Cummins Repair Manual NT855 Engine Big Cam III and Big Cam IV – PDF DOWNLOAD

Description

Cummins Repair Manual NT855 Engine Big Cam III and Big Cam IV

FILE DETAILS:

Cummins Repair Manual NT855 Engine Big Cam III and Big Cam IV

Language : English
Pages : 693
Downloadable : Yes
File Type : PDF
Size: 45.9 MB

CUMMINS REPAIR MANUAL NT855 ENGINE BIG CAM III AND BIG CAM IV – PDF DOWNLOAD:

DESCRIPTION:

Cummins Repair Manual NT855 Engine Big Cam III and Big Cam IV

FOREWORD:

• This manual provides instructions for troubleshooting and repairing the NT 855 engine in the chassis. Component and assembly rebuild procedures are provided in the NT 855 Engine Shop Manual. Refer to page 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.
• 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 Repair Manual NT855 Engine Big Cam III and Big Cam IV

MAIN MENU.......................................................................................  0
COVER PAGE......................................................................................  0
FOREWORD........................................................................................  2
TABLE OF CONTENTS...............................................................................  3
SECTION I  INTRODUCTION.........................................................................  4
	ABOUT THE MANUAL............................................................................  5
	HOW TO USE THE MANUAL.......................................................................  5
	SYMBOLS.....................................................................................  6
	ILLUSTRATIONS............................................................................... 10
	DEFINITION OF TERMS......................................................................... 11
	GENERAL REPAIR INSTRUCTIONS................................................................. 12
	GENERAL CLEANING INSTRUCTIONS............................................................... 13
SECTION E ENGINE IDENTIFICATION  ............................................................... 14
	ENGINE IDENTIFICATION....................................................................... 15
	ENGINE SPECIFICATIONS....................................................................... 16
	ENGINE DIAGRAMS............................................................................. 18
SECTION T TROUBLESHOOTING....................................................................... 20
	PROCEDURES AND TECHNIQUES................................................................... 20
	TROUBLESHOOTING SYMPTOMS.................................................................... 21
		COOLANT TEMPERATURE ABOVE NORMAL........................................................ 22
		COOLANT TEMPERATURE BELOW NORMAL........................................................ 25
		LOSS OF ENGINE COOLANT (OVERFLOW)....................................................... 27
		LOSS OF ENGINE COOLANT (EXTERNAL LEAKAGE)............................................... 28
		LOSS OF ENGINE COOLANT (INTERNAL LEAKAGE)............................................... 30
		FUEL IN COOLANT......................................................................... 31
		LOW LUBRICATING OIL PRESSURE............................................................ 32
		HIGH LUBRICATING OIL PRESSURE........................................................... 34
		LUBRICATING OIL TEMPERATURE ABOVE NORMAL................................................ 35
		LUBRICATING OR HYDRAULIC OIL IN THE COOLANT............................................. 36
		EXCESSIVE LUBRICATING OIL CONSUMPTION................................................... 37
		EXCESSIVE LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE................................ 39
		COOLANT IN THE LUBRICATING OIL.......................................................... 40
		FUEL IN THE LUBRICATING OIL............................................................. 41
		TURBOCHARGER NOISE...................................................................... 42
		LOW POWER OR EXCESSIVE SMOKE (LOW TURBOCHARGER BOOST PRESSURE).......................... 43
		TURBOCHARGER LEAKS (ENGINE OIL OR FUEL)................................................. 44
		AIR COMPRESSOR AIR PRESSURE RISES SLOWLY................................................ 45
		AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)....... 46
		EXCESSIVE AMOUNT OF OIL PASSING THROUGH AIR COMPRESSOR.................................. 47
		AIR COMPRESSOR WILL NOT PUMP AIR PRESSURE............................................... 48
		AIR COMPRESSOR WILL NOT STOP PUMPING AIR................................................ 49
		EXCESSIVE AIR COMPRESSOR NOISE.......................................................... 50
		ENGINE CRANKS, BUT WILL NOT START (NO SMOKE FROM EXHAUST)............................... 51
		ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE PRESENT).......................... 53
		ENGINE STARTS BUT WILL NOT KEEP RUNNING................................................. 55
		WARM ENGINE RUNS ROUGH OR MISFIRES IN OPERATING RANGE................................... 57
		ROUGH IDLE.............................................................................. 59
		ENGINE SURGES AT LOW IDLE............................................................... 61
		ENGINE WILL NOT REACH RATED SPEED WHEN LOADED........................................... 62
		LOW POWER............................................................................... 64
		EXHAUST SMOKE EXCESSIVE UNDER LOAD...................................................... 68
		ENGINE WILL NOT SHUT OFF................................................................ 70
