451-3552-00 cummins repair manual...

500 57th Street, Marion, IA 52302 USA

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Manual Part # 451-3552-00

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ISX/QSX AND M-11 INSTRUCTIONS

INJECTOR SLEEVE IDENTIFICATION – Copper & Stainless Steel

REMOVAL OF THE USED INJECTOR SLEEVES

REBUILDING THE CASTING INJECTOR SEAT

INSTALLATION OF NEW INJECTOR SLEEVES

MISCELLANEOUS, OPTIONAL HEAD SERVICING TOOLS

SERIES-SPECIFIC INSTRUCTIONS – ISX / QSX SERIES – SLEEVE REMOVAL & INSTALLATION

Sleeve Removal

(1) With valves removed, install the sleeve hold down clamp (416-6154-40) through the inside of the sleeve. Install washer and nut onto stud sticking out from face of head and tighten.

(2) The clamp will keep the sleeve from turning while tapping the sleeve. (3) Using extended tap (416-6156-60) and guide bushing (416-6156-32), using the tap lubricated with

Microfinish (468-9910-16) tap the injector sleeve about 3/8” to 1/2” deep. (4) Unbolt and remove the hold down clamp.

(5) Insert the sleeve remover (415-6136-00) threaded puller shaft of the removal tool down into the old sleeve.

(6) Continue to torque the shaft into the sleeve until the shaft grips the sleeve tightly with the threads. (7) With the puller bridge (or cup) in place between the puller nut and the face of the casting, and with

the thrust bearing and the two thrust washers between the puller nut and the puller bridge, continue tightening down the puller nut and pull out the old sleeve.

REMOVAL and INSTALLATION

Sleeve Installation

1. Using the carbon steel brush (450-6951-01) clean the inside of the injector sleeve bore.

2. Using the sleeve drive in tool (416-6156-51) and a hammer, drive the sleeve to the bottom of the casting.

3. Using sleeve nose roll-in tool (416-6156-43) back off hand knob, keep tool lubricated with “Quality Motor Oil” (NOT Microfinish), using the two bolts provided, bolt the tool to the

head. You can use a drill motor or a seat and guide machine to drive the tool. Turning the

tool at a slow RPM, turn the knob clockwise, rolling the nose of the sleeve in.

4. Using the roll-in tool to roll in the upper end of the injector sleeve (416-6156-53) can be

used in a seat and guide machine. Keeping the tool lubricated with a “Quality Motor Oil” (NOT Microfinish), roll in the upper end of the sleeve by running the machine clockwise

and letting the roll-in tool feed itself. To remove the tool, reverse the direction.

5. Using the sleeve nose roll-in tool (416-6156-43) repeat.

Cutting Injector Tip Protrusion (1) Using the guide bushing (416-6156-32), sleeve seat cutter (416-6156-27) and driving arbor (6114-10),

set up in a seat and guide machine, bolt gage finger (433-6991-00) to face of head, set gage (416-6156-94) with gage handle (414-6111-30) onto gage finger.

(2) Using Microfinish (468-9910-16) as lubricant, run the machine at a slow (60-85) RPM and may have to be varied to get a good finish. Cut sleeve until pilot end of cutter touches the gage.

(3) Tip protrusion can be checked with the tip protrusion gage (416-6156-50) and Guide Bushing (416-6156-32).

(4) The flat tip of the protrusion gage should be flush with the surface of the head.

Checking Injector Seat Area and Tip Protrusion (1) Tip protrusion can be checked with the tip protrusion gage (416-6156-50) and Guide Bushing (416-6156-

32). (2) The flat tip of the protrusion gage should be flush with the surface of the head. (3) In addition, Prussian Blue compound can be applied at the tip protrusion seat area of the gage to insure

a proper seat pattern.

Note: Pressure testing of the cylinder head should be preformed with injectors secured.

SERIES-SPECIFIC INSTRUCTIONS – ISX / QSX SERIES – CASTING REPAIR Rebuilding the casting injector seat

1) Remove the old injector sleeves

a) Using the Cummins sleeve remover, remove the old injector sleeve from the injector

holes in the casting.

2) Clean out the injector seat in the casting

a) Using the casting seat cutter (416-6156-28) with the driving arbor (414-6114-10) and the appropriate guide bushing (416-6156-32) clean up the seats at the bottom of the injector holes.

b) This will clean out any accumulations and clean up any corrosion in the seat. In addition and more important, it will clean out the serrations at the bottom of the seat.

3) Preliminary Check

a) Frequently small cracks may appear on the face of the head at the injector hole

area. If these cracks extend beyond the area that will be cover by the replacement plug, then these collateral cracks will need to be repaired. Their location on the face of the head should be clearly marked so they can be subsequently repaired using

Irontite A-200 or A-235 Plugs. b) It is important that this repair of these collateral cracks be done after the injector

hole repair is completed and the replacement plug has been torqued into the injector

hole. Otherwise, the torqueing in of the replacement plug might have a tendency to open up the collateral crack.

c) In some instances it may be desirable to drill a hole at the end of the collateral crack

before starting the injector hole repair in order to relieve the casting stress at the collateral crack.

4) Enlarging the Injector Hole a) With the pilot (416-6156-62) in the enlarging counterbore (434-6513-20), from the

face side of the cylinder head, guide the pilot into the injector hole and cut out the injector area of the casting, it will then be ready for the tapered reamer and in turn the tapered tap.

NOTE: Unless cracks extend to the valve seat area, valve seats do not need to be removed during nose plug machining and installation.

