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Cummins N14 Engine Troubleshooting and Repair Manual 3810456-01 – PDF DOWNLOAD
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Description
Cummins N14 Engine Troubleshooting and Repair Manual
FILE DETAILS:
Cummins N14 Engine Troubleshooting and Repair Manual
Language : English
Pages :812
Downloadable : Yes
File Type : PDF
Size:43.3 MB
Book Code: 3810456-01
CUMMINS N14 ENGINE TROUBLESHOOTING AND REPAIR MANUAL 3810456-01 – PDF DOWNLOAD:
DESCRIPTION:
Cummins N14 Engine Troubleshooting and Repair Manual
FOREWORD:
- This manual provides instructions for troubleshooting and repairing the N14 engine in the chassis. Component and assembly rebuild procedures are provided in the N14 Engine Shop Manual. Refer to Page i-2 in the Introduction for instructions on how to use this manual.
- The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures.
- This manual does not cover CELECT™ engine fuel systems troubleshooting and repairing information. For troubleshooting and repairing the CELECT™ system, consult the CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469.
- The repair procedures used in this manual are recommended by Cummins Engine Company, Inc. Some service procedures require the use of special service tools. Use the correct tools as described. The information, specifications, and recommended repair procedures in this publication are based on the information in effect at the time this manual was printed. Cummins Engine Company, Inc. reserves the right to make changes at any time without notice.
TABLE OF CONTENTS:
Cummins N14 Engine Troubleshooting and Repair Manual
MAIN MENU................................................................................................ 0 COVER PAGE............................................................................................... 1 FOREWORD................................................................................................. 2 TABLE OF CONTENTS........................................................................................ 3 SECTION I - INTRODUCTION................................................................................. 4 ABOUT THE MANUAL..................................................................................... 5 HOW TO USE THE MANUAL................................................................................ 5 SYMBOLS.............................................................................................. 6 SIMBOLOS............................................................................................. 7 SYMBOLE.............................................................................................. 8 SYMBOLES............................................................................................. 9 ILLUSTRATIONS........................................................................................ 10 GENERAL SAFETY INSTRUCTIONS.......................................................................... 11 IMPORTANT SAFETY NOTICE.......................................................................... 11 GENERAL REPAIR INSTRUCTIONS.......................................................................... 13 GENERAL CLEANING INSTRUCTIONS........................................................................ 14 SOLVENT AND ACID CLEANING........................................................................ 14 STEAM CLEANING................................................................................... 14 GLASS OR PLASTIC BEAD CLEANING................................................................... 14 DEFINITION OF TERMS.................................................................................. 15 SECTION E - ENGINE IDENTIFICATION........................................................................ 19 CUMMINS MODEL NAME................................................................................... 20 ENGINE DATAPLATE..................................................................................... 20 FUEL PUMP DATAPLATE.................................................................................. 21 ENGINE SPECIFICATIONS................................................................................ 22 GENERAL ENGINE DATA.............................................................................. 22 AIR INDUCTION SYSTEM............................................................................. 22 LUBRICATING OIL SYSTEM........................................................................... 22 COOLING SYSTEM................................................................................... 22 EXHAUST SYSTEM................................................................................... 22 FUEL SYSTEM...................................................................................... 23 ELECTRICAL SYSTEM................................................................................ 23 BATTERIES (SPECIFIC GRAVITY)..................................................................... 23 ENGINE DIAGRAMS...................................................................................... 24 SECTION T - TROUBLESHOOTING.............................................................................. 26 PROCEDURES AND TECHNIQUES............................................................................ 28 TROUBLESHOOTING SYMPTOMS CHART....................................................................... 28 AIR COMPRESSOR AIR PRESSURE RISES SLOWLY......................................................... 29 AIR COMPRESSOR NOISE EXCESSIVE................................................................... 30 AIR COMPRESSOR PUMPING EXCESS LUBRICATING OIL INTO AIR SYSTEM.................................... 31 AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE - NOT PUMPING CONTINUOUSLY................ 32 AIR COMPRESSOR WILL NOT PUMP AIR................................................................. 33 AIR COMPRESSOR WILL NOT STOP PUMPING............................................................. 34 ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING................................................. 35 ALTERNATOR OVERCHARGING.......................................................................... 36 COOLANT LOSS - EXTERNAL.......................................................................... 37 COOLANT LOSS - INTERNAL.......................................................................... 38 COOLANT TEMPERATURE ABOVE NORMAL - GRADUAL OVERHEAT.............................................. 39 COOLANT TERMPERATURE ABOVE NORMAL - SUDDEN OVERHEAT.............................................. 43 COOLANT TEMPERATURE BELOW NORMAL................................................................. 45 CRANKCASE GASES (BLOWBY) - EXCESSIVE............................................................. 46 ENGINE ACCELERATION/RESPONSE POOR................................................................ 47 ENGINE BRAKE - DOES NOT OPERATE.................................................................. 50 ENGINE BRAKE - LOW POWER OR SLOW TO ACTIVATE..................................................... 51 ENGINE BRAKE - ONE OR MORE CYLINDERS BRAKING WITH POWER SWITCH OFF............................... 53 ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST)......................................... 54 ENGINE DECELERATES SLOWLY (CELECT FUEL SYSTEM)................................................... 56 ENGINE DECELERATES SLOWLY (PT FUEL SYSTEM)....................................................... 57 ENGINE DIFFICULT TO START OR WILL NOT START - EXHAUST SMOKE PRESENT.............................. 59 ENGINE NOISE EXCESSIVE........................................................................... 61 ENGINE NOISE EXCESSIVE - COMBUSTION KNOCKS....................................................... 64 ENGINE NOISE EXCESSIVE - CONNECTING ROD.......................................................... 65 ENGINE NOISE EXCESSIVE - MAIN BEARING............................................................ 66 ENGINE NOISE EXCESSIVE - PISTON.................................................................. 67 ENGINE NOISE EXCESSIVE - TURBOCHARGER............................................................ 68 ENGINE POWER OUTPUT LOW - BASICS................................................................. 69 ENGINE POWER OUTPUT LOW - APPLICATION SPECIFIC .................................................. 72 INDUSTRIAL, ELECTRIC DRIVE TRANSMISSION.......................................................... 72 INDUSTRIAL, MECHANICAL DRIVE TRANSMISSION........................................................ 72 ENGINE POWER OUTPUT LOW - PERFORMANCE MEASUREMENT................................................ 76 ENGINE RUNS ROUGH AT IDLE........................................................................ 79 ENGINE RUNS ROUGH OR MISFIRES.................................................................... 82 ENGINE SHUTS OFF UNEXPECTEDLY OR DIES DURING DECELERATION........................................ 84 ENGINE SPEED SURGES AT LOW IDLE.................................................................. 86 ENGINE SPEED SURGES (OTHER THAN LOW IDLE)........................................................ 88 ENGINE VIBRATION - EXCESSIVE..................................................................... 91 ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTING MOTOR)...................................... 93 ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTING MOTOR)................................. 95 ENGINE WILL NOT SHUT OFF......................................................................... 97 ENGINE WILL START BUT WILL NOT KEEP RUNNING...................................................... 