		POOR DECELERATION....................................................................... 71
		ENGINE SURGES UNDER LOAD AT RATED SPEED - WIDE OPEN THROTTLE............................ 72
		ENGINE SURGES AT HIGH IDLE.............................................................. 73
		SURGE IN TOP GEAR - ROAD SPEED GOVERNOR NOT SET CORRECTLY............................... 74
		VARIABLE SPEED (VS) GOVERNOR SURGE - ENGINE UNDER LOAD.................................. 75
		FUEL LEAKAGE AT VARIABLE SPEED (VS) GOVERNOR............................................ 76
		VARIABLE SPEED GOVERNOR SPEED IS NOT SET CORRECTLY...................................... 77
		THROTTLE RESPONSE SLOW (ENGINE DIES GOING DOWNHILL)..................................... 78
		EXCESSIVE FUEL CONSUMPTION.............................................................. 79
		ENGINE WILL NOT CRANK OR CRANKS SLOWLY.................................................. 80
		AMMETER/VOLTMETER INDICATES ALTERNATOR IS NOT CHARGING, OR CHARGING AT A LOW RATE....... 81
		EXCESSIVE CRANKCASE GASES (BLOWBY)...................................................... 82
		EXCESSIVE ENGINE VIBRATION.............................................................. 83
		EXCESSIVE ENGINE NOISE.................................................................. 84
		MECHANICAL VARIABLE TIMING (MVT) WILL NOT SWITCH TO ADVANCED OR RETARDED TIMING MODE.... 85
		WHITE SMOKE - GENERAL INFORMATION....................................................... 86
		EXCESSIVE WHITE SMOKE AT IDLE........................................................... 87
		GENERAL ENGINE NOISE DIAGNOSTIC PROCEDURES.............................................. 89
		MAIN BEARING NOISE...................................................................... 90
		CONNECTING ROD BEARING NOISE............................................................ 91
		PISTON NOISE............................................................................ 92
SECTION 1 COOLING SYSTEM........................................................................ 94
	SERVICE TOOLS .............................................................................. 96
	GENERAL INFORMATION ........................................................................ 97
	SPECIFICATIONS .............................................................................101
	FLOW CHARTS ................................................................................106
	VENTING.....................................................................................109
	COOLING SYSTEM, MAINTENANCE ................................................................111
	COOLING SYSTEM, DRAIN ......................................................................111
	COOLING SYSTEM, FILL .......................................................................112
	COOLANT FILTER-REPLACE .....................................................................114
	DIESEL COOLANT ADDITIVES (DCA4) ............................................................115
	COOLING SYSTEM, CLEAN ......................................................................117
	COOLING SYSTEM - TEST FOR AIR OR COMBUSTION GASES...........................................119
	COOLING SYSTEM-PRESSURE TEST ...............................................................125
	HOSES-CHECK ................................................................................126
	COOLANT TEMPERATURE GAUGE-CHECK ............................................................127
	RADIATOR PRESSURE CAP-CHECK ................................................................127
	RADIATOR FINS-INSPECT ......................................................................128
	SHUTTER OPERATION-CHECK ....................................................................128
	FAN SHROUD SPACER & PULLEY-INSPECT .........................................................130
	WATER PUMP BELT-REPLACE ....................................................................131
	FAN DRIVE BELTS-REPLACE ....................................................................134
	ON-OFF FAN CLUTCH-CHECK ....................................................................136
	FAN CLUTCH, AIR ENGAGED TYPE ...............................................................138
	FAN CLUTCH, AIR DISENGAGED TYPE ............................................................138
	ON-OFF FAN CLUTCH-REPLACE ..................................................................139
	FAN CLUTCH VISCOUS TYPE ....................................................................141
	FAN HUB-REPLACE ............................................................................145
	IDLER PULLEY ASSEMBLY, WATER PUMP (BIG CAM IV AND NEW BIG CAM IV) -REPLACE .................147
	WATER PUMP- REPLACE ........................................................................148
	THERMOSTAT (BIG CAM III) - TEST "THERMOSTAT IN CHASSIS".....................................152
	THERMOSTAT (BIG CAM III) - REPLACE..........................................................153
	THERMOSTAT (BIG CAM III) - TEST "THERMOSTAT REMOVED"........................................155
	THERMOSTAT SEAL (BIG CAM III) - REPLACE.....................................................156
	THERMOSTAT, RADIATOR (BIG CAM IV) - CHECK...................................................157
	THERMOSTAT, BYPASS (BIG CAM IV) - CHECK.....................................................158
	THERMOSTAT HOUSING (BIG CAM IV) - REPLACE...................................................161
	THERMOSTAT (BIG CAM IV) - REPLACE...........................................................164
	THERMOSTAT SEAL, BYPASS (BIG CAM IV) - REPLACE..............................................166