5) Reaming the Injector Hole

a) With reamer (407-5213-10) and driver (449-6933-30) and coming from the face of the head, ream out the injector hole, operating the reamer at about 60/80 RPM. Do not ream too deep, just enough to get the tap started with a few threads is sufficient.

b) Keep reamer well lubricated with Irontite Tap-O (468-9920-08).

6) Tap the Injector Hole a) With Tap (407-5313-10) tap the reamed hole for the installation of the “J” Plug.

While tapping, keep the tap well lubricated with Irontite Tap-O (468-9920-08).

CUMMINS ISX / QSX INJECTOR CASTING REPAIR TOOLING

7) Install and Drill the Replacement Plug a) Clean the tapped casting area and the “J” tapered plug with a quality cleaner. It is

recommended to place Ceramic seal (468-9120-16) on the casting area along with

the threads of the plug. Thread the plug into the casting and torque to 200 ft lbs of torque.

b) Turn the casting over, and coming in from the spring side of the casting, using the taper length drill (416-6156-26) and drill bushing (416-6156-19) drill the plug all the way through.


8) Face off and peen the outer end of the plug a) Turn the casting back over with the face up using the end facing counterbore (416-

6156-61) and pilot (416-6156-62) Face off the outer end of the replacement plug.

Bring it down to about 1/16” above the face of the casting.

b) Now peen the outer rim of the plug, always peening away from the center of the

plug. After peening the outer rim of the plug, smooth off the end of the plug. If the

head is to be resurfaced later, bring the end of the plug down to about 1/32” above the face of the head. If there is not to be any later resurfacing of the head, then

finish off the end other plug smooth with the face of the casting.

9) Check for any collateral cracks a) At this stage, after the plug has been installed, check the area around the plug to

determine if any small cracks extend beyond the perimeter of the plug. If so, these

cracks should be now repaired, using the Irontite crack repair process. b) After any such repair is completed, make certain that the surface of the head is

smoothed as desired.



10) Cut a new injector seat in the rebuilt area a) Cut a new injector seat in the rebuilt injector seat area of the casting using the

casting seat cutter (416-6156-28) along with the driving arbor (414-6114-10) and

guide bushing (416-6156-32). b) One very important feature in cutting the new seat is to cut it to the correct depth.

This seat depth is controlled by the use of the gage finger (433-6991-00) and the

casting seat cutter gage (416-6156-29) in conjunction with the dimensional pilot at the end of the cutter.

c) Mount the gage finger on the casting with the flat surface of the gage finger directly below the injector hole.

d) Now, cut the new injector seat, bringing the cutter slowly down until the dimensional

pilot at the end of the cutter bottoms on the casting seat cutter gage. e) Here again a allowance must be made for any head resurfacing that may be

contemplated later in the rebuilding process by shimming up the seat cutter gage on

the gage finger accordingly.

11) In cutting, the seat cutter should be operated at about 60/80 RPM and should be kept well

lubricated at all times with our Irontite Tap-O (468-9920-08).

# Part Number Description # Part Number Description

1 434-6513-20 Enlarging Counter Bore Cutter 9 416-6156-32 Guide Bushing

2 416-6156-61 End Facing Counter Bore Cutter 10 416-6156-28 ISX / QSX Casting Seat Cutter

3 414-6114-10 Driving Arbor 11 452-2613-13 J-Solid Diesel Iron Plug (6)

4 416-6156-26 M14.5 Taper Length Drill 12 416-6156-62 Counter Bore Pilot (2)

5 449-6933-30 7/8 Split Sleeve Tap Driver #3MT 13 416-6156-29 Casting Seat Cutter Gage

6 407-5213-10 J-Tapered Reamer 14 414-6111-30 Gage Handle

7 407-5313-10 J-Tapered Tap 15 433-6991-00 Gage Finger

8 416-6156-19 Drill Bushing 16 467-1950-50 Tool Box with Tray

Instruction Manual & Parts Lists: Cummins Diesel

© Irontite by Kwik-Way Inc. Page 1

SERIES-SPECIFIC INSTRUCTIONS – M-11 SERIES – SLEEVE REMOVAL & INSTALLATION REMOVAL and INSTALLATION Sleeve Removal 1) Install the sleeve hold down clamp (416-6154-40) through the inside of the sleeve. Install washer and

nut onto stud sticking out from face of head and tighten. 2) The clamp will keep the sleeve from turning while tapping the sleeve. 3) Using tap (437-5331-36) and guide bushing (414-6114-36), tap the injector sleeve about 3/8” to 1/2”

deep. 4) Unbolt and remove the hold down clamp. Install puller mandrel (415-6132-49), long end though the

sleeve from the top side of the head then thread the sleeve puller body (415-6132-41) into the tapped sleeve.

5) Using a hydraulic press, turn the head over and pressing on the mandrel press the sleeve from the head.

Sleeve Installation 1) Using the carbon steel brush (450-6951-02) clean the inside of the injector sleeve bore being sure to

remove the old “O” ring and replacing it with a new one. 2) Using the sleeve drive in tool (416-6152-61) and a hammer, drive the sleeve to the bottom of the

casting. 3) Using sleeve nose roll-in tool (416-6152-45) back off hand knob before installing the tool into the

head, using the two bolts provided bolt the tool to the head, you can use a drill motor or a seat and guide machine to drive the tool.

4) Turning the tool at a slow RPM, turn the knob clockwise, rolling the nose of the sleeve in. (4) Using the roll-in tool to roll in the upper end of the injector sleeve (6152-43) can be used in a seat and

guide machine. (5) Roll in the upper end of the sleeve by running the machine clockwise and letting the roll-in tool feed

itself. (6) To remove the tool, reverse the machine. (7) Using the sleeve nose roll-in tool (416-6152-45) repeat step (3). Cutting Injector Tip Protrusion (1) Using the guide bushing (414-6114-36), sleeve seat cutter (416-6152-27) and driving arbor (414-

6114-10), set up in a seat and guide machine, bolt gage finger (433-6991-00) to face of head, set gage (416-6152-98) with gage handle (414-6111-30) onto gage finger.

