V/VT-378, V/VT-504, and V/VT-555 Engines

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1 V/VT-378, V/VT-504, and V/VT-555 Engines Service Manual Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CUMMINS OR IT S SUCCESSORS. CUMMINS AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CUM-S-V-VT378PLUS

2 ~. - -

3 Shop Manual Cummins Diesel V/VT-378, V/VT-504 and V /VT -555 C.I.D. Engines VT-555 VT-504 "Big Cam" V-378 Copyright 1979 Cummins Engine Company, Inc. Bulletin No Printed in U.S.A. 4-79

4 Table of Contents Group 0 - Engine Disassembly Group 1 - Cylinder Block Cylinder Block, Liners, Crankshaft, Main Bearings, Connecting Rods, Pistons, Vibration Damper, Gear Cover, Camshaft and Front Cover Group 2 - Cylinder Head Cylinder Head, Valve Seats, Injector Sleeves, Injector Tip Protrusion, Valve Guides, Springs, Crossheads and Guides Group 3 - Rocker Lever Rocker Levers, Cover and Crankcase Breather Group 4 - Tappets Tappets and Push Rods Group 5 - Fuel System Group 6 - Injectors and Connections Group 7 - Lubrication System Oil Pump, Oil Pan, Oil Dipstick, Oil Filters, Oil Lines and Oil Coolers Group 8 - Cooling System Engine Water Pump, Fan Hu~, Fan, Thermostats and Housing, Heat Exchanger, Converter Cooler and Raw Water Pump Group 9 - Drive Units Fuel Pump, Drive Pulley Group 10 - Air Intake System Cold Starting Aids, Air Cleaners and Piping, Turbochargers Group 11 - Exhaust System Group 12 - Air Equipment Group 13 - Electrical Equipment Group 14 - Engine Assembly and Testing Group 15 - Instruments and Controls Group 16 - Mounting Adaptations Flywheel and Marine Gear Group None Group 18 - Specifications Wear Limits, Lubricating Oil, Cooling, Grease and Torque Limits Group None Group 20 - Vehicle Braking Exhaust Brake and Intake Suppressor Group 21 - Power Generator... None Index....

5 2-6 V /VT -378, V NT -504 and V NT -555 C.I.D. Engines Shop Manual Fig. 2-10, (V10226). Counterbore for valve seat. 4. Cut the counterbore to inch [0.15 to 0.25 mm] deeper than the insert thickness to permit staking or peening of the head to hold the insert. Allow the cutter to dwell upon reaching the proper depth to insure a flat seating surface. 5. Install the swirl plate in the intake valve seat counterbores with the locking tang in positioning groove. Note: On engines certified by the Environmental Protection Agency and the California Air Research Board, the swirl plate is located 180 degrees from standard. See your local distributor for the correct replacement part. 6. Install the valve seat insert and stake the insert in the head using ST-1122 Tool Driver over the shaft of ST-1128 Insert Staking Tool. A 1/4 inch [6.35 mm] diameter round end punch may be used if a staking tool is not available. Caution: Over staking around the insert may crack the cylinder head. Grind Valve Seats 1. Use ST -685 Valve Seat Grinder and the correct arbor from ST-804 Valve Guide Arbor Set. 2. Check the valve seat width. It should be to inch [1.59 to 3.18 mm]. See 1 or 2, Fig If the seating area (1, Fig. 2-3) is wider than inch [3.18 mm] maximum, stock can be removed from above and below the valve seating area (1) with specially dressed stones. Narrowing should not extend beyond the chamfer or the valve seat insert. The chamfer provides metal for staking or peening. Table 2-1: Valve Seat Insert Insert Part ST- Oversize Oversize Outside No. Cutter Diameter Thickness Diameter ST Std / [0.25] [43.18/43.21] ST /1.711 [0.51] [0.13] [43.43/43.46] ST /1.721 [0.76] [0.25] [ 43.69/43.71] ST / [1.02] [0.38] [ 43.94/ 43.97] ST Std / [0.25] [ 43.18/43.21] ST / [0.51] [0.13] [43.43/43.46] ST /1.721 [0.76] [0.25] [ 43.69/43.71] ST /1.731 [1.02] [0.38] [ 43.94/43.97] Counterbore Counterbore Cylinder Head Insert Depth In Depth In Inside Diameter Thickness Head Intake Head Exhaust 1.697/ / / /0.339 [43.10/43.13] [4.47/4.60] [8.92/9.17] [8.36/8.61] 1.707/ / / / /43.38] [4.60/4.72] [9.04/9.30] [8.48/8.74] 1.717/ / / /0.349 [43.61 /43.64] [4.72/4.85] [9.17/9.42] [8.61/8.86] 1.727/ / / /0.354 [43.87/43.89] [4.85/4.98] [9.30/9.55] [8.74/8.99] 1.697/ / /0.361 [43.10/43.13] [ 4.98/5.11] [8.92/9.17] 1.707/ / /0.366 [ 43.36/43.38] [5.11/5.23] [9.04/9.30] 1.717/ / /0.371 [43.61/43.64] [5.23/6.36] [9.17/9.42] 1.727/ / /0.376 [43.87/43.89] [5.36/5.49] [9.30/9.55] Be sure to measure insert before machining head or installing insert in head.

