CEBM614SPO

KDC 614 SERIES ENGINE

SPECIFICATION MANUAL
1991 SERIES

IbmatsuDresser
[Rev. A]
 Specification Manual
614 Series Engine
1991 Model

KDC 614 Series Engine

This manual contains complete assembly and rebuild specifications for the 614 Series engine and related components. This
manual is intended as a quick reference guide for an experienced technician who is familiar with our product.

A series of specific service manuals (Troubleshooting and Repair, Shop, Alternative Repair, and so forth) are available and
can be ordered through your distributor using the form at the end of this manual.

This specification in this manual are based on the most current information at the time of publications. KDC reserves the right
to initiate any changes at any time without obligation.

[Rev. A]
 Table of Contents
Page

Additional Service Literature .............................................................................................................................

Air Compressor - Inspection Specifications.. ....................................................................................................
Air Compressor - Torque Values .......................................................................................................................
Blowby Measurement.. .......................................................................................................................................
Capscrew Markings and Torque Values ............................................................................................................
Capscrew Markings and Torque Values - Metric ..............................................................................................
Capscrew Markings and Torque Values . U.S. Customary ...............................................................................
Component Manufacturers Addresses .............................................................................................................
Air Compressors .............................................................................................................................................
Air Cylinders ...................................................................................................................................................
Air Heaters
1.m.. .... .....................................................................................................................................................
Arr siranrng Motors .......................................................................................................................................... 58
Alternators ....................................................................................................................................................... 58
Auxiliary Brakes.. ............................................................................................................................................. 58
Belts ............................................................................................................................................................... 58
Clutches ......................................................................................................................................................... 58
Coolant Heaters .............................................................................................................................................. 58
Drive Plates .................................................................................................................................................... 58
Electric Starting Motors ................................................................................................................................... 58
Engine Protection Controls ............................................................................................................................. 59
Fan Clutches .................................................................................................................................................. 59
Fans ............................................................................................................................................................... 59
Filters ............................................................................................................................................................. 59
Flexplates ....................................................................................................................................................... 59
Fuel Warmers ................................................................................................................................................. 59
Gauges ........................................................................................................................................................... 59
Governors ....................................................................................................................................................... 59
Hydraulic and Power Steering Pumps ............................................................................................................. 59
Oil Heaters ..................................................................................................................................................... 60
Torque Converters .......................................................................................................................................... 60
Component Specifications and Torque Values.. ............................................................................................... 10
Cylinder Block - Rebuild Specifications ............................................................................................................ 22
Cylinder Block - Torque Values.. ...................................................................................................................... 28
Cylinder Head - Rebuild Specifications ............................................................................................................ 29
Engine Assembly - Specifications.. ................................................................................................................... 10
Engine Assembly - Torque Values.. .................................................................................................................. 12
Cooling System Specifications .......................................................................................................................... 40
Air Intake System - Specifications.. .................................................................................................................. 42
Air Intake System - Torque Values.. ................................................................................................................. 42
Cooling System Torque Values ........................................................................................................................ 41
Drive Belt Tension.. ............................................................................................................................................ XI
Electrical System - Specifications ..................................................................................................................... 45
Electrical System - Torque Values.. ................................................................................................................... 45
Engine Diagrams .................................................................................................................................................. 3
Engine Identification ............................................................................................................................................ 1
Engine Dataplate ............................................................................................................................................... 1
Fuel Injection Pump Dataplate ........................................................................................................................... 2
Engine Specifications - General .......................................................................................................................... 7
Batteries (Specific Gravity). ................................................................................................................................ 9
Cooling System.. ................................................................................................................................................ 8
Electrical System ............................................................................................................................................... 9
Fuel System.. ..................................................................................................................................................... 8
General Engine Data ......................................................................................................................................... 7
Intake Air and Exhaust System.. ........................................................................................................................ 8
Lubrication System ............................................................................................................................................ 7
Engine Testing - General Specifications ........................................................................................................... 48
 Page
Engine Testing - Test Specifications . . .. . . .. . .. .. . . . . . .. .. .. .. . .. . .. .. . . .. . . . . .. .. . . . . .. . . . . . .. . .. . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . .. .. . .. .. . . . .. . . . 46
Exhaust System - Specifications .. . . . . . . . . . . . . . . . . . . . . . . .. ... . .. . .. .. .. . . .. . . . . . . . .. . . . . .. . . . .. . .. . .. . . .. . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . .. ... . .. . .. .. ... 44
Exhaust System - Torque Values .. .. . . . . . . . . . . . .. .. . . . .. .. . .. . .. .. .. .. .. .. . . . .. . . . . . .. . . . . . . . . .. . . .. .. .. . . . . . . . . . . . . . .. .. . .. . . . . . . . . . . . .. . ... . .. .. .. . .. 44
Fuel Systems - Rebuild Specifications . . .. . . . .. .. . . . . .. . .. . .. . ... . .. . . .. . . .. . . . . . . .. . . . . . .. . . . . .. .. . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . ... .. .. . . . . . ..
Fuel Injection Pump Sealing Washer . .. . . . . . . .. . .. . . . .. .. . ... .. .. . .. . . . .. . . . .. . . . . . . .. . . . . .. .. . .. . . .. . .. . . . . .. . . .. . . . . . . . . . . . . . . . . . . .. ... .. .. .. . . . . . Zf
Fuel Shutoff Solenoid Adjustment . .. . . . . . . . . . .. . . . . . . . . . . .. . .. ... . .. .. .. . . .. . . . . . . . .. . . . . .. . . . . . ... . .. . .. . . . . . . . . . . . . .. . .. . . . . . .. . . . . .. . .. ... . . . . . .. .
Fuel System - Torque Values .. .. .. . . . . . . . . . . . .. .. . . .. . . . . .. . . ... . .. .. .. . .. . . . .. . . . . . . . . .. . .. . . . . . . .. . . .. . .. .. . . . . .. . . . . .. . . . . . . . . . . . . . . . . .. ... . .. . . .... ::
Fuel System Specifications . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . ... . .. . . ... . .. .. . . . . . . .. . . . .. . . . . . .. . ... .. .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . .. ... .. .. . . ...... 32
Literature Survey Form . . . . . . . .. . .. .. .. . . . . . . . . . . .. . .. . . .. . . .. . . . . .. .. .. . .... . . . . .. . . .. . . . . .. . . . . . . .. . . . .. . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . .. . .. ... .. . . . .. . . . . 2
Lubricating Oil System - Specifications . . .. . . . .. . .. . .. . . .. .. .. .. . .. . .. . . . . .. . . . . . . .. . . .. . .. . . . .. . .. . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . .. .. . . . . .. . 37
Lubricating Oil System Torque Values . . . . ..._...................................................................................................... 38
Mounting Adaptations - Torque Values . . . .. .. . .. . . .. . . . . .. .. .. . .. .. . .. . . . . .. . . . . . .. . . . . .. .. .. . .. .. . . . .. . . . . . . . . . .. . . . . .. . . . . .. . . . .. . . . .. ... . .. . .. . . t;
REPTO .. . . . . . . . . . . . . . .. . . .. . . . . . . . . . .. . . ... . .. . . . . . . .. . . . . . . . . . . . . . . . . ... . .. . . ... .. . . . .. ... . .. .. . . . . .. . . . . . . .. . .. . . .. . . . . . . .. . .................................-..
Mounting Adaptations Specifications . . . . . . . . . . . . . . . . . .. . . . .. . ... . .. . .. . . .. . . . .. . . . .. . . . .. . . . .. ... . . .. . . . . . . .. . . . . . .. . . . .. . . . . . . . . .. . . .. . .. .. .. . . . .. .
Flywheel Housing (Wet Application) . . . . . . .. .. .. . . .. . . . . . . .. . . ... . .. .. . . .. . . .. .. . . . . .. . . .. . .. . . . .. . .. . . .. . . . . . . . . . . . . . .. . . .. . . . . . . .. . .. . .. .. .. .. . . .. . ::
Flywheel Ring Gear Installation . .. . . . . .. .. . . . . .. . . .. . . . . . . .. . .. . ... .. .. . . .. .. . .. . .. .. .. . . .. . . .. . .. . . .. . . . . . . . . . . .. . .. . . .. . . . . . . . . . . . . . . .. .. ... .. . . . .. .. 47
Newton-Meter to Foot-Pound Conversion Chart .,............................................................................................. 53
Pipe Plug Torque Values . . . . . . .. . .. .. .. . . . . . . . . . . . . . .. . . . . . . . . . .. .. . .. . .. .. .. .. . . . .. . .. . . . .. . . .. .. . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . .... . .. .. . . . . 56
Rocker Lever Assembly - Rebuild Specifications . . ... . .. . .. . .. . .. . . . .. . .. .. . . .. . . . . .. . . . .. . . . .. .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . .. .. .. . .. .. . . 32
Service Literature Ordering Location . . . . . . . . . . . . .. . . . .. . .. .. . . ... . .. . . .. . . . . . .. . . . .. .. . . . .. . . .. .. . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . .. . .. . . ... .. . . . .. . . 62
Specifications - General Information . . . . . . . . . . . . . .. . . . . .. . .. . .. .. .. . .. . . .. . . .. .. . . . . . . .. . . . .. . .. . .. . .. . . . . . . . .. . . .. .. . .. . .. . . . . . . . . . . .. . .. . ... . . .. . .. . . 6
Tap-Drill Chart - U.S. Customary & Metric . . . .. . . . . . . . . .. . .. . .. .. .. .. .. . . . .. . . . . . .. . . . .. .. . . . . .. . .. .. . . . . . . . .. . .. . . . . . . .. . . .. . .. .. . .. . .. .. .. . . . .. . . 57
Valve Tappet - Rebuild Specifications . . . . . .. . .. . . . . . . . . . . .. . .. ... . . .. . . .. . .. . . . . . . . .. .. . . .. . .. . . .. . .. . . . . . . . . .. . .. . .. .. . .. . . . . . . . . . . .. . .. . .. .. .. . . .. 32
Weight and Measures - Conversion Factors . . . . . . . . . . .. . .. .. . .. .. . . .. .. . .. .. . . . .. .. . . .. . . . .. . .. . . . . . . . . . .. .. .. . . . . . . . .. . . . . . .. .. . .. . .. . .. . . .. . . . . 52
 614 Series Engine Identification
Page 1

Engine Identification
Engine Dataplate
The engine dataplate shows specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.