98 FUEL CONSUMPTION - EXCESSIVE.....................................................................100 FUEL CONSUMPTION EXCESSIVE - PERFORMANCE TEST EVALUATION.........................................102 FUEL IN COOLANT..................................................................................105 FUEL IN THE LUBRICATING OIL......................................................................106 INTAKE MANIFOLD AIR TEMPERATURE ABOVE SPECIFICATION..............................................107 LUBRICATING OIL CONSUMPTION EXCESSIVE............................................................108 LUBRICATING OIL CONTAMINATED.....................................................................110 LUBRICATING OIL IN FUEL..........................................................................111 LUBRICATING OIL PRESSURE - HIGH..................................................................112 LUBRICATING OIL PRESSURE - LOW...................................................................113 LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE EXCESSIVE.........................................115 LUBRICATING OIL TEMPERATURE ABOVE SPECIFICATION..................................................117 LUBRICATING OR TRANSMISSION OIL IN THE COOLANT...................................................118 SMOKE, BLACK - EXCESSIVE.........................................................................119 SMOKE, BLACK - EXCESSIVE - PERFORMANCE MEASUREMENT...............................................121 SMOKE, WHITE - EXCESSIVE.........................................................................124 TURBOCHARGER BOOST PRESSURE LOW..................................................................127 TUBROCHARGER LEAKS - ENGINE OIL OR FUEL..........................................................128 VARIABLE SPEED (VS) GOVERNOR SPEED NOT SET CORRECTLY.............................................129 ENGINE NOISE DIAGNOSTIC PROCEDURES - GENERAL INFORMATION.........................................130 MAIN BEARING NOISE (REFER TO ENGINE NOISE EXCESSIVE - MAIN BEARING SYMPTOM CHART)................130 CONNECTING ROD BEARING NOISE (REFER TO ENGINE NOISE EXCESSIVE - CONNECTING ROD SYMPTOM CHART)....130 PISTON NOISE (REFER TO ENGINE NOISE EXCESSIVE - PISTON SYMPTOM CHART)............................130 DRIVEABILITY - GENERAL INFORMATION...............................................................131 DRIVEABILITY/LOW POWER - CUSTOMER COMPLAINT FORM.................................................133 DRIVEABILITY/LOW POWER/EXCESSIVE FUEL CONSUMPTION - CHECKLIST....................................134 FUEL CONSUMPTION - GENERAL INFORMATION...........................................................135 FUEL CONSUMPTION - AUTOMOTIVE CUSTOMER COMPLAINT FORM............................................136 FUEL CONSUMTPION - INDUSTRIAL CUSTOMER COMPLAINT FORM............................................137 OIL CONSUMPTION..................................................................................138 SECTION 1 - COOLING SYSTEM...............................................................................142 COOLING SYSTEM GENERAL INFORMATION...................................................................144 FUNCTIONS OF COOLING SYSTEM......................................................................144 COOLANT FLOW DIAGRAM.................................................................................145 COOLING SYSTEM SPECIFICATIONS........................................................................146 THERMAL CONTROL SETTINGS.............................................................................146 HEAVY DUTY COOLANT...................................................................................147 WATER............................................................................................147 ANTIFREEZE.......................................................................................147 SUPPLEMENTAL COOLANT ADDITIVES (SCA'S)...............................................................148 COOLANT BLENDING/MIXING..........................................................................148 COOLANT REPLACEMENT REQUIREMENT..................................................................149 FLEETGUARD DCA4 SERVICE FILTERS AND LIQUID PRECHARGE.............................................150 COOLANT CAPACITY CHART...........................................................................150 COOLING SYSTEM SERVICE TOOLS.........................................................................151 COOLING SYSTEM WATER.................................................................................154 ANTIFREEZE...........................................................................................154 COOLING SYSTEM SEALING ADDITIVES.....................................................................155 COOLING SYSTEM SOLUBLE OILS..........................................................................155 COOLANT ADDITIVE REQUIREMENT.........................................................................155 TESTING SCA CONCENTRATION LEVEL..................................................................157 COOLANT FILTER.......................................................................................158 REMOVAL..........................................................................................158 INSTALLATION.....................................................................................159 DRAINING THE COOLING SYSTEM..........................................................................160 CLEANING THE COOLING SYSTEM..........................................................................161 FILLING THE COOLING SYSTEM...........................................................................163 COOLING SYSTEM - TESTING FOR AIR OR COMBUSTION GASES.................................................166 OVERFLOW METHOD..................................................................................166 SIGHTGLASS METHOD................................................................................166 COMBUSTION GAS TESTING...........................................................................169 FAN, SHUTTER, OR HEATER AIR CONTROL VALVE CHECKING...............................................172 AIR COMPRESSOR CHECKING..........................................................................173 CYLINDER HEAD AND CYLINDER LINER.................................................................173 COOLING SYSTEM PRESSURE TESTING......................................................................174 HOSES - INSPECTION...................................................................................175 COOLANT TEMPERATURE GAUGE - CHECKING.................................................................176 VENTING THE COOLING SYSTEM...........................................................................176 ENGINE VENT LINE.................................................................................176 RADIATOR PRESSURE CAP................................................................................177 TESTING..........................................................................................177 INSPECTION.......................................................................................177 RADIATOR AND CHARGE AIR COOLED FINS..................................................................178 INSPECTION.......................................................................................178 RADIATOR SHUTTER OPERATION...........................................................................178 SHUTTERSTATS.....................................................................................178 CHECKING - COOLING SYSTEM TEMPERATURE ACTUATION..................................................178 CHECKING - INTAKE AIR TEMPERATURE ACTUATION......................................................180 FAN INSPECTION.......................................................................................182 FAN SHROUD INSPECTION................................................................................183 FAN SPACER AND PULLEY INSPECTION.....................................................................183 FAN BELTS............................................................................................183 REMOVAL..........................................................................................183 INSPECTION.......................................................................................184 INSTALLATION.....................................................................................185 FAN AND FAN HUB......................................................................................186 REMOVAL..........................................................................................186 INSPECTION.......................................................................................187 INSTALLATION.....................................................................................188 VISCOUS FAN CLUTCH...................................................................................189 TESTING..........................................................................................189 REMOVAL..........................................................................................191 INSTALLATION.....................................................................................192 ON-OFF THERMATIC FAN CLUTCH..........................................................................192 CHECKING - COOLING SYSTEM TEMPERATURE ACTUATION..................................................192 CHECKING - INTAKE AIR TEMPERATURE ACTUATION......................................................194 REMOVAL..........................................................................................194 INSTALLATION.....................................................................................196 WATER PUMP BELTS.....................................................................................197 REMOVAL..........................................................................................197 INSPECTION.......................................................................................197 