Factory Troubleshooting And Repair Manual For Cummins Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 693
Number: 3810298-00 (june 1986)
Bookmarks: Yes
Model
Cummins Engine
Big Cam III
Big Cam IV
NT855
Contents
-INTRODUCTION
About The Manual
How to Use The Manual
Symbols
Illustrations
Definition Of Terms
General Repair Instructions
General Cleaning Instructions
-ENGINE IDENTIFICATION
Engine Identification
Engine Specifications
Engine Diagrams
-TROUBLESHOOTING
Procedures And Techniques
Troubleshooting Symptoms
-COOLING SYSTEM
Service Tools
General Information
Specifications
Flow Charts
Venting
Cooling System, Maintenance
Cooling System, Drain
Cooling System, Fill
Coolant Filter-Replace
Diesel Coolant Additives (Dca4)
Cooling System, Clean
Cooling System – Test For Air Or Combustion Gases
Cooling System-Pressure Test
Hoses-Check
Coolant Temperature Gauge-Check
Radiator Pressure Cap-Check
Radiator Fins-Inspect
Shutter Operation-Check
Fan Shroud Spacer & Pulley-Inspect
Water Pump Belt-Replace
Fan Drive Belts-Replace
On-Off Fan Clutch-Check
Fan Clutch, Air Engaged Type
Fan Clutch, Air Disengaged Type
On-Off Fan Clutch-Replace
Fan Clutch Viscous Type
Fan Hub-Replace
Idler Pulley Assembly, Water Pump (Big Cam Iv And New Big Cam Iv) -Replace
Water Pump- Replace
Thermostat (Big Cam Iii) – Test “Thermostat In Chassis”
Thermostat (Big Cam Iii) – Replace
Thermostat (Big Cam Iii) – Test “Thermostat Removed”
Thermostat Seal (Big Cam Iii) – Replace
Thermostat, Radiator (Big Cam Iv) – Check
Thermostat, Bypass (Big Cam Iv) – Check
Thermostat Housing (Big Cam Iv) – Replace
Thermostat (Big Cam Iv) – Replace
Thermostat Seal, Bypass (Big Cam Iv) – Replace
Thermostat Seal, Radiator (Big Cam Iv) – Replace
Thermostat Housing Check Valve O-Rings (Big Cam Iv) – Replace
Thermostat Housing Check Valve Assembly (Big Cam Iv) – Replace
Radiator Check Valve Leakage (Big Cam Iv Only) – Check
Aftercooler Filter Screen (Big Cam Iv Only) – Clean
Water Manifold Sealing Ring Balance Orifices (Big Cam Iv Only) – Replace
Radiator Baffle Leakage (Big Cam Iv Only) – Check
Radiator (Two-Pass, Vertical-Flow) – Check
Radiator (Horizontal-Flow) – Check
Radiator (Three-Pass, Vertical-Flow) – Check
Head Gasket, Cylinder Liner, Crevice Seal Or Cylinder Block – Inspect For Coolant Leaks
-LUBRICATING OIL SYSTEM
Service Tools
General Information
Demand Flow And Cooling Lubricating System – Operation
Specifications
Flow Diagrams
Internal Engine Damage – Check
Oil Leaks (External) – Check
Oil Pressure Gauge – Check
Oil Temperature Gauge – Check
Oil Pan, Drain
Oil Pan. Fill
Oil Filters (Full Flow And Bypass) – Replace
Crankcase Breather And Tube – Replace
Dipstick Tube And Housing – Replace
Dipstick – Calibrate
Oil Transfer Tube – Replace
Oil Pan – Replace
Oil Cooler Bypass Valve – Check
Oil Filter Head – Replace
Oil Cooler Assembly – Replace
Oil Cooler Core – Replace
Oil Cooler Core – Pressure Test
Main Oil Pressure Regulator – Replace
Lubricating Oil Pump Signal Line Orifice – Clean “In Chassis”
Lubricating Oil Pump Signal Line Orifice – Clean “Pump Removed”
Lubricating Oil Pump – Replace
High Oil Pressure Relief Valve – Check
High Oil Pressure Relief Valve Replace
-COMBUSTION AIR SYSTEM
General Information
Specifications
Flow Diagrams
Service Tools
Turbocharger Turbine Seal Leaks Check
Compressor Seal Leakage – Check
Correct Turbocharger Installed – Check
Intake Air Restriction – Check
Exhaust Restriction – Check
Air Leaks – Check
Turbocharger Blade Damage – Check
Turbocharger Axial And Radial Clearance – Check