NOTE: The engine dataplate must not be changed unless

approved by KDC.

I
ENGINE SERIAL NO.

. ..,I
USERTVVILLE. ILLINOIS. SO048 U.S.*
-TIMING TDC KDC P/N

0
Warning Injury Hay Raault And VALVE LASH COLD INT. EXH. RATED NP AT RCY
Warranty I* Voldad If Fuel Rata
RPM Or Altltuder Exceed PIubll;ked FIRING ORDER FUEL RATE AT RATED HP MH=lSTROK
Ynxlmum Valuea For This Model And
Appllcatlon.
MADE IN U.S.A.
E.C.S. KDC MODEL

The KDC model designation represent the basic design and

configuration of your engine.

Example Engine Model Names:

(1) Number of cylinders

(2) Displacement per cylinder/l00 in cc

(3) Type of aspiration

T = Turbocharged
(4) A = Aftercooled
Engine Identification
Page 2 614 Series

Fuel Injection Pump Dataplate

The fuel injection pump dataplate is located on the side ,,
of the fuel injection pump. It provides information for fuel
pump calibration.

The Bosch fuel injection pump dataplate contains:

1. Pump Serial Number
2. Bosch Ten Digit Number
0 3. Bosch Designation Code
I I

1 o 9 400 230 097-+-@

PES6AlOOD320/3RS2691
Made in USA

la901 d

The Cummins part number for the fuel pump-governor

combination is located on the governor dataplate.

fD901 q rn

The Bosch governor dataplate contains:

1. Bosch Governor Designation Code
2. Cummins Pump Part Number

WRSV425 llOOAOC2190-8R
/i
614 Series Engine Diagrams
Page 3

Engine Diagrams
The following illustrations contain information about engine components, filter locations, drain points and access
locations for instrumentation and engine controls.
The information and configuration of components shown in these drawings are of a general nature. Some
component locations will vary depending on applications and installations.

High Pressure
X(inch]NPTF (Air)
Fuel Lines

Front Liing M22 x 1 SO (Air)

&e&et I

Fuel
Injection
Pump
Fuel/Water
Separator

Fud Trensfer
Pump

,_
__ __,.______.--
Tep for Magnetic
Pick-up

Front En&e
Mounting Bracket

Fuel Pump Side View

Engine Diagrams
Page 4 614 Series

TUtbOdl8~? Turbocharger
Wastegate Actuator, Air Outlet

Exhaust Outlet

Provision for
Coolant Heater

Provldon for
Cab Heater

Lubricating

R
Oil Cooler

Turbocharger H(inch]NPlF
Oil Drain (coolant)
Coolant Inlet

Turbocharger Side View

 Engine Diagrams
614 Series Page 5

Rear View

Front View
Engine Identification 614 Series
Page 6

Specifications - General Information

The specifications in this manual are organized in the same sequence as the 614 Series Engine Shop Manual. The minimum
and maximum tolerance limit specifications are listed in both metric and U.S. Customary dimensions. The metric dimension
is given first, followed by the U.S. Customary dimension in brackets; for example: 0.50mm [0.020 inch]. The assemMy and
rebuild specifications and torque values are provided to be sure the parts are assembled correctly, fit properly, and are
secured with the correct torque value.

Most of capscrews used to assemble the 614 Series engine are metric. Some components, such as the air compressor and
fuel injection pump are installed with U.S. Customary capscrews. Capscrew torque values are listed in newton meters and
foot pounds, unless otherwise specified, If a torque value is not listed, use the standard value for the capscrew. Referto the
Table of Contents for Capscrew Markings and Torque Values in this manual.
614 Series Engine Specifications - General
Page 7

Engine Specifications - General

General Engine Data

Bore ........................................................................ 114mm [4.49in]
Stroke ....................................................................... 135mm[5.32in]
Displacement ............................................................... 8.27 liters [504.5 in31
Compression ratio
614 .............................................................................. 18.411
614T ............................................................................. 17.3:1
814TA ............................................................................ 16.5:1
Firingorder ...................................................................... ..1~~~-2 .
Valve clearance
Intake. .................................................................. .0.30 mm [0.012 in]
Exhaust ................................................................. .0.61 mm [0.024 in]
Engine rotation (viewed from front of engine) ................................................ Clockwise
Aspiration
614 ................................................................... ..Natu~ly~pi~ .
614T ..................................................................... ..Tu~oc~rg .
614TA .......................................................... Turbocharged and Aftercooled
Engine weight (with standard accessories)
Dryweight.. .................................................... 570to606kg[1256to1335Ib]
Wetweight.. .................................................... 599to836kg [1320to1402Ib]

Lubrication System
Oil pressure
At idle (minimum allowable) ..................................................... 69 kPa [lo psi]
At rated speed (minimum allowable) .............................................. 207 kPa [30 psi]
Diierental pressure to open oil filter bypass valve ....................................... 138 kPa [20 psi]
Oil flow at rated speed (less flow though pressure regulator ............................. 106.8 Ipm [28.2 gpm]
Oil temperature at rated speed ......................................... 98.9 to 126.6C [210 to 26OF]
Oil temperature thermostat
Fuilyopen ................................................................. ..116C[241 F]
Closed ............................................ ..~.......................l~c[2190 q
Oil pan capacity (all engines) (high - low) .............................. 18.9 to 15.1 liters [20 to 16 U.S. Qts.]
Total system capacity
614 ............................................................... 23.6 liters 125.0 U.S. Qts.]
614T ............................................................... 23.8 liters 125.2 U.S. ots]
Englne Speciflcetione - General 614 Series
Page 0

Cooling System
Begins to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 to 83C (178 to 182fl
Fullyopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~oC[2O3o~
Top tank temperature
Maximum allowable ............................................................ 109C [212F]
Minimum recommended ......................................................... .70X [158F]
Pressure cap for 99C [21OFj system ................................................. 50 kPa [7 psi]
Pressure cap for 104C [220F] system ............................................... 103 kPa [15 psi]
Water Pressure (Upper manifold) at 2000 RPM engine speed ...................... 103 to 276 kPa [15 to 40 psi]
Coolant flow (thermostats fully opened, engine speed 2000 RPM) ........................... 258 Ipm [68 gpm]
Coolant capacity (engine only)
614,614T ............................................................ 9.9 liters [lo.5 U.S. Qts.]
614TA .............................................................. 10.9 liters [11.5 U.S. Cts.]

Intake Air and Exhaust System

Maximum allowable intake restriction at rated speed and load (with dirty air filter element)
614 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..50.8cmH.O[20inH20]
614T,614TA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5cmH,0[25inH20]
Maximum turbocharger outlet restriction at rated speed and load
614T,614TA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2mmHg[3inHg]
614T,614TA......................................................... 101.6cmHs0[40inH20]

Fuel System
Fuel transfer pump maximum inlet restriction ...................................... 95 mm Hg [3.75 in Hg]
Fuel transfer pump maximum output pressure
614,614T, 614TA ............................................................ 172 kPa [25 psi]
Minimum pressure to fuel pump inlet ............................................... 1.2 Bar 118psi]
Minimum flow to fuel injection pump ............................... 250 percent of rated fuel requirement
Fuel filter restriction (maximum pressure drop across filters) .................................. 35 kPa [5 psi]

Fuel pump gallery pressure ........................................................ 140 kPa [20 psi]

Fuel return restriction (maximum) ............................................. 518 mm Hg [20.4 in Hg]
 Engine Specifications - General
614 Series Page 9

Electrical System
Minimum Recommended Battery Capacity
12 Volt System
-18OC [OOF] Cold cranking amperes .. . .. .... .. . ... .. ... ...... .. . .. .. .... . .. . . .. . . ... . ...... ... . .. .. ... .. .. . . . .. . . .. . .... .... . .. .. ... .. . . 1800
(Reserve capacity amperes)* . . . . . .. . .. .... .. . .. .. .... .... .... . .. .. .. ... ... . .. . . .. .. ..... ... .. .. .. .. .. ... . . .. .. . .. . . .... .... ... .. .. .. . .. (640)
OC [32OF] Cold cranking amperes . .. .. ... ... . . ... .. .. .... ... .. . .. ... .. .. ... . .. .. ... . .. .. .. .. . .... .... .. .. . . . .. . . .. . .... . .. .i . . . . . . . . . . . 1280
(Reserve capacity amperes)* . . . .. . .. .. .. ... .. ... . .......... .. . ... . .... .. .. . . . .. . .. .. ..... ... .. .. .. ... ... .. .. .. . . . . ... ... ... .... . ... . .. . (480)
24 Volt System * *
-18OC [OOF] Cold cranking amperes .. . ... ... . ... .. .......... .. .. .. . ... .. ... . . .. . . .. .. ..... ... ... . ... .. .. .. . .. . . . . . .. .. ... .... ... . ... .. . .. . 900
(Reserve capacity amperes)* . . . . . .. . . ... ... . ... .. ... ..... ... . .. .. .. ... ... . . . .. . . .. ... ..... ... .. . ... .. .. .. . .. . . . .. . . .. ..... .. ... .. .. . .. . (320)
OC [32OF] Cold cranking amperes . . . .. ... . .. ... . ..... ... .... .. . .. ... . .... . .. . . . . ..-...................................................... 640
(Reserve capacity amperes)* . . . . .. . . .. ... .. .. . ... .... ... ..... . . .. ... . .... . .. . . . .. .. .. .. ... ... .. .. .. .. ... . . .. . . . .. .. ... .. .. .. .. .. ... .. .. (240)

* The number of plates within a given battery size determine reserve capacity. Reserve capacity determines the
length of time sustained cranking can occur.
* l Per battery (two 12 volt batteries in series) CCA Ratings are based on -18OC [OOF].