INSTALLATION.....................................................................................198 WATER PUMP IDLER PULLEY..............................................................................199 REMOVE...........................................................................................199 INSPECTION.......................................................................................199 INSTALLATION.....................................................................................200 WATER PUMP...........................................................................................200 REMOVAL..........................................................................................200 INSTALLATION.....................................................................................201 COOLANT FILTER HEAD INSERT...........................................................................203 REMOVAL..........................................................................................203 INSTALLATION.....................................................................................204 COOLANT FILTER SHUTOFF VALVE.........................................................................204 REMOVAL..........................................................................................204 INSPECTION.......................................................................................205 INSTALLATION.....................................................................................205 THERMOSTAT HOUSING...................................................................................206 REMOVAL..........................................................................................206 INSTALLATION.....................................................................................208 THERMOSTAT SEAL......................................................................................209 INSPECTION.......................................................................................209 REMOVAL..........................................................................................209 INSTALLATION.....................................................................................210 THERMOSTAT...........................................................................................210 TESTING - IN CHASSIS.............................................................................210 TESTING - OUT OF CHASSIS.........................................................................211 SECTION 2 - LUBRICATING SYSTEM...........................................................................212 LUBRICATING SYSTEM GENERAL INFORMATON................................................................214 LUBRICATING OIL PUMP PRESSURE REGULATOR..........................................................214 LUBRICATING OIL PUMP HIGH PRESSURE LIMIT VALVE...................................................216 LUBRICATING OIL FILTER BYPASS VALVE..............................................................217 LUBRICATING OIL COOLER OIL THERMOSTAT............................................................217 LUBRICATING OIL FILTER...........................................................................218 LUBRICATING OIL..................................................................................219 LUBRICATING OIL SYSTEM FLOW DIAGRAM..................................................................220 LUBRICATING OIL SYSTEM FLOW DIAGRAM..................................................................221 LUBRICATING OIL SYSTEM FLOW DIAGRAM - VISCOSITY SENSOR AND STC VALVE.................................222 LUBRICATING OIL SYSTEM SPECIFICATIONS................................................................223 LUBRICATING OIL SYSTEM SERVICE TOOLS.................................................................224 LUBRICATING OIL SYSTEM DIAGNOSTIC CHECKING...........................................................226 LUBRICATING OIL AND FILTER ANALYSIS..................................................................229 LUBRICATING OIL..................................................................................229 LUBRICATING OIL FILTER...........................................................................229 LUBRICATING OIL FILTER...............................................................................230 REMOVAL..........................................................................................230 CLEANING.........................................................................................230 INSTALLATION.....................................................................................230 LUBRICATING OIL LEAKS................................................................................231 CRANKCASE BREATHER...................................................................................232 REMOVAL..........................................................................................232 CLEANING AND INSPECTION..........................................................................232 INSTALLATION.....................................................................................233 DRAINING THE LUBRICATING OIL SYSTEM..................................................................234 FILLING THE LUBRICATING OIL SYSTEM...................................................................234 PRIMING THE LUBRICATING OIL SYSTEM...................................................................235 DIPSTICK TUBE AND HOUSING............................................................................236 REMOVAL..........................................................................................236 CLEANING AND INSPECTION..........................................................................236 INSTALLATION.....................................................................................237 DIPSTICK CALIBRATION.................................................................................237 LUBRICATING OIL TRANSFER TUBE........................................................................238 REMOVAL..........................................................................................238 CLEANING AND INSPECTION..........................................................................238 INSTALLATION.....................................................................................239 LUBRICATING OIL PAN..................................................................................240 REMOVAL..........................................................................................240 CLEANING AND INSPECTION..........................................................................240 INSTALLATION.....................................................................................241 LUBRICATING OIL PUMP.................................................................................242 REMOVAL..........................................................................................242 CLEANING AND INSPECTION..........................................................................242 INSTALLATION.....................................................................................244 HIGH LUBRICATING OIL PRESSURE RELIEF VALVE...........................................................245 REMOVAL..........................................................................................245 CLEANING AND INSPECTION..........................................................................246 TESTING..........................................................................................247 INSTALLATION.....................................................................................248 MAIN LUBRICATING OIL PRESSURE REGULATOR..............................................................250 REMOVAL..........................................................................................250 CLEANING AND INSPECTION..........................................................................250 INSTALLATION.....................................................................................251 LUBRICATING OIL PUMP SIGNAL LINE.....................................................................251 REMOVAL..........................................................................................251 CLEANING AND INSPECTION..........................................................................251 INSTALLATION.....................................................................................252 LUBRICATING OIL PUMP SIGNAL LINE ORIFICE (IN CHASSIS)................................................252 REMOVAL..........................................................................................252 CLEANING.........................................................................................253 INSTALLATION.....................................................................................253 VISCOSITY SENSOR - STC ENGINES.......................................................................254 REMOVAL..........................................................................................254 CLEANING AND INSPECTION..........................................................................255 INSTALLATION.....................................................................................257 LUBRICATING OIL COOLER ASSEMBLY......................................................................260 REMOVAL - ASSEMBLY...............................................................................260 REMOVAL - OIL COOLER CORE........................................................................262 REMOVAL - LUBRICATING OIL FILTER HEAD............................................................262 REMOVAL - LUBRICATING OIL FILTER BYPASS VALVE....................................................263 REMOVAL - OIL COOLER TRANSFER HOUSING............................................................263 REMOVAL - LUBRICATING OIL THERMOSTAT.............................................................264 CLEANING AND INSPECTION - LUBRICATING