(2) Use a good cutting fluid, run the machine at a slow RPM and may have to be varied to get a good finish.

(3) Cut sleeve until pilot end of cutter touches the gage. (4) Tip protrusion can be checked with the flat tip protrusion gage (414-6111-19) and injector. (5) The protrusion should be between the steps of the gage. Note: It is always safe practice to install an injector with Prussian Blue compound applied at the seat area to insure proper seating of Injector.



The Irontite tools and processes for heavy duty diesel engines are related primarily to the injector sleeve areas of the engines. The engines of a company may fit into designated categories. With respect to the Cummins Engines, they are grouped as follows (cylinder heads with copper injector sleeves): 220 series 250, L-10 and Early M-11 series C&J series Small V series Which respective series can be identified by the respective configuration of the injector sleeve and the following respective engine identifying numbers: 419-6192-21 – 220 series engines using this sleeve have bored of 4-7/8” and 5-1/8” and include: NHD – 180 NHE – 195 NH – 220 NT – 743 419-6192-51 – 250 and L-10/M-11 engines using this sleeve with a 5-1/2” bore include: NH – 230 NTC – 400 NHC – 250 NTA – 370 NTC – 250 NT – 380 Super – 250 NTA – 400 Super – 250/270 NTA – 420 NT – 270 NT – 855 NT – 280 V – 903 NTC – 290 V 8 – 265 NT – 310 V – 785 NTC – 335 V – 927 NTC – 350 VT – 903

VT – 1710 N – 14 419-6192-71 – C&J series engines using this sleeve have bores of 4-1/8” and 4-7/6” and include: JN – 130 JNF – 130 C – 160 CF – 160 CR – 160 C – 175 C – 180 C – 190 CS – 195 JS – 6 JNS – 6 JT – 6 419-6192-81 – Small V series engines using this sleeve have a 4-5/8” bore and include: V6 – 140 V8E – 170 V8 – 185 V – 352 V – 378 V – 470

V – 504 V – 555 VT – 555 V8 – 210

L-10/M11 series with 5-1/2” bore that use this sleeve include: L-10 – 300 L-10 – 400

L-10 – 350 L-10 – BC IV Formula

O-Rings



Cummins diesel engine servicing and service tools 1 – Injector sleeve removal tools 2 – Casting repair of injector seat area 3 – Injector sleeve installation and replacement 4 – Miscellaneous Cummins injector servicing tools

The Irontite injector servicing tools for use with the Cummins engines are necessarily designed to services a specific series of Cummins engines. A few of the tools are interchangeable, but in general the dimensions of the tools for servicing one specific series of engines are not right for servicing engines of a different series. Accordingly, it is important when ordering tools to identify them with the series of the engine to be serviced. Sleeve removal tools - Cummins The sleeve removal tools consist of two mandrels, each with tapered end, and a removal tool body with buttress threads at one end. The mandrel is positioned up in the used sleeve with the tapered end down. The removal tool body is brought up into the sleeve with the tapered end of the mandrel in the tool. As the mandrel is forced down, the buttressed threads on the tool expand and grab a hold on the sleeve, continue to press down on the mandrel and pull out the sleeve. The use of a press on the mandrel is recommended. Complete Removal Tools – For Copper Injector Sleeves 415-6132-20 – for 220 series engine 415-6132-50 – for 250, L-10 and Early M-11 series 415-6132-70 – for C&J series engine 415-6132-80 – for small V series engine Mandrels 415-6132-29 – for 250, L-10 and Early M-11 series 415-6132-59 – for C&J and Small V engines Tool bodies 415-6132-21 – for 220 series engine 415-6132-51 – for 250, L-10, Early M-11 and Small V engines and Komatsu 155/455 engines 415-6132-71 – for C&J series engine

Mandrel

Tool Body



CASTING SEAT REPAIR TOOLS - Cummins

Gauge Finger (All Series)

Casting Seat Cutter Gauges Casting Seat Cutter

433-6991-00

For 220 And 250: 414-6111-20 For L-10 & M-11 Series: 414-6111-26

For C&J Series: 414-6111-25 For ISX: 414-6111-27

For 220, 250 And L-10 Series: 414-6114-26

For C&J And Small V Series: 414-6114-25

ISX Series: 414-6114-27

Counterbore Pilots Guide Bushings

For 220, 250 and L-10: 414-6113-40; For C7J and SmV: 414-6113-45

For ISX: 414-6113-60

For 220 Series : 414-6114-30 For 250 And SmV Series: 414-6114-32 For L-10 & M-11 Series: 414-6114-36

For C&J Series: 414-6114-35

Casting seat repair tools for rebuilding the casting injector seat Combination

Counterbore And Tapered Reamer

(All Series)

Tapered Tap (All Series)

Tap Driver (All Series)

Drill Bushing

414-6112-10 (ISX Counterbore

Cutter: 434-6513-20; Tapered Reamer [J]:

407-5213-10)

407-5310-80 (ISX: 407-5313-10)

449-6933-30

220 Series 414-6113-10 250 Series 414-6113-12 L-10 Series 414-6113-16 C & J Series 414-6113-15 SmV Series 414-6113-18 ISX Series 414-6113-19

End Facing Counterbore (All Series)

Driving Arbor (All Series)

Tapered Plugs (All Series)