Batteries (Specific Gravity)

State of Charge
1.260 - 1.280 100%
1.230 - 1.250 75%
1.200 - 1.220 50%
1.170 - 1.190 25%
1.110 - 1.130 Discharged
Component Specifications and Torque Values
Page 10 614 Series

Componentor Assembly (Procedure) Ref.No./Steps Metric U.S.

Component Specifications and Torque Values

Engine Assembly - Specifications
Cylinder Liner Protrusion 0.025 mm MIN
0.122 mm MAX .
zE.8 i::
Note: Use Part No. 3922503, Cylinder Liner Clamp
Set to seat the liner into the bore. Check the liner
protrusion with the clamps removed.

Cylinder Liner-to-Block Clearance 0.229 mm MIN 0.009 in

Cylinder Liner Out-of-Round 0.04 mm MAX 0.0016 in

Cylinder Block Upper Liner Bore I.D. 132.900 mm MIN 5.2323 in

132.990 mm MAX 5.2356 in

Cylinder Liner Top Press Fit O.D. 132.938 mm MIN 5.2339 in

132.958 mm MAX 5.2346 in

Crankshaft End Clearance

New 0.157 mm MIN i-fj;tf ;;
0.334 mm MAX .

0.535 mm MAX 0.0210 in

Piston Ring Gap (New)

Top Ring Gap 0.49 mm MIN 0.0157 in
0.70 mm MAX 0.0275 in
Intermediate Ring Gap 0.49 mm MIN 0.0157 in
0.70 mm MAX 0.0275 in
Oil Control Ring Gap 0.80
0.30 mm MAX
MIN ;zrxli&
. ;;
 Component Specifications and Torquepz;;;;
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Connecting Rod Bearing Side Clearance 0.100 mm MIN 0.0039

0.330 mm MAX 0.0130

Oil Pump Drive Gear Backlash A 0.08 mm MIN cy; I;

0.45 mm MAX
Oil Pump Idler Gear Backlash B 0.08 mm MIN 0.003 in
0.45 mm MAX 0.018 in

Camshaft Gear Backlash 0.152 mm MIN 0.006 in

0.380 mm MAX 0.015 in

Camshaft End Clearance 0.12 mm MIN

0.46 mm MAX

Flywheel Bore Runout T.I.R. 0.127 mm MAX 0.0050 in

Flywheel Face Runout T.I.R. Radius (A)

mm in
203 8 0.203 mm 0.008 in
264 10 0.254 mm 0.010 in
305 12 0.012 in
356 14 E$ :: yOI;; I;
406 16 01406 mm

Valve Adjustment Clearance

Intake Valve 0.30 mm
Exhaust Valve 0.61 mm
Corepoont Specifications and Torque Values
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Vibration Damper Face Alignment

(Wobble) T.I.R. 0.28 mm MAX 0.011 in

Vibration Damper Eccentricity T.I.R. 0.28 mm MAX 0.011 in

Engine Assembly - Torque Values

Cylinder Liner Clamps 68 Nom 50 ft-lb

Main Bearing Cap Capscrews Step 1 50 Nom

119 Nom
32 176 Nom

-Fmnl
I
Connecting Rod Nuts Step 1 40 N*m
80 N*m
: 120 Nom

r8ar Housing Mounting Capscrews

24 Nom 18 ft-lb
Ml2 60 Nom 44 ft-lb

Oil Pump Mounting Capscrews 24 Nom 18 ft-lb

 Component Specifications and Torqu;:;:;;
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Water Pump Mounting Capscrews 24 N*m 18 ft-lb

Oil Pump Suction Tube to Block A 9 Nom 80 in-lb

Brace to Block 9 Nom 80 in-lb
Brace to Suction Tube : 9 N*m 80 in-lb

Oil Pan Mounting Capscrews 24 N*m 18 ft-lb

Note: Tighten the capscrews in the sequence
shown. Start at the center of the oil pan and
alternate toward both ends.

Oil Pan Drain Plug 80 Nom 59 ft-lb

Timing Pin Torx Capscrews 8 Nom 71 in-lb

Flywheel Housing Mounting Capscrews 60 Nom 44 ft-lb

Flywheel Housing Access Plate

Capscrews 24 Nom 18 ft-lb
 Component Specifications and Torque Values
Page 14 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Flywheel Mounting Capscrews 140 Nom 101 ft-lb

Starting Motor Mounting Capscrews 77 Nom 57 ft-lb

Coolant Heater 12 Nom 106 in-lb

Oil Cooler Mounting Capscrews 24 Nom 18 ft-lb

Oil Filter Head Mounting Capscrews 24 Nom 18 ft-lb

Cylinder Head Mounting Capscrews Step 1 70 Nom (All Capscrews) 52 ft-lb

145 Nom (Long Only) 105 ft-lb
3 Rotate 90 Degrees (All Capscrews)
Note: Tighten the capscrews in the sequence
shown. Start at the center of the cylinder head
and alternate toward both ends.
I-Fro,% I

Rocker Lever Retaining Clamp Capscrews 55 Nom 41 ft-lb

Rocker Lever Adjusting Screw Locknut 24 Nom 18 ft-lb

 Component Specifications and Torquepz;Fz
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Valve Cover Capscrews 24 Nom 18 ft-lb

Note: Tighten the capscrews in the sequence
shown. Start at the center of the valve cover
and alternate toward both ends.

Crankcase Breather Tube

Support Bracket Capscrews A 24 Nom 18 ft-lb
B 43 Nom 32 ft-lb

Injection Nozzle Clamp Capscrew 24 Nom 18 ft-lb

Fuel Drain Manifold

Banjo Connector
l Injector 9 Nom
l Filter Head 15 Nom

Engine Lifting Bracket Capscrews 77 N*m 57 ft-lb

Intake Manifold Cover Capscrews 24 Nom 18 ft-lb

Aftercooler Assembly Capscrews 24 Nom 18 ft-lb

Component Specifications and Torque Values
Page 16 614 Series *

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

After-cooler Coolant Supply Tube

Capscrews 6 Nom 53 in-lb

Exhaust Manifoki Mounting Capscrews 43 Nom 32 ft-lb

Turbocharger Mounting Studs 10 Nom 89 in-lb

Turbocharger Mounting Nut 45 Nom 33 ft-lb

Turbocharger Oil Drain Mounting

Capscrew 24 Nom 18 ft-lb

Turbocharger Oil Drain Line Hose Clamps 5 Nom 44 in-lb

Turbocharger Turbine Housing Capscrews 20 Nom 15 ft-lb

 Component Specifications and Torque Values
614 Series Page 17

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Turbocharger Compressor Housing Clamp

V-Band Clamp Nut 8 Nom 71 in-lb
Actuator Bracket Brace Capscrews 13 Nom 115 in-lb

Turbocharger Oil Supply Hose

Fittings 24 Nom 18 ft-lb
Hose Connection 35 Nom 26 ft-lb

Turbocharger Exhaust Outlet:

Band Clamp 8 Nom 71 in-lb
Capscrews 43 N*m 32 ft-lb

Turbocharger Air Crossover Hose Clamps 5 Nom 44 in-lb

Water Outlet Connection Capecrews 24 Nom 18 ft-lb

Coolant Vent Line Fitting 8 Nom 71 in-lb

Coolant Vent Petcock 5 Nom 44 in-lb

Component Specifications and Torque Values
Page 18 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Coolant Vent Line Tube 8 Nom 71 in-lb

Coolant Inlet Connection Hose Clamps 5 N*m 44 in-lb

Alternator Mounting Bracket Capscrews 24 Nom 1a ft-lb

Water Pump Mounting Capscrew 24 Nom 18 ft-lb

Alternator Mounting Capscrew A 43 Nom 32 ft-lb

24 Nom 18 ft-lb
: 80 Nom 59 ft-lb

Belt Tensioner Mounting Bracket 24 Nom 18 ft-lb

Belt Tensioner Mounting Capscrews 43 N*m 32 ft-lb

 Component Specifications and Torqwi;$;;
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Fan Hub Mounting Capscrews 24 N*m 18 ft-lb