6 14-10 V /VT -378, V /VT -504 and V /vt -555 C.I.D. Engines Shop Manual Crankshaft PulleyNibration Damper V /VT -378 and V /VT Clean the crankshaft and vibration damper mating faces thoroughly with a wire brush or abrasive cloth. Install the pulleylvibration damper combination to the crankshaft. Torque the capscrews alternately in 30 to 35 ft-ib [41 to 47 N om] increments to a final torque of 110 to 120 ft-ib [149to 162 Nom]. 2. With a dial gauge mounted to the front cover check the vibration damper eccentricity and wobble as shown in Fig and Fig Wobble must not exceed inch per 1 inch of radius [0.15 mm per 25 mm]. Eccentricity must not exceed inch per 1 inch of diameter [0.10 mm per 25 mm]. 3. When an accessory drive pulley is mounted in front of the vibration damper the pulley must also be checked. Readings taken with an indicator gauge mounted to the gear case cover must not exceed the values given above. 4. On Marine engines secure the sea water pump drive pulley to the vibration damper. Torque the capscrews to 30 to 32 ft-ib [41 to 43 Nom]. VNT Clean the crankshaft and vibration damper mounting surface, Position the vibration damper to the crankshaft and secure it with hardened washers and capscrews. Tighten alternately in 30 to 35 ft-ib [41 to 47 N om] increments to a final torque of 135 to 140 ft-ib [183 to 190 Nom]. 2. With a dial gauge mounted to the front cover check the vibration damper eccentricity and wobble as shown in Fig and Fig The run-out must not exceed values given for V-378 and V Install the drive pulley (if removed) to the vibration damper. The pulley must also be checked. Readings taken with an indicator gauge mounted to gear cover must not exceed the values above. Torque the capscrews in 20 ft-ib [27 N om] increments to a final torque of 90 to 100 ft-ib [122 to 136 Nom]. Fig , (V114161). Check eccentricity., Fig , (V114162). Check wobble. Cylinder Heads 1. Make sure the breather vent tube assemblies on the naturally aspirated cylinder heads are in place. On turbocharged engines check to see that the vent holes are plugged. Note: Resurfaced blocks require thicker head gaskets than new blocks. They are available in inch [25 mm] and inch [0.51 mm] oversize. Oversize head gaskets still have grommets and a-rings. 2. Install the head gasket over the oil ring dowels so the word "Top" on the gasket is visible. Install the guide studs in the block. Caution: When assembling the new style cylinder head gasket to the engine make sure the two (2) end cap gaskets are properly located. The block and head surfaces must be clean and dry and oil or adhesive must never be used. 3. Use an ST-862 Head Lifting Bracket to lift the cylinder head with a hoist and lower it into place over the ring dowels.

