Manual

Index
Page X-1
About the Manual ................................................................................................i-1
General Information...........................................................................................i-1
Accessory Drive .................................................................................................9-1
Assemble..........................................................................................................9-4
Clean and Inspect for Reuse............................................................................9-1
Disassemble.....................................................................................................9-2
Finishing Steps.................................................................................................9-5
Initial Check......................................................................................................9-5
Install.................................................................................................................9-5
Measure............................................................................................................9-4
Preparatory Steps.............................................................................................9-1
Remove.............................................................................................................9-1
Acronyms and Abbreviations ...........................................................................i-17
General Information.........................................................................................i-17
Additional Service Literature ............................................................................L-1
General Information..........................................................................................L-1
Aftercooler Assembly ......................................................................................10-3
Assemble........................................................................................................10-6
Clean and Inspect for Reuse..........................................................................10-5
Disassemble...................................................................................................10-5
Finishing Steps...............................................................................................10-8
Initial Check....................................................................................................10-3
Install...............................................................................................................10-7
Preparatory Steps...........................................................................................10-4
Pressure Test..................................................................................................10-6
Remove...........................................................................................................10-5
Aftertreatment Diesel Exhaust Fluid Dosing Unit .......................................11-40
Finishing Steps.............................................................................................11-43
General Information......................................................................................11-40
Initial Check..................................................................................................11-40
Install.............................................................................................................11-43
Preparatory Steps.........................................................................................11-41
Remove.........................................................................................................11-41
Test...............................................................................................................11-42
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing .........11-47
Finishing Steps.............................................................................................11-51
Flush.............................................................................................................11-49
General Information......................................................................................11-47
Initial Check..................................................................................................11-48
Preparatory Steps.........................................................................................11-48
Test...............................................................................................................11-50
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter .............................11-44
Finishing Steps.............................................................................................11-47
General Information......................................................................................11-44
Initial Check..................................................................................................11-44
Inspect for Reuse..........................................................................................11-46
Install.............................................................................................................11-46
Preparatory Steps.........................................................................................11-45
Remove.........................................................................................................11-45
Aftertreatment Diesel Exhaust Fluid Line Restriction Test ........................11-53
Finishing Steps.............................................................................................11-56
General Information......................................................................................11-53
Initial Check..................................................................................................11-54
Preparatory Steps.........................................................................................11-54
Remove.........................................................................................................11-54
Test...............................................................................................................11-55
Aftertreatment Diesel Exhaust Fluid Tank Filter .........................................11-51
Finishing Steps.............................................................................................11-53
General Information......................................................................................11-51
Inspect for Reuse..........................................................................................11-52
Install.............................................................................................................11-52
Preparatory Steps.........................................................................................11-51
Remove.........................................................................................................11-52
Aftertreatment Nozzle ....................................................................................11-36
Clean and Inspect for Reuse........................................................................11-38
Finishing Steps.............................................................................................11-39
General Information......................................................................................11-36
Initial Check..................................................................................................11-37
Install.............................................................................................................11-38
Preparatory Steps.........................................................................................11-37
Remove.........................................................................................................11-37
Aftertreatment Selective Catalytic Reduction (SCR) Catalyst ...................11-33
Clean and Inspect for Reuse........................................................................11-34
Finishing Steps.............................................................................................11-36
General Information......................................................................................11-33
Install.............................................................................................................11-35
Preparatory Steps.........................................................................................11-33
Remove.........................................................................................................11-34
Aftertreatment Testing ...................................................................................14-54
Regeneration................................................................................................14-54
Air Cleaner Assembly (Engine Mounted) .......................................................10-8
Clean...............................................................................................................10-9
General Information........................................................................................10-8
Initial Check....................................................................................................10-8
Install.............................................................................................................10-10
Remove...........................................................................................................10-9
Air Compressor ..............................................................................................12-22
