Cummins n14 руководство по ремонту

1. Содержания книг

2. Содержание Инструкция по ремонту двигаиелей Cummins N14

n

В настоящем издании представлены инструкция по эксплуатации и техническому обслуживанию, а также руководство по ремонту двигателей CUMMINS N14 с системами управления CELECT, CELECT PLUS и STC.

Книга будет полезна всем владельцам техники, оснащенной двигателями CUMMINS (VOLVO, FREIGHTLINER, INTERNATIONAL и др.), специалистам, работающим в области авторемонта, а также всем интересующимся двигателями подобного класса.n

Купить электронные книги по ремонту автомобилей на русском языке можно в любой стране Европейского союза (Австрия, Бельгия, Болгария, Великобритания, Венгрия, Германия, Греция, Дания, Ирландия, Испания, Италия, Кипр, Латвия, Литва, Люксембург, Мальта, Нидерланды, Польша, Португалия, Румыния, Словакия, Словения, Финляндия, Франция, Хорватия, Чехия, Швеция и Эстония.), а также странах СНГ ( Россия, Беларусь, Кыргызстан, Таджикистан, Узбекистан, Туркменистан, Молдова, Азербайджан, Армению, Казахстан.)

Оплатить выбранную книгу можно с помощью любой банковской карты (Visa, MasterCard и т.д.), а также PayPal, WebMoney и других популярных платёжных систем .

• Page 2
  This manual provides instructions for troubleshooting and repairing the N14 engine in the chassis. Component and assembly rebuild procedures are provided in the N14 Engine Shop Manual. Refer to Page i-2 in the Introduction for instructions on how to use this manual.
• Page 3
  Table of Contents Section Introduction ……………………… Engine Identification……………………Troubleshooting……………………..Cooling Systems Repair …………………… Lubricating Oil Systems Repair………………… Combustion Air System Repair ………………… Compressed Air System Repair ………………..Fuel System Repair……………………Electrical System Repair…………………… Base Engine Components System Repair ………………Engine Testing (‘‘In-Chassis’’) …………………. Engine — Remove and Install………………….
• Page 4
  Section i — Introduction Page i-1 Section i — Introduction Section Contents Page About the Manual …………………………. i-2 Definition Of Terms ……………………….i-12 General Cleaning Instructions…………………….. i-11 Glass or Plastic Bead Cleaning ……………………i-11 Solvent and Acid Cleaning ……………………..i-11 Steam Cleaning ………………………..
• Page 5
  Page i-2 About the Manual This N14 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, spec- ifications, diagrams, and service tools, where applicable.
• Page 6
  Section i — Introduction Symbols Page i-3 Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: WARNING — Serious personal injury or extensive property damage can result if the warning instructions are not followed.
• Page 7
  Symbols Section i — Introduction Page i-4 Simbolos Los si ´ mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando aparece uno de estos si ´ mbolos, su significado se especifica en la parte inferior. ADVERTENCIA — Serios dan ˜…
• Page 8
  Section i — Introduction Symbols Page i-5 Symbole In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbole haben folgende Bedeutung: WARNUNG — Wird die Warnung nicht beachtet, dann besteht erho ¨ hte Unfall- und Bescha ¨ digungsgefahr. VORSICHT — Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und Bescha ¨…
• Page 9
  Symbols Section i — Introduction Page i-6 Symboles Les symboles suivants sont utilise ´ s dans ce manuel pour aider a ` communiquer le but des instructions. Quand l’un de ces symboles apparai ˆ t, il e ´ voque le sens de ´ fini ci-dessous: AVERTISSEMENT — De graves le ´…
• Page 10
  Section i — Introduction Illustrations Page i-7 Illustrations The illustrations used in the ″Repair Sections″ of this manual are intended to give an example of a problem and to show what to look for and where the problem can be found.
• Page 11
  • Always use proper tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins ReCon replacement parts. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary.
• Page 12
  Section i — Introduction General Safety Instructions Page i-9 doubt, contact your state and local environmental authorities or the Environmental Protection Agency for guidance as to proper handling and disposal of used engine oil and coolant/antifreeze. • The CELECT™ injector solenoids receive high voltage when the engine is operating. Do not touch the injector solenoids or the solenoid wires when the engine is operating.
• Page 13
  • Cummins Engine Company, Inc. does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Cummins Service Information. In particular, un- authorized repair to safety-related components can cause personal injury. Below is a partial listing of…
• Page 14
  General Cleaning Instructions Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Company, Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit].
• Page 15
  In the direction of a circle in respect to the centerline of a round part or a bore. Centimeter Compulink™: A Cummins service tool used for electronic system analysis and to repro- gram the system Concentricity: A measurement of the difference between the centers of either two or more parts, or the bores in one part.
• Page 16
  Section i — Introduction Definition Of Terms Page i-13 Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corn- ing, Silastic 732, Loctite Superflex, General Electric 1473, and General Elec- tric 1470. DCA: Diesel Coolant Additive D.C.: Direct Current Deutsch Connector: An electrical connector Dye Penetrant Method:…
• Page 17
  Definition Of Terms Section i — Introduction Page i-14 Meter Magnetic Particle Inspection: A method of checking for cracks in either steel or iron parts. This method requires a Magnaflux machine, or an equivalent machine that imparts a mag- netic field on the part being checked. Mallet: A hand tool consisting of a soft head;…
• Page 18
  SRI, Amoco Rykon Premium No. 2, Texaco Premium RB, and Shell Dolium Aeroshell No. 5 is not compatible with the other greases and must not be mixed. Cummins Engine Co., Inc., uses Aeroshell No. 5 on new engines and components.
• Page 19
  Section E — Engine Identification Page E-1 Section E — Engine Identification Section Contents Page Cummins Model Name ……………………….E-2 Engine Dataplate…………………………. E-2 Engine Diagrams……………………….E-6, E-7 Engine Specifications ……………………….E-4 Air Induction System……………………….E-4 Batteries (Specific Gravity)……………………..E-5 Cooling System ………………………… E-4 Electrical System ……………………….
• Page 20
  Cummins Model Name Section E — Engine Identification Page E-2 Cummins Model Name The Cummins model name provides information as shown N 14 330 E in the accompanying illustration. = CELECT™ Identification = Cruise Horsepower = Displacement (Liters) = Engine Model Designation…
• Page 21
  Section E — Engine Identification Fuel Pump Dataplate Page E-3 Fuel Pump Dataplate On step timing control (STC) engines, the fuel pump dataplate is located on the top of the fuel pump. It pro- vides information for fuel pump calibration. On CELECT™…
• Page 22
  104°C [220°F] All other horsepower ratings ………………..100°C [212°F] Coolant alarm activitation temperature N14 460E and 430E………………..104± 1°C [220± 2°F] All other horsepower ratings ………………100± 1°C [212± 2°F] Minimum recommended coolant temperature …………….70°C [158°F] Minimum recommended radiator pressure cap ……………..
• Page 23
  Section E — Engine Identification Engine Specifications (Cont’d.) Page E-5 Engine Specifications (Cont’d.) Fuel System Maximum allowable restriction to fuel pump: With clean fuel filter (STC engines) …………….102 mm Hg [4 in. Hg] With dirty fuel filter (STC engines) …………….203 mm Hg [8 in.
• Page 24
  Engine Diagrams Section E — Engine Identification Page E-6 Engine Diagrams The following drawings contain information about engine components, filter locations, drain points, and access locations for instrumentation and engine controls. The information and configuration of components shown in these drawings are of a general nature. Some component locations will vary depending on applications and installations.
• Page 25
  Section E — Engine Identification Engine Diagrams (Continued) Page E-7 Engine Diagrams (Continued)

• Page 26: Table Of Contents

  Section T — Troubleshooting Page T-1 Section T — Troubleshooting Section Contents Page Procedures and Techniques ……………………..T-3 Troubleshooting Symptoms Charts……………………T-3 Air Compressor Air Pressure Rises Slowly …………………. T-4 Air Compressor Noise Excessive ……………………T-5 Air Compressor Pumping Excess Lubricating Oil Into Air System …………..T-6 Air Compressor Will Not Maintain Adequate Air Pressure — Not Pumping Continuously……..

• Page 27
  Section T — Troubleshooting Page T-2 Page Lubricating Oil Pressure — High ……………………T-87 Lubricating Oil Pressure — Low ………………….T-88, T-89 Lubricating Oil Sludge in the Engine Crankcase Excessive …………..T-90, T-91 Lubricating Oil Temperature Above Specification ………………T-92 Lubricating or Transmission Oil in the Coolant………………..

• Page 28: Procedures And Techniques

  Section T — Troubleshooting Procedures and Techniques Page T-3 Procedures and Techniques A thorough analysis of the customer’s complaint is the key to successful troubleshooting. The more information known about a complaint, the faster and easier the problem can be solved. The Troubleshooting Symptoms Charts beginning on Page T-4 are organized so that a problem can be located and corrected by doing the easiest and most logical things first.

• Page 29: Air Compressor Air Pressure Rises Slowly

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-4 Air Compressor Air Pressure Rises Slowly Cause Corrections Replace air compressor air cleaner (if Intake Air Restriction to Air Compressor installed). Check engine intake air restriction — — — — — — — — — — Excessive (Naturally Aspirated Air if air compressor inlet is installed in intake Compressors Only)

• Page 30: Air Compressor Noise Excessive

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-5 Air Compressor Noise Excessive Cause Corrections To check carbon buildup, refer to Procedure Carbon Buildup Excessive in the Air 4-01. To replace air compressor head, refer to — — — — — — — — — — Discharge Line, Check Valve, and/or Procedure 4-06.

• Page 31: Air Compressor Pumping Excess Lubricating Oil Into Air System

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-6 Air Compressor Pumping Excess Lubricating Oil Into Air System Cause Corrections Replace air compressor air cleaner (if Intake Air Restriction to Air Compressor installed). Check engine intake restriction if — — — — — — — — — — Excessive (Naturally Aspirated Air air compressor inlet is installed in intake Compressor Only)

• Page 32: Air Compressor Will Not Maintain Adequate Air Pressure — Not Pumping Continuously

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-7 Air Compressor Will Not Maintain Adequate Air Pressure — Not Pumping Continuously Cause Corrections Block vehicle wheels and check for system air leaks with spring brakes applied and — — — — — — — — — — Air System Leaks released.

• Page 33: Air Compressor Will Not Pump Air

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-8 Air Compressor Will Not Pump Air Cause Corrections Check air governor operation. Refer to Air Governor Malfunctioning or Set — — — — — — — — — — Procedure 4-04. Incorrectly Check unloader valve operation.

• Page 34: Air Compressor Will Not Stop Pumping

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-9 Air Compressor Will Not Stop Pumping Cause Corrections Block vehicle wheels and check for system air leaks with spring brakes applied and — — — — — — — — — — Air System Leaks released.

• Page 35: Alternator Not Charging Or Insufficient Charging

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-10 Alternator Not Charging or Insufficient Charging Cause Corrections Check belt tension. Refer to Procedure 6-04. — — — — — — — — — — Alternator Belt Loose Battery Cable or Connection Loose, Check battery cables and connections.