OIL COOLER ASSEMBLY........................................264 CLEANING AND INSPECTION - OIL COOLER CORE........................................................264 CLEANING AND INSPECTION - LUBRICATING OIL FILTER HEAD............................................265 CLEANING AND INSPECTION - LUBRICATING FILTER BYPASS VALVE........................................265 CLEANING AND INSPECTION - OIL COOLER TRANSFER HOUSING............................................266 CLEANING AND INSPECTION - OIL COOLER BYPASS VALVE................................................266 TESTING OIL COOLER CORE..........................................................................266 TESTING - OIL COOLER BYPASS VALVE................................................................268 INSTALLATION - OIL COOLER BYPASS VALVE...........................................................268 INSTALLATION - OIL COOLER TRANSFER HOUSING.......................................................269 INSTALLATION - LUBRICATING OIL FILTER HEAD.......................................................269 INSTALLATION - LUBRICATING OIL FILTER BYPASS VALVE...............................................269 INSTALLATION OIL COOLER CORE.....................................................................270 INSTALLATION - LUBRICATING OIL COOLER ASSEMBLY...................................................271 PISTON COOLING NOZZLES...............................................................................273 REMOVAL..........................................................................................273 CLEANING AND INSPECTION..........................................................................273 INSTALLATION.....................................................................................274 LUBRICATING OIL PRESSURE GAUGE.......................................................................275 TESTING..........................................................................................275 LUBRICATING OIL TEMPERATURE GAUGE....................................................................275 INSTALLATION.....................................................................................275 TESTING..........................................................................................276 SECTION 3 - COMBUSTION AIR SYSTEM........................................................................277 COMBUSTION AIR SYSTEM GENERAL INFORMATION............................................................278 AIR INTAKE SYSTEM FLOW DIAGRAM.......................................................................279 EXHAUST SYSTEM FLOW DIAGRAM..........................................................................280 COMBUSTION AIR SYSTEM SPECIFICATIONS.................................................................281 AIR INDUCTION SYSTEM.............................................................................281 EXHAUST SYSTEM...................................................................................281 COMBUSTION AIR SYSTEM SERVICE TOOLS..................................................................282 AIR LEAKS - TESTING..................................................................................283 TURBOCHARGER SEAL LEAK - TESTING.....................................................................284 TURBINE SEAL.....................................................................................284 TESTING - COMPRESSOR SEAL........................................................................286 TURBOCHARGER - VERIFYING CORRECT PART NUMBER.........................................................287 INTAKE AIR RESTRICTION...............................................................................288 CHECKING.........................................................................................288 EXHAUST RESTRICTION..................................................................................289 CHECKING.........................................................................................289 TURBOCHARGER BLADE DAMAGE............................................................................290 CHECKING.........................................................................................290 TURBOCHARGER AXIAL AND RADIAL CLEARANCE..............................................................291 CHECKING.........................................................................................291 RADIAL BEARING CLEARANCE - CHECKING..............................................................291 AXIAL CLEARANCE - CHECKING.......................................................................292 TURBOCHARGER REPLACEMENT.............................................................................293 REMOVAL..........................................................................................293 CLEANING AND INSPECTION..........................................................................294 INSTALLATION.....................................................................................296 EXHAUST MANIFOLD.....................................................................................298 REMOVAL..........................................................................................298 CLEANING AND INSPECTION..........................................................................299 INSTALLATION.....................................................................................299 INTAKE MANIFOLD......................................................................................301 REMOVAL..........................................................................................301 CLEANING AND INSPECTION..........................................................................302 INSTALLATION.....................................................................................302 CHARGE AIR COOLER....................................................................................303 PRESSURE DROP CHECKING...........................................................................303 CLEANING AND INSPECTION..........................................................................307 SECTION 4 - COMPRESSED AIR SYSTEM........................................................................309 COMPRESSED AIR SYSTEM GENERAL INFORMATION............................................................310 COMPRESSED AIR SYSTEM FLOW DIAGRAMS..................................................................312 COMPRESSED AIR SYSTEM SPECIFICATIONS.................................................................313 13.2 CFM SINGLE CYLINDER AIR COMPRESSOR (SS 296).................................................313 15.0 CFM SINGLE CYLINDER AIR COMPRESSOR (SS 338).................................................313 30.0 CFM TWO CYLINDER AIR COMPRESSOR (ST676).....................................................314 COMPRESSOR SPRING FORCE SPECIFICATIONS...........................................................315 COMPRESSED AIR SYSTEM SERVICE TOOLS..................................................................316 CARBON BUILDUP, AIR COMPRESSOR.......................................................................317 GASKET LEAKS, AIR COMPRESSOR.........................................................................319 CHECKING.........................................................................................319 COMPRESSOR UNLOADER VALVE............................................................................319 CHECKING.........................................................................................319 REMOVAL..........................................................................................320 CLEANING AND INSPECTION..........................................................................320 INSTALLATION.....................................................................................321 AIR GOVERNOR (AIR COMPRESSOR WILL NOT PUMP)..........................................................321 CHECKING.........................................................................................321 AIR GOVERNOR.........................................................................................322 CHECKING.........................................................................................322 AIR COMPRESSOR, CYLINDER HEAD........................................................................324 REMOVAL..........................................................................................324 INSPECTION.......................................................................................325 INSTALLATION.....................................................................................327 AIR COMPRESSOR.......................................................................................329 REMOVAL..........................................................................................329 INSPECTION.......................................................................................330 INSTALLATION.....................................................................................330 SECTION 5 - FUEL SYSTEM..................................................................................333 FUEL SYSTEM GENERAL INFORMATION......................................................................335 THEORY OF OPERATION - PT FUEL SYSTEM.............................................................336 THEORY OF OPERATION - STC........................................................................339 FUEL SYSTEM FLOW DIAGRAMS............................................................................344 PT (TYPE G) AFC FUEL PUMP........................................................................345 PT (TYPE G) AFC VS FUEL PUMP.....................................................................346 (PT (TYPE G) AFC PT-PACER FUEL PUMP..............................................................347 PT (TYPE D) STC INJECTOR.........................................................................348 FUEL SYSTEM