Module 8 - Tools

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QSV Diesel Engines

Module 8 - Special Tools

Cummins Corporate Training

QSV Diesel CUMMINS CORPORATION


Cummins Corporate Training

D / Special Tools / BMG / 01-01 / Rev. 03


Tools Module

Learning Objectives
After completing this module you will be aware of the special tool
requirements for the QSV Diesel engine range and know how they
are used.

Agenda
☛ Hydraulic Tensioning.
☛ Service tools.
☛ Lifting Tools.

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Hydraulic Tensioning

PISTON PISTON
O-RINGS

CYLINDER

SPACER

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Connection of Hydraulic Tensioning Tools

Hydraulic Cylinders

Hydraulic Pump

Gauge

DANGER !
High pressure - always
wear eye protection.

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Hydraulic Tensioning - Cylinder Head Studs

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Hydraulic Tensioning Procedure

☛ Screw nuts to stud and tighten with nut pin.


☛ Place jacking spacers on studs, ensure they are correctly seated.
(on head nuts rotate spacers so they only contact one head).
☛ Screw jacking cylinders to studs.
☛ Connect hoses, series connection pump to each cylinder in turn
and then to the gauge.
☛ Purge air from cylinders. Open valve on pump and screw each
cylinder clockwise to remove any oil trapped in the cylinder and
allow the piston to fully retract. Caution! Pistons only have small
amount of travel.
☛ Tighten the cylinder until it makes contact with the sleeve. Back off
a 1/4-turn (90º). Important!
☛ Close valve on pump and apply pressure to jack until desired first
stage pressure indicated on the gauge.

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Hydraulic Tensioning Procedure
☛ Tighten nuts using the nut pin then release the hydraulic pressure.
☛ Pressurise again, but to second-stage value and re-tighten nuts
with pin. All must turn otherwise repeat after cleaning all nuts,
studs and surfaces.
☛ Release pressure slowly, screw down the jacks to retract the
pistons before removal.
☛ Remove hoses and unscrew jacks.
REMEMBER: When installing head nuts first check the head stud
torque, all studs should be installed to 100Nm.
Nut Removal
☛ Procedure as installation except when installing spacers back off
jacks by 3/4-turn (270º), pump to removal pressure then unscrew
the nuts by 1-turn (360º) before finally removing jacks and nuts.
☛ Screw down the jacks with pump connected to retract the pistons
before removal.

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Hydraulic Tensioning Pressures - Privicat Jacks Only
N ut T ype R em oval Install pressure N otes
Pressure B ar (P S I)
B ar (P SI)
C ylinders
C ylinder 890 (13083) 1st 785(11540) 4 x M 30 .U se
H ead 2nd 870(12789) S pacer N o1.
90 deg F ittings
M ain B earing 990 (14553) 1st 875(12863) M 30 Jack. U se
2nd 970(14259) S pacer N o2.
T orque to
C onnecting N /A T orque N /A T orque 50 / 120 / 220
R od B earing W rench W rench N m (12 P oint
17m m )
Two-stage tensioning procedure: First-stage approximately 90% of final value. Ensure
ALL nuts turn when pressure increased to final value. Check threads are clean and
fully seated at each stage.
IMPORTANT: Check that the correct spacer is used for the head and mains studs, the
length of each spacer is different !

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Special Lifting Tools

Major Component Lifting Tools


A number of special handling tools are available, e.g. Flywheel &
Flywheel Housing, Free-End Cover, Oil Cooler, etc. Details available
from Cummins.

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Service Tools

Take and Review the Demonstration Tools Listed !

1). Hydraulic Jacks, Pump, Coupler, Gauge and Hoses. 2). Cylinder Head
Lifting Fixture. 3). Valve Spring Compressor. 4). Piston Ring Compressor &
Expander. 5). 180-900Nm Torque Wrench. 6). Head and Mains Stud
Extractors. 7). Piston, Rod and Liner Lifting Fixture. 8). Piston Pin Circlip
Pliers.

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Service Tools

SPC - 836104 JACKS ONLY ( HEAD & MAINS)


SPC - 836107 SHORT HOSE

SPC - 836103 PUMP ONLY


SPC - 836106 LONG HOSE

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Service Tools

SPC - 861026

SPC - 803011
SPC - 846010
SPC - 848004

SPC - 837001

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Service Tools

SPC - 848003

SPC - 843004

SPC - 832004
SPC - 843003

SPC - 803011 SPC - 843002

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Service Tools

SPC - 836100
SPC - 836110

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Assembly of Piston / Rod lifting tool
☛ Fasten the piston lifting flange to piston
crown with two screws.
☛ Install the clamp dolly over the top of the
piston lifting flange into the top of the
liner.
☛ Attach the two half flanges to the groove
in the liner rim and secure in place with
the spring clips.
☛ Tighten down the threaded ring to lock
the assembly in place.

Clamp Dolly

Half Half
Flange Flange
Piston Lifting Flange

SPC - 836100

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Service Tools

SPC - 82003
SPC 848008

SPC - 846001/2

SPC 846005

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Module 8 - Special Tools

Demonstration of
Hydraulic Tensioning

- End -
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Cummins Corporate Training

D / Special Tools / BMG / 01-01 / Rev. 03

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