Taper Length Drill

414-6113-30 (ISX: 434-6513-66)

414-6114-10 (ISX: 414-6114-10)

452-2610-80 (ISX: J Solid Plugs

452-2613-13)

For 220, 250 And L-10 Series: 414-6113-20

For C&J And Small V Series: 414-6113-25

For ISX Series: 414-6113-26



The tools are designed to service specific series of engines. It is important when ordering tools to identify the tools with the series of the engines to be serviced. A few of the tools are interchangeable, but in general the dimensions of the tools for one specific series of engines are not right for servicing engines of a different series. Preliminary removal of old injector sleeves Before commencing the service work on the engine, whether to rebuild the injector seat area of the casting of to install new injector sleeves, the old injector sleeves must first be removed. The Irontite injector sleeve removal tools come in several sizes to accommodate the various series of engines, The tools consist of: 1 – A tool mandrel which is placed up into the injector hole, and 2 – A split tool body with buttress threads at the upper end of the tool body. The lower end of the mandrel is tapered and when it is pressed down into the tool body, it expands the threads on the tool body, which grip the sleeve. Continued downward pressure on the mandrel forces the injector sleeve out of the casting. Use of a press is recommended. Rebuilding the casting injector seat 1) Remove the old injector sleeves

a) Using the Cummins sleeve removers, remove the old injector sleeves from the injector holes in the casting. 2) Clean out the injector seats in the casting

a) Using the casting seat cutter (414-6114-26 or 414-6114-25), with the driving arbor (414-6114-10) and the appropriate guide bushing (414-6114-30/414-6114-35) clean up the seats at the bottom of the injector holes

b) This will clean out any accumulations and clean up any corrosion in the seat. In addition, and more important, it will clean out the serrations at the bottom of the seat. Make certain also to clean out any o-ring grooves in the casting.

3) Check the cleaned injector seats a) At the ends of the casting seat cutters are dimensional pilots. At this stage these pilots are used in

conjunction with the casting seat cutter gages (414-6111-20/414-6111-28) to measure the position of the seat in relation to the face of the head, or in other words, to see if the casting thickness at the bottom of the seat is within the permissible tolerances

b) The casting seat cutter gages are designed with two sets of steps. At one end the two steps have a hole between the two steps. This end and these two steps are used at this time to check the injector seat.

c) With this gage for the small V series engine heads the two steps at the right, with the hole between the, are used for checking the seat

d) Using the casting seat cutter with driving arbor and guide bushing, insert the cutter into the hole in the casting with the dimensional pilot at the end of the cutter protruding above the face of the casting.

e) Place the seat cutter gage down on the face of the head with the flat side of the gage against the face of the head and with the hole in the gage over the end of the dimensional pilot.

f) If the tip of the dimensional pilot protrudes above the upper step on the gage the seat is too close to the face of the head or the casting is too thin at this point. In this situation, the injector seat area must be rebuilt.

g) To be satisfactory, the end of the dimensional pilot must protrude between the upper and lower steps on the gage.

h) In evaluating the position of the end of the pilot relative to the steps on the gage, adequate allowance must be made for any subsequent resurfacing of the face of the head. Such resurfacing will make the casting thinner at the injector seat area.

4) Ream out and tap the injector hole a) Using the combination counterbore and reamer (414-6112-10) with the tap driver (449-6933-30), and

coming in from the face side of the head, ream out the injector hole, operating the reamer at about 60/80



RPM. Ream out the hole until about ½” to ¾” of the cutting flutes remain above the surface of the casting. Keep the reamer well lubricated at all times.

b) Then, using the Irontite tapered tap (407-5310-80) with the tap driver, tap out the hole for the installation of the Irontite “H” replacement plug (452-2610-80). While tapping, keep the tap well lubricated with the Irontite tap-o.

5) Install and drill the replacement plug

a) Dip the Irontite “H” plug in Irontite ceramic seal and then torque it into the tapped injector hole, using about 145/150 foot pounds of torque.

b) Turn the casting over, and coming in from the other side, using the taper length drill (611320/611325) and drill bushing (414-6113-10/414-6113-18), drill the plug all the way through.

6) Face off and peen the outer end of the plug a) Turn the casting back with the face up and using the end

facing counterbore (414-6113-30) with the appropriate pilot (611340/611345) face off the outer end of the replacement plug. Bring it down to about 1/16” above the face of the casting.

b) Now peen the outer rim of the plug, always peening away from the center of the plug.

c) After peening the outer rim of the plug, smooth off the end of the plug. If the head is to be resurfaced later, bring the end of the plug down to about 1/32” above the face of the head. If there is not to be any later resurfacing of the head, then finish off the end of the plug smooth with the face of the casting.

7) Check for and repair any collateral cracks a) At this stage, after the plug has been installed, check the area around the plug to determine if any small

cracks in the casting extend beyond the perimeter of the plug. If so, these cracks should now be repaired, using the Irontite crack repair process.

b) After any such repair is completed, make certain that the surface of the face of the smoothed as desired. 8) Cut a new injector seat in the rebuilt injector area

a) Cut a new injector seat in the rebuilt injector seat area of the casting using the casting seat cutter (414-6114-26 or 414-6114-25) along with the driving arbor (611410) and the appropriate guide bushing (414-6114-30 /414-6114-35).

b) One very important feature in cutting the new seat is to cut it to the correct depth. This seat depth is controlled by the use of the gage finger (699100) and the casting seat cutter gages (414-6111-20 /414-6111-28) in conjunction with the dimensional pilots at the end of the cutters.

c) First mount the gage finger on the casting as shown here, with the flat surface of the gage finger directly below the injector hole.