• Page 36: Alternator Overcharging

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-11 Alternator Overcharging Cause Corrections Replace voltage regulator. Refer to the — — — — — — — — — — Voltage Regulator Malfunctioning vehicle manufacturer’s service manual. Replace battery. — — — — — — — — — — Battery Cell Damaged (Open)

• Page 37: Coolant Loss — External

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-12 Coolant Loss — External Cause Corrections Check coolant level. Refer to the — — — — — — — — — — Coolant Level High manufacturer for specifications. Visually Inspect For Leaks: Hoses, Hose Tighten or replace if necessary.

• Page 38: Coolant Loss — Internal

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-13 Coolant Loss — Internal Cause Corrections Inspect and test the lubricating oil — — — — — — — — — — Lubricating Oil Cooler Leaking cooler. Refer to Procedure 2-19. Inspect oil cooler transfer housing and Oil Cooler Transfer Housing and/or Oil — — — — — — — — — -…

• Page 39: Coolant Temperature Above Normal — Gradual Overheat

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-14 Coolant Temperature Above Normal — Gradual Overheat Cause Corrections Inspect for external leaks on engine and — — — — — — — — — — Coolant Level Low radiator and make repairs. Add coolant. Refer to Procedure 1-09.

• Page 40
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-15 Coolant Temperature Above Normal — Gradual Overheat (Continued) Cause Corrections Check the radiator pressure cap. Refer Radiator Cap Incorrect or Malfunction- — — — — — — — — — — to Procedure 1-15.
• Page 41
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-16 Coolant Temperature Above Normal — Gradual Overheat (Continued) Cause Corrections Check thermostat. Refer to Procedure 1-32. — — — — — — — — — — * Thermostat Incorrect or Malfunctioning Inspect the shutters.
• Page 42
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-17 Coolant Temperature Above Normal — Gradual Overheat (Continued) Cause Corrections Check and replace check valve as Check Valve Damaged With Remote — — — — — — — — — — necessary.

• Page 43: Coolant Temperature Above Normal — Sudden Overheat

  Section T — Troubleshooting Page T-18 Coolant Temperature Above Normal — Sudden Overheat Cause Corrections Refer to the N14 CELECT™ System Electronic Fault Codes Active — Coolant — — — — — — — — — — Troubleshooting and Repair Manual, Temperature Sensor Bulletin No.

• Page 44
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-19 Coolant Temperature Above Normal — Sudden Overheat (Continued) Cause Corrections Check thermostat. Refer to Procedure 1-32. — — — — — — — — — — * Thermostat Incorrect or Malfunctioning Check for air or combustion gases in * Air or Combustion Gases in the — — — — — — — — — -…

• Page 45: Coolant Temperature Below Normal

  Section T — Troubleshooting Page T-20 Coolant Temperature Below Normal Cause Corrections Refer to the N14 CELECT™ System * Electronic Fault Codes Active — — — — — — — — — — — Troubleshooting and Repair Manual, Coolant Temperature Sensor Bulletin No.

• Page 46: Crankcase Gases (Blowby) — Excessive

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-21 Crankcase Gases (Blowby) — Excessive Cause Corrections Check breather and/or vent tube Crankcase Breather and/or Vent Tube — — — — — — — — — — restriction. Refer to Procedure 2-05. Restricted Check turbocharger seals.

• Page 47: Engine Acceleration/Response Poor

  — — — — — — — — — — components. Matched to Engine For CELECT™ Engines: Refer to N14 CELECT™ System Trouble- • Active Electronic Fault Codes — — — — — — — — — — shooting and Repair Manual, Bulletin No.

• Page 48
  — — — — — — — — — — Compulink™ in monitor modes. Refer to the • Boost Sensor Malfunctioning N14 CELECT™ System Troubleshooting and • Coolant Temperature Sensor Malfunction- Repair Manual, Bulletin No. 3810469. • Intake Manifold Temperature Sensor Malfunctioning Check throttle linkage adjustment.
• Page 49
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-24 Engine Acceleration/Response Poor (Continued) Cause Corrections Refer to Compuchek Test Procedures Install Compuchek . Perform ‘‘Low — — — — — — — — — — Manual, Bulletin No. 3810485 (NT). Power Test’’…

• Page 50: Engine Brake — Does Not Operate

  Page T-25 Engine Brake — Does Not Operate Cause Corrections Refer to N14 CELECT™ System Trouble- • Electronic Fault Codes Active — — — — — — — — — — shooting and Repair Manual, Bulletin No. • High Counts of Inactive Fault Codes 3810469.

• Page 51
  Page T-26 Engine Brake — Low Power or Slow to Activate Cause Corrections Refer to N14 CELECT™ System Trouble- • Electronic Fault Codes Active — — — — — — — — — — shooting and Repair Manual, Bulletin No.
• Page 52
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-27 Engine Brake — Low Power or Slow to Activate (Continued) Cause Corrections * Adjust slave piston clearance and Slave Piston Adjustment Incorrect or — — — — — — — — — — check for freedom of movement.
• Page 53
  Engine Brake — One or More Cylinders Braking With Power Switch Off Cause Corrections Refer to N14 CELECT™ System Trouble- • Electronic Fault Codes Active — — — — — — — — — — shooting and Repair Manual, Bulletin No.
• Page 54
  Use manual override (STC only). Refer to Procedure 5-04. Replace or repair electric — — — — — — — — — — Shutoff Valve Closed problem. On CELECT™ refer to the N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. Auxiliary Shutdown Device (Skinner Repair or replace.
• Page 55
  For STC engines, refer to Procedure 5-02. — — — — — — — — — — Fuel Pump (Gear or Shaft) Not Turning For CELECT™ engines, refer to the N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin 3810469, Procedure 6-01.

• Page 56: Engine Decelerates Slowly (Celect™ Fuel System

  — — — — — — — — — — ECM Calibration Incorrect ECM with engine rating. Compulink™ required. Perform cylinder cut out test. Refer to N14 — — — — — — — — — — Injector Malfunctioning CELECT™ System Troubleshooting and…

• Page 57: Engine Decelerates Slowly (Pt Fuel System)

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-32 Engine Decelerates Slowly (PT Fuel System) Cause Corrections Check for free movement and adjust if — — — — — — — — — — Throttle Return Spring or Linkage Binding necessary.

• Page 58
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-33 Engine Decelerates Slowly (PT Fuel System) (Continued) Cause Corrections Perform the Compuchek Low Power Refer to Compuchek Test Procedures — — — — — — — — — — (Deceleration Ratio) Test and the Cylinder Manual, Bulletin No.

• Page 59: Engine Difficult To Start Or Will Not Start — Exhaust Smoke Present

  Page T-34 Engine Difficult to Start or Will Not Start — Exhaust Smoke Present Cause Corrections Refer to N14 CELECT™ System Trouble- — — — — — — — — — — Electronic Fault Codes Active shooting and Repair Manual, Bulletin No.

• Page 60
  Procedure 5-10. For CELECT™ — — — — — — — — — — Injector O-ring Damaged or Missing engines, refer to the N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. Verify problem, recalibrate if necessary.

• Page 61: Engine Noise Excessive

  — — — — — — — — — — Refer to ‘‘Lubricating Oil Pressure Low’’ Symptom Chart. Refer to Oil Specifications in the N14 Operation and Maintenance Manual, Bulletin — — — — — — — — — — Lubricating Oil Thin or Diluted No.

• Page 62
  Replace or rebuild injectors. On PT engines, refer to Procedure 5-10. For CELECT™ — — — — — — — — — — Injector Malfunction engines, refer to the N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. Valve Train and/or Overhead Components…
• Page 63
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-38 Engine Noise Excessive* (Continued) Cause Corrections Disconnect drive train to isolate. — — — — — — — — — — Drive Train Noise Excessive Check gear backlash and gear teeth. Gear Train Backlash Excessive or Gear — — — — — — — — — — Refer to Procedure 7-39.

• Page 64: Engine Noise Excessive — Combustion Knocks

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-39 Engine Noise Excessive — Combustion Knocks Cause Corrections Check winterfront, under hood air. Refer — — — — — — — — — — Ambient Air Temperature Too Low to Procedure 1-17. Repair or replace ether starting aids.

• Page 65: Engine Noise Excessive — Connecting Rod

  Inspect the crankshaft journals. Refer Crankshaft Journals Damaged or — — — — — — — — — — to the N14 Engine Shop Manual, Out-Of-Round Bulletin No. 3810487. * Refer to Engine Noise Diagnostic Procedures on General Information symptom chart before using this Symptom…

• Page 66: Engine Noise Excessive — Main Bearing

  Main Bearings Damaged, Worn or 7-23. Inspect the crankshaft journals. Refer — — — — — — — — — — Wrong Bearings Installed to the N14 Engine Shop Manual, Bulletin No. 3810487. Inspect the crankshaft journals. Refer to Crankshaft Journals Damaged or — — — — — — — — — — the N14 Engine Shop Manual, Bulletin No.

• Page 67: Engine Noise Excessive — Piston

  Refer to Procedure 7-25. Remove the connecting rod(s). Refer to Connecting Rod(s) Bent or — — — — — — — — — — Procedure 7-26. Refer to the N14 Engine Out-Of-Alignment Shop Manual, Bulletin No. 3810487. Remove pistons. Refer to Procedure 7-25.

• Page 68: Engine Noise Excessive — Turbocharger

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-43 Engine Noise Excessive — Turbocharger* Cause Corrections Check for correct turbocharger in- — — — — — — — — — — Incorrect Turbocharger Installed stalled. Refer to Procedure 3-03. Check for loose or damaged piping. — — — — — — — — — — Exhaust Air Leaks Refer to Procedure 3-01.

• Page 69
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-44 Engine Power Output Low — Basics Cause Corrections Refer to ‘‘Customer Complaint Form’’ and the ‘‘Low Power Checklist’’ at the end of this — — — — — — — — — — Verify Complaint Section.
• Page 70
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-45 Engine Power Output Low — Basics (Continued) Cause Corrections Check fuel pump dataplate for correct codes. — — — — — — — — — — Fuel Pump Incorrect Visually inspect air filter and restriction — — — — — — — — — — Intake Air Restriction Excessive indicator and replace air filter if necessary.
• Page 71
  — — — — — — — — — — • Spongy Throttle — PT fuel pump and fuel tank. For CELECT™ • Misfire — Midrange engines, refer to the N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. Check AFC air tube and fuel drain lines for restriction and/or leaks.

• Page 72: Engine Power Output Low — Application Specific

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-47 Engine Power Output Low — Application Specific Industrial, Electric Drive Transmission Cause Corrections Refer to manufacturer’s instructions and — — — — — — — — — — Electrical Loading of Engine Not Correct Bulletin No.

• Page 73
  — — — — — — — — — — Fuel or Air Delivery Problem Road Test. Refer to the Performance Mea- surement Section following the Application Specific Problems Section. (Continued) * Refer to N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469.
• Page 74
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-49 Engine Power Output Low — Application Specific (Continued) Genset (Continued) Cause Corrections Check operation. Refer to the manufac- — — — — — — — — — — Governor Actuator Malfunctioning turer’s instructions.
• Page 75
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-50 Engine Power Output Low — Application Specific (Continued) Marine (Continued) Cause Corrections Check, repair, or replace the marine gear. — — — — — — — — — — Marine Gear Failure or Malfunction Refer to the marine gear manufacturer’s instructions.

