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L10 Series
CUMMINS L10 Series Repair Manual
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e
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L1
0
and
M1
1
Series
Engines
Copyrigh
t
R
1995
Bulletin
No.
38
1
03
1
0-0
1
Cummins
Engine
Company
,
Inc
.
Printed
7/95
All
right
s
reserv
ed
2
Table of Contents
TABLE OF CONTENTS
3
INTRODUCTION
5
ABOUT THE MANUAL
6
ACRONYMS AND ABBREVIATIONS
17
ENGINE IDENTIFICATION
7
ELECTRONIC CONTROL MODULE (ECM) DATAPLATE
7
ENGINE DATAPLATE
7
GENERAL CLEANING INSTRUCTIONS
16
GLASS OR PLASTIC BEAD CLEANING
16
SOLVENT AND ACID CLEANING
16
STEAM CLEANING
16
GENERAL REPAIR INSTRUCTIONS
14
WELDING ON A PACE CONTROLLED VEHICLE
15
WELDING ON A PT PACER CONTROLLED VEHICLE
15
WELDING ON A VEHICLE WITH AN ELECTRONIC CONTROLLED FUEL SYSTEM
5
GENERAL SAFETY INSTRUCTIONS
13
IMPORTANT SAFETY NOTICE
13
HOW TO USE THE MANUAL
6
ILLUSTRATIONS
12
SYMBOLS
8
GENERAL REPAIRS - GROUP 00
19
CAPSCREW MARKINGS AND TORQUE VALUES
24
CAPSCREW MARKINGS AND TORQUE VALUES - METRIC
24
CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY
25
CLOSED END "BLIND" INSERTS
31
CLOSED END INSERTS - METRIC INTERNAL THREADS, SAE EXTERNAL THREADS (3822709 KIT)
36
CLOSED END INSERTS - SAE INTERNAL AND EXTERNAL THREADS
36
GENERAL INFORMATION
31
REPAIR PROCEDURE
31
COILED THREAD INSERTS
26
COILED INSERT PART NUMBERS - METRIC THREADS
28
COILED THREAD INSERT PART NUMBERS - UNIFIED THREADS
29
DRILL SIZE AND BOTTOM TAP PART NUMBERS - UNIFIED THREADS
30
DRILL SIZE AND "PLUG" TAP PART NUMBERS - UNIFIED THREADS
30
DRILL SIZES
28
GENERAL INFORMATION
26
REPAIR PROCEDURE
26
TAP PART NUMBERS
29
CUP PLUGS
49
CUP PLUG REMOVAL
49
CAP PLUG INSTALLATION
51
CUP PLUG REMOVAL
49
CUP PLUG SPECIFICATIONS
52
GENERAL INFORMATION
49
EPOXY METAL FILLERS
59
APPLICATION GUIDELINES
59
EPOXY METAL FILLER SUPPLIERS
61
GENERAL INFORMATION
59
KEYLOCK OPEN END THREAD INSERTS
37
GENERAL INFORMATION
37
KEYLOCK THREAD INSERTS - MICRODOT K-SERTS - METRIC THREADS
41
KEYLOCK THREAD INSERTS - MICRODOT K-SERTS - UNIFIED THREADS
41
KEYLOCK THREAD INSERTS - TRIDAIR KEENSERTS - METRIC THREADS
41
KEYLOCK THREAD INSERTS - TRIDAIR KEENSERTS - UNIFIED THREADS
40
KEYLOCK THREAD INSERTS - UNIFIED THREADS
40
REPAIR PROCEDURE
37
LIQUID PENETRANT INSPECTION
53
GENERAL INFORMATION
53
INSPECTION PROCEDURE
53
OPEN END THREAD REPAIR INSERTS
42
GENERAL INFORMATION
42
INSPECTION
42
REFERENCE DATA AND FUNCTIONAL CHECKLIST
46
REPAIR PROCEDURE
42
PIPE PLUG HOLE REPAIR USING OVERSIZE COPPER PLATED PLUGS
47
GENERAL INFORMATION
47
OVERSIZE (COPPER PLATED) PIPE PLUGS - TORQUE VALUES
48
REPAIR PROCEDURE
47
PIPE PLUG TORQUE VALUES
25
SERVICE TOOLS - GENERAL REPAIRS
20
STRAIGHT THREAD HOLE REPAIR
22
GENERAL INFORMATION
22
STRAIGHT THREAD HOLE - EXPLODED
21
TAPER THREADED PLUGS FOR MINOR DEFECT REPAIR
62
GENERAL INFORMATION
62
REPAIR PROCEDURE
62
CYLINDER BLOCK AND CRANKSHAFT - GROUP 01
69
CAM FOLLOWER STUD THREAD REPAIR
115
GENERAL INFORMATION
115
REPAIR PROCEDURE
115
SPECIFICATIONS - CAM FOLLOWER STUD REPAIR
121
CAMSHAFT BORE REPAIR
81
CAMSHAFT BORE CUTTING TOOL - INSTALLATION
84