Assemble
......................................................................................................12-25
Clean and Inspect for Reuse........................................................................12-24
Finishing Steps.............................................................................................12-30
Install.............................................................................................................12-27
Preparatory Steps.........................................................................................12-23
Pressure Test................................................................................................12-22
Remove.........................................................................................................12-23
Time..............................................................................................................12-25
Air Compressor (Oil Carryover) ....................................................................12-34
Inspect for Reuse..........................................................................................12-34
Air Compressor Carbon Buildup ....................................................................12-2
Clean...............................................................................................................12-3
Initial Check....................................................................................................12-2
Preparatory Steps...........................................................................................12-3
Air Compressor Coolant Lines .....................................................................12-10
Initial Check..................................................................................................12-10
Inspect for Reuse..........................................................................................12-11
Install.............................................................................................................12-11
Preparatory Steps.........................................................................................12-10
Remove.........................................................................................................12-11
Air Compressor Cylinder Head, Single Cylinder .........................................12-11
Assemble......................................................................................................12-15
Clean and Inspect for Reuse........................................................................12-13
Disassemble.................................................................................................12-14
Finishing Steps.............................................................................................12-17
Initial Check..................................................................................................12-11
Install.............................................................................................................12-16
Preparatory Steps.........................................................................................12-12
Remove.........................................................................................................12-13
Air Compressor Cylinder Head, Two Cylinder ............................................12-18
Clean and Inspect for Reuse........................................................................12-19
Finishing Steps.............................................................................................12-19
Install.............................................................................................................12-19
Preparatory...................................................................................................12-18
Remove.........................................................................................................12-18
Air Compressor Oil Drain Line ......................................................................12-20
Initial Check..................................................................................................12-20
Inspect for Reuse..........................................................................................12-20
Install.............................................................................................................12-20
Remove.........................................................................................................12-20
Air Compressor Rear Bearing Housing, Two Cylinder ...............................12-37
Clean and Inspect for Reuse........................................................................12-38
Finishing Steps.............................................................................................12-39
General Information......................................................................................12-37
Install.............................................................................................................12-38
Preparatory Steps.........................................................................................12-37
Remove.........................................................................................................12-37
Air Compressor Unloader and Valve Assembly ..........................................12-21
Initial Check..................................................................................................12-21
Air Crossover ..................................................................................................10-10
Clean and Inspect for Reuse........................................................................10-11
Finishing Steps.............................................................................................10-13
General Information......................................................................................10-10
Install.............................................................................................................10-12
Remove.........................................................................................................10-10
Air Governor (Air Compressor Pumps Continuously) ................................12-31
Initial Check..................................................................................................12-31
Air Governor (Air Compressor Will Not Pump) ...........................................12-30
Inspect for Reuse..........................................................................................12-30
Air in Fuel ............................................................................................................6-5
General Information..........................................................................................6-5
Test...................................................................................................................6-5
Air Inlet Connection .......................................................................................10-13
Clean and Inspect for Reuse........................................................................10-14
Finishing Steps.............................................................................................10-14
General Information......................................................................................10-13
Install.............................................................................................................10-14
Remove.........................................................................................................10-13
Air Intake Connection ....................................................................................10-67
Clean and Inspect for Reuse........................................................................10-69
Finishing Steps.............................................................................................10-73
Install.............................................................................................................10-70
Preparatory Steps.........................................................................................10-67
Remove.........................................................................................................10-68
Air Intake Connection Adapter ......................................................................10-77
Clean and Inspect for Reuse........................................................................10-79
Finishing Steps.............................................................................................10-80
General Information......................................................................................10-77
Install.............................................................................................................10-79
Preparatory Steps.........................................................................................10-77
Remove.........................................................................................................10-78
Air Intake Manifold .........................................................................................10-15
Clean and Inspect for Reuse........................................................................10-17
Finishing Steps.............................................................................................10-19
General Information......................................................................................10-15
Install.............................................................................................................10-18
Preparatory Steps.........................................................................................10-15