• Page 76: Engine Power Output Low — Performance Measurement

  Check fuel plumbing. Replace as necessary. For PT engines, refer to Procedure 5-01. For Fuel Inlet (Suction Line) Restriction — — — — — — — — — — CELECT™ engines, refer to the N14 Excessive CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469.

• Page 77
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-52 Engine Power Output Low — Performance Measurement (Continued) Cause Corrections Fuel Rate Low, Fuel Pressure OK, Intake Check for correct parts for CPL. Refer Manifold Pressure High, Ambient Air — — — — — — — — — — to CPL Manual, Bulletin No.
• Page 78
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-53 Engine Power Output Low — Performance Measurement (Continued) Cause Corrections Internal Engine Parts (Pistons, Rings, Check engine for high crankcase — — — — — — — — — — Cam, Etc.) Incorrect, Worn or pressure (low compression).

• Page 79: Engine Runs Rough At Idle

  — — — — — — — — — — Engine Idle Speed Low Manual, Bulletin No. 3379084. For CELECT™, refer to the N14 Operation and Maintenance Manual, Bulletin No. 3666024. Perform the Run Rough test and the cylinder performance test if indicated. Refer to…

• Page 80
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-55 Engine Runs Rough at Idle (Continued) Cause Corrections Verify by operating engine from a — — — — — — — — — — Fuel Grade Incorrect or Fuel Quality Poor temporary tank that contains good fuel.
• Page 81
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-56 Engine Runs Rough at Idle (Continued) Cause Corrections Perform cylinder cut out test. Refer to the — — — — — — — — — — CELECT™ Injector Malfunctioning CELECT™ System Troubleshooting and Repair Manual, Bulletin No.

• Page 82: Engine Runs Rough Or Misfires

  — — — — — — — — — — Bulletin No. 3387266-R. Temperature Refer to N14 CELECT™ System Trouble- • Electronic Fault Codes Active — — — — — — — — — — shooting and Repair Manual, Bulletin No.

• Page 83
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-58 Engine Runs Rough or Misfires (Continued) Cause Corrections Adjust to specification. Refer to Proce- Engine Brakes or Exhaust Brakes — — — — — — — — — — dure 7-05. Adjustment Incorrect Check for a bent or mislocated push rod, — — — — — — — — — -…

• Page 84: Engine Shuts Off Unexpectedly Or Dies During Deceleration

  Engine Shuts Off Unexpectedly or Dies During Deceleration Cause Corrections • Electronic Fault Codes Active Refer to N14 CELECT™ System Trouble- • High Counts of Inactive Fault Codes — — — — — — — — — — shooting and Repair Manual, Bulletin No.

• Page 85
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-60 Engine Shuts Off Unexpectedly or Dies During Deceleration Cause Corrections Calibrate or replace injectors as necessary. — — — — — — — — — — Injector Malfunctioning Refer to the STC Injector Shop Manual, Bulletin No.

• Page 86: Engine Speed Surges At Low Idle

  Refer to manufacturer’s instructions. Adjust idle speed. On CELECT™ engines, refer to the N14 Operation and Maintenance — — — — — — — — — — Engine Low Idle Speed Set Incorrectly Manual, Bulletin No. 3666024. On STC…

• Page 87
  Refer to Procedure 5-19 for PT — — — — — — — — — — Fuel Drain Line Restriction Excessive engines. For CELECT™ engines, refer to N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. Check and clean passage.

• Page 88: Engine Speed Surges (Other Than Low Idle)

  Page T-63 Engine Speed Surges (Other Than Low Idle) Cause Corrections Refer to N14 CELECT™ System Trouble- • Electronic Fault Codes Active — — — — — — — — — — shooting and Repair Manual, Bulletin No. • High Counts of Inactive Fault Codes 3810469.

• Page 89
  9. Power Control Unit (PCU) Malfunctioning 7. Check EFC valve. 8. Replace EFC valve. 9. Replace PCU. Refer to N14 CELECT™ System Troubleshoot- CELECT™ ing and Repair Manual, Bulletin No. 3810469. — — — — — — — — — — 1.
• Page 90
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-65 Engine Speed Surges (Other Than Low Idle) (Continued) Cause Corrections 1. Standby units. Verify that coolant heaters Genset and Industrial are operating. Reduce electric governor — — — — — — — — — — Application (EFC Control) gain and/or stability settings.

• Page 91: Engine Vibration — Excessive

  — — — — — — — — — — Engine Idle Speed Too Low for PT engines. On CELECT™ engines, refer to the N14 Operation and Maintenance Manual, Bulletin No. 3666024. Check fan. Refer to Procedure 1-18. — — — — — — — — — -…

• Page 92
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-67 Engine Vibration — Excessive (Continued) Cause Corrections Check flywheel. Refer to Procedure 7-44. Flywheel Loose or Damaged/Flywheel — — — — — — — — — — Check flywheel housing alignment. Refer Housing Misaligned to Procedure 7-44.

• Page 93: Engine Will Not Crank Or Cranks Slowly (Air Starting Motor)

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-68 Engine Will Not Crank or Cranks Slowly (Air Starting Motor) Cause Corrections Increase pressure using external air supply. — — — — — — — — — — Air Pressure Insufficient in Air Tank Disengage engine driven units.

• Page 94
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-69 Engine Will Not Crank or Cranks Slowly (Air Starting Motor) (Continued) Cause Corrections Air Starting Motor Malfunctioning or Refer to the manufacturer’s instructions. — — — — — — — — — — Incorrect Starting Motor Used Remove starting motor.

• Page 95: Engine Will Not Crank Or Cranks Slowly (Electric Starting Motor)

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-70 Engine Will Not Crank or Cranks Slowly (Electric Starting Motor) Cause Corrections Disengage engine driven units. Refer to — — — — — — — — — — Engine Drive Units Engaged the operation and maintenance manual.

• Page 96
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-71 Engine Will Not Crank or Cranks Slowly (Electric Starting Motor) (Continued) Cause Corrections Normal occurrence. Service kit, Part — — — — — — — — — — Hot Start No. 3803386, available to eliminate problem.

• Page 97: Engine Will Not Shut Off

  Refer to Procedure 5-19 on PT — — — — — — — — — — Fuel Drain Line Restricted engines. On CELECT™ engines, refer to N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. Check valve for correct operation (must open Overhead Fuel Tank Check Valve Not at 2 kPa [0.3 psi]).

• Page 98: Engine Will Start But Will Not Keep Running

  Page T-73 Engine Will Start But Will Not Keep Running Cause Corrections Refer to N14 CELECT™ System Trouble- • Electronic Fault Code Active — — — — — — — — — — shooting and Repair Manual, Bulletin No. • High Counts of Inactive Fault Codes 3810469.

• Page 99
  — — — — — — — — — — Fuel Pump Delivery Inadequate Rebuild and Calibration Manual, Bulletin No. 3379084. On CELECT™ engines, refer to N14 CELECT™ System Troubleshooting and Repair Manual, Bulletin No. 3810469. For PT, use the manual override to check.

• Page 100: Fuel Consumption — Excessive

  Address driver related factors. Refer to the — — — — — — — — — — Driver Technique Incorrect N14 Operation and Maintenance Manual, Bulletin No. 3666024. Vehicle and Environmental Factors Consider vehicle and environmental (Ambient Temperatures, Wind, Tires,…

• Page 101
  Page T-76 Fuel Consumption — Excessive (Continued) Cause Corrections Refer to fault code index in the N14 • Electronic Fault Codes Active* CELECT™ System Troubleshooting and • High Counts of Inactive Fault Codes* — — — — — — — — — — Repair Manual, Bulletin No.

• Page 102: Fuel Consumption Excessive — Performance Test Evaluation

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-77 Fuel Consumption Excessive — Performance Test Evaluation NOTE: After conducting the performance test, use this chart to analyze the performance data. Cause Corrections Clean/replace air filter element or — — — — — — — — — — Intake Air Restriction Excessive damaged air intake piping.

• Page 103
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-78 Fuel Consumption Excessive — Performance Test Evaluation (Continued) Cause Corrections Fuel Rate Low, Fuel Pressure OK, Intake Remove injectors and check for correct part Manifold Pressure High, Ambient Air number for CPL. Refer to CPL Manual, — — — — — — — — — — Temperature Between 0 and 38°C [32 and Bulletin No.
• Page 104
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-79 Fuel Consumption Excessive — Performance Test Evaluation (Continued) Cause Corrections Adjust valves and injectors. Refer to — — — — — — — — — — Overhead Adjustments Incorrect Procedure 7-04. Check the hydromechanical STC oil — — — — — — — — — — STC Operation in Advanced Mode Only…
• Page 105
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-80 Fuel in Coolant Cause Corrections Check coolant supply. Drain coolant — — — — — — — — — — Bulk Coolant Supply Contaminated and replace with non-contaminated coolant. Replace the fuel heater. Refer to the — — — — — — — — — — Fuel Heater Malfunctioning manufacturer’s recommendations.
• Page 106
  Long Periods of Engine Idling (More idle speed. To adjust idle speed for Than 10 Minutes) CELECT™, refer to the N14 Operation and Maintenance Manual, Bulletin No. 3666024. For STC, refer to the PT Fuel Pump Rebuild and Calibration Manual, Bulletin No.

• Page 107: Intake Manifold Air Temperature Above Specification

  Intake Manifold Air Temperature Above Specification Cause Corrections Check intake manifold temperature gauge/ Intake Manifold Temperature Gauge/ sensor operation. Refer to the N14 CELECT™ — — — — — — — — — — CELECT™ Sensor Malfunctioning System Troubleshooting and Repair Manual, Bulletin No. 3810469.

• Page 108: Lubricating Oil Consumption Excessive

  Check and revise oil change intervals. — — — — — — — — — — Extended Oil Change Intervals Refer to the N14 Operation and Mainte- nance Manual, Bulletin No. 3666024. Change oil. Refer to the N14 Operation — — — — — — — — — — Oil Does Not Meet Specifications and Maintenance Manual, Bulletin No.

• Page 109
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-84 Lubricating Oil Consumption Excessive (Continued) Cause Corrections Refer to ‘‘Lubrication Oil in Fuel’’ — — — — — — — — — — STC Valve Defective or Plumbing Incorrect Symptom Chart. Check air compressor operation.

• Page 110: Lubricating Oil Contaminated

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-85 Lubricating Oil Contaminated Cause Corrections Perform an oil analysis to determine the — — — — — — — — — — Identify Contamination contaminates. Check bulk oil supply. Change engine oil — — — — — — — — — — Bulk Oil Supply Contaminated and filters.

• Page 111: Lubricating Oil In Fuel

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-86 Lubricating Oil in Fuel Cause Corrections Check STC valve plumbing. Refer to — — — — — — — — — — STC Valve Plumbing Incorrect Procedure 5-12. Remove the STC valve, and inspect the STC Valve Barrel O-rings Missing, — — — — — — — — — — barrel o-rings.