7 Index 1 Index Accessory Drive Camshaft. Assemble Assemble Bushing. Replace Disassemble Bushings. Inspect Inspect Disassemble Install Inspect Pulleys Install Remove Key Data Specifications... '".. 9-3, Remove Acid Cleaning Capacity. Lubricating Oil Pan Adapter Assembly, Spin-On Lube Oil Filter Capscrew Torques Adapter Inspect, Spin-On Lube Oil Filter Chassis Dynamometer Testing Adapter, Crankshaft, Install Cleaning. Bead Blast Adapter. Flywheel. Remove Solvent and Acid Air Cleaner Restriction Indicator Steam Air Cleaners. Service Clearance, Valve Air Compressor Cold Starting Aids Install Cold Weather Starting Procedure Remove Compressor. Air Air Connections, Remove Install Cranking Motor... " Remove Equipment... '" Connecting Rod and Piston Assemblies. Remove Intake Connections and Manifolds. Remove Assemble to Piston Intake Manifolds. Install Clean Manifold Crossover. Install Inspect Restriction Nuts, Torque Starter Repair Alignment. Marine Gear Connecting Rods and Piston. Install Alternator. Install Controls. Nason Safety Arctic Ope~ations Converter Cooler Assembly Specifications. Engine Coolant. Engine Coolant Recommendations Back Pressure. Exhaust Cooling Fans Bead Blast Cleaning Cooling System Specifications Bearing Caps. Inspect Corrosion Shell. Inspect Counterbore. Inspect Shells and Thrust Ring Crack Detection. Cylinder Head Belt Tension, Adjust Crankcase Breathers, Clean and Inspect Belts. Install Cranking Motor Belts. Remove Cranking' Motor. Install Block. Clean Crankshaft Adapter. Install Disassemble and Main Bearings. Install Exploded View... ". 1-1 and Main Bearings, Remove Inspect Assemble Service Tools... " Clean Specifications Disassemble Brakes. Exhaust Inspect Braking, Vehicle Pulley, Install Break-In Oil Thrust Ring. Inspect Breathers, Clean and Inspect Crosshead Guides and Crosshead. Inspect By-Pass Filter Crosshead Guides, Replace Assembly Crossheads. Adjust Disassemble: Inspect Inspect Install

8 2 Index Cylinder Block, Clean Firing Order Disassemble Installation... " Exploded View Storage Inspect Storage, Permanent Service Tools Storage, Temporary... '" Specifications , 18-7 Test Procedure Water Cover Plate, Install Testing Cylinder Head, Assemble Exhaust Back Pressure Capscrew Torque Brakes Clean Manifolds, Install Cover, Install Manifolds, Remove Crack Detection System Disassemble System Specifications Exploded View Exploded View, Cylinder Block Resurface Cylinder Head Service Tools Engine Specifications , 18-9 Lubricating Oil Pump Test Rocker Lever and Shaft Water Hole Repair... " Tappet Cylinder Heads, Install Water Pump Cylinder Heads, Remove Cylinder Liner Bore, Inspect Fan Hub and Fan, Install Clean Assemble Counterbore, Inspect Disassemble Inspect Inspect Lower Bore, Inspect Remove Lower Bore, Repair Fan, Remove Protrusion, Inspect Fans, Radiator Cylinder Liners, Install Filter and Adapter Assembly Cylinder Liners, Remove Firing Order Flywheel Adapter, Remove Damper, Clean... " Housing, Install Inspect Housing, Remove Install Install Remove Remove Vibration Ring Gear, Replace Dataplate Front Cover, Install DCA Water Filter , 18-4 Oil Seal, Install Delco-Remy Equipment Remove Dipstick Front Engine Supports, Install and Tube, Install Front Engine Supports, Remove and Tube, Remove Front Lifting Bracket, Remove Disassembly Service Tools Front Water Connections, Remove Dye Penetrants Crossover, Install Dynamometer Crossover, Remove Dynamometer Testing, Chassis Fuel Connections, Remove Fuel Lines, Install Electrical Components Fuel Lines, Remove Electrical Equipment... " Fuel Oil Filter, Install Engine Assembly and Testing Fuel Oil Recommendations Assembly Service Tools Fuel Pressures Assembly Specifications , Fuel Pump Drive, Install Coolant Remove Dataplate Disassembly...'.0-2 Specifications Fuel Pump, Install Dynamometer Nameplate Exploded View Remove