Fuel Ir$ection Pump

Ft;d;tlng Nuts 44 Nom 32 R-lb
Hand Tight

Fuel Injection Pump Timing Pin Access

Plug 40 Nom 30 ft-lb

Fuel Injection Pump Drive Gear Nut

A Pump 92 Nom 68 ft-lb
104 Nom 77 ft-lb
k%upmupmp 165 Nom 122 ft-lb

Fuel Injection Pump Supply Banjo Fitting 24 N*m 18 ft-lb

Fuel Filter Head Adapter 4 Nom 35 in-lb

Fuel Filter Adapter Nut 32 Nom 24 ft-lb

Fuel Filter
Install the filter as specified by the filter manufacturer.
Component Specifications and Torque Values
Page 20 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

High Pressure Fuel Line Fittings 30 Nom 22 ft-lb

High Pressure Fuel Line Support Bracket 2 24 Nom 18 ft-lb

Gear Cover Capscrews 24 N*m 16 ft-lb

Vibration Damper 200 Nom 148 ft-lb

Pulley to Vibration Damper 77 Nom 57 ft-lb

Fan Hub Pulley Mounting Capscrews 45 Nom 32 ft-lb

Front Engine Support Bracket Mounting

Capscrews 112 Nom 83 ft-lb
l Without Support 60 Nom 44 R-lb

Fuel Transfer Pump Mounting Capscrews 24 Nom 18 f&lb

 Component Specifications and Toquepz;$
614 Series

Componentor Assembly (Procedure) Ref.No./Stepe Metric U.S.

Fuel Transfer Pump Fuel Line Fittings 24 Nom 18 ft-lb

Fuel Injection Pump Solenoid 10 Nom 89 in-lb

Air Compressor Mounting Nuts 77 Nom 57 ft-lb

Air Compressor Support Brace Capscrews 43 Nom 32 ft-lb

AK Compreesor Oil Supply Line Fitting 8 Nom 71 in-lb

Air Compressor Coolant Supply Line

Fitting 35 N*m 28 in-lb

A$kmpressor Connections
5 Nom
Outlet 24 N*m
Component Specifications and Torque Values
Page 22 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Cylinder Block - Rebuild Specifications

Cylinder Block Head Deck Flatness
End-to-End
Side-to-Side x::;z
Fi K
0.0030 in
0.0030 in

Cylinder Block Upper Liner Bore I.D. 132.900 mm MIN 5.2323 in

132.990 mm MAX 5.2358 in

Cylinder Block Counterbore Depth from

Cylinder Block Head Deck 122.930 mm MIN 4.8397 in
123.000 mm MAX 4.8425 in

Cylinder Block Height from Head Deck to

Top of Main Bearing Bore 309.40 mm MIN ;g.;m; 1;
309.60 mm MAX . .

Cylinder Block Height from Head Deck.

pozce to Centerlme of the Mam Beanng
361 .QO mm MIN 14.248 in
362.10 mm MAX 14.256 in

Main Bearing Bore Diameter

With New Bearings 98.079 mm MIN
98.125 mm MAX yEm;
.
;;

Without Bearings 104.982 mm MIN 4.1331 in

105.018 mm MAX 4.1346 in

Camshaft Bore Diameter

Without Bushing 64.01 mm MAX 2.520 in

With Bushing Installed 60.12 mm MAX 2.367 in

 Component Specifications and Torque Values
614 Series Page 23

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Vahre Tappet Bore Diameter 16.00 mm MIN

16.05 mm MAX

Cylinder Liner Inside Diameter 114.000 mm MIN 4.4662 in

114.117 mm MAX 4.4926 in

Cylinder Liner Out-of-Round 0.04 mm MAX 0.0016 in

Cylinder Liner Taper 0.04 mm MAX 0.0016 in

Cylinder Liner Seat Area Depth 123.013 mm

123.039 mm
MIN
MAX
4.6430
4.6440
in
in
-.
ED
Cylinder Liner O.D. (Top Press Pii) 132.936 mm MIN 5.2336 in
132.956 mm MAX 5.2346 in

Piston Pin Bore Inside Diameter 45.006 mm MIN 1.7719 in

45.025 mm MAX 1.7726 in

Piston Pin Outside Diameter 44.993 mm MIN 1.7714 in

1.7718 in .
45.003 mm MAX
Q-
-77E
Note:Discardthe piston pin if it is more than
0.03 mm [O.OOl inch] out of round.

J
Component Specifications and Torque Values
Page 24 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Piston Skirt Outside Diameter 113.814 mm MIN 4.4810 in

113.886 mm MAX 4.4840 in

Top Ring Groove Keystone Angie Wear

Use micrometer and Part No. 3823966. 113.938 mm MIN 4.4857 in

Intermediate Ring Groove Keystone Angie

Wear
Use micrometer and Part No. 3823965. 114.323 mm MIN 4.5009 in

Intermediate Rectangular Ring Side

Clearance 0.070 mm MIN
0.150 mm MAX .
;.Ix&gg
I,

Oil Control Ring Side Clearance 0.020 mm MIN 0.0008 in

0.130 mm MAX 0.0051 in

E,,kshaft Seal Wear Groove, Front and

0.025 mm MAX 0.010 in

Crankshaft Connecting Rod Journal

l Outside Diameter 75.962 mm MIN 2.9906 in
76.013 mm MAX 2.9926 in

l Out-of-Round 0.050 mm 0.0020 in

l Taper 0.013 mm K 0.0005 in

Crankshaft Main Searing Journal

l Outside Diameter 97.982 mm MIN 3.8568 in
98.031 mm MAX 3.8595 in

l Out-of-Round 0.050 mm 0.0020 in

l Taper 0.013 mm MME 0.0005 in

Crankshaft Thrust Face Width (Standard) 42.975 mm MIN 1.6919 in

43.076 mm MAX 1.6959 in
 Component Specifications and TorqueP~;~~
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Crankshaft Rear Seal Flange O.D. 199.975 mm MIN 5.1171 in

130.025 mm MAX 5.1191 in

Crankshaft Damper Pilot O.D. 23.924 mm MIN 0.9419 in

24.000 mm MAX 0.9449 in

Crankshaft Gear Journal O.D. 75.987 in MIN

76.008 mm MAX

Crankshaft End Clearance

New 0.157 mm MIN 0.0062 in
0.334 mm MAX 0.0131 in

Used 0.535 mm MAX 0.0210 in

Crankshaft Gear Bore I.D. 75.898 mm MIN 2.9881 in

75.923 mm MAX 2.9891 in

Crankshaft Gear Installation

- Austempered Gear: 149% MAX 300F
l Temperature 45 Min. MIN 45 Min.
l Time 6 Hrs. MAX 6 Hrs.

- Steel Gear: 177% MAX 350F

l Temperature 45 Min. MIN 45 Min.
l Time 6Hrs. MAX 6 Hrs.

Standard Main Bearing Thickness (Used) 3.446 mm MIN 0.1357 in

3.454 mm MAX 0.1360 in

Main Bearing Clearance With Plastigauge 0.066 mm MIN 0.0026 in

0.134 mm MAX 0.0053 in
Component Specifications and Torque Values
Page 26 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Thrust Bearing Flange Thickness 3.417 mm MIN 0.1345 in

3.530 mm MAX 0.1389 in

Connecting Rod Piston Pin I.D.

With Bushing 45.023 mm MIN 1.7726 in
45.060 mm MAX 1.7740 in

Without Bushing 48.988 mm MIN 1.9286 in

49.012 mm MAX 1.9296 in

Connecting Rod Crankshaft Bore I.D.

(With Bearings) 76.046 mm MIN 2.9939 in
76.104 mm MAX 2.9962 in

Connecting Rod Bearing Clearance (With

Plastigauge) 0.033 mm MIN 0.0013 in
0.117 mm MAX 0.0046 in

Connecting Rod Bearing Side Clearance 0.100 mm MIN 0.0039

0.330 mm MAX 0.0130

Connecting Rod Bearing Thickness

(Standard) 2.428 mm MIN 0.0956 in
2.471 mm MAX 0.0973 in

Connecting Rod Length 215.975 mm MIN 8.5029 in

216.025 mm MAX 8.5049 in

Connecting Rod Bend (Alignment)

l Without Bushing 0.20 mm MAX 0.008 in

l With Bushing 0.15 mm MAX 0.006 in

 Component Specifications and Torque Values
614 Series Page 27

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Connecting Rod Twist

l Without Bushing 0.50 mm 0.020 in

l With Bushing 0.30 mm 0.012 in

Camshaft Bore Diameter

l With Bushing 60.12 mm 2.367 in

l Without Bushing 64.01 mm 2.520 in

Note: If one of the bushings exceed the
specifications, all of the bushings must be
replaced.

Camshaft Journal Outside Diameter 59.962 mm MIN 2.3607 in

60.013 mm MAX 2.3627 in

Camshaft Lobe Diameter

Intake Lobe MIN 2.0383 in
E:Eiti MAX 2.0571 in

Exhaust Lobe 51.596 mm MIN 2.0313 in

52.073 mm MAX 2.0501 in

Fuel Transfer Pump Lobe 41.310 mm MIN 1.6264 in

41.829 mm MAX 1.6468 in

Camshaft Nose (Gear Mounting Surface)

Outside Diameter 41.562 mm MIN 1.6363 in
41.580 mm MAX 1.6370 in

El
Camshaft Thrust Plate Thickness 9.340 mm MIN
9.580 mm MAX 0

0
-rlG

Camshaft Gear Bore Inside Diameter 41.480 mm MIN 1.6331 in

41.505 mm MAX 1.6341 in
Component Specifications and Torque Values
Page 28 614 Series

Component or Assembly (Procedure) Ref.No./Steps MetriC U.S.