SPECIFICATIONS...........................................................................349 BASIC APPLICATION REQUIREMENTS...................................................................349 FUEL OIL RECOMMENDATIONS.........................................................................350 FUEL SYSTEM - SERVICE TOOLS..........................................................................351 FUEL SYSTEM MISCELLANEOUS INFORMATION................................................................355 INSTALLATION PUBLICATIONS........................................................................355 OVERHEAD FUEL TANK REQUIREMENTS..................................................................355 PROPER USE OF FUEL SYSTEM GAUGES.................................................................356 FUEL SYSTEM MAINTENANCE..............................................................................358 FUEL FILTER......................................................................................358 FUEL LINES AND BRACKETS..........................................................................359 FUEL PUMP............................................................................................361 REMOVE (NON-PT PACER)............................................................................361 CLEANING AND INSPECTION..........................................................................362 FUEL PUMP TO AIR COMPRESSOR (NON-PT PACER) - INSTALLATION........................................362 FUEL PUMP TO ACCESSORY DRIVE - INSTALLATION......................................................363 THROTTLE LEVER BREAKOVER - CHECKING..............................................................365 VARIABLE SPEED (VS) THROTTLE LINKAGE ADJUSTMENT..................................................365 REMOVAL (P.T. PACER).............................................................................366 INSTALLATION (P.T. PACER)........................................................................370 FUEL PUMP FLOW CHECKING, ROTATION AND PRIMING........................................................374 FLOW CHECKING....................................................................................374 PRIMING..........................................................................................374 CHECKING ROTATION................................................................................375 FUEL PUMP SHUTOFF VALVE..............................................................................376 FUEL PUMP ON-ENGINE ADJUSTMENT.......................................................................378 IDLE SPEED.......................................................................................378 VS GOVERNOR......................................................................................380 AIR ACTUATED ROAD SPEED GOVERNOR.................................................................381 AIR ACTUATED ROAD SPEED GOVERNOR.....................................................................381 VS THROTTLE SHAFT....................................................................................382 REMOVAL..........................................................................................382 INSTALLATION.....................................................................................384 VS GOVERNOR ADJUSTING SCREW SEALING JAM NUTS.........................................................385 REMOVAL..........................................................................................385 INSTALLATION.....................................................................................385 VS GOVERNOR IDLE SPRING..............................................................................385 REMOVAL..........................................................................................385 INSTALLATION.....................................................................................386 FUEL GEAR PUMP CHECK VALVE...........................................................................386 REMOVAL..........................................................................................386 INSTALLATION.....................................................................................387 INJECTORS............................................................................................388 REMOVAL - STC INJECTORS..........................................................................388 INSTALLATION - STC INJECTORS.....................................................................389 STC OIL CONTROL VALVE................................................................................392 TESTING..........................................................................................392 REMOVAL..........................................................................................395 INSTALLATION.....................................................................................396 STC OIL VALVE PLUMBING SCHEMATIC.................................................................397 STC OIL DELIVERY SYSTEM DIAGNOSTIC TESTING...........................................................397 STC OIL DELIVERY SYSTEM BLOCKAGE - OIL RIFLE TO OIL MANIFOLD.........................................399 STC OIL DELIVERY SYSTEM BLOCKAGE/LEAKAGE - OIL MANIFOLD TO INJECTORS.................................400 CYLINDER MISFIRING/SMOKING LOCATION..................................................................402 CYLINDER CUTOUT..................................................................................402 EXHAUST MANIFOLD TEMPERATURE.....................................................................403 TILTING BACK EXHAUST MANIFOLD....................................................................403 AIR IN FUEL TESTING..................................................................................403 FUEL SUCTION LINE (GEAR PUMP DRAIN)..............................................................403 FUEL SUCTION LINE (SIGHTGLASS)...................................................................406 AIR ACTUATED ROAD SPEED GOVERNOR.................................................................407 LUBRICATING OIL DILUTION BY FUEL TESTING.............................................................409 BLACK LIGHT METHOD (PREFERRED)...................................................................409 FUEL PASSAGE PRESSURIZE METHOD (OPTIONAL)........................................................409 FUEL PUMP INLET RESTRICTION..........................................................................412 FUEL PUMP DRAIN LINE RESTRICTION.....................................................................413 AFC NO-AIR CHECK.....................................................................................414 POWER CHECK..........................................................................................417 FUEL CONSUMPTION CHECK...............................................................................417 THROTTLE RESPONSE TEST...............................................................................422 STC ENGINE.......................................................................................422 STALL SPEED TESTING..................................................................................425 CONVERTER STALL SPEED CHECKING...................................................................425 TIME TO STALL CHECKING...........................................................................428 OPERATING IN NORMAL TIMING...........................................................................429 STALL SPEED CHECK LIST...............................................................................430 STALL SPEED TOO LOW..............................................................................430 STALL SPEED TOO HIGH.............................................................................431 VE/VMS - ROAD TEST - THROTTLE RESPONSE TEST WORKSHEET................................................432 SECTION 6 - ELECTRICAL SYSTEM............................................................................433 ELECTRICAL SYSTEM GENERAL INFORMATION................................................................434 STARTING SYSTEM SPECIFICATIONS.......................................................................435 ELECTRICAL SYSTEM SERVICE TOOLS......................................................................436 BATTERIES............................................................................................437 CHECKING.........................................................................................437 BATTERY CABLES AND CONNECTIONS.......................................................................437 CHECKING.........................................................................................437 STARTER CONNECTIONS..................................................................................438 CHECKING.........................................................................................438 ALTERNATOR BELT......................................................................................439 ADJUSTMENT.......................................................................................439 ALTERNATOR REPLACEMENT...............................................................................440 REMOVAL..........................................................................................440 INSTALLATION.....................................................................................441 STARTING MOTOR REPLACEMENT...........................................................................442 REMOVAL..........................................................................................442 INSTALLATION.....................................................................................442 SECTION 7 - BASE ENGINE COMPONENTS.......................................................................444 BASE ENGINE COMPONENTS GENERAL INFORMATION...........................................................448 