• Page 112: Lubricating Oil Pressure — High

  Change the oil and check oil specifica- Oil Does Not Meet Specifications (Oil — — — — — — — — — — tions. Refer to N14 Operation and Mainte- Viscosity Too High) nance Manual, Bulletin No. 3666024. Perform lubricating system test. Refer to…

• Page 113: Lubricating Oil Pressure — Low

  Exceeding Limit Refer to specifications. Change oil and filters and check oil specifications. Refer to the N14 Operation — — — — — — — — — — Oil Does Not Meet specifications and Maintenance Manual, Bulletin No.

• Page 114
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-89 Lubricating Oil Pressure — Low (Continued) Cause Corrections Clean or replace viscosity sensor. Refer — — — — — — — — — — Viscosity Sensor Plugged or Defective to Procedure 2-18. Perform lubricating system test.

• Page 115: Lubricating Oil Sludge In The Engine Crankcase Excessive

  — — — — — — — — — — Bulk Oil Supply Contaminated and filters. Replace oil with non- contaminated supply. Change oil and filters. Refer to the N14 Operation and Maintenance Manual, — — — — — — — — — — Oil Does Not Meet Specifications Bulletin No.

• Page 116
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-91 Lubricating Oil Sludge in the Engine Crankcase Excessive (Continued) Cause Corrections Injector Cup Spray Incorrect or Replace injectors. Refer to Procedure 5-10. — — — — — — — — — — Injectors Damaged Check injection timing.

• Page 117: Lubricating Oil Temperature Above Specification

  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-92 Lubricating Oil Temperature Above Specification Cause Corrections Add or drain engine oil. Refer to Proce- — — — — — — — — — — Oil Level Incorrect dures 2-06 and 2-07. Check dipstick calibration.

• Page 118: Lubricating Or Transmission Oil In The Coolant

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-93 Lubricating or Transmission Oil in the Coolant Cause Corrections Check coolant supply, flush system, and — — — — — — — — — — Bulk Coolant Supply Contaminated replace with non-contaminated coolant. Replace filter.

• Page 119
  Corrections Refer to the fault code index for procedure. • Electronic Fault Codes Active* Refer to N14 CELECT™ System — — — — — — — — — — • High Counts of Inactive Fault Codes Troubleshooting and Repair Manual, Bulletin No.
• Page 120
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-95 Smoke, Black — Excessive (Continued) Cause Corrections Check turbocharger wheel clearance. — — — — — — — — — — Turbocharger Wheel Clearance Incorrect Refer to Procedure 3-07. Connect auxiliary fuel supply and — — — — — — — — — — Fuel Quality Poor operate engine.
• Page 121
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-96 Smoke, Black — Excessive — Performance Measurement NOTE: After conducting the performance test, use this chart to analyze the performance data. Cause Corrections Clean/replace air filter element or — — — — — — — — — — Intake Air Restriction Excessive damaged air intake piping.
• Page 122
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-97 Smoke, Black — Excessive — Performance Measurement (Continued) Cause Corrections Fuel Rate Low, Fuel Pressure OK, Intake Check for correct parts for CPL. Refer Manifold Pressure High, Ambient Air — — — — — — — — — — to CPL Manual, Bulletin No.
• Page 123
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-98 Smoke, Black — Excessive — Performance Measurement (Continued) Cause Corrections Check injection timing. Refer to — — — — — — — — — — Injection Timing Incorrect Procedure 7-22. Check engine for high crankcase Internal Engine Parts Incorrect or Worn — — — — — — — — — — pressure (low compression).
• Page 124
  Repair Manual, Bulletin No. 3810469. Check sensor and replace if necessary. In Range Sensor Failure Refer to N14 CELECT™ System Trouble- — — — — — — — — — — • Coolant Temperature shooting and Repair Manual, Bulletin No.
• Page 125
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-100 Smoke, White — Excessive (Continued) Cause Corrections Check viscosity sensor. Refer to On STC Engines, Low Oil Rifle Pres- — — — — — — — — — — Procedure 2-18. sure During Cold Start Up Check STC oil delivery system.
• Page 126
  Refer to • Valve Protrusion Incorrect Procedure 7-25. Check the valve protrusion. • Pistons or Rings Incorrect, Damaged, or Refer to N14 Shop Manual, Bulletin No. Worn 3810487. Check for head gasket coolant leak. Refer to Procedure 7-17.
• Page 127
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-102 Turbocharger Boost Pressure Low Cause Corrections Check part number versus Control Parts List (CPL) and replace turbocharger if — — — — — — — — — — Turbocharger Incorrect necessary. Refer to CPL Manual, Bulletin No.
• Page 128
  Page T-103 Turbocharger Leaks — Engine Oil or Fuel Cause Corrections Review vehicle operation. Refer to N14 Operating For Extended Periods Under — — — — — — — — — — Operation and Maintenance Manual, Light or No Load Conditions Bulletin No.
• Page 129
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-104 Variable Speed (VS) Governor Speed Not Set Correctly Cause Corrections Make sure the lower lever linkage opens PT Fuel Pump Lower (Automotive) — — — — — — — — — — the throttle wide open.

• Page 130: Main Bearing Noise (Refer To Engine Noise Excessive — Main Bearing Symptom Chart

  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-105 Engine Noise Diagnostic Procedures — General Information NOTE: When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate noise caused by these units.