9 Index 3 Fuel System Lower Bore, Inspect Fuel System Priming Lower Bore, Repair Protrusion, Inspect Gear Cover Spacer Plate, Install Liners, Install Gear Cover Spacer Plate, Remove Liners, Remove Gear Housing, Install Lubricating Oil Coolers, Assemble Grease Recommendations Coolers, Disassemble Coolers, Inspect Head, Assemble Coolers, Install Capscrew Torque Coolers, Repair Clean Dipstick Cover, Install Filter and Adapter Disassemble Filter and Adapter, Assembly Exploded View Filter and Adapter, Inspect Resurface Filter, Assemble Service Tools Filter, Install , Specifications , 18-9 Filters Heads, Install Filters, Inspect Heads, Remove Hose Size Heat Exchanger, Assemble and Test Hose Specifications Clean Lines Disassemble Lines, Assemble Inspect and Repair Pan... " Install Pan Capacity..., Remove Pan, Inspect Hose Specifications Pan, Repair Pump, Assemble Injection Timing Pump, Disassemble Injection Timing Specifications Pump, Exploded View Injector Recess Surface Repair Pump, Inspect Sleeves Pump, Install Sleeves, Replace Pump, Remove Tip Protrusion Pump, Repair Injectors Pump Specifications Adjust System Service Tools Install... '" Lubricating System, Prime Remove Lubricating System Specifications Installation, Engine Instrument and Control Main Bearing Bore, Inspect Intake Air Restriction Caps, Inspect Air System Gapscrew Torque Ai r System Specifications Main Bearings, Install... " Connections and Manifold, Remove Main Bearings, Remove Manifolds and Connections, Clean and Inspect Marine Gear Alignment Manifolds, Install Install , 16-1 Suppressors Oil Cooler, Install Oil Cooler, Remove Key Data... ~ Oil Coolers Marine Rear Accessory Drive, Install Leece-Neville Equipment Mechanical Controls, Remove Left Bank Water Header Cover Plate, Install Mount Cylinder Block to Engine Stand Lifting Bracket, Remove Mount Engine on Engine Stand Lifting Eye, Install Mounting Adaptations Liner Bore, Inspect Clean Nameplate, Fuel Pump Counterbore, Inspect Nason Safety Controls ,16-1 Inspect Normal Starting Procedure