d) As indicated before, (see step 3) the casting seat cutter gages have two sets of steps. One set of these

steps with the hole between them was used in checking the depth of the old injector seat. e) Now the other set of steps on the gages, without the hole, is used

in conjunction with the gage finger and the dimensional pilots at the ends of the cutters to control the depth of the new injector seat in the casting.

f) The gage is placed on the flat surface of the gage finger with the upper step directly below the injector hole.

g) Now, cut the new injector seat, bringing the cutter slowly down until

the dimensional pilot at the end of the cutter bottoms on the top step of the casting seat cutter gage.



h) Here again allowance must be made for any head resurfacing that may be contemplated later in the rebuilding process by shimming up the seat cutter gage on the gage finger accordingly.

i) In cutting, the seat cutter should be operated at about 60/80 RPM and should be kept well lubricated at all times.

j) Here is a picture of a finished rebuilt injector seat on a 250 series

head, which is now ready for the installation of a new injector sleeve. Note the serrations in the new seat.



CASTING SEAT REPAIR TOOL KITS – Cummins

450-6110-22 – 220 Series Kit 450-6110-26 – L-10 Series Kit

414-6111-20 Casting Seat Cutter Gauge w/Handle 414-6111-26 Casting Seat Cutter Gauge w/ Handle 414-6112-10 Counterbore And Tapered Reamer

(Carbide) 414-6112-10 Counterbore And Tapered Reamer

(Carbide) 407-5310-80 Tapered Tap 407-5310-80 Tapered Tap 449-6933-30 Tap Driver (7/8 splt slv #3MT) 449-6933-30 Tap Driver (7/8 splt slv #3MT) 452-2610-80 Tapered Plugs (5) 452-2610-80 Tapered Plugs (5) 414-6113-10 Drill Bushing 414-6113-16 Drill Bushing 414-6113-20 9/16” Tapered Length Drill 414-6113-20 9/16” Tapered Length Drill 414-6113-30 End Facing Counterbore 414-6113-30 End Facing Counterbore 414-6113-40 Counterbore Pilot 414-6113-40 Counterbore Pilot 414-6114-10 Driving Arbor 414-6114-10 Driving Arbor 414-6114-30 Guide Bushing 414-6114-36 Guide Bushing 414-6114-26 Seat Cutter (Carbide) – 220/250/L-10 414-6114-26 Seat Cutter (Carbide) – 220/250/L-10 433-6991-00 Gauge Finger 433-6991-00 Gauge Finger 467-1611-08 1/8” HEX Key 467-1611-08 1/8” HEX Key 467-1950-50 Tool Box 467-1950-50 Tool Box

450-6110-25 – 250 Series Kit 450-6110-28 – Small V Series Kit

414-6111-20 Casting Seat Cutter Gauge W/Handle 414-6111-28 Casting Seat Cutter Gauge W/ Handle 414-6112-10 Counterbore And Tapered Reamer

(Carbide) 414-6112-10 Counterbore And Tapered Reamer

(Carbide) 407-5310-80 Tapered Tap 407-5310-80 Tapered Tap 449-6933-30 Tap Driver (7/8 splt slv #3MT) 449-6933-30 Tap Driver (7/8 splt slv #3MT) 452-2610-80 Tapered Plugs (5) 452-2610-80 Tapered Plugs (5) 414-6113-12 Drill Bushing 414-6113-18 Drill Bushing 414-6113-20 9/16” Tapered Length Drill 414-6113-25 ½” Taper Length Drill (C&J/SmV) 414-6113-30 End Facing Counterbore 414-6113-30 End Facing Counterbore 414-6113-40 Counterbore Pilot 414-6113-45 Counterbore Pilot 414-6114-10 Driving Arbor 414-6114-10 Driving Arbor 414-6114-32 Guide Bushing 414-6114-32 Guide Bushing 414-6114-26 Seat Cutter (Carbide) – 220/250/L-10 414-6114-25 Seat Cutter (Carbide) C&J/SmV 433-6991-00 Gauge Finger 433-6991-00 Gauge Finger 467-1611-08 1/8” HEX Key 467-1611-08 1/8” Hex Key 467-1950-50 Tool Box 467-1950-50 Tool Box

450-6110-27 – C&J Series Kit

450-6110-60 – ISX / QSX Series Kit

414-6111-25 Casting Seat Cutter Gauge W/Handle 434-6513-20 Enlarging Counterbore Cutter 414-6112-10 Counterbore And Tapered Reamer

(Carbide) 414-6113-60 Enlarging Counterbore Pilot (2)

407-5310-80 Tapered Tap 449-6933-30 7/8” Split Sleeve Tap Driver 449-6933-30 Tap Driver (7/8 splt slv #3MT) 407-5213-10 Tapered Reamer (j) 452-2610-80 Tapered Plugs (5) 407-5313-10 Tapered Tap (j) 414-6113-15 Drill Bushing 452-2613-13 J Solid Diesel Iron Plug (5) 414-6113-25 ½” Tapered Length Drill (C&J/SmV) 414-6113-19 Drill Bushing 414-6113-30 End Facing Counterbore 414-6113-26 Taper Length Drill 414-6114-35 Guide Bushing 434-6513-66 End Facing Counterbore Cutter 414-6114-25 Seat Cutter (Carbide)-C&J/SmV 416-6156-32 Seat Cutter Guide Bushing 433-6991-00 Gauge Finger 414-6114-10 Driving Arbor 467-1611-08 1/8” HEX Key 414-6114-27 Casting Seat Cutter (Carbide) 467-1950-50 Tool Box 414-6111-27 Casting Seat Cutter Gauge 414-6111-30 Gauge Handle 433-6991-00 Gauge Finger 467-1950-50 Tool Box