BASE ENGINE COMPONENTS SERVICE TOOLS.................................................................449 ROCKER HOUSING COVERS................................................................................456 REMOVAL..........................................................................................456 CLEANING AND INSPECTION..........................................................................456 INSTALLATION.....................................................................................457 ENGINE LIFTING BRACKETS..............................................................................458 REMOVAL..........................................................................................458 CLEANING AND INSPECTION..........................................................................458 INSTALLATION.....................................................................................458 ENGINE LIFTING BRACKET - SERVICE BRACKET.............................................................459 INSPECTION.......................................................................................459 INSTALLATION.....................................................................................459 REMOVAL..........................................................................................460 OVERHEAD ADJUSTMENT..................................................................................461 INJECTORS - STC ENGINE - OBC METHOD..............................................................462 VALVES - STC ENGINES.............................................................................466 INJECTORS - STC ENGINES - IBC METHOD.............................................................468 VALVES - STC ENGINES.............................................................................472 INJECTORS - CELECT ENGINES.......................................................................474 VALVES - CELECT ENGINES..........................................................................478 ENGINE BRAKE ADJUSTMENT..............................................................................480 ENGINE BRAKE - C-BRAKE...........................................................................480 ENGINE BRAKE REPLACE.................................................................................484 REMOVAL..........................................................................................484 CLEANING AND INSPECTION..........................................................................485 INSTALLATION.....................................................................................486 PUSH RODS REPLACE....................................................................................487 REMOVAL..........................................................................................487 INSPECTION.......................................................................................488 INSTALLATION.....................................................................................489 STC OIL PLUMBING ....................................................................................490 REMOVAL..........................................................................................490 CLEANING AND INSPECTION..........................................................................493 INSTALLATION.....................................................................................494 ROCKER LEVERS REPLACE................................................................................496 REMOVAL..........................................................................................496 CLEANING AND INSPECTION..........................................................................497 ASSEMBLE.........................................................................................499 ROCKER LEVER HOUSINGS REPLACEMENT....................................................................500 REMOVAL..........................................................................................500 CLEANING AND INSPECTION..........................................................................503 INSTALLATION.....................................................................................504 CYLINDER BLOCK COUNTERBORE LEAK......................................................................511 INSPECTION.......................................................................................511 CYLINDER BLOCK DECK SURFACE..........................................................................512 INSPECTION FOR REUSE.............................................................................512 CYLINDER BLOCK COUNTERBORE - LEAK TESTING............................................................512 CYLINDER HEAD CAPSCREW HOLES.........................................................................516 CHECKING.........................................................................................516 CYLINDER HEAD CAPSCREW HOLE..........................................................................516 SALVAGING........................................................................................516 BLOCK PREPARATION TO PREVENT CONTAMINATION FROM MACHINING DEBRIS.................................516 REPAIR PROCEDURE.................................................................................517 CYLINDER LINER PROTRUSION............................................................................521 LINER INSTALLATION TOOL..........................................................................521 CYLINDER HEAD GASKET(S) REPLACEMENT..................................................................523 CYLINDER HEADS REPLACE...............................................................................525 REMOVAL..........................................................................................525 CLEANING AND INSPECTION..........................................................................527 VALVE-TO-SEAL LEAKAGE TEST.......................................................................530 INSTALLATION.....................................................................................533 FLANGE HEAD CAPSCREW INSTALLATION................................................................534 CYLINDER HEAD PRESSURE TESTING.......................................................................538 OFF ENGINE LEAK TEST.............................................................................538 ON-ENGINE LEAK TEST..............................................................................540 CAM FOLLOWERS REPLACE................................................................................542 REMOVAL..........................................................................................542 DISASSEMBLE......................................................................................543 CLEANING AND INSPECTION..........................................................................544 INSPECTION.......................................................................................545 ASSEMBLE.........................................................................................546 INSTALLATION.....................................................................................547 INJECTION TIMING (GENERAL INFORMATION)...............................................................548 INJECTION TIMING.....................................................................................549 TIMING TOOL INSTALLATION.........................................................................550 MAIN AND THRUST BEARINGS REPLACE.....................................................................558 REMOVAL..........................................................................................558 CLEANING AND INSPECTION..........................................................................560 INSTALLATION.....................................................................................561 CONNECTING ROD BEARINGS REPLACEMENT..................................................................567 REMOVAL..........................................................................................567 CLEANING AND INSPECTION..........................................................................568 INSTALLATION.....................................................................................570 PISTONS AND RINGS REPLACEMENT........................................................................572 REMOVAL..........................................................................................572 CLEANING AND INSPECTION..........................................................................577 INSTALLATION.....................................................................................580 CONNECTING RODS REPLACEMENT..........................................................................585 REMOVAL..........................................................................................585 CLEANING AND INSPECTION..........................................................................586 INSTALLATION.....................................................................................588 CYLINDER LINERS REPLACEMENT..........................................................................591 REMOVAL..........................................................................................591 3376015 LINER PULLER.............................................................................592 6675629 LINER PULLER.............................................................................593 CLEANING AND INSPECTION..........................................................................594 INSTALLATION.....................................................................................602 LINER INSTALLATION TOOL..........................................................................603 ACCESSORY DRIVE PULLEY REPLACEMENT...................................................................607 