Camshaft Gear Installation

- Austempered Gear: 149% 300F
l Temperature 4.5 Min. E 45 Min.
l Heating Time 6 Hrs. MAX 6 Hrs.

- Steel Gear: 177% MAX 35O=F

l Temperature 45 Min. MIN 45 Min.
l Heating Time 6 Hrs. MAX 6 Hrs.

Vibration Damper Face Alignment

(Wobble ) T.I.R. 0.28 mm MAX 0.011 in

Vibration Damper Eccentricity T.I.R. 0.28 mm MAX 0.011 in

Vibration Damper Thickness

Measure the thickness at four locations 90 degrees apart approximately 3.18 mm IO.125 in] from
the outside diameter. The difference between any two of the four measurements must not exceed
0.25 mm [O.OlO in].

Rear Cover Crankshaft Seal Bore I.D. 149.96 mm MIN z*g ;;

150.04 mm MAX .

Cylinder Block - Torque Values

Cylinder Block Pipe Plugs (Into Cast Iron) Size
Refer to chart on page V-56. 10 Nom 1116 inch 7 ft-lb
15 Nom 118 inch 11 ft-lb
25 Nom l/4 inch
35 N*m ;;; !$I
;z !E ;l;Ii;h
95 N:m

Cylinder Block - Main Bearing Cap

ChpSCRiW 1 50 Nom
119 Nom
: 176 Nom
 Component Specifications and Torque Values
614 Series Page 29

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Connecting Rod Capacrew Nuts 40 Nom 30 ft-lb

: 80 N*m 60 ft-lb
3 120 Nom 88 ft-lb

Cylinder Head - Rebuild Specifications

FzM&r Head Capscrew Free Length
81.5 mm MAX 3.21 in
l Long 182.6 mm MAX 6.40 in

Cylinder Head Flatness

End-t*End 0.200 mm 0.0079 in
Side-to-Side 0.076 mm 1% 0.0030 in
Local Flatness
(Within a 51 mm [2.0 inch] area) 0.0254 mm MAX 0.001 in

Fili Head Thickness

115.75 mm MIN 4.557 in
118.25 mm MAX 4.577 in

l Machined 114.75 mm MIN 4.518 in

Injector Nozzle lip Protrusion 3.0 mm MIN 0.118 in

4.0 mm MAX 0.157 in

~&vewGuide I.D. (Installed)

9.539 mm MIN 0.3756 in
9.559 mm MAX 0.3763 in

l used 9.591 mm MAX 0.3776 in

;Vck; Guide Height (Installed)

20.65 mm MIN 0.813 in
21.16 mm MAX 0.833 in

22.50 mm MIN 0.886 in

23.01 mm MAX 0.906 in
Component Specifications and Torque Values
Page 30 614 Series

Component or Assembly (Procedure) Ref.No./Stepe Metric U.S.

Valve Guide Bore I.D. 15.931 mm MIN 0.6272 in

15.971 mm MAX 0.6288 in

Valve Guide (New) O.D. 15.988 mm MIN 0.6294 in

16.000 mm MAX 0.6299 in

Valve Seat-to-Valve Guide Concentricity

(360 Degree9 0.05 mm MAX 0.002 in

Valve Recess in Cylinder Head 1.09 mm MIN 0.043 in

1.62 mm MAX 0.064 in

Eakt Insert Bore I.D. (Standard Insert) A

53.930 mm MAX 2.1231 in

47.027 mm MAX 1.8515 in

EzUv: Insert Bore Depth (Standard Insert) B

12.20 mm MAX 0.480 in

Exhaust 9.83 mm MAX 0.387 in

EEkt Sealing Surface Angle

Exhaust
 Component Specifications and Torque Values
614 Series Page 31

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Valve Seat Width Limit 1.5 mm MIN 0.060 in

2.0 mm MAX 0.080 in

Valve Seat Vacuum

New 508 mm Hg MIN 20 in Hg
635 mm Hg MAX 25 in Hg

Used 457 mm Hg MIN 18 in Hg

Acceptable leakage rate in 10 seconds. 254 mm Hg MAX 10 in Hg

Valve Spring Free Height A 65.66 mm Nominal 2.585 in

(7-l/2 coils)

I I

Valve Spring Working Height B 50.80 mm Nominal 2.00 in

;r;g Force at Assembled Height
C 464.5 N MIN 104.4 Ibf
513.5 N MAX 115.4 Ibf

C 450.0 N MIN 101.2 Ibf

Valve Spring at Opening Height B 37.90 mm Nominal 1.492 in

;rr$g Force at Opening Height
C 959.5 N MIN 215.7 Ibf
1060.5 N MAX 238.4 Ibf

Used C 940.0 N MIN 211.3 Ibf

Valve Stem O.D. 9.46 mm MIN 0.372 in

9.50 mm MAX 0.374 in

Valve Head Thickness at O.D. 1.50 mm MIN 0.059 in

Rocker Lever Assembly - Rebuild Specifications
Page 32 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Rocker Lever Assembly - Rebuild Specifications

Rocker Lever gore I.D. 22.256 mm MIN 0.8782 in
22.301 mm MAX 0.8780 in

Rocker Lever Shaft O.D. 22.199 mm MIN 0.8740 in

22.231 mm MAX 0.8752 in

Valve Tappet - Rebuild Specifications

Valve Tappet Stem O.D. 15.925 mm MIN 0.6270 in
15.980 mm MAX 0.6291 in

Valve Tappet Visual Limits

Inspect the socket stem and face Normal Wear
for excessive wear, cracks or damage Abnormal (Do not use)
Abnormal (Do not use)
Concavity (A) 0.025 mm 0.001 in

Valve Tappet Face

1. A single pit cannot bs greater than 2 mm [0.078 in] in diameter.
2. Interconnection of pits is not allowed and is treated as one pit.
3. Total pits when added together should not exceed 8 mm [0.238 in]
diameter or a total of 4 percent of the tappet face.
4. No pitting is allowed on the edges of the wear face of the valve tappet.

Fuel Systems - Rebuild Specifications

Note: This manualdoes not cover fuel injection pump rebuild or calibration.
Rebuild and calibration should be performedin a facilii certified in the
rebuild and calibration of the fuel injection pumps.

Fuel System Specifications

Engine Low Idle Speed
Refer to the engine dataplate.
 Fuel Systems - Rebuild Specifications
614 Series Page 33

Component or Assembly (Prowdun) Ref.No./Steps Metric U.S.

Fuel Transfer Pump Inlet Restriction

6C, 6CT 95 mm Hg MAX 3.75 in Hg
6CTA 153 mm Hg MAX 6inHg

Fuel Transfer Pump O&t Pressure at

High Idle
6C, 6CT 172 kPa 25 psi
6CTA 207 kPa 30 psi

Fuel Injection Pump

Fuel inlet Pressure 140 kPa MIN 20 psi

Fuel Injection Pump

Fuel Return Line Restriction 518 mm Hg MAX 20.4 in Hg

Fuel Filter Restriction

Pressure Drop Across Filter 35 kPa MAX 5 psi

Fuel Drain Line Restriction 70 kPa MAX 10 psi

E;Fo\eion Pump Throttle Lever

3.18 mm
6.35 mm

I -
Fuel Systems - Rebuild Specifications
Page 34 614 Series

Component or Aeeembty (Procedure) Ref.No./Steps Metric U.S.

Fuel Shutoff Solenoid Adjustment

- Synchro-Start
l Plunger Stroke Gap 0.04 mm 0.118 in
l Plunger Stroke Length 25.4 mm k!% 1.0 in
- Trombette
l Plunger Stroke Gap 0.118 in
l Plunger Stroke Length k? 1: K 1.3 in

Fuel Shutoff Soknoid Adjustment

RQVK Governor A 66.9 mm 2.64 in

Fuel System - Torque Values

Air Fuel Control (AFC) Pitting 24 Nom 18 f&lb

Fuel Filter
Note: install the filter as specified by the filter manufacturer.