	THERMOSTAT SEAL, RADIATOR (BIG CAM IV) - REPLACE............................................168
	THERMOSTAT HOUSING CHECK VALVE O-RINGS (BIG CAM IV) - REPLACE...............................169
	THERMOSTAT HOUSING CHECK VALVE ASSEMBLY (BIG CAM IV) - REPLACE..............................171
	RADIATOR CHECK VALVE LEAKAGE (BIG CAM IV ONLY) - CHECK......................................175
	AFTERCOOLER FILTER SCREEN (BIG CAM IV ONLY) - CLEAN.........................................177
	WATER MANIFOLD SEALING RING BALANCE ORIFICES (BIG CAM IV ONLY) - REPLACE....................178
	RADIATOR BAFFLE LEAKAGE (BIG CAM IV ONLY) - CHECK...........................................182
	RADIATOR (TWO-PASS, VERTICAL-FLOW) - CHECK..................................................182
	RADIATOR (HORIZONTAL-FLOW) - CHECK..........................................................183
	RADIATOR (THREE-PASS, VERTICAL-FLOW) - CHECK................................................183
	HEAD GASKET, CYLINDER LINER, CREVICE SEAL OR CYLINDER BLOCK - INSPECT FOR COOLANT LEAKS.....184
SECTION 2 LUBRICATING OIL SYSTEM................................................................186
	SERVICE TOOLS...............................................................................187
	GENERAL INFORMATION.........................................................................188
	DEMAND FLOW AND COOLING LUBRICATING SYSTEM - OPERATION......................................189
	SPECIFICATIONS..............................................................................192
	FLOW DIAGRAMS...............................................................................193
	INTERNAL ENGINE DAMAGE - CHECK..............................................................194
	OIL LEAKS (EXTERNAL) - CHECK................................................................195
	OIL PRESSURE GAUGE - CHECK..................................................................196
	OIL TEMPERATURE GAUGE - CHECK...............................................................196
	OIL PAN, DRAIN..............................................................................197
	OIL PAN, FILL...............................................................................197
	OIL FILTERS (FULL FLOW AND BYPASS) - REPLACE................................................198
	CRANKCASE BREATHER AND TUBE - REPLACE.......................................................200
	DIPSTICK TUBE AND HOUSING - REPLACE.........................................................202
	DIPSTICK - CALIBRATE........................................................................203
	OIL TRANSFER TUBE - REPLACE.................................................................204
	OIL PAN - REPLACE...........................................................................206
	OIL COOLER BYPASS VALVE - CHECK.............................................................208
	OIL FILTER HEAD - REPLACE...................................................................210
	OIL COOLER ASSEMBLY - REPLACE...............................................................212
	OIL COOLER CORE - REPLACE...................................................................216
	OIL COOLER CORE - PRESSURE TEST.............................................................221
	MAIN OIL PRESSURE REGULATOR - REPLACE.......................................................223
	LUBRICATING OIL PUMP SIGNAL LINE ORIFICE - CLEAN "IN CHASSIS"...............................224
	LUBRICATING OIL PUMP SIGNAL LINE ORIFICE - CLEAN "PUMP REMOVED".............................225
	LUBRICATING OIL PUMP - REPLACE..............................................................228
	HIGH OIL PRESSURE RELIEF VALVE - CHECK......................................................231
	HIGH OIL PRESSURE RELIEF VALVE REPLACE......................................................232
SECTION 3 COMBUSTION AIR SYSTEM.................................................................236
	GENERAL INFORMATION.........................................................................237
	SPECIFICATIONS..............................................................................238
	FLOW DIAGRAMS...............................................................................239
	SERVICE TOOLS...............................................................................240
	TURBOCHARGER TURBINE SEAL LEAKS CHECK.......................................................240
	COMPRESSOR SEAL LEAKAGE - CHECK.............................................................242
	CORRECT TURBOCHARGER INSTALLED - CHECK......................................................243
	INTAKE AIR RESTRICTION - CHECK..............................................................243
	EXHAUST RESTRICTION - CHECK.................................................................244
	AIR LEAKS - CHECK...........................................................................245
	TURBOCHARGER BLADE DAMAGE - CHECK...........................................................247
	TURBOCHARGER AXIAL AND RADIAL CLEARANCE - CHECK.............................................248
	TURBOCHARGER - REPLACE......................................................................249
	SERIES TURBOCHARGER - REPLACE...............................................................254
	EXHAUST MANIFOLD - REPLACE..................................................................260
	AFTERCOOLER - REPLACE.......................................................................263
	AFTERCOOLER - PRESSURE TEST.................................................................270
SECTION 4 COMPRESSED AIR SYSTEM.................................................................272