CASTING SEAT REPAIR TOOLS - Cummins

450-6110-80 – Combination C&J And Small V Series Kit

450-6110-30 – Combination 220/250 Series Kit

414-6111-25 Casting Seat Cutter W/Gauge Handle

414-6111-20 Casting Seat Cutter Gauge W/Gauge Handle

414-6111-28 Casting Seat Cutter Gauge W/Handle

414-6112-10 Counterbore And Tapered Reamer (Carbide)

414-6112-10 Counterbore And Tapered Reamer (Carbide)

407-5310-80 Tapered Tap

407-5310-80 Tapered Tap 449-6933-30 Tap Driver 449-6933-30 Tap Driver 452-2610-80 Tapered Plugs (5) 452-2610-80 Tapered Plugs (5) 414-6113-10 Drill Bushing 414-6113-15 Drill Bushing 414-6113-12 Drill Bushing 414-6113-18 Drill Bushing 414-6113-20 Taper Length Drill 414-6113-25 Taper Length Drill 414-6113-30 End Facing Counterbore 414-6113-30 End Facing Counterbore 414-6113-40 Counterbore Pilot 414-6113-45 Counterbore Pilot 414-6114-10 Driving Arbor 414-6114-10 Driving Arbor 414-6114-30 Guide Bushing 414-6114-32 Guide Bushing 414-6114-32 Guide Bushing 414-6114-32 Guide Bushing 414-6114-26 Seat Cutter (Carbide) 414-6114-25 Seat Cutter (Carbide) 433-6991-00 Gauge Finger 433-6991-00 Gauge Finger 467-1611-08 1/8” Hex Key 467-1611-08 1/8” HEX Key 467-1950-50 Tool Box 467-1950-50 Tool Box 450-6110-90 – Combination Kit For All Five Series

414-6111-20 Seat Cutter Gauge W/Handle 414-6111-25 Seat Cutter Gauge W/Handle 414-6111-26 Seat Cutter Gauge W/Handle 414-6111-28 Seat Cutter Gauge W/Handle 414-6112-10 Counterbore And Tapered

Reamer (Carbide)

407-5310-80 Tapered Tap 449-6933-30 Tap Driver 452-2610-80 Tapered Plugs (5) 414-6113-10 Drill Bushing 414-6113-12 Drill Bushing 414-6113-15 Drill Bushing 414-6113-16 Drill Bushing 414-6113-18 Drill Bushing 414-6113-20 Taper Length Drill 414-6113-25 Taper Length Drill 414-6113-30 End Facing Counterbore 414-6113-40 Counterbore Pilot 414-6113-45 Counterbore Pilot 414-6114-10 Driving Arbor 414-6114-30 Guide Bushing 414-6114-32 Guide Bushing 414-6114-35 Guide Bushing 414-6114-36 Guide Bushing 414-6114-25 Seat Cutter (Carbide) 414-6114-26 Seat Cutter (Carbide) 433-6991-00 Gauge Finger 467-1611-08 1/8” HEX Key 467-1950-50 Tool Box



Sleeve installation tools for installing new Cummins injector sleeves

Sleeve Roll-in Tools

INSTALLATION OF NEW INJECTOR SLEEVES - Cummins

416-6152-21 – Sleeve Drive-In Tools For 220 Series 416-6152-51 – Sleeve Drive-In Tools For 250 Series 416-6152-61 – Sleeve Drive-In Tools For L-10 Series 416-6152-71 – Sleeve Drive-In Tools For C&J Series 416-6152-81 – Sleeve Drive-In Tools For SmV Series

416-6152-23 – Regular 220 Series Sleeve Roll-In Tools 416-6152-73 – Regular C&J Series Sleeve Roll-In Tools

With Spring Tension: 416-6152-53 – Spring Tension Sleeve Roll-In Tools For 250 And L-10 Series 416-6152-83 - Spring Tension Sleeve Roll-In Tools For Small V Series 414-6114-10 – Driving Arbor (All Series) 433-6991-00 – Gauge Finger (All Series) Guide Bushings Sleeve Seat Cutters Injector Sleeve Seat Cutter Gauges

Flat Top Protrusion Gauges

Sleeve Seat Cutters 416-6152-27 –220, 250 And L-10 Series 416-6152-77 – For C&J Series

416-6152-87 –For SmV Series

416-6152-26 – 220 Series 414-6114-32 – 250 And SmV Series

414-6114-36 – L-10 And C&J Series

Complete Kits 450-6152-20 – Complete Kit For 220 Series 450-6152-50 – Complete Kit For 250 Series 450-6152-30 – Complete Kit For M-11 Series 450-6152-60 – Complete Kit For C&J And SmV Series 450-6152-40 – Complete Kit For L-10 Series 450-6152-70 – Complete Kit For C&J Series 450-6152-80 – Complete Kit For Smv Series 450-6152-90 – Complete Kit For All Five Series

414-6111-12 – For 220 And 250 Series 414-6111-14 – For Early 903 414-6111-16 – For Late 903 414-6111-17 – For C&J Series 414-6111-19 – For L-10 Series

414-6111-18 – For SmV Series

416-6152-94 –220 And 250 Series 416-6152-95 – For Early 903 416-6152-96 – For Late 903 416-6152-97 – For C&J Series 416-6152-98 – For L-10 Series

416-6152-99 – For SmV Series



INSTALLATION OF NEW INJECTOR SLEEVES 1) Drive the injector sleeve in place

a) At the bottom of the injector seat in the casting are a series of small serrations. These serrations must be clean so that when the sleeve is driven in place the tip on the sleeve will be seated right into these serrations. These serrations help the injector sleeve prevent water from leaking in from the water jacket.

b) If the seat of the casting has just been rebuilt the serrations will be new and clean. If not then use the casting seat cutter (414-6114-26 or 414-6114-25) to clean them out.

c) Before installing the new sleeve brush Irontite ceramic seal onto the nose of the sleeve and onto the seat in the casting. Ceramic seal here will further help seal the nose of the seat and prevent water leakage. Lubricate and install an O-Ring in the casting groove. Drop the sleeve into the hole or put it on the appropriate drive-in tool (416-6152-21/416-6152-81) and insert the sleeve into the hole.

d) With a machinist’s hammer drive the sleeve down into the casting seat until the sleeve bottoms in the casting.