Fuel Injection Pump Sealing Washer

- Bosch Pump
l Sealing Washer A 24 Nom 18 ft-lb
l Sealing Washer D 15 Nom 11 ft-lb

Fuel Injection Pump Sealing Washer

- Nip ndenso Pump
l &%ing Washer A 24 Nom 18 Rib
l Sealing Washer 14 Nom 10 ft-lb
l Sealing Washer : 27 Nom 20 ft-lb
l Sealing Washer D 70 Nom 50 f-t-lb
l Sealing Washer (Bleed Screw) E 5 Nom 36 in-lb

Fuel Filter Heed Adapter 4 Nom 35 in-lb

Fuel Filter Adapter Nut 32 Nom 24 ft-lb
 Fuel Systems - Rebuild Specifications
614 Series Page 35

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Fuel Filter Head Banjo Fittings 24 Nom 18 f-t-lb

Fuel Injection Pump Solenoid Mounting

Cspscrews 43 Nom 32 ft-lb

Fuel Injection Pump Supply Banjo Fiing 24 N*m 18 ft-lb

Fuel Injection Pump

Mounting Nuts 44 N*m 32 ft-lb
Studs Hand Tight

Fuel Injection Pump Lower Support

Bracket
Ml0 Pump to Support Bracket Capscrew 24 Nom 18 ft-lb
Ml0 Support Bracket to Block Cap-screw 77 Nom 57 ft-lb

Fuel Injection Pump Drive Gear Nut

A Pump 92 Nom 88 ft-lb
MW Pump 104 Nom 77 it-lb
P Pump 188 Nom 122 ft-lb

Fuel Injection Pump liming Pin Access

Plug 15 N*m 11 ft-lb
Fuel Systems - Rebuild Specifications
Page 36 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Fuel Shutoff Solenoid Mounting Bracket

Capscrews 10 Nom 89 in-lb

Fuel Transfer Pump Fittings

30 Nom
: pnt;p 30 N*m
- Hand Primer 30 N*m

Fuel Transfer Pump 24 Nom 18 ft-lb

Fuel Line Fittings

Fuel Transfer Pump Mounting Capscrews 24 Nom 18 ft-lb

High Pressure Fuel Line Fiiings 30 N*m 22 ft-lb

High Pressure Fuel Line Support Bracket 2 24 Nmrn 18 ft-lb

Injector Opening Pressure

a. Open valve
b. Operate spray tester lever at one stroke per second
c. Read pressure indicated when spray began
 Lubricating Oil System - Specificd$
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Leakage Test:
a. Open valve
b. Operate spray tester lever to hold pressure 20 bar [290 psi] below opening pressure
c. No drops should fall from the tip within 20 seconds

Injector Nozzle Clamp Capscrew 24 N*m 18 ft-lb

injector Nozzle Banjo Fitting 9 Nom 80 in-lb

Lubricating Oil System - Specifications

Lubricating Oil Thermostat
l Fully Open Temperature 116C 240F
l Maximum Opening Distance 45.9 mm 1.80 in

Oil Capacii of Pan (All Engines):

- Low Level 15.1 liters 16.0 U.S. Qts.
- High Level 18.9 liters 20.0 U.S. Qts.

Tog6S em Capacity
Jst 23.6 liters
6CTk.3 23.8 liters

Oil Cookr Element Distortion 0.8 mm MAX 0.031 in

;;kFr Element Pressure Test

70 psi
Temperature 18OOF
Lubricating Oil System Torque Values
Page 38 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Oil pressure Regulator Spring

?w&Frss Length
86.63 mm Nominal 3.411 in

Spring Load at 53.98 mm t2.125 in]

Valve Open 190 N MIN 42.8 Ibf
Spring Load at 69.33 mm t2.375 in]
Assembled 153 N MIN 34.4 Ibf

Oil Pump Gerotor Tip Clearance 0.025 mm MIN 0.001 in

0.178 mm MAX 0.007 in

Oil Pump Port Plate Clearance 0.025 mm MIN

0.127 mm MAX .
KE .I::

Oil Pump Body Bore Clearance 0.127 mm MIN

0.381 mm MAX .
Z-E .I::

,-_

Oil Pump Drive Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in

Oil Pump Idler Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in

Lubricating Oil System Torque Values

Crankcase Breather Tube Bracket
M8 (Valve Cover) 24 Nom 18 ft-lb
Ml2 (Cylinder Head) 80 N*m 59 ft-lb
 Lubricating Oil System Torque Values
614 Series Page 39

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Oil Cooler Cover Mounting Capscrews 24 Nom 18 ft-lb

Oil Filter Head Mounting Capscrews 24 Nom 18 ft-lb

Oil Cooler Cover Pipe Plugs

10 Nom 74 in-lb
10 Nom 74 in-lb
36 Nom 27 f&lb
46 Nom 35 ft-lb

Oil Pressure Regulator Plug 80 N*m 59 ft-lb

Oil Drain Plug 80 Nom 59 R-lb

Oil Pan Mounting Capscrews 24 Nom 18 ft-lb

Note: Tighten the capscrews in the sequence
shown. Start at the center of the oil pan and
alternate toward both ends.

Oil Pump Suction Tube Bracket

Suction Tube to Block 9 Nom 80 in-lb
Brace to Block 9 Nom 80 in-lb
Brace to Suction Tube 9 Nom 80 in-lb

Oil Pump Mounting Capscrews 24 Nom 18 ft-lb

Coo;;% System Specifications
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Oil Temperature Thermostat 50 Nom 37 ft-lb

Cooling System Specifications

Fan Hub Assembled Height 124.85 mm MIN 4.915 in
125.65 mm MAX 4.946 in

Fan Hub Searing Installation Force 9000 N MIN 2023 Ibf

Fan Hub Shaft End Clearance 0.15 mm MAX 0.006 in

Radiator Cap Pressure Test

104% [220F] 103 kPa MIN 15 psi
99% [21 ooq 48 kPa MIN 7 psi

Thermostat Operating Temperature

Initial Opening Temperature 81% MIN 178F
83C MAX 182F

Fully Open Temperature 95% MAX 203F

Maximum Open Distance 41.5 mm MAX 1.63 in

Viscous Fan Drive Operating Temperature

Start Modulation
Maximum Speed
 Cooling System Specifsa;f;~
614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Cooling System Torque Values

Belt Tensioner Mounting Capscrew 43 Nom 32 ft-lb

Fan Hub Mounting Capscrew 24 Nom 18 ft-lb

Fan Hub Pulley Mounting Capscrews 45 Nom 33 ft-lb

Coolant Inlet Hose Clamps 5 N*m 44 in-lb

Thermostat Housing Mounting Capscrews 24 Nom 18 ff-lb

Water Pump Mounting Capscrews 24 Nom 18 ft-lb

Water Outlet Connection 24 Nom 18 ft-lb

E;;in.s System Specifications
614 Series

Component or Assembly (Procedure) Flef.No./Steps MetriC U.S.

Air Intake System - Specifications

Intake Air Restrictii
Naturally Aspirated ;;; :; # MAX 20.0 in H,O
Turbocharged 2 MAX 25.0 in H,O

Turbochzwger Shafl Radial Clearance (Side

to Sii) 0.21 mm MIN 0.008 in
0.46 mm MAX 0.018 in
Note: Specifications and instructions for rebuilding
the turbocharger are provided in the Hl Turbocharger
Shop Manual, Bulletin No. 3810321.

Turbocharger Shaft Axial Clearance (End

Cleerance) 0.03 mm MIN 0.001 in
0.08 mm MAX 0.003 in

Charge Air Cooler

Differential Pressure Across Cooler 21 kPa MAX 3 psi

Wastegate Actuator Calibration

l Air Pressure 165 kPa MIN 24 psi
179 kPa MAX 26 psi

l Actuator Rod Movement MIN ij?&j i;

Oi? Fl: MAX .

Air Intake System - Torque Values

Turbocharger Mounting Nut 45 Nom 33 ft-lb

Tuuerger Oil Drain Mounting

24 Nom 18 ft-lb
 Cooling System Specifications
614 Series Page 43

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Turbocharger Air Crossover Hose Clamps 5 N*m 44 in-lb

Turbocharger Oil Drain Tube Hose Clamps 5 N*m 44 in-lb

Turbocharger Turbine Housing Capscrews 11 N*m 97 in-lb

T$xxharger Compressor Housing Clamp

8 Nom 71 in-lb

Turbocharger Oil Supply Hose Connection id Nom 11 ft-lb

Turbocharger Discharge Elbow Clamp Nut 8 Nom 71 in-lb

Turbocharger Mounting Studs

Use two mounting nuts locked together 10 Nom 89 in-lb
Exhaust System - Specifications
Page 44 614 Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Exhaust System - Specifications

Exhaust Restriction 7.5 cm Hg MAX 3.0 in Hg

Exhaust Manifold Flatness 0.20 mm MAX 0.008 in

Exhaust System - Torque Values

Exhaust Manifold Mounting Capscrews:
l Flan ed Head 43 Nom 32 ft-lb
l Hex a ead 43 N*m 32 ft-lb

Air Compressor - Inspection Specifications

Crankshaft End Clearance
l Single Cylinder Air Compressor 0.05 mm MIN 0.002 in
0.15 mm MAX
l Two Cylinder Air Compressor MIN :-zz i::
::z 1: MAX 01008 in
Note:Specificationsand instructionsfor rebuilding
the air compressors are provided in the Air Equipment
Rebuild Manuals, Bulletin Nos. 3810242 and 3810257.
Air Compressor - Torque Values
Air Compressor Brace to Air Compressor
lMM;ing Capscrews
43 Nom 32 ft-lb
Bendix 43 N*m 32 ft-lb
Midland 32 Nom 24 ft-lb

Air Compressor Brace to Cylinder Block

Mounting Capscrew 43 Nom 32 ft-lb

ii&Compressor Flange Mounting Nuts

77 Nom 57 ft-lb
Stud to Gear Housing Hand Tight
 Electrical System - Specifications
614 Series Page 45

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

A&Co~~~ssor Oil Supply Hose

15 N*m 12 ft-lb

Air Compressor Coolant Line Connection 35 Nom 26 lt-lb

Electrical System - Specifications

Drive Belt 360N MIN
490 N MAX 1g
Engine has an automatic belt tensioner, no
adjustment necessary.

