cummins v378, 504, 555, vt555 & v903.pdf

7/24/2019 Cummins V378, 504, 555, VT555 & V903.pdf

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Operation

and

Maintenance

Manual

Cummins

Automotive

Diesel

Engines

Ma

intenance

Operations

2-19

'C'MaintenanGe

Check

At

each

"C"

Mainrenance

Check, f

irst

perform

all

,,A,,,

and

"B"

Checks

in

addition

to

those

following

-

Steam

Clean

Engine

Steam

is

the

most

satisfactory

method

of

cleaning

a

dirty

engine

or

piece

of

equipment.

lf

steam

is

not

available,

use

mineral

spirits

or

some

other

solvent

to

wásh

the

engine.

Al

I electrical

,components

and

wiring

should

be

protected

from

the

full

force

of

the

cleaner.,prJy

nozzle.

Check

Alternator

And

Cranking

Motor

Brushes

And

Commutators

Failure

of

an

alternator.

or

cranking

motor

may

cause

unit

downtime

and

nearly

always

"

,u.rii

¡n

.*p.nriuu

rep

lacement.

'l

.

lnspect

terminals.

for

corrosion

and

loose

connections

and

wiring

for

frayed

insuration.

cnecr

mtunting

borts

for

tightness

and

check

belt

for

alignment,

propu,

tension

and

wear.

2.

Slrp

rings

and

brushes

can

be

inspected

through

alternator

end

frame,assglblV.

lf

slip ring;are

d¡rty,

they

should

be

cleaned

with

400

grain

or

f

iner

pf,lishing cloth.

Note:

Never

use

emery

cloth

to

clean

slip rings.

Hold

polishing

cloth

against

sr

ip

rings

with

alternator

in

operation

and

blow

away

all

dust

alter

cleaning

operation.

3.

Check

alternator

bearings

for

wear.

Shaft

will

be

excessively

loose

if

bearings

are

worn.

4.

lf

brushes

are

worn

close

to

the

holder,

the

alternator

must

be

removed

and

sent

to

manufaciurer,s

rebuild

stat

ion.

6*

Adjust

Injectors

And

Valves

It is

essential

in

jectors

and

valves

be in

correct adjustment

at

all

times

for

engine

to

operate

properly.

One-controls

engine

breathing;

the

other

controls

iuel'delivery

to

the

cyl

i nders.

Final

operating

adjustments

must

be

made

using

correct

values

as

stated.

Temperature

Settings

The

following

temperature

conditions

provide

the

necessary

Definition

of

"Cold

Set,,

Engine

must

have

reached

a

stabilized

temperature

to

be

with¡n

10

deg.

F

temperature).

Definition

of

"Hot

Set',

1.

Set

injectors

and

valves

immediately

after

the

engine

has

reached

normal

stabilized

operat¡ng

oil'tempeüture.

2.

,lf

oil

temperature

gauge

is unavailable,

set injectors

and

valves

immediately

after

engine

has

op.rui"á-ut

rated

speed

and

load

or

at h¡gh

idle for

Jperiod

oi

ZO,rutu,

Valve

Set

Mark

Alignment

(V-gO3

Series)

Bar

crankshaft

in

d¡rection

of

rotation

until

No.

1

,,VS,,

mark

¿pp6¿¡5

on

the vibration

damper

cránksf¡att

pulley

or

accessory

drive

puiley

as used.

See Fig.

2-26for

location

of

valve

set

marks.

ln

this

position,

bot-h

intaks

and

exhaustvalves

must be

closed

for

cylinder

No

l;-it-not,

advance

crankshaft

one

revolution.

See

Fig.

221

ai¿Table

2-5.

Note:

Once

familiar

with

injector

start

at

any

cylinder

and follow

ad

iu

stments.

stabilization

of

engine

components

to

assure

accurate

sett

i

n

gs.

temperature

(oil

of

ambient

air

and

valve

adjustment,

firing

order

to

make

f

ig,2-26,

(V514115)

Valve

set marks

7/24/2019 Cummins V378, 504, 555, VT555 & V903.pdf


2-20

1-5-4-8-6-3-7 -2

1-4-2-5-3-6

Fig,2-27,

(V'11462't

V8 F¡r¡ng order diagram

Before adjustments tighten injector, hold down

capscrew to

30

to

35

ft-lbs

[4.1

to 4.8

kg

m]

torque.