10 4 Index Oil, Break-In Priming the Fuel System Cooler, Remove Priming the Lubricating System Coolers, Assemble Protrusion, Cylinder Liner Coolers, Disassemble... ".7-9 Protrusion, Injector Coolers, Repair Push Rod Specification Dipstick Push Rods Filter and Adapter Install Filter and Adapter, Assemble Remove Filter and Adapter, Inspect Filter Assembly Radiator Fans Filter, Install ,14-30 Raw Sea Water Pump, Assemble Filters Disassemble Filters, Inspect Inspect Hose Size Install Hose Specifications Raw Water Pump, Remove Lines Rear Accessory Drive, Install Lines, Assemble Rear Gear Cover, Inspect Pan Rear Gear Cover, Remove Pan Capacity Rear Gear Housing, Install Pan, Inspect... '" Rear Lifting Eye, Install Pan, Install Rear Oil Seal, Install Pan, Remove Recommendations, Coolant Pan, Repair Fuel Oil Performance Specifications Grease... " Pressure Gauge Oil Viscosity Pump, Assemble Restriction Pump, Disassemble Restriction Indicator Pump, Exploded View Ring Gear, Replace Pump, Inspect Rocker Lever and Shaft, Exploded View Pump, Install Assemblies, Install..., Pump, Remove Covers, Clean and Inspect Pump, Repair... " Service Tools Pump Specifications Specifications Seal, Install ,14-17 Rocker Levers and Shaft Specifications Temperature Gauge Assemble Viscosity Recommendations Disassemble..., Overs peed Stop..., Inspect Remove Paint Engine... " Repair Pan... '" Capacity Safety Control Inspect Sea Water Pump, Assemble Install Disassemble Remove Inspect Repair..., Install..., Permanent Engine Storage Service Tools, Cylinder Block Pipe Plug Torque Specifications... '" Cylinder Head Piston Assemblies, Remove Disassembly Clean... " Engine Assembly Inspect Lubricating Oil System... " Install Rocker Lever Pin Bushings, Replace Tappet Ring, Inspect Water Pump Rings. Install Solvent and Acid Cleaning to Connecting Rod, Assemble Spacer Plate, Install Preparing a Stored Engine for Service Spacer Plate, Remove Pressure Gauge Specifications

11 Index 5 Accessory Drive... " , Timing Specifications Cooling System Tip Protrusion, Injector Cylinder Block ,18-7 Top Surface Refinishing Cylinder Head ,18-9 Torque Specifications, Capscrew Engine Assembly ,18-13 Torque Speci'fications, Pipe Plug Exhaust System Turbocharger Fuel Pump Drive and Connections, Inspect Injection Timing and Connections, Remove Intake Air System Oil Flow, Inspect Lubrication Oil Hose Lubricating Oil Pump Vacuum Pump Lubricating System Vacuum Pump, Install Oil Performance Valve Clearance Pipe Plug Torque Covers, Remove Rocker Lever Guides, Inspect Rocker Levers and Shaft Guides, Replace Tappet Seat, Grind Tappet and Push Rod Seat Insert, Replace Water Pump , Seat, Test Spin-On Lubricating Oil Filter Set Marks Location Starter Springs, Inspect Starter, Install Valves, Adjust Starting Aids Clean Starting Procedure, Cold Weather Grind Starting Procedure, Normal Inspect Steam Clean Engine Exterior Vehicle Braking Steam Cleaning Vibration Damper Storage, Engine, Permanent Clean Storage, Engine, Temporary Inspect Suppressors, Intake Install Remove... O-4 Tachometer ,15-1 Viscosity Recommendations, Oil Tappet and Push Rod Specifications Assemble Water Connections, Install Assembly, Inspect... " Connections, Remove Bores, Inspect Filter, DCA ,18-4 Cover Plates, Remove Filter, Install Disassemble Filter, Remove..., Exploded View... " Pump, Assemble Inspect..., Pump, Assemble, Raw Sea Service Tools Pump, Disassemble... '" Specifications Pump, Disassemble, Raw Sea Tappets, Install Pump, Exploded View Tappets, Remove Pump, Inspect Temperature Gauge, Oil Pump, Inspect, Raw Sea Temperature Gauge, Water Pump, Install Temporary Engine Storage Pump, Install, Raw Sea Test Proced ure, Engine Pump, Remove Testing, Chassis Dynamometer Pump, Remove, Raw Sea Testing, Engine... " Pump Service Tools Thermostat and Housing, Assemble Pump Specifications ,18-11 Disassemble Temperature Gauge Inspect Wear Limits Thermostat Housing, Install Wiring Diagrams Thermostat Housing, Remove Thrust Ring, Inspect Timing, Injection

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