Cummins NT 855 BC-III BC-IV Engines Troubleshooting and Repair Manual

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This Big Cam Ill and Big Cam IV, NT 855 Engines Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems and to provide recommended repair procedures. The manual is divided into sections. Some sections contain reference numbers and procedure numbers. The reference numbers provide general information, specifications, diagrams, and service tools, where applicable. The procedure numbers describe specific repair procedures and are referred to in the Troubleshooting Logic Charts.


TABLE OF CONTENTS :

Engine Identification
- General Engine Specifications
- Engine Diagrams
Troubleshooting
- Procedures and Techniques
- Symptoms List
- Symptoms Cause and Corrections Charts
Engine Systems Repair
- Cooling
- Lubricating Oil
- Combustion Air
- Compressed Air
- Fuel
- Electrical
- Base Engine
Engine Testing (²In-Chassis²)
Engine - Remove and Install 1
Engine Component Specifications


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bulletin No. : 3810298-00
Total Pages : 693


This (OEM) manual pdf download has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER PAGE
FOREWORD
TABLE OF CONTENTS
SECTION I INTRODUCTION
ABOUT THE MANUAL
HOW TO USE THE MANUAL
SYMBOLS
ILLUSTRATIONS
DEFINITION OF TERMS
GENERAL REPAIR INSTRUCTIONS
GENERAL CLEANING INSTRUCTIONS
SECTION E ENGINE IDENTIFICATION
ENGINE IDENTIFICATION
ENGINE SPECIFICATIONS
ENGINE DIAGRAMS
SECTION T TROUBLESHOOTING
PROCEDURES AND TECHNIQUES
TROUBLESHOOTING SYMPTOMS
COOLANT TEMPERATURE ABOVE NORMAL
COOLANT TEMPERATURE BELOW NORMAL
LOSS OF ENGINE COOLANT (OVERFLOW)
LOSS OF ENGINE COOLANT (EXTERNAL LEAKAGE)
LOSS OF ENGINE COOLANT (INTERNAL LEAKAGE)
FUEL IN COOLANT
LOW LUBRICATING OIL PRESSURE
HIGH LUBRICATING OIL PRESSURE
LUBRICATING OIL TEMPERATURE ABOVE NORMAL
LUBRICATING OR HYDRAULIC OIL IN THE COOLANT
EXCESSIVE LUBRICATING OIL CONSUMPTION
EXCESSIVE LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE
COOLANT IN THE LUBRICATING OIL
FUEL IN THE LUBRICATING OIL
TURBOCHARGER NOISE
LOW POWER OR EXCESSIVE SMOKE (LOW TURBOCHARGER BOOST PRESSURE)
TURBOCHARGER LEAKS (ENGINE OIL OR FUEL)
AIR COMPRESSOR AIR PRESSURE RISES SLOWLY
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)
EXCESSIVE AMOUNT OF OIL PASSING THROUGH AIR COMPRESSOR
AIR COMPRESSOR WILL NOT PUMP AIR PRESSURE
AIR COMPRESSOR WILL NOT STOP PUMPING AIR
EXCESSIVE AIR COMPRESSOR NOISE
ENGINE CRANKS, BUT WILL NOT START (NO SMOKE FROM EXHAUST)
ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE PRESENT)
ENGINE STARTS BUT WILL NOT KEEP RUNNING
WARM ENGINE RUNS ROUGH OR MISFIRES IN OPERATING RANGE
ROUGH IDLE
ENGINE SURGES AT LOW IDLE
ENGINE WILL NOT REACH RATED SPEED WHEN LOADED
LOW POWER
EXHAUST SMOKE EXCESSIVE UNDER LOAD
ENGINE WILL NOT SHUT OFF
POOR DECELERATION
ENGINE SURGES UNDER LOAD AT RATED SPEED - WIDE OPEN THROTTLE
ENGINE SURGES AT HIGH IDLE
SURGE IN TOP GEAR - ROAD SPEED GOVERNOR NOT SET CORRECTLY
VARIABLE SPEED (VS) GOVERNOR SURGE - ENGINE UNDER LOAD
FUEL LEAKAGE AT VARIABLE SPEED (VS) GOVERNOR
VARIABLE SPEED GOVERNOR SPEED IS NOT SET CORRECTLY
THROTTLE RESPONSE SLOW (ENGINE DIES GOING DOWNHILL)
EXCESSIVE FUEL CONSUMPTION
ENGINE WILL NOT CRANK OR CRANKS SLOWLY
AMMETER/VOLTMETER INDICATES ALTERNATOR IS NOT CHARGING, OR CHARGING AT A LOW RATE
EXCESSIVE CRANKCASE GASES (BLOWBY)
EXCESSIVE ENGINE VIBRATION
EXCESSIVE ENGINE NOISE
MECHANICAL VARIABLE TIMING (MVT) WILL NOT SWITCH TO ADVANCED OR RETARDED TIMING MODE
WHITE SMOKE - GENERAL INFORMATION
EXCESSIVE WHITE SMOKE AT IDLE
GENERAL ENGINE NOISE DIAGNOSTIC PROCEDURES
MAIN BEARING NOISE
CONNECTING ROD BEARING NOISE
PISTON NOISE
SECTION 1 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
SECTION 2 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
SECTION 3 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
SECTION 4 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
SECTION 5 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 SHUTOFF 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
SECTION 6 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
SECTION 7 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 NOOZLES - 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
SECTION 8 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)
SECTION 9 ENGINE REMOVE AND INSTALL
GENERAL INFORMATION
SERVICE TOOLS
ENGINE REMOVE
ENGINE MOUNTS - INSPECT
ENGINE - INSTALL
SECTION 10 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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