Cummins BIG CAM III, BIG CAM IV and NT-855C Diesel Engines Diagnostic and Repair Manual (cummins-3810298)

Illustrated factory Diagnostic and Repair Manual for Cummins Diesel Engines Models BIG CAM III, BIG CAM IV and NT-855C.

This manual will assist you in diagnosing, troubleshooting, assembling, disassembling, and repairing for your diesel engine.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models:
   BIG CAM III
   BIG CAM IV
   NT-855C

Format: PDF, 693 pages
Language: English
Publication Date: 01 Jan 2005
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
   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