Note':

Remove

key,

and

using

either

3/8

inch

hex drive for

female

type

barring

device

or

5/8

inch

six-point

socket

for

male

type

barring device,

press

inward

until

barring

gear

engages

drive

gear;

then

advance.

FiS.2-28.

After

completion

of

adjustment,

be sure drive

retracts

and install

key

into safety lock

groove.

V-903 And

VT-903

lnjector Adjustment,

Using Dial

lnd¡cator Method

This method involves

adjusting injector

plunger

travel

with

an accurate

dial

indicator

rather

than tightening the

adjusting

screw

to

a

specified torque.

The

"indicator method"

eliminates

errors

in

adjustment

caused

by

friction

in the

screw

threads

and

distortion

from

overt¡ghtening

the

adjusting screw locknut.

A check can be

made

of the

adjustment

without

disturbing

the

locknut or

screw

setting.

The

valves can

also

be

checked

or

set

while

adjusting

the

injectors

by this method.

See

Table 2-6

for

specif icat io ns.

Note: Values

listed in Table

2-6

are to be used

for

either

"Cold

Set"

or

"Hot

Set".

The timing mark

locations

(Fig's.

2-29

and

2-30) are used

with

the

dial indicator

method of setting injectors

and

Operation

and Maintenance

Manual

Cummins

Automotive

Diesel

Engines

Ma

intena nce

Oper¿ti ons

Fig.2-29,

(V514126'l

Location

of

t¡ming

marks

on

front

cover and

vrbrat¡on damper

F¡9,

2-30,

1V514127J

Locat¡on

of t¡ming marks on

accessory

drive

support

Table

2-5

Engine "V"

Series

Firing

Order

Right

Hand

Right

Hand

VB

V6

F

ig. 2-2a,

(

V5

1 486)

Eng¡ne barrin

g

arrangement

7/24/2019 Cummins V378, 504, 555, VT555 & V903.pdf


r.1*

Table

2-6

Adiu$trnent

L¡mits

Llsing

lndicator

Method

Of

Adiustment

-

nch

[mm]

Operation and

Maintenance

Manual

Cummins

Automotive

Diesel

Engines

Ma

intenance

Operations

2-2

4. Allow

the injector

plunger

to rise and

then bottom

ag

and set

indicator

af

zero

(0).

We

recommend

lever

released

and

plunger

bottomed

again

to check

setting.

5.

Release

the

lever

completely,

indicator should

show

total

readinq as

indicated

in

Table

2-6.

(Use

proper

va

depending

if

new adjustment

or

reset check.)

Adjust

correct

tolerance

as

necessarY.

6.

Tighten

the

adiusting

screw

locknut

to

30

to

40

ft

[a.1

io 5.5

kg

m]

and

actuate

the

injector

plunger

sev

iim.r

ur a

check

of the

adjustment'

Tighten

to

25

to

ft-lbs

[3.5

to

4.8

kg

m]

when

using

5T-669 Adapter

torque

wrench.

Crosshead

Adjustment

1.

Loosen

valve

crosshead

adiusting

screw

locknut

and

b

off

screw

one turn.

lnjector

Plunger Travel

Adjustment

Value

Reset

Limit

Valve

Clearance

lntake

Exhaust

0.180

to 0.181

[4.57

to

4.60]

0.179

tó

0.182

0.012

0.025

[4.55

to

4.62]

10.301

t0.641

valv'es.

Alignment,

ln

either location,

should

be

held

to

one-half

inch

[12.7

mm]

of

pointer.

Using

regular

engine barring

device

(Fig.

2-281

,

rofafe

engine in dlrection

of rotation

untii

"VS"

mark

for cylinder

2-8

is

aligned

with

pointer.

ln this

position

both

the intake

and

exhaust

valve

rocker levers

for

number

2

cylinder

should

be

free and

can

be

moved up and

down.

lf

not,

bar

engine

another

360 deg.

in direction

of

rotation

and

realign

the 2-8

"VS"

mark.