CAMSHAFT BORE CUTTING TOOL - SETTING CUTTER
87
CAMSHAFT BORES - MACHINING
89
CAMSHAFT BUSHING AND SALVAGE SLEEVE - ASSEMBLY
83
CAMSHAFT BUSHING ASSEMBLY AND SALVAGE SLEEVE - INSTALLATION
93
GENERAL INFORMATION
81
INITIAL PREPARATION AND INSPECTION
81
SPECIFICATIONS - CAMSHAFT BORE REPAIR
95
CRANKSHAFT INSPECTION AND RECONDITIONING
211
CRANKSHAFT CIRCUMFERENTIAL DEFECTS (COIL SHOT) - INSPECTION
243
CRANKSHAFT DE-MAGNETIZATION
244
CRANKSHAFT INSPECTION
219
CRANKSHAFT LONGITUDINAL DEFECTS (HEAD SHOT) - INSPECTION
241
CRANKSHAFT - CLEANING
245
CRANKSHAFT MAGNETIC CRACK INSPECTION - CONTINUOUS METHOD
233
CRANKSHAFT RECONDITIONING PROCESS
254
CRANKSHAFT THREAD - REPAIR
275
CRANKSHAFT THRUST BEARING SURFACE REPAIR
274
EQUIPMENT
211
GENERAL INFORMATION
211
GRINDING MACHINE AND WHEELS
245
GRINDING THE CONNECTING ROD BEARING JOURNALS
260
GRINDING THE MAIN BEARING JOURNALS
267
MAGNETIC INSPECTION - LIMITS OF ACCEPTABILITY
234
PROCESSING AFTER GRINDING
276
CRANKSHAFT - EXPLODED VIEW
210
CYLINDER BLOCK CRANKSHAFT THRUST SURFACE MACHINING
194
CRANKSHAFT THRUST FACE - MACHINING
201
CRANKSHAFT THRUST SURFACE CUTTING TOOL - INSTALLATION
196
CRANKSHAFT THRUST SURFACE CUTTING TOOL - SETTING CUTTER
198
FINAL INSPECTION
203
GENERAL INFORMATION
194
INITIAL PREPARATION AND INSPECTION
194
SPECIFICATIONS - CYLINDER BLOCK CRANKSHAFT THRUST SURFACE MACHINING
205
CYLINDER BLOCK IDLER SHAFT RING DOWEL BORE REPAIR
135
GENERAL INFORMATION
135
REPAIR PROCEDURE
135
CYLINDER BLOCK - EXPLODED VIEW
74
CYLINDER BLOCK RESURFACING
75
GENERAL INFORMATION
75
INITIAL PREPARATION AND INSPECTION
75
SPECIFICATION - CYLINDER BLOCK RESURFACING
80
CYLINDER HEAD CAPSCREW THREAD REPAIR
108
GENERAL INFORMATION
108
REPAIR PROCEDURE
108
SPECIFICATIONS - CYLINDER HEAD CAPSCREW THREAD REPAIR
114
CYLINDER LINER COUNTERBORE MACHINING (ELECTRIC CUTTING TOOL)
153
GENERAL INFORMATION
153
REPAIR PROCEDURE
154
SPECIFICATIONS - CYLINDER LINER COUNTERBORE MACHINING
163
CYLINDER LINER COUNTERBORE MACHINING (MANUAL CUTTING TOOL)
141
GENERAL INFORMATION
141
REPAIR PROCEDURE
142
SPECIFICATIONS - CYLINDER LINER COUNTERBORE MACHINING
152
FLYWHEEL HOUSING MOUNTIN CAPSCREW THREAD REPAIR
130
GENERAL INFORMATION
130
REPAIR PROCEDURE
130
SPECIFICATIONS - FLYWHEEL HOUSING MOUNTING CAPSCREW THREAD REPAIR
131
GEAR PLATE AND GEAR COVER MOUNTING CAPSCREW THREAD REPAIR
126
GENERAL INFORMATION
126
REPAIR PROCEDURE
127
SPECIFICATIONS - GEAR PLATE AND GEAR COVER MOUNTING CAPSCREW THREAD REPAIR
129
IDLER GEAR BUSHING REPAIR
206
GENERAL INFORMATION
206
REPAIR PROCEDURE
207
SPECIFICATIONS - IDLER GEAR BUSHING REPAIR
208
IDLER GEAR CAPSCREW THREAD REPAIR
122
GENERAL INFORMATION
122
REPAIR PROCEDURE
123
SPECIFICATION - IDLER GEAR CAPSCREW THREAD REPAIR
125
LUBRICATING OIL PUMP MOUNTING CAPSCREW THREAD REPAIR
132
GENERAL INFORMATION
132
REPAIR PROCEDURE
132
MAIN BEARING BORE REPAIR
164
FINAL INSPECTION
191
GENERAL INFORMATION
164
INITIAL PREPARATION AND INSPECTION
164
MAIN BEARING BORE ALIGNMENT - INSPECTION
166
MAIN BEARING BORE CUTTING TOOL - SETTING CUTTER
173
MAIN BEARING BORE DOWEL HOLES - REDRILLING
187
MAIN BEARING BORE - MACHINING
176
MAIN BEARING BORE REPAIR SLEEVE - INSTALLATION