2) Expand the upper end of the injector sleeve a) Insert the sleeve installation tool (416-6152-23/416-6152-83)

into the sleeve and operating the tool at about 50RPM roll it slowly down into the sleeve until the tool bottoms. All operating parts of the tool must be kept lubricated with a light oil at all times.

b) As the tool is brought down into the sleeve the rollers on the tool expand and the upper end of the sleeve in turn expands to a diameter within the specified limits.

c) Now reverse the roll-in tool and draw it back out. 3) Cut the seat in the new injector sleeve

a) Cut the seat in the new injector sleeve using the sleeve seat cutter (416-6152-27/416-6152-87) with the driving arbor (414-6114-10) and the appropriate guide bushing (416-615-226/416-6114-36).

b) Here again, a very important feature is cutting the seat to the correct depth in the injector sleeve. Here the seat depth is controlled by the use of the gage finger (433-6991-00) and the injector sleeve seat cutter gages operated in conjunction with the dimensional pilots at the ends of the sleeve seat cutters.

c) After the new sleeve has been driven in place and the upper end of the sleeve has been rolled out, then mount the gage finger on the head as shown here, with the flat surface of the gage finger directly below the injector hole.

d) Now place the injector sleeve seat cutter gage on the flat

surface of the gage finger, also directly below the injector hole.

e) With the sleeve seat cutter in the driving arbor with guide

bushing, insert the cutter down into the sleeve with the dimensional pilot protruding through the hole in the sleeve down toward the top surface of the sleeve seat cutter gage.



f) Operating the cutter at about 50 RPM, bring the cutter down slowly until the dimensional pilot bottoms on the top of the gage.

g) At all times keep the cutter well lubricated with a light oil, using the two slots at the sides of the guide bushing.

h) While any head resurfacing should be done before the installation of the new injector sleeves, if, by chance, any future head resurfacing is contemplated, the sleeve seat cutter gage should be shimmed up accordingly.

Tip Protrusion

The depth of the cut of the injector seat determines, of course, the amount of tip protrusion when the injector mandrel and injector tip are in place in the new sleeve.

The projected tip protrusions with the seat cutters and respective seat cutter gages supplied with the respective kits are as follows:

Series Engine Kit Sleeve Seat Cutter Sleeve Seat Cutter Gage Indicated Tip Protrusion 220 Series 416-6152-27 416-6152-94 .060-.070 250 Series 416-6152-27 416-6152-94 .060-.070 L10 Series 416-6152-27 416-6152-98 .090-.100 C&J Series 416-6152-77 416-6152-97 .050-.065 SmV Series 416-6152-87 416-6152-99 .110-.120

In addition to the gages included in the kits, there are available 3 additional gages which, when used with the 416-6152-27 sleeve seat cutter, project the following tip protrusions:

416-6152-27 416-6152-95 .075-.090 416-6152-27 416-6152-92 .045-.055 416-6152-27 416-6152-96 .090-.105

The respective Cummins shop manuals, of course, give recommended tip protrusions for the respective engines. Achieving the desired tip protrusion should be readily possible with the above array of seat cutter gages used with the respective indicated sleeve seat cutters. As a further aid, Irontite has flat tip protrusion gauges that are used to measure the actual tip protrusion with the injector mandrel and tip in place in the new sleeve. The several tip protrusion gages are as follows: Supplied with this Series Engine Kit Tip Protrusion Gage Number Tip Protrusion Range 220 Series 414-6111-12 .060-.070 250 Series 414-6111-12 .060-.070 L10 Series 414-6111-19 .090-.100 C&J Series 414-6111-17 .050-.065 SmV Series 414-6111-18 .110-.120 In addition there are 3 other flat tip protrusion gages available:

414-6111-14 .075-.090 414-6111-15 .045-.055 414-6111-16 .090-.105



Placing a flat tip protrusion gage down on the face of the head immediately tells you if the tip protrusion falls within the range of the particular flat gage. These flat gages allow a check of the tip protrusion after the sleeve is in place with the seat cut so that the protrusion can be verified or any needed modification can be made before the head is placed in service.