Note:

No.

2 cylinder

is

selected

for

purpose

of

illustration

only. Any

other cylinder could

be

used,

if

so

desired.

1. Set up the ST-1170

lndicator Support

with the indicator

extension atop the

in

jector

plunger f

lange

at

No.

2 cyllnder.

Fis.2-31

.

Fig.2-31,

(V5141'l4l

D¡al

¡nd¡cator

¡n

place

-

extension

in contact

with

plunger

2.

Make sure

that

the

indicator

extension

is secure

in

indicator

stem

and

not against

the

rocker

fever.

3.

Using

ST-125,1

Acluator,

Fig 232,

bar

the

lever

icr''vard

until

inlector

plunger

is boiiomed

rn

cuo

to

sQUeez3

crl

filn-r

from

between

plunger

and

cuP.

2.

Use

light

finger

pressure

at

rocker

lever

contact

sur

to

hold trosshead

in

contact

with valve

stem

(with

adiusting

screw).

&

3.

Turn

down

crosshead

adjusting

screw

until

it touc

valve

stem.

4.

Hold adjusting

screw

in this

position

and

torque

lock

to

25

to 30

ft'-lbs

[3.5

to

4.1

kg m] .

Note:

lnsure that

crosshead

retainers

on

exhaust

valve

used) are

positioned

equally

on both

sides

of

spring

crossheads

and

valve

springs

properly

5.

Check

clearance

between

crosshead

and

valve sp

retainer

with

wire

gauge.

There

must be

a

minimum

0.025

inch

[0.64

mm]

clearance

at

this

point.

Fig,2-32,

(v51412A1.

Bottoming

injector

plunger

¡n

cup

7/24/2019 Cummins V378, 504, 555, VT555 & V903.pdf


-22

Valve

Adjustment

The same

engine

position

used

in adjusting

injectors is used

for

setting intake

and

exhaust

valves.

1.

Loosen

locknut

and back

off adjusting screw.

lnseri

feeler

gauge

between

rocker

lever

and top

of

crosshead.

Valve

clearances

are

shown in Table

2-6.

Turn screw

down

until lever

just

touches

gauge

and

lock adjusting screw

in

this

position

with

locknut.

Torque

adjusting screw

locknuts

to 30 to 40

ft-lbs

14.1

to 5.5

kg

ml

or

25

to

35

ft-lbs

13"5

to

4.8

kg

ml

when

using

a

ST

669

Adapter.

2.

Always

make

f

inal

valve

adjustment after injectors

are

ad

j

usted

.

lnjector

Plunger, Valve

Adjustment

Using

Torque

Method, V-378,

V-504,

V-555, VT-555

Ensines

Valve

Set Mark

Alignment

Turn

crankshaft

in direction of rotation

unt¡l

a

"VS"

mark

appears

on the

vibration

damper, crankshaft

pulley

or

accessory

drive

pulley.

See

Fig.

2-33

for

location

of

valve

set

marks. In

this

position

both intake

and exhaust

valves

must

be

closed

for

that

cylinder; if not,

advance

crankshaft

one revolution.

See

Fig.

2-34,

Fig.2-27

and Table2-5 for

firing

order.

Fig.

2-33,

(V11913)

Valve

set

marks

Before

adiusting

injector,

tighten

injector

hold-down

capscrew

to 30

to

35

ft-lbs

[4.1

to 4.8

kg

m]

torque.

The

injector

plungers

must be

adjusted

with an

inch-pound

torque

wrench

to

a

definite

torque

setting.

A

torque

wrench

and

a screwdriver

adapter

can

be

used

for

this

adiustment.

Fig.

2 35.

Operation

and

Malntenance

Manual

Cummins

Automotive

Diesel

Engines

Ma intenance

Operations

Fig.

?-34,

(V11461)

V6 Firing

order

1

.

Turn

adiusting

screw

down

unt¡l

plunger

contacts

cup'

Advance

an additional

'1

5

degrees

to squeeze

oil

from

cup.