180
MAIN BEARING BORE TOOL - INSTALLATION
170
MAIN BEARING CAP - INSTALLATION
186
REPAIR SLEEVE AND REPLACEMENT CAP - MACHINING
189
SPECIFICATIONS - MAIN BEARING BORE REPAIR
193
MAIN BEARING CAPSCREW THREAD REPAIR
99
GENERAL INFORMATION
99
REPAIR PROCEDURE
100
SPECIFICATIONS - MAIN BEARING CAPSCREW THREAD REPAIR
107
PISTON COOLING NOZZLE THREAD REPAIR
96
GENERAL INFORMATION
96
SERVICE TOOLS - CYLINDER BLOCK
71
SPECIFICATIONS - CRANKSHAFT REPAIR
292
VISCOSITY SENSOR
97
GENERAL INFORMATION
97
INITIAL PREPARATION
98
VISCOSITY SENSOR INSTALLATION
99
CYLINDER HEAD - GROUP 02
295
CYLINDER HEAD RESURFACING
299
CYLINDER HEAD COMBUSTION FACE - MACHINING
300
FINAL INSPECTION
302
GENERAL INFORMATION
299
INITIAL PREPARATION AND INSPECTION
299
SPECIFICATIONS - CYLINDER HEAD RESURFACING
305
EXHAUST MANIFOLD CAPSCREW THREADED HOLE REPAIR
335
GENERAL INFORMATION
335
REPAIR PROCEDURE
335
EXHAUST MANIFOLD MOUNTING SURFACE REFACING
331
EXHAUST MANIFOLD MOUNTING SURFACE - MACHINING
332
FINAL INSPECTION
333
GENERAL INFORMATION
331
INITIAL INSPECTION
331
SPECIFICATIONS - EXHAUST MANIFOLD MOUNTING SURFACE
334
EXHAUST MANIFOLD REPAIR
336
CENTER SECTION MOUNTING SURFACES - MACHINING
339
GENERAL INFORMATION
336
INITIAL PREPARATION AND INSPECTION
337
REPAIR PROCEDURE
338
INJECTOR HOLD DOWN CAPSCREW THREADED HOLE REPAIR
341
GENERAL INFORMATION
341
INJECTOR SLEEVE - REPLACEMENT
326
GENERAL INFORMATION
326
INITIAL INSPECTION
327
INJECTOR SLEEVE BEAD SEAT - REPAIR
327
INJECTOR SLEEVES - INSTALLATION
328
INJECTOR SLEEVES - REMOVAL
326
OVERSIZE VALVE GUIDES - INSTALLATION
306
GENERAL INFORMATION
306
INITIAL PREPARATION AND INSPECTION
306
OVERSIZE VALVE GUIDE - INSTALLATION
307
SPECIFICATIONS - OVERSIZE VALVE GUIDE
309
VALVE GUIDE BORE - MACHINING
306
OVERSIZE VALVE SEAT INSERTS - INSTALLATION
310
GENERAL INFORMATION
310
INITIAL INSPECTION
310
OVERSIZE VALVE SEAT INSERT - INSTALLATION
317
SPECIFICATIONS - OVERSIZE VALVE SEAT INSERTS
319
VALVE SEAT INSERT BORE - MACHINING
311
SERVICE TOOLS - CYLINDER HEAD
296
VALVE SEATS - GRINDING
320
FINAL INSPECTION
324
GENERAL INFORMATION
320
GRINDER WHEEL - DRESSING
321
INITIAL INSPECTION
320
SPECIFICATIONS - VALVE SEAT INSERT
325
VALVE SEAT INSERT - GRINDING
322
ADDITIONAL SERVICE LITERATURE
344
ADDITIONAL SERVICE LITERATURE
345
SERVICE LITERATURE ORDERING LOCATION
346
COMPONENT MANUFACTURERS
350
COMPONENT MANUFACTURERS' ADDRESSES
351
AIR COMPRESSORS
351
AIR CYLINDERS
351
AIR HEATERS
351
AIR STARTING MOTORS
351
ALTERNATORS
351
AUXILIARY BRAKES
351
BELTS
351
CATALYTIC CONVERTORS
351
CLUTCHES
351
COOLANT HEATERS
351
DRIVE PLATES
351
ELECTRIC STARTING MOTORS
352
ENGINE PROTECTION CONTROLS
352
FAN CLUTCHES
352
FANS
352
FILTERS
352
FLEXPLATES
352
FUEL WARMERS
352
GAUGES
352
GOVERNORS
352
HEAT SLEEVES
353
HYDRAULIC AND POWER STEERING PUMPS
353
OIL HEATERS
353
TORQUE CONVERTERS
353
INDEX
354
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CUMMINS L10 Series Specifications
General
Engine Model
L10 Series
Configuration
Inline 6
Displacement
10 liters
Bore
125 mm
Stroke
136 mm
Aspiration
Turbocharged
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