Turbocharger – Replace
Series Turbocharger – Replace
Exhaust Manifold – Replace
Aftercooler – Replace
Aftercooler – Pressure Test
-COMPRESSED AIR SYSTEM
General Information
Specifications
Flow Diagrams
Service Tools
Carbon Buildup, Air Compressor Check
Gasket Leaks, Air Compressor – Check
Air Governor And Compressor Unloader Valve – Check
Air Governor-Check
Lubricating Oil Usage. Air Compressor – Check
Unloader Valve -Check
Air Compressor, Cylinder Head – Replace
Air Compressor, Replace
-FUEL SYSTEM
General Information
Specifications
Flow Diagrams
Service Tools
Fuel Pump Adjust
Injectors – Replace
Fuel Pump – Replace
Fuel System Maintenance
Variable Speed (Vs) Governor Leaking Fuel
Fuel Shut-Off Valve
Fuel Pump – Flow Check, Prime And Rotation
Air Leaks
Cylinder Misfire
Engine Oil Dilution By Fuel Oil
Fuel Line Restriction
Fuel Consumption Check
Low Power Check
Throttle Response Time By Road Test
Engine Stall Speed And Time Check
Driveability – Low Power Check List
Fuel Consumption – Check List
-ELECTRICAL SYSTEM
General Information
Specifications
Service Tools
Batteries – Check
Battery Terminal Connections – Check
Starting Circuit-Check
Alternator Belt – Adjust
Alternator – Output Test
Alternator – Replace
Starting Motor – Replace
-BASE ENGINE COMPONENTS
Service Tools
General Information
Rocker Housing Covers – Replace
Engine Lifting Brackets – Replace
Crossheads, Valves And Injectors Adjust
Jacobs Engine Brake – Adjust
Jacobs Engine Brake – Check
Jacobs Engine Brake – Replace
Push Rods – Replace
Rocker Levers/Rocker Lever Housing – Replace
Cylinder Head Gasket(S) – Replace
Cylinder Heads – Replace
Cylinder Head – Pressure Test
Cam Followers (Fixed Injection Timing) – Replace
Mechanical Variable Timing (MVT) System
Cam Followers (MVT Injection Timing) – Replace
Injection Timing (General Information)
Injection Timing (Fixed)
Injection Timing (MVT)
Piston Cooling Nozzles – Replace
Main And Thrust Bearings – Replace
Connecting Rod Bearings – Replace
Pistons And Rings – Replace
Connecting Rods – Replace
Cylinders Liners Replace
Accessory Drive Pulley – Replace
Wear Sleeve, Accessory Drive Pulley – Replace
Seal. Accessory Drive – Replace
Accessory Drive – Replace
Vibration Damper – Check
Crankshaft Pulley – Replace
Seal, Front Crankshaft – Replace
Camshaft Bearing Support – Replace
Front Engine Support Bracket – Replace
Gear Cover – Replace
Crankshaft Gear – Replace
Camshaft – Replace
Camshaft Gear – Replace
Camshaft Bushing – Replace
Flywheel – Replace
Seal. Rear Cranshaft – Replace
Flywheel Housing – Replace
Flywheel Housing Redowel To Cylinder Block
Pipe Plugs And Cup Plugs – Replace
-ENGINE TESTING (“IN CHASSIS”)
Service Tools
General Engine Test Specifications And Procedures
Chassis Dynamometer Operation
Engine Run-In Procedure (Chassis Dynamometer)
Engine Run-In Procedure “In-Chassis” (On And Off-Highway Vehicles)
-ENGINE REMOVE AND INSTALL
General Information
Service Tools
Engine Remove
Engine Mounts – Inspect
Engine – Install
-ENGINE COMPONENT SPECIFICATIONS
General Information
Conversion Factors
Pipe Plug Torque Values
Capscrew Markings And Torque Values
Decimal And Metric Equivalents
Cooling System Torque Values
Lubricating Oil System Torque Values
Combustion Air System Torque Values
Compressed Air System Torque Values
Fuel System Torque Values
Electrical System Torque Values
Base Engine Components Torque Values
ALPHABETICAL INDEX
ADDITIONAL SERVICE LITERATURE
ACCESSORY COMPONENT MANUFACTURERS
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