	GENERAL INFORMATION.........................................................................273
	SPECIFICATIONS .............................................................................274
	FLOW DIAGRAMS...............................................................................276
	SERVICE TOOLS...............................................................................277
	CARBON BUILDUP, AIR COMPRESSOR CHECK........................................................277
	GASKET LEAKS, AIR COMPRESSOR - CHECK........................................................281
	AIR GOVERNOR AND COMPRESSOR UNLOADER VALVE - CHECK..........................................282
	AIR GOVERNOR - CHECK........................................................................284
	LUBRICATING OIL USAGE, AIR COMPRESSOR - CHECK...............................................286
	UNLOADER VALVE -CHECK.......................................................................287
	AIR COMPRESSOR, CYLINDER HEAD - REPLACE.....................................................289
	AIR COMPRESSOR, REPLACE.....................................................................292
SECTION 5 FUEL SYSTEM...........................................................................296
	GENERAL INFORMATION.........................................................................297
	SPECIFICATIONS..............................................................................298
	FLOW DIAGRAMS...............................................................................303
	SERVICE TOOLS ..............................................................................305
	FUEL PUMP ADJUST............................................................................311
	INJECTORS - REPLACE.........................................................................327
	FUEL PUMP - REPLACE.........................................................................331
	FUEL SYSTEM MAINTENANCE.....................................................................336
	VARIABLE SPEED (VS) GOVERNOR LEAKING FUEL ..................................................340
	FUEL SHUTOFF VALVE .........................................................................343
	FUEL PUMP - FLOW CHECK, PRIME AND ROTATION..................................................345
	AIR LEAKS...................................................................................348
	CYLINDER MISFIRE............................................................................355
	ENGINE OIL DILUTION BY FUEL OIL ............................................................356
	FUEL LINE RESTRICTION.......................................................................359
	FUEL CONSUMPTION CHECK......................................................................361
	LOW POWER CHECK.............................................................................366
	THROTTLE RESPONSE TIME BY ROAD TEST.........................................................368
	ENGINE STALL SPEED AND TIME CHECK...........................................................371
	DRIVEABILITY - LOW POWER CHECK LIST.........................................................378
	FUEL CONSUMPTION - CHECK LIST...............................................................380
SECTION 6 ELECTRICAL SYSTEM.....................................................................383
	GENERAL INFORMATION.........................................................................384
	SPECIFICATIONS..............................................................................385
	SERVICE TOOLS...............................................................................386
	BATTERIES - CHECK...........................................................................387
	BATTERY TERMINAL CONNECTIONS - CHECK........................................................388
	STARTING CIRCUIT - CHECK....................................................................388
	ALTERNATOR BELT - ADJUST....................................................................394
	ALTERNATOR - OUTPUT TEST....................................................................395
	ALTERNATOR - REPLACE........................................................................397
	STARTING MOTOR - REPLACE....................................................................399
SECTION 7 BASE ENGINE COMPONENTS................................................................400
	SERVICE TOOLS...............................................................................402
	GENERAL INFORMATION.........................................................................404
	ROCKER HOUSING COVERS - REPLACE.............................................................404
	ENGINE LIFTING BRACKETS - REPLACE...........................................................406
	CROSSHEADS, VALVES AND INJECTORS ADJUST.....................................................407
	JACOBS ENGINE BRAKE - ADJUST................................................................419
	JACOBS ENGINE BRAKE - CHECK ................................................................421
	JACOBS ENGINE BRAKE - REPLACE...............................................................424
	PUSH RODS - REPLACE.........................................................................428
	ROCKER LEVERS/ROCKER LEVER HOUSING - REPLACE................................................431
	CYLINDER HEAD GASKET(S) - REPLACE...........................................................438
	CYLINDER HEADS - REPLACE....................................................................443
	CYLINDER HEAD - PRESSURE TEST ..............................................................453