• Page 131
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-106 Driveability — General Information Driveability is a term which in general describes vehicle performance on the road. Driveability problems for an engine can be caused by several different factors. Some of the factors are engine related and some are not. Before troubleshooting, it is important to determine the exact complaint and whether the engine has a real driveability problem, or if it simply does not meet driver expectations.
• Page 132
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-107 Engine related Poor Acceleration/Response can be caused by several different factors such as: — Low No-Air Setting — Plugged ASA — AFC Delay — Excessive Drainline Restriction — Low Throttle Leakage —…
• Page 133
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-108 Driveability/Low Power — Customer Complaint Form Customer Name/Company Date (1). How did the problem occur? Suddenly Gradually (2). At what hour/mileage did the problem begin? miles Since New After engine repair? After equipment repair? After change in equipment use? After change in selectable programmable parameters?
• Page 134
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-109 Driveability/Low Power/Excessive Fuel Consumption — Checklist Vehicle/Equipment Specifications: Year, Type and Model Transmission (RT14609, etc) Duty Cycle Rear Axle Ratio, No. of Axles Application: Industrial Marine Genset Automotive Typical GVW Engine Rating: Trailer Type and Size Height Width…
• Page 135
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-110 Fuel Consumption — General Information The cause of excessive fuel consumption is hard to diagnose and correct because of the potential number of factors involved. Actual fuel consumption problems can be caused by any of the following factors: —…
• Page 136
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-111 Fuel Consumption — Automotive Customer Complaint Form Customer Name/Company Date Answer the following questions. Some questions require making an X next to the appropriate answer. (1). What fuel mileage is expected? Expected (2).
• Page 137
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-112 Fuel Consumption — Industrial Customer Complaint Form Customer Name/Company Date Answer the following questions. Some questions require making an X next to the appropriate answer. (1). What fuel consumption is expected? Expected (2).
• Page 138
  Oil Consumption In addition to the information that follows, a service publication entitled Technical Overview of Oil Consumption is available, Bulletin 3379214-00. Cummins defines ‘‘Acceptable Oil Usage’’ as outlined in the following table: ACCEPTABLE OIL USAGE ANY TIME DURING COVERAGE PERIOD…
• Page 139
  Added Oil Miles-Hours-Kilometers Oil Added Brand & Viscosity of Oil Used Start Test Last Mileage/Hours/Kilometers Minus Start Mileage/Hours/Kilometers Equals Test Mileage/Hours/Kilometers Divided By Oil Added Equals Usage Rate Customer Signature Cummins Dealer Cummins Distributor Cummins Engine Company, Inc. Form 4755…
• Page 140
  Section T — Troubleshooting Troubleshooting Symptoms Charts Page T-115 Cummins Engine Company, Inc. Box 3005 Columbus, Indiana U.S.A. 47202-3005 Oil Consumption Report Customer Name Dist./Dlr. Engine Model Mi/Km/Hr Engine Serial No. CPL No. Vehicle Make/Model Date 1. Review of maintenance history.
• Page 141
  Troubleshooting Symptoms Charts Section T — Troubleshooting Page T-116 NOTES…
• Page 142
  Section 1 — Cooling System Page 1-1 Section 1 — Cooling System Section Contents Page Antifreeze ………………………….. 1-13 Cleaning the Cooling System ……………………. 1-20 Coolant Additive Requirement ……………………1-14 Testing SCA Concentration Level……………………1-16 Coolant Filter …………………………1-17 Installation …………………………1-18 Removal…………………………..
• Page 143
  Section 1 — Cooling System Page 1-2 Page On-Off Thermatic Fan Clutch …………………….. 1-51 Checking — Cooling System Temperature Actuation………………1-51 Checking — Intake Air Temperature Actuation ………………..1-53 Installation …………………………1-55 Removal …………………………1-53 Radiator and Charge Air Cooled Fins ………………….1-37 Inspection …………………………
• Page 144
  (engine cold). The following publications, available through Cummins Distributors or Cummins Dealers, provide cooling system installation recommendations and specifications ap- proved by Cummins Engine Company, Inc.: • Automotive Installation Recommendations (Cooling System), Bulletin No.
• Page 146
  At 2300 RPM ……………………317 kPa [46 psi] At 1700 RPM ……………………165 kPa [24 psi] Coolant Alarm Activation Temperature N14 460E …………………..104 ± 1°C [220 ± 2°F] All Other Ratings ………………..100 ± 1°C [212 ± 2°F] Maximum Allowable Top Tank Temperature: N14 460E ……………………..
• Page 147
  Sulfur 100 PPM as (SO Antifreeze Cummins/Fleetguard recommends using a low-silicate antifreeze concentrate that meets ASTM D4985 specifi- cations (less than .10% silicate, expressed as Na Low-silicate antifreeze must be mixed with quality water at a 50/50 ratio (40 to 60% working range). A 50/50 miture of antifreeze and water gives a -34°F freeze point and a…
• Page 148
  The system must be precharged with the correct concentration of SCA. Cummins/Fleetguard uses the SCA unit to define the required concentration level to protect against liner pitting. When coolant is replaced in the field, it must be replaced with Heavy Duty Coolant precharged with SCA’s.
• Page 149
  Supplemental Coolant Additives (SCA’s) Section 1 — Cooling System Page 1-8 This chart shown on next page must be followed to de- termine how much liquid SCA must be added to precharge different quantities of make-up coolant (water and low-silicate antifreeze). Remember, a service filter must also be installed.
• Page 150
  Section 1 — Cooling System Supplemental Coolant Additives (SCA’s) Page 1-9 Fleetguard DCA4 Service Filters and Liquid Precharge Fleetguard Part No. Cummins Part No. DCA4 Units DCA4 Spin-on Coolant Filters WF-2070 3318157 WF-2071 3315116 WF-2072 3318201 WF-2073 3315115 WF-2074 3316053…
• Page 151
  Cooling System Service Tools The following special tools are recommended to perform procedures in Section 1. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description…
• Page 152
  Section 1 — Cooling System Cooling System Service Tools Page 1-11 Tool No. Tool Description Tool Illustration Thermostat Seal Driver Used to position the thermostat seal in the thermostat housing and cover. ST-1225 Optical Tachometer Measure engine rpm. 3377462 Reflective Tape (in optical tachometer, Part No. 3377462) Used with optical tachometer, Part No.
• Page 153
  Cooling System Service Tools Section 1 — Cooling System Page 1-12 Tool No. Tool Description Tool Illustration Cooling System Test Kit — Fleetguard Use to measure Supplemental Cooling Additive (SCA) concen- tration. CC-2626 Refractometer Use to measure glycol (antifreeze) concentration. CC-2800…
• Page 154
  Section 1 — Cooling System Cooling System Water (1-01) Page 1-13 Cooling System Water (1-01) Always use good quality soft water in the coolant mix- ture. Water added to the cooling system must meet the specifications given in the accompanying chart. Antifreeze (1-02) Low-silicate antifreeze must be mixed with quality water at a 50/50 ratio (40 to 60% working range).
• Page 155
  NOTE: Cummins Engine Company requires that a service filter be used and SCA liquid added when the coolant is changed or a significant (more than 50 percent) coolant loss occurs.
• Page 156
  Section 1 — Cooling System Coolant Additive Requirement (1-05) Page 1-15 After changing the coolant, the initial charge of DCA4 (or equivalent) concentration must be 1.5 unit per 3.8 liters [1 U.S. gallon] of coolant in the system. NOTE: The cooling system must be clean before adding DCA4 (or equivalent).
• Page 157
  Coolant Additive Requirement (1-05) Section 1 — Cooling System Page 1-16 Testing SCA Concentration Level Testing is required whenever existing coolant is used again after an engine repair and after the engine has experienced a coolant loss. Use the CC-2626 test kit to determine the SCA level of the cooling system.
• Page 158
  Section 1 — Cooling System Coolant Filter (1-06) Page 1-17 If the concentration is above 3 units per gallon, do not Above 3 Units replace the service filter. Test the coolant at subsequent oil drain intervals until the concentration is back under 3 units.
• Page 159
  Coolant Filter (1-06) Section 1 — Cooling System Page 1-18 Warning: Do not remove the radiator cap from a hot engine. Hot steam will cause serious personal injury. Remove the coolant system pressure cap and close the shutoff valve before removing the coolant filter. Failure to do so can cause personal injury from heated coolant spray.
• Page 160
  Section 1 — Cooling System Draining the Cooling System (1-07) Page 1-19 Operate the engine until the coolant temperature is above 82°C [180°F], and check for leaks. Draining the Cooling System (1-07) Position the vehicle on level ground. Warning: Wait until the coolant temperature is below 50°C [120°F] before removing the system pressure cap.
• Page 161
  Cleaning the Cooling System (1-08) Section 1 — Cooling System Page 1-20 • Open the engine draincock. • Open the oil cooler draincock (or plug). Cleaning the Cooling System (1-08) Warning: Wait until the coolant temperature is below 50°C [120°F] before removing the coolant system pres- sure cap.
• Page 162
  Section 1 — Cooling System Cleaning the Cooling System (1-08) Page 1-21 Caution: Fleetguard RESTORE contains no antifreeze. Do not allow the cooling system to freeze during the cleaning operation. Immediately add 3.8 liters [1 U.S. gallon] of Fleetguard RESTORE, RESTORE PLUS, (or equivalent) for each 38 to 57 liters [10 to 15 gallons] of cooling system capacity, and fill the system with plain water.
• Page 163
  Filling the Cooling System (1-09) Section 1 — Cooling System Page 1-22 Fill the cooling system with Heavy Duty Coolant and install the correct service filter. Refer to the Fleetguard~ DCA4 Service Filter Selection Chart on previous page. Refer to Procedure 1-09. Install the pressure cap.
• Page 164
  Section 1 — Cooling System Filling the Cooling System (1-09) Page 1-23 Proper mixing of coolant required: • Pour water into the container • Add low-silicate antifreeze • Add DCA4 liquid • Thoroughly blend the components Following the correct order for mixing the coolant will prevent additive dropout during the mixing process.
• Page 165
  Filling the Cooling System (1-09) Section 1 — Cooling System Page 1-24 Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill (or expansion) tank. NOTE: Some radiators have two fill locations, both of which must be filled when the cooling system is drained.
• Page 166
  Section 1 — Cooling System Cooling System — Testing For Air Or Combustion Gases (1-10) Page 1-25 Cooling System — Testing For Air Or Combustion Gases (1-10) Overflow Method Warning: Wait until the temperature is below 50°C [120°F] before removing the coolant system pressure cap.
• Page 167
  Cooling System — Testing For Air Or Combustion Gases (1-10) Section 1 — Cooling System Page 1-26 Install coolant sightglass analyzer, Part No. 3823211, to the engine block pressure and water pump inlet pressure Compuchek fittings. NOTE: The needle valve (1) on the coolant sightglass an- alyzer, Part No.
• Page 168
  Section 1 — Cooling System Cooling System — Testing For Air Or Combustion Gases (1-10) Page 1-27 Loosen the radiator cap to prevent any pressure buildup in the top tank. Warning: Wait until the temperature is below 50°C [120°F] before loosening the coolant system pressure cap.
• Page 169
  Cooling System — Testing For Air Or Combustion Gases (1-10) Section 1 — Cooling System Page 1-28 A continuous flow of air bubbles indicates the following: • Defective fan, shutter or heater air control valve. • Air compressor head or head gasket leakage. •…
• Page 170
  Section 1 — Cooling System Cooling System — Testing For Air Or Combustion Gases (1-10) Page 1-29 Insert the rubber tip of the combustion gas leak test instrument in the radiator fill neck. Hold the instrument down firmly and turn back and forth to make sure that an air tight seal is formed between the tester and radiator fill neck.
• Page 171
  Cooling System — Testing For Air Or Combustion Gases (1-10) Section 1 — Cooling System Page 1-30 Check the test instrument to make sure that it is firmly sealed in the radiator fill neck. Insert the tip of the rubber ball into the hole in the top of the test instrument.
• Page 172
  Section 1 — Cooling System Cooling System — Testing For Air Or Combustion Gases (1-10) Page 1-31 A negative result from the combustion leak tester, cou- pled with a continuous flow of air bubbles from the pre- vious test, indicates the following: •…
• Page 173
  Cooling System — Testing For Air Or Combustion Gases (1-10) Section 1 — Cooling System Page 1-32 Air Compressor Checking Caution: The air compressor discharge line must be disconnected at the compressor to allow the compres- sor to discharge air to the atmosphere during this next test to prevent the compressor from overheating.
• Page 174
  Section 1 — Cooling System Cooling System Pressure Testing (1-11) Page 1-33 If no indication of leakage is found from the cylinder head, check for cylinder block counterbore leaks. Refer to Pro- cedure 7-13. Cooling System Pressure Testing (1-11) Warning: Wait until the temperature is below 50°C [120°F] before removing the coolant system pressure cap.
• Page 175
  Hoses — Inspection (1-12) Section 1 — Cooling System Page 1-34 Inspect for coolant leaks and repair if necessary. Remove the pressure test equipment and the plug from the pressure relief valve overflow tube (if equipped). Install the coolant system pressure cap. Hoses — Inspection (1-12) Caution: Do not bend or deform the hoses during in- spection.
• Page 176
  Section 1 — Cooling System Coolant Temperature Gauge — Checking (1-13) Page 1-35 Coolant Temperature Gauge — Check- ing (1-13) Check for a blown fuse in the temperature gauge sending unit circuit. Check the wiring from the gauge to the sending unit for a broken connection.
• Page 177
  Radiator Pressure Cap (1-15) Section 1 — Cooling System Page 1-36 Radiator Pressure Cap (1-15) Testing Warning: Do not remove the radiator pressure cap until the coolant temperature is below 50°C [120°F]. Failure to do so can cause personal injury from heated coolant spray.
• Page 178
  Section 1 — Cooling System Radiator and Charge Air Cooled Fins (1-16) Page 1-37 Radiator and Charge Air Cooled Fins (1-16) Inspection Visually inspect the radiator for plugged radiator fins. Use 550 kPa [80 psi] air pressure to blow the dirt and debris from the fins.
• Page 179
  Radiator Shutter Operation (1-17) Section 1 — Cooling System Page 1-38 Install a master temperature gauge which is known to be accurate into the thermostat housing. A thermocouple can be used. Restrict the radiator air flow. Operate the engine at maximum power. When the coolant temperature reaches the temperature stamped on the control, check the shutters to see if they are open.
• Page 180