REMOVAL..........................................................................................607 INSPECTION.......................................................................................608 INSTALLATION.....................................................................................608 WEAR SLEEVE, ACCESSORY DRIVE PULLEY REPLACEMENT......................................................609 REMOVAL..........................................................................................609 CLEANING AND INSPECTION..........................................................................610 INSTALLATION.....................................................................................610 SEAL, ACCESSORY DRIVE REPLACEMENT....................................................................611 REMOVAL..........................................................................................611 CLEANING AND INSPECTION..........................................................................611 INSTALLATION.....................................................................................612 ACCESSORY DRIVE REPLACEMENT..........................................................................613 REMOVAL..........................................................................................613 CLEANING.........................................................................................615 INSPECTION.......................................................................................616 INSTALLATION.....................................................................................617 VIBRATION DAMPER.....................................................................................619 REMOVAL..........................................................................................619 CLEANING AND INSPECTION..........................................................................620 INSTALLATION.....................................................................................621 CRANKSHAFT PULLEY REPLACEMENT........................................................................623 REMOVAL..........................................................................................623 INSPECTION.......................................................................................623 INSTALLATION.....................................................................................624 SEAL, FRONT CRANKSHAFT REPLACEMENT...................................................................624 REMOVAL..........................................................................................624 CLEANING AND INSPECTION..........................................................................625 INSTALLATION.....................................................................................626 CAMSHAFT BEARING SUPPORT REPLACEMENT.................................................................627 REMOVAL..........................................................................................627 CLEANING AND INSPECTION..........................................................................628 INSTALLATION.....................................................................................628 FRONT ENGINE SUPPORT BRACKET REPLACEMENT.............................................................630 REMOVAL..........................................................................................630 CLEANING AND INSPECTION..........................................................................631 INSTALLATION.....................................................................................631 GEAR COVER REPLACEMENT...............................................................................632 REMOVAL..........................................................................................632 CLEANING AND INSPECTION..........................................................................634 INSTALLATION.....................................................................................635 CRANKSHAFT GEAR REPLACEMENT..........................................................................638 REMOVAL..........................................................................................638 CLEANING AND INSPECTION..........................................................................639 INSTALLATION.....................................................................................640 CAMSHAFT REPLACEMENT.................................................................................641 REMOVAL..........................................................................................641 CLEANING AND INSPECTION..........................................................................642 INSTALLATION.....................................................................................644 CAMSHAFT GEAR REPLACEMENT............................................................................647 REMOVAL (CAMSHAFT REMOVED).......................................................................647 CLEANING AND INPECTION...........................................................................647 INSTALLATION (CAMSHAFT REMOVED)..................................................................649 CAMSHAFT BUSHING REPLACEMENT.........................................................................651 REMOVAL..........................................................................................651 CLEANING AND INSPECTION..........................................................................652 INSTALLATION.....................................................................................653 FLYWHEEL REPLACEMENT.................................................................................657 REMOVAL..........................................................................................657 CLEANING AND INSPECTION..........................................................................658 INSTALLATION.....................................................................................659 SEAL, REAR CRANKSHAFT REPLACEMENT....................................................................664 REMOVAL..........................................................................................664 CLEANING AND INSPECTION..........................................................................665 INSTALLATION.....................................................................................665 FLYWHEEL HOUSING REPLACEMENT.........................................................................668 REMOVAL..........................................................................................668 CLEANING AND INSPECTION..........................................................................669 INSTALLATION.....................................................................................670 FLYWHEEL HOUSING REDOWEL TO CYLINDER BLOCK...........................................................676 STRAIGHT THREAD PLUGS, PIPE PLUGS AND CUP PLUGS REPLACEMENT..........................................682 STRAIGHT THREAD PLUGS - REMOVAL..................................................................682 STRAIGHT THREAD FITTINGS - CLEANING AND INSPECTION...............................................682 STRAIGHT THREAD PLUGS - INSTALLATION.............................................................682 STRAIGHT THREAD FITTINGS - INSTALLATION..........................................................683 PIPE PLUGS - REMOVAL.............................................................................684 CLEANING AND INSPECTION..........................................................................684 PIPE PLUGS - INSTALLATION........................................................................685 CUP PLUGS - REMOVAL..............................................................................686 CLEANING AND INSPECTION..........................................................................686 CUP PLUGS - INSTALLATION.........................................................................687 STRAIGHT THREAD PLUGS - REMOVAL..................................................................682 SECTION 8 - ENGINE TESTING...............................................................................688 ENGINE TESTING GENERAL INFORMATION...................................................................689 IN-SERVICE RUN-IN................................................................................689 ENGINE DYNAMOMETER RUN-IN........................................................................689 CHASSIS DYNAMOMETER, PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN....................................689 DEFINITIONS OF TERMS ON ENGINE PERFORMANCE CURVE.....................................................690 CUMMINS N14 HEAVY DUTY ENGINE OPERATING CURVE DEFINITIONS........................................690 GENERAL RUN-IN PROCEDURES............................................................................691 GENERAL ENGINE TEST/RUN-IN SPECIFICATIONS............................................................693 ENGINE TESTING - SERVICE TOOLS.......................................................................694 ENGINE DYNAMOMETER - INSTALL ENGINE..................................................................696 COOLANT PLUMBING.................................................................................696 INTAKE AIR TEMPERATURE CONTROL...................................................................697 AIR INLET RESTRICTION............................................................................699 EXHAUST RESTRICTION..............................................................................699 LUBRICATING OIL TEMPERATURE......................................................................699 LUBRICATING OIL PRESSURE.........................................................................699 INTAKE MANIFOLD PRESSURE.........................................................................700 