	CAM FOLLOWERS (FIXED INJECTION TIMING) - REPLACE............................................455
	MECHANICAL VARIABLE TIMING (MVT) SYSTEM ....................................................460
	CAM FOLLOWERS (MVT INJECTION TIMING) - REPLACE..............................................472
	INJECTION TIMING (GENERAL INFORMATION)......................................................491
	INJECTION TIMING (FIXED)....................................................................492
	INJECTION TIMING (MVT)......................................................................500
	PISTON COOLING NOOZLES - REPLACE............................................................507
	MAIN AND THRUST BEARINGS - REPLACE..........................................................509
	CONNECTING ROD BEARINGS - REPLACE...........................................................518
	PISTONS AND RINGS - REPLACE.................................................................523
	CONNECTING RODS - REPLACE...................................................................536
	CYLINDERS LINERS REPLACE....................................................................542
	ACCESSORY DRIVE PULLEY - REPLACE............................................................555
	WEAR SLEEVE, ACCESSORY DRIVE PULLEY - REPLACE...............................................557
	SEAL, ACCESSORY DRIVE - REPLACE.............................................................558
	ACCESSORY DRIVE - REPLACE...................................................................561
	VIBRATION DAMPER - CHECK....................................................................564
	CRANKSHAFT PULLEY - REPLACE.................................................................570
	SEAL, FRONT CRANKSHAFT - REPLACE............................................................572
	CAMSHAFT BEARING SUPPORT - REPLACE..........................................................574
	FRONT ENGINE SUPPORT BRACKET - REPLACE......................................................577
	GEAR COVER - REPLACE........................................................................579
	CRANKSHAFT GEAR - REPLACE...................................................................585
	CAMSHAFT - REPLACE..........................................................................588
	CAMSHAFT GEAR - REPLACE.....................................................................596
	CAMSHAFT BUSHING - REPLACE..................................................................600
	FLYWHEEL - REPLACE..........................................................................606
	SEAL, REAR CRANSHAFT - REPLACE..............................................................613
	FLYWHEEL HOUSING - REPLACE..................................................................617
	FLYWHEEL HOUSING REDOWEL TO CYLINDER BLOCK..................................................625
	PIPE PLUGS AND CUP PLUGS - REPLACE..........................................................631
SECTION 8 ENGINE TESTING ("IN CHASSIS").........................................................635
	SERVICE TOOLS...............................................................................636
	GENERAL ENGINE TEST SPECIFICATIONS AND PROCEDURES...........................................637
	CHASSIS DYNAMOMETER OPERATION...............................................................641
	ENGINE RUN-IN PROCEDURE (CHASSIS DYNAMOMETER)...............................................643
	ENGINE RUN-IN PROCEDURE "IN-CHASSIS" (ON AND OFF-HIGHWAY VEHICLES)..........................645
SECTION 9 ENGINE REMOVE AND INSTALL.............................................................647
	GENERAL INFORMATION ........................................................................648
	SERVICE TOOLS...............................................................................648
	ENGINE REMOVE...............................................................................648
	ENGINE MOUNTS - INSPECT.....................................................................651
	ENGINE - INSTALL............................................................................651
SECTION 10 ENGINE COMPONENT SPECIFICATIONS......................................................654
	GENERAL INFORMATION.........................................................................655
	CONVERSION FACTORS..........................................................................656
	PIPE PLUG TORQUE VALUES.....................................................................657
	CAPSCREW MARKINGS AND TORQUE VALUES.........................................................657
	DECIMAL AND METRIC EQUIVALENTS..............................................................659
	COOLING SYSTEM TORQUE VALUES................................................................660
	LUBRICATING OIL SYSTEM TORQUE VALUES........................................................662
	COMBUSTION AIR SYSTEM TORQUE VALUES.........................................................664
	COMPRESSED AIR SYSTEM TORQUE VALUES.........................................................666
	FUEL SYSTEM TORQUE VALUES...................................................................669
	ELECTRICAL SYSTEM TORQUE VALUES.............................................................670
	BASE ENGINE COMPONENTS TORQUE VALUES........................................................671
ALPHABETICAL INDEX..............................................................................679
ADDITIONAL SERVICE LITERATURE...................................................................687
ACCESSORY COMPONENT MANUFACTURERS...............................................................690

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]