Batteries Specific Gravity State of

7EiL: %zzgq

Eiiiz
at 27% [WOOF] f;hj
1.260 to 1.280 100% 1.26s1.280
1.230 to 1.250 75% 75% 1230.1250
1.200 to 1.220 50% 1200.1220
1.170 to 1.190 25%
25% 1.170-1.190
1.110 to 1.130 Discharged
Discharged 1.110-1.130

Electrical System - Torque Values

BeltTensioner Capscrew 44 Nom 32 ft-lb

Alternator Mounting
Ml 0 Capscrew A 44 Nom 32 ft-lb
Lower Suppoti Bracket
M8 Capscrew B 24 Nom 18 ft-lb
Ml 0 Capscrew 44 Nom 32 ft-lb

Mounting Capscrews C 77 Nom 57 ft-lb

Starting Motor Mounting Capscrew 77 Nom 57 ft-lb

Engine Testing - Test Specifications
Page 46 614Series

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Coolant Heater 12 Nom 106 in-lb

Temperature Sensor
Installation - Cast Iron 50 N*m 37 ft-lb
Installation - Aluminum 30 Nom 22 ft-lb

Oil Heater Element 120 Nom 69 ft-lb

Oil Pressure Switch

Installation - Cast Iron 16 N*m 12 ft-lb
Installation - Aluminum 10 Nom 69 in-lb

Engine Testing - Test Specifications

Notex The specifications and instructions for testing
the engineare provided in the C Series Shop Manual,
Bulletin No. 3666008.

Crankcase Gases (Blowby) Limits

Refer to Engine Testing - General Specifications, page 46.

Mounting Adaptations Specifications

Flywheel Housing (wet Application)
Set Screw Installation Depth 0.00 mm MN 0.000 in
3.00 mm MAX 0.118 in
 Mounting Adaptations - Torque Values
614 Series Page 47

Component or Assembly (Procedure) Ref.No./Steps Metric U.S.

Flywheel Ring Gear Installation

l Temperature 177% 360F

. Time Interval 30 Min. MIN 30 Min.
6 Hours MAX 6 Hours

Mounting Adaptations - Torque Values

Flywheel Housing Access Plate
Capscrews 24 Nom 16 ft-lb

Flywheel Housing Mounting Capscrews 60 Nom 44 ft-lb

Flywheel Mounting Capecrews 140 Nom 101 ft-lb

h;FTesting - General Specifications
614 Series

Engine Testing - General Specifications

Note: Due to variations in ratings of different engine models, refer to the specific engine data sheet for the particular
engine model being tested.
Maintain the following limits during an engine run-in on a dynamometer:
Intake Restriction: (Maximum)
. Clean Filter ........................................................................................................ 380 mm H.# [15 in. H,O]
l Dirty Filter ......................................................................................................... 635 mm Ha0 [25 in. H,O]
Air inlet Temperature (Maximum) ............................................................................................... 38OC [lOOoF]
Exhaust Temperature ............................................................................................................. 7OOOC[l 290F]
Exhaust Back Pressure: (Maximum)
l industrial ............................................................................................................... 76 mm Hg 13.0 in. Hg]
l EPA Certified ...................................................................................................... 114 mm Hg 14.5 in. Hg]
Smoke: (Steady State - Rated Power and RPM)
l Bosch Smoke Meter (Maximum) ................................................................................................ 2.5 Units
l Celesco Smoke Meter (Maximum) ......................................................................................... 4% Opacity
Coolant Temperature (Maximum) ............................................................................................. 1OOOC[212OF]
Lubricating Oil Temperature (Maximum) ................................................................................ 126.6OC [260F]
Lubricating Oil Pressure:
l Low Idle (Minimum Allowable) .......................................................................................... 69 kPa [lo psi]
l Rated Speed (Minimum Allowable) ................................................................................. 207 kPa [30 psi]
Fuel Filter Restriction (Maximum)
. Dirty Filter ............................................................................................................. 89 mm Hg [3.5 in. Hg]
Fuel Return Restriction (Maximum) ............................................................................................ 35 kPa [5 psi]

Blowby: *New (UMin) l Worn (L/Min)

l 6C8.3 (Maximum) (Rectangular intermediate ring) 44 88
l 6CT8.3 (Maximum) (Rectangular intermediate ring) 113 228
l 6CTA8.3 (Maximum) (Rectangular intermediate ring) 113 226
l All Engines With Reverse Twist Intermediate Ring 145 290
l Blowby checking tool, Part No. 3822566, has a special 7.67 mm [0.302 in.] orifice that must be used to obtain
an accurate reading.
Refer to the blowby conversion chart on the following page to convert liters/minute into inches/water.
 Blowby Measurement
614 Series Page 49

Blowby Measurement
Blowby is generally recorded in liters/minute.
Install the Part No. 3822566, Engine Blowby Tool, to the
crankcase breather tube in the valve cover.
Install a water manometer to the engine blowby tool.
Use the Blowby Conversion Chart to convert the ma-
nometer reading to liters/minute.
Note: A pressuregauge can be used to record the engine
blowby.
Minimum Gauge Capacity: 1270mm Hz0 [SO inches
WI.

Blowby Conversion git1;~(7.67 mm rO.302 in])

Inches
of
Water Liters/Minute
1 50
2 84
3 103
4 119
5 133
6 145
7 155
8 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17
18 226
19 229
20 235
21 239
22 242
23 246
24 248
Drive Belt Tension
Page 50 614 Series

Drive Belt Tension

SAE Belt Size Belt Tension Belt Te;;zdt Range
New
Click-type N Ibf N Ibf
0.380 in. 3822524 620 140 270 to 490 60 to 110
0.440 in. 3822524 620 140 270 to 490 60 to 110
112 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
314 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
718 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 1OOto200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240

* A belt is considered used if it has been in service for ten minutes or longer.
l If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
 FRACTION, DECIMAL, MILLIMETER CONVE;fFW&
614 Series

FRACTION, DECIMAL, MILLIMETER CONVERSIONS

THBS. TZ. N%. TZ. INCHES MM T&. T&i. N& Tit. INCHES MM
1 0.0156 0.397 33 0.5156 13.097
1 0.0313 0.794 17 0.5313 13.494
3 0.0469 1.191 35 0.5469 13.691
1 0.0625 1.588 9 0.5625 14.288
5 0.0781 1.984 37 0.5781 14.684
3 0.0938 2.381 19 0.5938 15.081
7 0.1094 2.778 39 0.6094 15.478
I 1 I t 0.1250 1 3.175 1 5 1 t 0.6250 1 15.875 I
9 0.1406 3.572 41 0.6406 16.272
5 0.1563 3.969 21 0.6563 16.669
I I I I 11 I 0.1719 I 4.366 I I I I 43 I 0.6719 I 17.066 I
3 0.1675 4.763 11 0.6875 17.463
13 0.2031 5.159 45 0.7031 17.859
7 0.2188 5.556 23 0.7188 18.256
,
15 0.2344 5.953 47 0.7344 18.653
114 0.2500 6.350 314 0.7500 19.050

I , I , I I
I I
27 0.4219 10.716 59 0.9219 23.416
7 0.4375 11.113 15 0.9375 23.813
I
29 0.4531 11.509 61 0.9531 24.209
15 0.4688 11.906 31 0.9688 24.606
31 0.4844 12.303 63 0.9844 25.003
l/2 0.5000 12.700 1 IN. 1.0000 25.400

CONVERSION INCH = 25.4Mtvl

I FACTOR:1
I
Weight and Measures - Conversion Factors
Page 52 614 Series

Weight and Measures - Conversion Factors

QUANTITY U.S. CUSTOMARY METRIC FROM U.S. FROM METRIC
CUSTOMARY TO U.S.
TO METRIC CUSTOMARY
I I
MULTIPLY BY MULTIPLY BY
1 Unit Name 1 Abbe. 1 Unit Name 1 Abbr.
Area sq. inch in* sq. millimeters 1 m* 645.16 0.001550
sea.centimeters I c* 6.452 0.155
sq. foot ft2 sq. meter m* 0.0929 10.764
Fuel pounds per mhr gramsper glkw-hr 808.277 0.001645
Consumption horsepower ki+owatthour
hour
Fuel miles per km/l
Performance gallon
9,,lps per liters per I/km
kiter
Force pounds force lbf Newton N 4.4482 0.224809
Length inch in millimeters mm 25.40 0.039370
foot ft millimeters I mm
Power horsepower hp kilowatt kw
Pressure pounds force psi kilopascal kPa
per sa. in
inches of
mercury
in Hg kilopascal kPa 3.3769
I 0.29613
I
1
inches of in H20 kilopascal kPa 0.2488 4.019299
water
inches of in Hg millimeters mm Hg 25.40 0.039370
mercury I 1 of mercury I I I
inches of in H2C millimeters mm H20
water of water
bars bars kilopascals kPa
bars bars millimeters of mm Hg
mercury
Temperature fahrenheit OF centigrade OC (OF-32) i 1.8 (1.8 x C) +32
Torque 1 pound force 1 ft lb 1 Newton-meter 1 Nom 1.35582 0.737562
1 per foot ! ! ! I I

I Po;y;cp I in lb
I
Newton-meter
I
Nom 0.113 8.850756
1
Velocity miles/hour mph kilometers/hour kph I
1.6093 0.8214
Volume: gallon (U.S.) gal. liter I 3.7853 0.264179
liquid
gallon (Imp*) gal. liter I 4.548 0.219978
displacement
cubic inch . in3 liter I 0.01639 61.02545
cubic inch in3 cubic cm3 18.387 0.08102
centimeter I I
Weight (mass) pounds (avoir.) lb kilograms kg
Work British Thermal BTU joules j
Unit
Eriiph Thermal BTU kilowatt-hour kw-hr o.ooo293
I 3414
I
horsepower hphr kilowatt-hour kw-hr 0.746 1.341
hours
 Newton-Meter to Foot-Pound Conversion Chart
614 Series Page 53

Newton-Meter to Foot-Pound Conversion Chart

Nom ft-lb Nom B-lb Nom ft-lb
1 8.850756 in-lb 55 41 155 114

5 44 in-lb 80 44 160 118

8 53 in-lb 65 48 185 122

7 62 in-lb 70 52 170 125

8 71 in-lb 75 55 175 129

9 80 in-lb 80 59 180 133

10 89 in-lb 85 63 185 136

1 0.737562 R-lb 90 66 190 140

12 9 95 70 195 144

14 10 100 74 200 148

15 11 105 77 205 151

16 12 110 81 210 155

18. 13 115 85 215 159

20 15 120 89 220 162

25 18 125 92 225 165

30 22 130 96 230 170

35 28 135 100 235 173

40 30 140 103 240 177

45 33 145 107 245 180

50 37 150 111 250 184

NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.