2.

Loosen

adjusting

screw

one turn, then,

uslng a

torque

wrench

calibrated

in inch-pound

and

a

screwdriver

adapter,

tighten the

adjusting

screw

to

values

shown in Table

2--/

for

cold

setting

and

tighten

the

locknut.

Note:

Values

listed in f ar|e

2-1

and

2-9

are

to

be

used

for

either

"Cold

Set"

or

"Hot

Set".

3.

Hold-

iniector adjusting

screw

and

tighten injector

locknut

to

vi..rlues indicated in

Table 2-8.

When 5T-669

Adapter

is

used,

nut torque is

reduced

to

compensate

for

additional

torque arm

length.

Fig.

2-36.

Ad

just

crossheads

and

valves as

described in

Crosshead

and

Valve

Adjustment

Pages2-21

and

22 and Table

2-9.

dl

Fig. 2-35,

(V51488)

Adjusting

¡niector

plungers

7/24/2019 Cummins V378, 504, 555, VT555 & V903.pdf


Operation

and

Maintenance

lVanual

Cummins

Automotive Diesel

Engines

Ma

in renance

Opera

lions

1-/

Engine

Model

Table2-7: lnjector

Plunger

Ad¡ustment Torque

lnjector

And

Valve

Adjustment

Using

ST-1170

Dial lndicator Method t\iH-NT Series

This method involves

adjusting

injector

plunger

travel wi

an accurate

dial

ind¡cator

rather

than

tightening th

adjusting

screw

to

a

specified torque.

A

check can

be mad

of

the adjustment

without

disturbing

the

locknut

or scre

settinq.

The valves can also be checked

or

set

wh

adjustin the

injectors

by

this method.

See

Table

2-10.

Temperature

conditions described as

"Cold

Set"

or

"H

Set"

must

be

observed when

recheck

is

being

performed.

travel

exceeds recheck values,

adjust

to

proper

value

show

in

"Adjustment

Value"

column.

Check

and/or

adjust

Valv

as

necessary.

Note:

lf

injectors

were removed

for

cleaning

or replaceme

t¡ghten injector, hold-down

capscrews

in

alternate steps

lOto 12

ft-lbs.

[1.4to

1.7 kg

m]

torque.

Table 2-10:lnjector and Valve

Set

Position

Set

v-378,

504, 555,

VT-555

60 inch-lb

[0.7

ks

m]

Table

2"8:

Injector

And

Valve

l-ocknut

Torque

(AllModels)

with sT-669

Without

ST-669

Bar

in

Direction

Pulley

Position

Set

Cylinder

lniector

Valv

Sta

rt

Adv. To

Adv. To

Adv. To

Adv. To

Adv.

To

A

or

1-6VS

B

or

2-5VS

C or 3-4VS

A or

1-6VS

B

or

2-5VS

C

or

3-4VS

3

6

2

4

1

5

5

3

b

2

4

1

25 to 35

ft-lbs

[3.5

to

4.8

kg ml

30

to

40

ft-lbs

[4.1

to

5.5

ks m]

Note:

lf

cylinder

head

gasket

or any components

of

actuating

train

have been

replaced,

engine must

be started

and brought

to operat¡ng

temperature,

then allowed

to cool

thoroughly. Cylinder

head capscrews

must be

retorqued.

See Shop

Manual.

lnjector

plungers

should

then

be

reset

to

values

listed

above.

Table

2.9:

Valve

Clearance

-

Inch

Imm]

lntake

Valves

Set

Exhaust

Valves

Set

V-378,

5M,

555, VT-555

Engines

0.012

[0.30]

Maintenance Adjustment

The

appropriate

check

values

in

Table 2-11

are applicab

to enqines which have

operated long

enough

to

warra

checking of injector setting

and

valve

clearance.

Fig.2-36,

(V51489)

T¡9hten¡ng

injector adjusting screw locknut

F

ig.

2-37,

(V5149O)

Adjust¡ng crossheads

0.022

[0.56]

cummins v378, 504, 555, vt555 & v903.pdf

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