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
VIDEO PREVIEW OF THE MANUAL:
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]
Kody –