  Section 1 — Cooling System Radiator Shutter Operation (1-17) Page 1-39 When the coolant temperature drops to approximately 6°C [10°F] below the temperature stamped on the con- trol, the shutters will be fully closed. If the shutters do not operate correctly, refer to the shut- ter manufacturer’s service manual.
• Page 181
  Radiator Shutter Operation (1-17) Section 1 — Cooling System Page 1-40 Run the engine at low idle until oil pressure reaches 69 kPa [10 psi] minimum. Immediately load the engine to full power so that air temperature rises more quickly than the coolant temperature.
• Page 182
  A bent or damaged fan blade can fail during operation and cause serious personal injury or property damage. NOTE: Replace the original equipment fan with a fan of the identical part number. Cummins Engine Company, Inc. must approve any other fan changes.
• Page 183
  Fan Shroud Inspection (1-19) Section 1 — Cooling System Page 1-42 Visually check the fan for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted. Tighten the capscrews if necessary. Replace damaged fans.
• Page 184
  Section 1 — Cooling System Fan Belts (1-21) Page 1-43 Turn the adjusting screw counterclockwise to release tension, and remove the belts. Visually inspect the pulleys for cracks or broken grooves. Replace if necessary. Inspection Visually inspect the belts for the following: •…
• Page 185
  Fan Belts (1-21) Section 1 — Cooling System Page 1-44 Installation Install new belts on the pulley. When a drive pulley uses two or more belts, replace the belts as a complete set. NOTE: To prevent damage, do not roll a belt over the pulley or pry it on with a tool.
• Page 186
  Section 1 — Cooling System Fan and Fan Hub (1-22) Page 1-45 Tighten the fan hub mounting capscrews. Torque Value: 108 N•m [80 ft-lb] Measure the belt tension again using Service Tool, ST- 1138. Adjust if necessary. When satisfactory belt tension is obtained, loosen the adjusting screw 1/2-turn to prevent breakage.
• Page 187
  Fan and Fan Hub (1-22) Section 1 — Cooling System Page 1-46 Inspection Remove the fan drive belts. Refer to Procedure 1-21. Inspect the fan hub for the following: • Freedom of rotation. • Cracks. • Grease seal leakage. Repair or replace the fan hub if the fan hub does not rotate freely or if there is evidence of cracks, or grease seal leakage.
• Page 188
  Section 1 — Cooling System Fan and Fan Hub (1-22) Page 1-47 The end clearance on ‘‘Step-Bore’’ fan hub (without bear- ing spacer) must be 0.08 mm to 0.25 mm [0.003-inch to 0.010-inch]. Installation Install the new fan hub and capscrews. Use your fingers to tighten the capscrews.
• Page 189
  Testing Use a fan RPM measuring device to check the operation of the viscous fan hub. A strobe or Cummins optical tachometer, Part No. 3377462, can be used. Mark a spot on the fan hub pulley and one fan blade so the measuring device can determine the pulley and the fan speed.
• Page 190
  To avoid personal injury, do not put your hands in the path of the rotating fan. Caution: Do not exceed 100°C [212°F] (104°C [220°F] for the N14-460E) coolant temperature. Higher coolant temperatures can damage the engine. When the coolant temperature reaches 91°C [195°F], measured fan speed must reach a minimum of 85 per- cent of a pulley speed.
• Page 191
  Viscous Fan Clutch (1-23) Section 1 — Cooling System Page 1-50 If a fan speed measuring device is not available and the complaint is overheating, remove the viscous fan hub bimetal strip and the control pin. This will cause the fan hub to operate all the time.
• Page 192
  Section 1 — Cooling System On-Off Thermatic Fan Clutch (1-24) Page 1-51 Installation Install the fan on the viscous fan clutch. Install the cap- screws or the hexagon nuts which hold the fan to the clutch. Make sure the correct number of spacers are still on the fan hub.
• Page 193
  On-Off Thermatic Fan Clutch (1-24) Section 1 — Cooling System Page 1-52 NOTE: If winterfronts or radiator covers are used, a mini- mum fixed opening of 120 square inches (i.e., 10 x 12 inches, 11 x 11 inches, etc.) is required at all times. Shutterstat and thermatic fan controls must operate in the same temperature range as the thermostat with which they are used.
• Page 194
  On-Off Thermatic Fan Clutch (1-24) Page 1-53 The fan clutch must disengage before the coolant tem- perature drops to 90°C [194°F]. Cummins Engine Com- pany, Inc. recommends the fan disengage at 3°C [6°F] below the temperature stamped on the fan temperature sensor.
• Page 195
  On-Off Thermatic Fan Clutch (1-24) Section 1 — Cooling System Page 1-54 Disconnect the signal line. Loosen the capscrews which attach the fan hub to the bracket. Remove the fan hub adjusting capscrew, and remove the fan belts. Loosen the fan hub capscrews, and remove the fan hub.
• Page 196
  Section 1 — Cooling System On-Off Thermatic Fan Clutch (1-24) Page 1-55 Installation Install the fan hub assembly on the fan hub bracket. The capscrew must not be tightened at this time. Install the fan drive belts on the fan hub and the accessory pulley.
• Page 197
  Water Pump Belts (1-25) Section 1 — Cooling System Page 1-56 Install the fan hub signal line. Tighten the fan belts. Refer to Procedure 1-21. Water Pump Belts (1-25) Removal Remove the fan drive belts. Refer to Procedure 1-21. Loosen the idler pulley shaft lock nut. Turn the adjusting screw counterclockwise to release tension, and remove the water pump belt.
• Page 198
  Section 1 — Cooling System Water Pump Belts (1-25) Page 1-57 Visually inspect and replace the belt for the following characteristics: • Cracks. • Glazing. • Tears or cuts. Visually inspect the pulley alignment. Pulley misalign- ment must not exceed 0.5 mm per cm [1/16-inch per foot] of distance between the pulley centers.
• Page 199
  Water Pump Idler Pulley (1-26) Section 1 — Cooling System Page 1-58 Tighten the idler pulley shaft lock nut. Torque Value: 68 N•m [50 ft-lb] Loosen the adjusting screw 1/2-turn to prevent breakage. Measure the belt tension again. Adjust if necessary. Water Pump Idler Pulley (1-26) Remove Remove the water pump drive belt.
• Page 200
  Section 1 — Cooling System Water Pump (1-27) Page 1-59 Installation Install the new idler pulley in the water pump body. Install the washer and the lock nut on the back of the pulley shaft. NOTE: Do not tighten the lock nut until the water pump drive belt has been installed and adjusted.
• Page 201
  Water Pump (1-27) Section 1 — Cooling System Page 1-60 Remove the coolant inlet transfer connection from the water pump. Remove the six mounting capscrews from the water pump. NOTE: The water pump must be removed carefully to pre- vent damage to the impeller. Remove the water pump from the engine.
• Page 202
  Section 1 — Cooling System Water Pump (1-27) Page 1-61 Install the water transfer tube attached to the thermostat housing in the water pump. Install the water pump to the block using the six mounting capscrews. Tighten the capscrews to the following torque values: •…
• Page 203
  Coolant Filter Head Insert (1-28) Section 1 — Cooling System Page 1-62 Install and adjust water pump belt. Refer to Procedure 1-25. NOTE: Belt tension can increase when the locknut is tightened. Fill the engine with Heavy Duty Coolant. Refer to Pro- cedure 1-09.
• Page 204
  Section 1 — Cooling System Coolant Filter Shutoff Valve (1-29) Page 1-63 Installation Install the insert into the oil cooler housing. Tighten the insert. Torque Value: 47 N•m [35 ft-lb] Install the coolant filter (DCA4). Turn the manual shutoff valve to the ‘‘ON’’ position. The valve is in the ‘‘ON’’…
• Page 205
  Coolant Filter Shutoff Valve (1-29) Section 1 — Cooling System Page 1-64 Remove the shutoff valve and o-ring. Inspection Clean the filter head and shutoff valve with a fiber brush and solvent. Inspect the filter head and shutoff valve for cracks, pit- ting, corrosion, or other damage.
• Page 206
  Section 1 — Cooling System Thermostat Housing (1-30) Page 1-65 Lubricate the o-ring with Lubriplate 105 or equivalent, and install the shutoff valve in the filter head. Install the retaining capscrew and washer. Torque Value: 20 N•m [15 ft-lb] Turn the valve to the ‘‘ON’’ position. The valve is in the ‘‘ON’’…
• Page 207
  Thermostat Housing (1-30) Section 1 — Cooling System Page 1-66 Remove the four capscrews that attach the thermostat housing to the rocker housing. Remove the thermostat housing from the water transfer tube. Remove the four thermostat cover capscrews and dis- assemble the thermostat housing.
• Page 208
  Section 1 — Cooling System Thermostat Housing (1-30) Page 1-67 Installation Install the thermostat in the cover. Install a new gasket on the thermostat housing. Install the thermostat cover and four mounting capscrews. Tighten the capscrews. Torque Value: 47 N•m [35 ft-lb] Install the CELECT™…
• Page 209
  Thermostat Seal (1-31) Section 1 — Cooling System Page 1-68 Fill the engine with Heavy Duty Coolant. Refer to Pro- cedure 1-09. Start the engine, and check for leaks. Thermostat Seal (1-31) Inspection Visually inspect the thermostat seal for cracks, corrosion, or other damage.
• Page 210
  Section 1 — Cooling System Thermostat (1-32) Page 1-69 Installation Caution: When installing a new seal, the flat side of the seal must be toward the mandrel for correct installation. Use thermostat seal mandrel, Part No. ST-1225, and a lead hammer to install the seal. A counterbore in the housing bore locates the seal.
• Page 211
  Thermostat (1-32) Section 1 — Cooling System Page 1-70 If more than 100cc [3.3 fluid ounces] of coolant is col- lected, the thermostat or the thermostat seal is leaking. Remove the thermostat and test operation as described below. Refer to Procedure 1-30 for thermostat removal and Procedure 1-31 for thermostat seal inspection.
• Page 212
  Section 2 — Lubricating System Page 2-1 Section 2 — Lubricating System Section Contents Page Crankcase Breather ……………………….2-21 Cleaning and Inspection ……………………..2-21 Installation …………………………2-22 Removal …………………………2-21 Dipstick Calibration ……………………….2-26 Dipstick Tube and Housing ……………………..2-25 Cleaning and Inspection ……………………..
• Page 213
  Section 2 — Lubricating System Page 2-2 Page Lubricating Oil Pump Signal Line ……………………2-40 Cleaning and Inspection ……………………..2-40 Installation …………………………2-41 Removal …………………………2-40 Lubricating Oil Pump Signal Line Orifice (In Chassis) ………………. 2-41 Cleaning …………………………2-42 Installation …………………………2-42 Removal …………………………
• Page 214
  Section 2 — Lubricating System Lubricating System General Information Page 2-3 Lubricating System General Informa- tion The demand flow and cooling (DFC) lubricating system incorporates a lubricating oil pump (1) with a pressure sensitive regulator circuit (2) and a high pressure limit valve (3).
• Page 215
  Lubricating System General Information Section 2 — Lubricating System Page 2-4 An internal vent drilling (1) in the pressure regulator cavity allows any oil that has leaked past the plunger into the spring cavity to drain back into the oil pan. The regulator plunger remains in the downward or open position until the main oil rifle pressure drops below 275 kPa [40 psi].
• Page 216
  Section 2 — Lubricating System Lubricating System General Information Page 2-5 Oil from the oil rifle (1) enters the viscosity sensor and flows through the long annular area (2). When the oil is cold, there is a very high pressure drop from the oil rifle to the undercut area (3).
• Page 217
  Lubricating System General Information Section 2 — Lubricating System Page 2-6 When the oil pressure exceeds 965 kPa [140 psi] in the lubricating oil pump, for instance during cold start-up, the oil pressure in the pump overcomes the limit valve spring force.
• Page 218
  Lubricating Oil Filter A combination oil filter is present on the N14. The upper portion of the filter contains the full flow filter element while the lower portion contains the bypass filter element.
• Page 219
  Lubricating System General Information Section 2 — Lubricating System Page 2-8 Lubricating Oil Use Cummins Premium Blue 15W-40 multi-viscosity oil or equivalent which meets API Classification CE or CF-4 for turbocharged engines. Caution: Limited use of oils, such as 5W-30 or 10W-30, may aid in starting the engine and provide sufficient oil flow at ambient temperatures below -5°C [23°F].
• Page 223
  Lubricating Oil System Specifications Section 2 — Lubricating System Page 2-12 Lubricating Oil System Specifications Oil pressure at idle (minimum allowable) at 93°C [200°F] ……… 69 kPa [10 psi] minimum At no load governed speed: Automotive and Industrial …………….240 to 310 kPa [35 to 45 psi] Oil capacity of standard engine: Combination Full Flow/Bypass Lubricating Oil Filter …………
• Page 224
  Lubricating Oil System Service Tools The following special tools are recommended to perform procedures in Section 2. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description…
• Page 225
  Lubricating Oil System Service Tools Section 2 — Lubricating System Page 2-14 Tool No. Tool Description Tool Illustration Lube Suction O-ring Expander Used to assemble the straight lube suction tube and flange. 3376844…
• Page 226
  Checking (2-01) 1. This procedure describes a test for the operation of the lubricating oil systems for the N14 engine model. NOTE: This procedure requires the use of 15W-40 engine oil and the oil sump temperature to be 79 to 96°C [175 to 205°F].
• Page 227
  Lubricating Oil System Diagnostic Checking (2-01) Section 2 — Lubricating System Page 2-16 NOTE: If the oil filter outlet pressure is within, or exceeds specifications at high idle and the main oil rifle pressure is below specifications, proceed to step 6. 4.
• Page 228
  Section 2 — Lubricating System Lubricating Oil System Diagnostic Checking (2-01) Page 2-17 NOTE: If the oil pump outlet pressure is less than the spec- ification, check for damage to the oil transfer tube, the oil pressure regulators, and the lubricating oil pump. Refer to Procedures 2-11 (Lubricating Oil Transfer Tube), 2-13 (Lu- bricating Oil Pump) and 2-15 (Main Lubricating Oil Pressure Regulator).
• Page 229
  • Coolant leaks. • Oil diluted with fuel. • Metal particles causing wear. For additional oil analysis information, refer to Cummins Engine Oil Recommendations, Bulletin No. 3810340. NOTE: Do not disassemble an engine for repair based only on the results of an oil analysis. The oil filter must also be inspected.
• Page 230
  Section 2 — Lubricating System Lubricating Oil Filter (2-03) Page 2-19 Inspect the filter element for evidence of moisture or metal particles. Metal Probable Source Copper Bearings and Bushings Chromium Piston Rings Iron Cylinder Liners Lead Bearing Overlay Material Aluminum Piston Wear or Scuffing Lubricating Oil Filter (2-03) Removal…
• Page 231
  Lubricating Oil Leaks (2-04) Section 2 — Lubricating System Page 2-20 Confirm that the oil level in the pan is to the full mark. Operate the engine, until the water temperature reaches 82°C [180°F]. Check the oil pressure and check for leaks. Lubricating Oil Leaks (2-04) Use a steam cleaner or a high pressure washer to clean the engine.