SLEEVE INSTALLATION TOOLS - Cummins

450-6152-20 – 220 series kit 450-6152-70 – C&J series kit

416-6152-21 Drive-In Tool 416-6152-71 Drive-In Tool 416-6152-23 Roll-In Tool 416-6152-73 Roll-In Tool 414-6114-10 Driving Arbor 414-6114-10 Driving Arbor 416-6152-26 Guide Bushing 414-6114-36 Guide Bushing 416-6152-27 Seat Cutter (Carbide) 416-6152-77 Seat Cutter (Carbide) 416-6152-94 Seat Cutter Gauge w/Handle 416-6152-97 Seat Cutter Gauge w/Handle 433-6991-00 Gauge Finger 433-6991-00 Gauge Finger 414-6111-12 Tip Protrusion Gauge 414-6111-17 Tip Protrusion Gauge

450-6152-50 – 250 series kit 450-6152-80 – Small V Series Kit

416-6152-51 Drive-In Tool 416-6152-81 Drive-In Tool 416-6152-53 Roll-In Tool w/Tension Spring 416-6152-83 Roll-In Tool w/Tension Spring 414-6114-10 Driving Arbor 414-6114-10 Driving Arbor 414-6114-32 Guide Bushing 414-6114-32 Guide Bushing 416-6152-27 Seat Cutter (Carbide) 416-6152-87 Seat Cutter (Carbide) 416-6152-94 Seat Cutter Gauge w/Handle 416-6152-99 Seat Cutter Gauge w/Handle 433-6991-00 Gauge Finger 433-6991-00 Gauge Finger 414-6111-12 Tip Protrusion Gauge 414-6111-18 Tip Protrusion Gauge

450-6152-40 – L10 series kit

416-6152-61 Drive-In Tool 416-6152-53 Roll-In Tool w/Tension Spring 414-6114-10 Driving Arbor 414-6114-36 Guide Bushing 416-6152-27 Seat Cutter (Carbide) 416-6152-98 Seat Cutter Gauge w/Handle 433-6991-00 Gauge Finger 414-6111-19 Tip Protrusion Gauge



SLEEVE INSTALLATION TOOLS – Cummins

450-6152-30 – M-11 series kit 450-6152-90 – All 5 series kit

416-6152-21 Drive-In Tool (220) 416-6152-21 Drive-In Tool (220) 416-6152-51 Drive-In Tool (250) 416-6152-51 Drive-In Tool (250) 416-6152-23 Roll-In Tool 416-6152-61 Drive-In Tool (L-10) 416-6152-53 Roll-In Tool w/Tension Spring 416-6152-71 Drive-In Tool (C&J) 414-6114-10 Driving Arbor 416-6152-81 Drive-In Tool (SmV) 416-6152-26 Guide Bushing (220) 416-6152-23 Roll-In Tool (220 & 250) 414-6114-32 Guide Bushing (250) 416-6152-53 Roll-In Tool w/Tension Spring 416-6152-27 Seat Cutter (Carbide) 416-6152-73 Roll-In Tool (C&J & SmV) 416-6152-94 Seat Cutter Gauge w/Handle 416-6152-83 Roll-In Tool w/Tension Spring 433-6991-00 Gauge Finger 414-6114-10 Driving Arbor 414-6111-12 Tip Protrusion Gauge

(220/250) 416-6152-26 Guide Bushing (220)

414-6111-19 Tip Protrusion Gauge (L-10)

450-6156-00 – ISX / QSX SERIES Kit

416-6156-51 Sleeve Drive-In Tool 416-6156-43 Sleeve Nose Roll-In Tool 416-6156-53 Roll-In Tool 416-6154-40 Injector Tube Clamp Assy 415-6136-00 Removal Tool 416-6156-60 Extended Tap 414-6114-10 Driving Arbor 414-6156-32 Guide Bushing 416-6156-27 Seat Cutter (Carbide) 416-6156-94 Gauge 416-6111-30 Gauge Handle 433-6991-00 Gauge Finger 414-6156-50 Tip Protrusion Gauge 414-6951-01 Casting Cleaning Brush 467-1612-00 L Wrench – 5/16” 467-1612-01 T Wrench – 5/16” 468-9910-16 Microfinish Tap & Lube



Miscellaneous Cummins head servicing tool and materials

Head Grooving Tools

418-6191-00 Complete Tools

418-6191-11 3/8” Pilot

418-6191-12 7/16” Pilot

418-6191-13 ½” Pilot

418-6191-21 Tool Bit

418-6199-21 Tool Bit For Cummins St 913 Grooving Tool

In addition, as a convenience, tool bits for the ST 913 grooving tool are available: 418-6199-21

Cummins Injector Sleeves

419-6192-21 For 220 Series 419-6192-51 For 250 And L -10 Series (Std.) 419-6192-71 For C&J Series 419-6192-81 For Small V Series 419-6192-52 O-Rings For 250, L10 And Small V Series

Sleeves

Cummin Leak Detectors 417-6172-20 For 220 Series 417-6172-50 For 250 And SmV Series 417-6172-60 For L-10 Series 417-6172-70 For C&J Series Special

Tools

414-6113-49 Special Pilot For Use When End Facing Off H-2 Plugs

414-6111-40 1” Parallels (Pair) 417-6152-24 Torque Wrench Adapter

Special Gauges For Cummins 903 Engine Heads 416-6152-95 Early 903 W/Handle 416-6152-96 Late 903 W/Handle Cummins 250 Roll In Tool Tension Spring Unit

416-6153-60 Complete Tension Spring Unit

PRODUCT UPDATE (May 9, 1983) Cummins 250 Roll-In Tool – Change in Dimensions In the past the Cummins 250 Roll-In Tool would hang up on the top of the sleeve after the sleeve had been rolled out. This could occur because of a rough cut at the top of the sleeve or because the sleeve was slightly longer than normal. To eliminate this, the cage and rollers on the tool have been lengthened, requiring some modiciation in the diameters of the rollers and arbor. The drawing (below) shows the comparison to the old tool and what is available today. For ordering replacement parts, if the tool cannot be sent in for evaluation, be sure to specify whether the parts needed are

irontite by kwik-way inc.500 57

th Street, Marion, IA 52302 USA

800-423-3384319-377-9421

FAX 319-377-9101

www.irontite.com

12172012

2525 18th St. SW, Suite D

Cedar Rapids, IA 52404 USA

800-5535953319-377-9421

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