Ca;r;w Markings and Torque Values
614 Series

Capscrew Markings and Torque Values

A Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as
the capscrew being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the
surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:

Metric - MS1.25 X 25 U.S. Customary [5/16 X 18 X l-1121

M8 1.25 25 5/l 6 18 l-112
Major Distance Length Major Number Length
Thread Between in Thread Threads in
Diameter in Threads in Millimeters Diameter per Inch Inches
Millimeters Millimeters in Inches

NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better
torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
 Capscrew Markings and Torquepi;:;;
614SefieS

Capscrew Markings and Torque Values - Metric

Commercial Steel Class

8.8
Capscrew Head Markings

SF Torque Torque Torque

Diam. Cast iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb
6 9 5 7 4 12 9 7~ 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 loo 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135

Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8
Capscrew Head Markings
These are allSAE Grade 5 (3)line

Torque - Grade 5 Capscrew Cepscrew Torque - Grede 8 Cspscrew

Capscrew Body Sue Iroil Aluminum Cast Iron Aluminum
Nom ft-lb Nom ft-lb Nom ft-lb N*m ft-lb
114 - 20 9 6 15 11 8 6
-26 12 9 : 7 16 9 7
5116 - 18 15 16 12 :: 16 12
- 24 E 17 E 24 19
316 - 16 :: : 55 40 25 ii
- 24 z ii 35 25 60 45 35 25
7116 - 14 60 35 65 35
- 20 2 zz 40 :: 70 :
112 - 13 E 70 55 130 95 75 zi
-20 100 75 :z 60 150 110 80
9116 - 12 135 100 110 80 190 140 110 ii
- 18 150 110 115 65 210 155 115 85
516 - 11 135 150 110 190 150 110
- 18 :: 155 160 120 z 215 160 120
314 - 10 325 240 255 190 460 340 255 190
- 16 365 270 210 515 380 265 210
718 - 9 490 360 iis 260 550 380 280
- 14 530 390 420 310 iz 610 420 310
l-8 720 530 570 420 1100 820 570 420
- 14 800 590 650 480 1200 890 650 480
Pipe Plug Torque Values
Page 56 614 Series

Pipe Plug Torque Values

Sire Torque Torque

In Cast Iron or
Thread Actual Thread O.D. In Aluminum Components Steel Components
in in N*m ft-lb Nom ft-lb
l/l6 0.32 5 45 in-lb 15 10
l/8 0.41 15 10 20 15
l/4 0.54 20 15 25 20
318 0.68 25 20 35 25
l/2 0.85 35 25 55 40
314 1.05 45 35 75 55
1 1.32 60 45 95 70
l-114 1.66 75 55 115 85
l-112 1.90 85 65 135 100
 Tap-Drill Chart - U.S. Customary & Metric
614 Series Page 57

Tap-Drill Chart - U.S. Customary & Metric

NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60%
and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60% range as these sizes WIII provrde about
90% of the potential holding power. Drill sizes in the 75% range are recommended for shallow hole tapping (less than 1 112times the hole
diameter) in soft metals and mild steel.

Dlill Drill
Dlill
Sk E Sk She
48 44omm 750mm 13.25mm
1.95mm I 2-24 16 l&4 6/8-11 17i32
5/84 4.5Omm 7.6Omm M16x1.5 13.5Omm
3-48 N M15x1.5 13.75mm
gem; 1115.5x.9 ZQmm 7.7Omm 5%11 35/64
M2.5x.45 12-24 12-28 14 M9x1.25 7.75mm M16x2 14.COmm
13 7.8Omm 1425mm
3-48 3056 2 4.7Omm 7.9Omm 5/8-18 9118
2.10mm 15.5x.9 4.75mm 3/8-16 5/16 M16x2 M16x1.5 14.50mm
M2.5x.45 M2.6x.45 2.15mm 12-28 Y16 M9X1.25 M9xl 6l8-18 37164
3-56 4-38 12 rmm 14.75mm
&mm 4.8Omm 8.10mm MlEx1.5 15.COmm
M2.6x.45 2.25mm 11 M9Xl 8.2Omm 19.22
436 4-40 4.9hn-n P 15.25mm
?&hll 10 8.25mm w64
2:35mm 8.3Omm M17x1.5 15SOmm
4-40 4-48 U6x1 kOmm 3&16 l/8-27NPl 21164 M17x1.5 MlEx2.5 15.75mm
E+2 8.4Omm 5l8
M3x.6 2.4Omm Lhnm 3&24 Q MlEx2.5 MlEK2 16.OOmm
4.48 41 1/4-20 7 MlOx1.5 8.5Qmm MlEr2 1826mm
2.45mm 13l64 8.6Omm 3/410 41l84
40 8 R MlExl.5 16.5Omm
M3x.6 M3x.5 2.5Omm ffixl 5.2Omm 3/8-24 8.70mm W-10 M19x2.5 21/32
39 5 ll8aNPT Ill32 M18x1.5 18.75mm
540 U6x.75 5.25mm MlOX1.25 8.75mm M19x2.5 17.OOmm
M3x.5 ZOmm 5.3Omm MlOx1.5 8.8Omm 43l64
5.40 544 IW20 4 S 17.26mm
ZOmm d6x.76 5.4Omm 8.9Omm W-18 3/4-18 11118
544 6-32 36 l/4-28 MlOX1.25 MlOxl 9.OOmm M2OZQ.5 17.5omm
2.75mm LOmm 7 17.75fnm
7l64 7/Z 9.10mm 45m4
35 5.8Omm 23d64 wOx2.5 M2OX2 18.OLhm
2.8Omm l14-28 MlOxl 9.2Omm M2Ox2 18.25mm
LOmm 9.3Omm 23l32
632 El 5.75mm 711614 U M20xl.5 18.5Omm
2.9Omm L4Omm 47164
LOmm Mllxl.5 9.Wmm wOx1.5 18.75mm
M3.5~6 EOmm 5.9Omm 3l8 19.OOmm
6.40 A V 3/4
TlOmm W64 kmm 19.25mm
U7Xl E.oOmm 9.7Omm 7iE-9 49164
E&mm B 9.76mm M22x2.5 19.50mm
M4x.75 3.25mm 6.lOmm MllXl.5 9.8Omm 7/8-9 25l32
c 7116-14 W 19.75mm
M4x.7 EOmm XIX1 6.20mm 9.9Omm M22x2.5 M22X2 2O.OOmm
M4x.75 3hOmm 7116-20 25l84 7/8-14 51164
M4x.7 8-32 U7x.75 Lllm lO.OOmm M2272 20.25mm
&mm 6:3Wmn 7/1620 X M-1.5 2OSOmm
6-36 E M12xl.75 10.2Omm 71614 XV18
20.75mm
8-32 E4 114
3.6Omm A7x.75 6.4hn-n b32 M22x1.5 M24x3 21 .OOmm
8-36 6.5Cumn z
k&mm !I1818 M12x1.75 M12x1.5 10.5Omm Emm
khnm l/2-13 2764
M4.5x.76 &mill G Ml2x1.5 M12x1.25 10.75mm M24x3 E!Zmm
l&24 6.7Omm Mwxl.25 ll.OOmm 21.75mm
EOmm 17164 w-13 7118 55l64
U8x1.25 8.7% l/4-18NPT M24x2 22.ODmm
M4.5x.75 F&mm iIlk 11.25mm 1-8 7/8
LOmm 11.5Omm M24r2 22.25mm
E32 6.9Omm 29164 M24xl.5 22SOmm
1024 22 i.1&24 I 11.75mm 57l64
M5Xl 4.Oihm Ix1 25 U8Xl 7.Obnm 11.5Omm Exl.5 22.75mm
10.32 J l/2-2U 29164 M25X2 23.OOmm
2 7.lOnlm 911612 15l32 l -12
M5x.9 4.1Omm ill&24 K M14x2 12.00m M25x2 Z!Emm
M5Xl M5x.8 4.2Omm 9132 12.25mm lX12 l-14 w64
19 Ix1 7.2Omm 911812 31l64 M25x1.5 23SOmm
E9 4.25mm 7.25mm Ml4x2 M14x1.5 12.50mm M20x1.5 23.75mm
M5x:8 4.3Omm 7.3Omm 911618 112 la-14 lY16
10 Ml4X1.5 M14x1.25 12.75mm
11164 \.4Omm M14x1.25 13.OOmm
17 M 9/16-18 3364
NOTES
NOTES
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