• Page 232: Crankcase Breather

  Section 2 — Lubricating System Crankcase Breather (2-05) Page 2-21 Operate the engine until the water temperature reaches 82°C [180°F]. Inspect the exterior of the engine for leak- ing gaskets, seals, o-rings, pipe plugs, or fittings. NOTE: Before removing and replacing any gaskets, check the capscrews to make sure they are tightened to the correct torque values.

• Page 233: Installation

  Crankcase Breather (2-05) Section 2 — Lubricating System Page 2-22 Use solvent to clean the breather tube, vapor barriers, and rubber gasket. Dry it with compressed air. Inspect the breather tube, the baffle plate, the rubber gasket, and the rocker housing cover for cracks or other damage.

• Page 234: Dipstick Calibration

  Section 2 — Lubricating System Draining the Lubricating Oil System (2-06) Page 2-23 Draining the Lubricating Oil System (2-06) Warning: Hot oil can cause serious personal injury. Operate the engine until the water temperature reaches 60°C [140°F]. Shut the engine off. Remove the oil drain plug and oil filter.

• Page 235
  On CELECT™ engines, remove the lubricating oil tem- perature sensor from the lubricating oil pump cover. Lubricating oil pumps on N14 STC engines are equipped with a 9/16-18 UNF Compuchek coupling nipple. Use the coupler, Part No. 3376859, to connect the priming pump to the coupling.

• Page 236: Dipstick Tube And Housing

  Section 2 — Lubricating System Dipstick Tube and Housing (2-09) Page 2-25 Fill the engine with lubricating oil. Refer to Procedure 2-07. Operate the engine until it reaches a temperature of 82°C [180°F], and check for leaks. Dipstick Tube and Housing (2-09) Removal Remove the four capscrews and housing.

• Page 237: Installation

  Dipstick Calibration (2-10) Section 2 — Lubricating System Page 2-26 Installation Install the dipstick tube housing and a new gasket. Install the four capscrews, and tighten. Torque Value: 47 N•m [35 ft-lb] NOTE: Check the dipstick calibration. Refer to Procedure 2-10.

• Page 238: Removal

  Section 2 — Lubricating System Lubricating Oil Transfer Tube (2-11) Page 2-27 Remove the dipstick, and scribe a mark across the dip- stick at the indicated ‘‘HIGH’’ oil level. Mark the ‘‘HIGH’’ oil level with an ‘‘H’’. NOTE: The dipstick will break if the scribe mark is too deep. Lubricating Oil Transfer Tube (2-11) Removal Remove the two capscrews from the flange at the oil pan…

• Page 239
  Lubricating Oil Transfer Tube (2-11) Section 2 — Lubricating System Page 2-28 Installation Install a new rectangular sealing ring in the lubricating oil pump mounting flange. Use clean vegetable oil to lubricate the seal. Install the sealing ring expander (1), Part No. 3376844, into the end of the lubricating oil transfer tube, and push the tube through the flange.
• Page 240
  Section 2 — Lubricating System Lubricating Oil Pan (2-12) Page 2-29 Fill the engine with clean 15W-40 oil. Refer to Procedure 2-07. Operate the engine until the water temperature reaches 82°C [180°F], and check for oil leaks. Lubricating Oil Pan (2-12) Removal Drain the lubricating oil.
• Page 241
  Lubricating Oil Pan (2-12) Section 2 — Lubricating System Page 2-30 Remove all gasket material from the cylinder block and the oil pan surfaces. Inspect the inside and the outside of the oil pan for cracks around the suction tube mounting studs. Check for a cracked or broken suction tube mounting clip.
• Page 242
  Section 2 — Lubricating System Lubricating Oil Pump (2-13) Page 2-31 Lubricating Oil Pump (2-13) Removal Remove the demand flow and cooling (DFC) signal line between the cylinder block main oil rifle and the lubri- cating oil pump. On STC engines, remove the DFC signal line between the viscosity sensor and the lubricating oil pump.
• Page 243
  90 degrees apart. Drive Shaft End Clearance 0.051 0.002 0.203 0.008 Rebuild the lubricating oil pump if the driveshaft end clearance does not meet specifications. Refer to the N14 Engine Shop Manual, Bulletin No. 3810487.
• Page 244
  Section 2 — Lubricating System Lubricating Oil Pump (2-13) Page 2-33 Installation Use 15W-40 oil to lubricate the shaft, the gears, and the bushings. Also, lubricate the area between the driven gear and the body. Install the driven gear on the shaft. Install a new gasket on the pump body, and install the cover.

• Page 245: High Lubricating Oil Pressure Relief Valve

  High Lubricating Oil Pressure Relief Valve (2-14) Section 2 — Lubricating System Page 2-34 Install the lubricating oil pump in the mounting hole in the cylinder block gear flange. Install the five mounting capscrews. Tighten the cap- screws. Torque Value: 54 N•m [40 ft-lb] Install the DFC signal line.

• Page 246: Cleaning And Inspection

  Section 2 — Lubricating System High Lubricating Oil Pressure Relief Valve (2-14) Page 2-35 Remove all gasket material from the lubricating oil pump body and cover. Warning: Carefully remove the retainer plug (1). The pressure relief valve spring (4) is under compression. Use the light duty puller kit, Part No.

• Page 247
  High Lubricating Oil Pressure Relief Valve (2-14) Section 2 — Lubricating System Page 2-36 Measure the relief valve seat depth in the lubricating oil pump. The maximum depth is 46.73 mm [1.840 inch]. Testing Remove the lubricating oil pump. Refer to Procedure 2-13.

• Page 248: Installation

  Section 2 — Lubricating System High Lubricating Oil Pressure Relief Valve (2-14) Page 2-37 NOTE: If the plug depth is within specifications and the engine oil pressure is out of specifications, check the high oil pressure relief valve and the main oil pressure regulator. Refer to Procedures 2-14 and 2-15, respectively.

• Page 249
  High Lubricating Oil Pressure Relief Valve (2-14) Section 2 — Lubricating System Page 2-38 Install the spring (4), the washer (3), the valve disc (2), and the retainer plug (1) in the bore in the locating plate. Make sure the prongs on the disc are down (toward the washer) and the cup side of the retainer plug is up (toward the mandrel).

• Page 250: Removal

  Section 2 — Lubricating System Main Lubricating Oil Pressure Regulator (2-15) Page 2-39 Confirm that the oil level in the oil pan is to the full mark. Operate the engine until the water temperature reaches 82°C [180°F]. Check the oil pressure, and check for oil leaks.

• Page 251
  Lubricating Oil Pump Signal Line (2-16) Section 2 — Lubricating System Page 2-40 Installation Install new o-rings on the plunger retainer plug. Lubricate the o-rings with vegetable oil. Install the plunger (4), the spring (3), the retainer plug (2) and the capscrew (1). Tighten the retainer plug capscrew.
• Page 252
  Section 2 — Lubricating System Lubricating Oil Pump Signal Line Orifice (In Chassis) (2-17) Page 2-41 Installation Install the DFC signal line. Tighten the signal line tube nuts. Torque Value: 14 N•m [120 in-lb] Operate the engine until the water temperature reaches 82°C [180°F].
• Page 253
  Lubricating Oil Pump Signal Line Orifice (In Chassis) (2-17) Section 2 — Lubricating System Page 2-42 Cleaning Use an acetylene torch tip cleaner or equivalent that is 1.0 mm [0.040-inch] or less in diameter to clean the orifice. NOTE: The diameter of the orifice is 1.0 mm [0.040-inch]. Do not attempt to drill out the orifice or use a larger diameter wire to clean the orifice.
• Page 254
  Section 2 — Lubricating System Viscosity Sensor — STC Engines (2-18) Page 2-43 Viscosity Sensor — STC Engines (2-18) Removal Remove the oil transfer tube. Refer to Procedure 2-11. Disconnect the pressure signal line (1) from the lubricat- ing pump fitting (2). Disconnect the rifle pressure supply line (3) from the oil rifle fitting (4).
• Page 255
  Viscosity Sensor — STC Engines (2-18) Section 2 — Lubricating System Page 2-44 Remove the hoses and bracket from the viscosity sensor. 1. Main oil rifle pressure. 2. Modified pressure signal to pressure regulator. 3. Return to oil pan. Cleaning and Inspection Use ultrasonic cleaners, Part No.
• Page 256
  Section 2 — Lubricating System Viscosity Sensor — STC Engines (2-18) Page 2-45 Remove the viscosity sensor fittings (1) and (2). Remove and inspect the filter screens (3). Replace damaged or plugged screens. Remove the viscosity sensor fitting (1). Inspect the injector orifice plug (3) for damage or restric- tion.
• Page 257
  Viscosity Sensor — STC Engines (2-18) Section 2 — Lubricating System Page 2-46 Install the injector orifice plug (3) and gasket (4). Install the fitting (1), using a new o-ring (2) and tighten. Torque Value: 31 N•m [23 ft-lb] NOTE: Lubricate the o-ring with vegetable oil. Installation Install the bracket to the viscosity sensor.
• Page 258
  Section 2 — Lubricating System Viscosity Sensor — STC Engines (2-18) Page 2-47 Connect the pressure signal line (1) to the lubricating pump fitting (2) and the rifle pressure supply line (3) to the oil rifle fitting (4). Install the oil transfer tube. Refer to Procedure 2-11. Operate the engine until the water temperature reaches 82°C [180°F], and check for leaks.
• Page 259
  Viscosity Sensor — STC Engines (2-18) Section 2 — Lubricating System Page 2-48 Connect an oil pressure gauge of known accuracy to the main oil rifle. Operate the engine until the oil temperature stabilizes. Observe the oil rifle pressure as the temperature of the oil is increasing.