ENGINE BLOWBY....................................................................................700 FUEL RATE........................................................................................700 FUEL INLET RESTRICTION...........................................................................701 ENGINE SPEED (RPM) WITH A VERIFIED TECHOMETER....................................................701 FUEL PRESSURE....................................................................................701 FUEL DRAIN LINE RESTRICTION......................................................................702 AIR COMPRESSOR...................................................................................702 STARTING MOTOR...................................................................................703 CELECT ENGINE THROTTLE CONTROL...................................................................703 FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER..............................................707 INSTALLATION.....................................................................................707 OPERATION........................................................................................708 INTAKE MANIFOLD BOOST PRESSURE CORRECTION FACTORS....................................................710 ENGINE RUN-IN PROCEDURE - ENGINE DYNAMOMETER.........................................................721 DYNAMOMETER WORKSHEET................................................................................725 CHASSIS DYNAMOMETER OPERATION........................................................................726 GENERAL TEST PROCEDURE - CHASSIS DYNAMOMETER.........................................................728 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER....................................................729 FUEL PRESSURE (STC ENGINES ONLY).................................................................729 FUEL RATE........................................................................................730 FUEL INLET RESTRICTION...........................................................................730 FUEL DRAIN LINE RESTRICTION......................................................................731 INTAKE MANIFOLD PRESSURE.........................................................................732 INTAKE AIR TEMPERATURE CONTROL - CHASSIS DYNAMOMETER TEST........................................732 CHARGE AIR COOLER RESTRICTION....................................................................733 INTAKE AIR RESTRICTION...........................................................................734 EXHAUST AIR RESTRICTION..........................................................................734 ENGINE BLOWBY....................................................................................735 LUBRICATING OIL PRESSURE.........................................................................736 COOLANT PRESSURE.................................................................................736 ENGINE RUN-IN PROCEDURE - CHASSIS DYNAMOMETER........................................................736 ENGINE RUN-IN PROCEDURE WITHOUT DYNAMOMETER..........................................................740 ON-HIGHWAY.......................................................................................740 OFF-HIGHWAY......................................................................................740 SECTION 9 - ENGINE REMOVE AND INSTALL....................................................................741 ENGINE REMOVE AND INSTALL GENERAL INFORMATION........................................................742 ENGINE REMOVE AND INSTALL SERVICE TOOLS..............................................................743 ENGINE REMOVAL.......................................................................................744 ENGINE MOUNTS INSPECTION.............................................................................749 ENGINE INSTALLATION..................................................................................749 SECTION V - ENGINE COMPONENT SPECIFICATIONS..............................................................752 ENGINE COMPONENT SPECIFICATIONS GENERAL INFORMATION..................................................753 TITLE OF PUBLICATION.............................................................................753 COMPONENT SPECIFICATIONS AND TORQUE VALUES...........................................................754 COOLING SYSTEM SPECIFICATIONS - SECTION 1........................................................754 COOLING SYSTEM TORQUE VALUES.....................................................................755 LUBRICATING OIL SYSTEM SPECIFICATIONS - SECTION 2................................................758 LUBRICATING SYSTEM TORQUE VALUES.................................................................759 COMBUSTION AIR SYSTEM SPECIFICATIONS - SECTION 3.................................................763 COMBUSTION AIR SYSTEM TORQUE VALUES..............................................................764 COMPRESSED AIR SYSTEM SPECIFICATIONS - SECTION 4.................................................766 COMPRESSED AIR SYSTEM TORQUE VALUES..............................................................766 FUEL SYSTEM SPECIFICATIONS - SECTION 5...........................................................768 FUEL SYSTEM TORQUE VALUES........................................................................770 ELECTRICAL SYSTEM SPECIFICATIONS - SECTION 6.....................................................774 ELECTRICAL SYSTEM TORQUE VALUES..................................................................774 BASE ENGINE COMPONENTS SPECIFICATIONS - SECTION 7................................................776 BASE ENGINE COMPONENTS TORQUE VLAUES.............................................................784 INJECTION TIMING CODES...........................................................................789 DRIVE BELT TENSION ..................................................................................790 FRACTION, DECIMAL, MILLIMETER CONVERSIONS............................................................791 WEIGHT AND MEASURES - CONVERSION FACTORS.............................................................792 NEWTON-METER TO FOOT POUND CONVERSION CHART..........................................................793 CAPSCREW MARKINGS AND TORQUE VALUES..................................................................794 CAPSCREW MARKINGS AND TORQUE VALUES - METRIC.....................................................795 CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY.............................................796 PIPE PLUG TORQUE VALUES..............................................................................797 TORQUE VALUES FOR STRAIGHT THREAD FITTINGS AND PLUGS.................................................797 TAP-DRILL CHART - U.S. CUSTOMARY & METRIC............................................................798 SECTION L - SERVICE LITERATURE...........................................................................799 ADDITIONAL SERVICE LITERATURE........................................................................800 SERVICE LITERATURE ORDERING LOCATION.................................................................801 LITERATURE ORDER FORM................................................................................802 SECTION C - COMPONENT MANUFACTURERS......................................................................804 COMPONENT MANUFACTURERS' ADDRESSES...................................................................805 AIR COMPRESSORS..................................................................................805 AIR CYLINDERS....................................................................................805 AIR HEATERS......................................................................................805 AIR STARTING MOTORS..............................................................................805 ALTERNATORS......................................................................................805 AUXILIARY BRAKES.................................................................................805 BELTS............................................................................................805 CLUTCHES.........................................................................................805 COOLANT HEATERS..................................................................................805 DRIVE PLATES.....................................................................................805 ELECTRIC STARTING MOTORS.........................................................................805 ENGINE PROTECTION CONTROLS.......................................................................806 FAN CLUTCHES.....................................................................................806 FANS.............................................................................................806 FILTERS..........................................................................................806 FLEXPLATES.......................................................................................806 FUEL WARMERS.....................................................................................806 GAUGES...........................................................................................806 GOVERNORS........................................................................................806 HYDRAULIC AND POWER STEERING PUMPS...............................................................806 OIL HEATERS......................................................................................807 TORQUE CONVERTERS................................................................................807 INDEX....................................................................................................808
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