• Page 260: Lubricating Oil Cooler Assembly

  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-49 Operate the engine until the oil temperature stabilizes. The temperature must be between 82°C [180°F] and 93°C [200°F]. Observe the oil rifle pressure as the oil temperature rises. Observe the oil pressure at the oil main rifle.

• Page 261
  Lubricating Oil Cooler Assembly (2-19) Section 2 — Lubricating System Page 2-50 For those engine applications utilizing the low mount oil cooler arrangement, follow this procedure. Remove the capscrew which holds the oil cooler support bracket to the cylinder block at the rear of the oil cooler. Remove one of the capscrews which holds the oil cooler support to the cylinder block.
• Page 262
  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-51 Removal — Oil Cooler Core Remove the oil cooler core holddown capscrews. NOTE: The oil cooler core can be removed from the transfer housing while still installed on the engine. Remove the oil cooler core from the oil cooler transfer connection (housing) by pulling the oil cooler water trans- fer tubes out of the o-ring adapters.
• Page 263
  Lubricating Oil Cooler Assembly (2-19) Section 2 — Lubricating System Page 2-52 Removal — Lubricating Oil Filter Bypass Valve Loosen the retaining plug with a 5/16 inch hexagon allen wrench. Remove the retaining plug (1), the plunger (2), spring (3), and poppet valve (4), from the lubricating oil cooler trans- fer housing (5).

• Page 264: Cleaning And Inspection — Lubricating Oil Cooler Assembly

  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-53 Removal — Lubricating Oil Thermostat Remove the thermostat, and the spacer plate. Cleaning and Inspection — Lubricating Oil Cooler Assembly Clean the gasket material from the cooler support and the cylinder block.

• Page 265
  Lubricating Oil Cooler Assembly (2-19) Section 2 — Lubricating System Page 2-54 Cleaning and Inspection — Lubricating Oil Filter Head Clean all gasket surfaces. NOTE: Do not allow dirt or gasket material to get into the oil passages. Cleaning and Inspection — Lubricating Oil Filter Bypass Valve Clean the poppet valve spring, plunger, and retaining plug.

• Page 266: Cleaning And Inspection — Oil Cooler Bypass Valve

  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-55 Use the valve spring tester, Part No. 3375182, to mea- sure the spring force. Compress the spring to a height of 59.18 mm [2.330 inch]. The force required to compress the spring to the specified height must be: MIN: 105.2 N [23.65 lbf] MAX: 123.8 N [27.85 lbf]…

• Page 267
  Lubricating Oil Cooler Assembly (2-19) Section 2 — Lubricating System Page 2-56 Install and clamp a short section of hose over either the inlet or outlet transfer tube of the oil cooler. Install a plug into the opposite end of the section of hose and install clamp.
• Page 268
  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-57 Testing — Oil Cooler Bypass Valve Caution: The flash point of new lubricating oil is ap- proximately 221°C [430°F]. Do not allow oil temperature in the container to exceed 149°C [300°F]. Do not allow water droplets to enter the container of hot oil.

• Page 269: Installation — Lubricating Oil Filter Bypass Valve

  Lubricating Oil Cooler Assembly (2-19) Section 2 — Lubricating System Page 2-58 Installation — Oil Cooler Transfer Housing Place the spacer plate and a new spacer gasket on the oil cooler support. If the oil cooler is the low mount type, use the drop mount connection instead of the spacer plate.

• Page 270
  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-59 Tighten the retaining plug. Torque Value: 34 N•m [25 ft-lb] Installation — Oil Cooler Core Lubricate new o-rings with vegetable oil and install on the oil cooler core transfer tubes. Install the connection retainer and o-rings adapters with new o-rings.
• Page 271
  Lubricating Oil Cooler Assembly (2-19) Section 2 — Lubricating System Page 2-60 Install the oil cooler core mounting gaskets and holddown capscrews. Tighten the holddown capscrews. Torque Value: 27 N•m [20 ft-lb] Alternately tighten the connection retainer capscrews. Torque Value: 47 N•m [35 ft-lb] Installation — Lubricating Oil Cooler Assembly Install two guide studs in the oil cooler support mounting…
• Page 272
  Section 2 — Lubricating System Lubricating Oil Cooler Assembly (2-19) Page 2-61 Install the oil cooler assembly over the guide studs, and push it against the cylinder block. Install the oil cooler support bracket capscrew. Do not tighten at this time. Install four of the support mounting capscrew, and re- move the two guide studs.
• Page 273
  Piston Cooling Nozzles (2-20) Section 2 — Lubricating System Page 2-62 Fill the cooling system. Refer to Procedure 1-09. Check to be sure the lubricating oil system is full. Prelubricate the system. Operate the engine at low idle until the oil pressure comes up to 69 kPa [10 psi] minimum.

• Page 274: Installation

  Section 2 — Lubricating System Piston Cooling Nozzles (2-20) Page 2-63 Visually inspect the piston cooling nozzles for cracks or damage. Visually inspect the screws for damaged or mutilated threads. Replace any parts that are damaged. Installation Use vegetable oil to lubricate the new o-rings. Do not soak the new o-rings in engine oil.

• Page 275: Lubricating Oil Leaks

  Lubricating Oil Pressure Gauge (2-21) Section 2 — Lubricating System Page 2-64 Install the starting motor (if removed). Refer to Procedure 6-06. Fill and install the lubricating oil filter. Refer to Procedure 2-03. Operate the engine until it reaches a temperature of 82°C [180°F], and check for coolant or lubricating oil leaks.

• Page 276
  Section 2 — Lubricating System Lubricating Oil Temperature Gauge (2-22) Page 2-65 Testing 1. Check the following for defects: • Electrical wiring broken. • Sending unit malfunction, or leaking (refer to step No. 2). 2. Use a master gauge of known accuracy to verify the reading of the suspect gauge.
• Page 277
  Section 3 — Combustion Air System Page 3-1 Section 3 — Combustion Air System Section Contents Page Air Intake System Flow Diagram ……………………3-3 Air Leaks — Testing ……………………….3-7 Charge Air Cooler……………………….3-27 Cleaning and Inspection……………………..3-31 Pressure Drop — Checking ……………………..3-27 Combustion Air System General Information ………………..
• Page 278
  Combustion Air System General Information Section 3 — Combustion Air System Page 3-2 Combustion Air System General Information The Combustion Air System consists of intake air piping, turbocharger, charge air cooler (CAC) piping, CAC, and exhaust piping. The turbocharger uses exhaust gas energy to turn the turbine wheel.
• Page 281
  (Ambient air temperature 0 to 38° C [32 to 100° F]) …………..17°C [30°F] Maximum temperature rise between ambient air and intake manifold inlet air temperature N14-460E ……………………..24°C [43°F] All other ratings ……………………21°C [38°F] Maximum intake restriction (clean air filter element) Normal-duty type air cleaner …………….
• Page 282
  Combustion Air System Service Tools The following special tools are recommended to perform procedures in Section 3. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description…
• Page 283
  Section 3 — Combustion Air System Air Leaks — Testing (3-01) Page 3-7 Air Leaks — Testing (3-01) Caution: Engine intake air must be filtered to prevent dirt and debris from entering the engine. If intake air piping is damaged or loose, unfiltered air will enter the engine and cause premature wear.
• Page 284
  Turbocharger Seal Leak — Testing (3-02) Section 3 — Combustion Air System Page 3-8 Turbocharger to exhaust manifold mounting gasket. • Replace the gasket. Refer to Procedure 3-08. Turbine housing sealing surface air leak. • Tighten the V-band clamp. Torque Value: 8.5 N•m [75 in-lb] •…
• Page 285
  Section 3 — Combustion Air System Turbocharger Seal Leak — Testing (3-02) Page 3-9 Shut off the engine. Allow the turbocharger to cool, and remove the exhaust pipe from the turbine. Use a high intensity black light (Part No. 3377253 or 3377394) to inspect the turbine outlet for oil.
• Page 286
  Turbocharger Seal Leak — Testing (3-02) Section 3 — Combustion Air System Page 3-10 Use a high intensity black light, Part No. 3377253 or 3377394, to inspect the turbine inlet for leaks. NOTE: A yellow glow indicates an oil leak from the engine. If a yellow glow is not seen in the turbine inlet, replace the turbocharger.
• Page 287
  Section 3 — Combustion Air System Turbocharger — Verifing Correct Part Number (3-03) Page 3-11 If oil is present only in the discharge side, check for intake restriction. Refer to Procedure 3-04. If no intake restriction is found, replace the turbocharger. Refer to Procedure 3-08.
• Page 288
  Intake Air Restriction (3-04) Section 3 — Combustion Air System Page 3-12 Intake Air Restriction (3-04) Checking Install a vacuum gauge or water manometer in the intake air piping. NOTE: The gauge adapter must be installed at a 90 degree angle to the air flow in a straight section of pipe, 127 mm [5.0 inch], before the turbocharger compressor inlet.
• Page 289
  Section 3 — Combustion Air System Exhaust Restriction (3-05) Page 3-13 Remove the test equipment. Exhaust Restriction (3-05) Checking NOTE: The gauge adapter must be installed at a 90 degree angle to the air flow in a straight section of pipe, 127 mm [5 inch], from the turbocharger turbine outlet.
• Page 290
  Turbocharger Blade Damage (3-06) Section 3 — Combustion Air System Page 3-14 Remove the test equipment. Turbocharger Blade Damage (3-06) Checking Remove the intake and the exhaust pipes from the turbocharger. Visually inspect the turbocharger compressor impeller blades for damage. Rebuild or replace the turbocharger if damage is found.
• Page 291
  Section 3 — Combustion Air System Turbocharger Axial and Radial Clearance (3-07) Page 3-15 Inspect the turbine wheel for damage. Rebuild or replace the turbocharger if damage is found. Refer to Procedure 3-08. Install the intake and exhaust pipes to the turbocharger and tighten the clamps.
• Page 292
  Turbocharger Axial and Radial Clearance (3-07) Section 3 — Combustion Air System Page 3-16 With the feeler gauge in the same location, gently push the compressor wheel away from the compressor hous- ing and feeler gauge. Measure and record the clearance. Subtract the smaller clearance from the larger clearance.
• Page 293
  Section 3 — Combustion Air System Turbocharger Replacement (3-08) Page 3-17 Install the intake and exhaust pipes to the turbocharger and tighten the clamps. Torque Value: 8.5 N•m [75 in-lb] Operate the engine and check for air leaks. Turbocharger Replacement (3-08) Removal Remove the oil supply and the oil drain tubes from the turbocharger.

• Page 294: Cleaning And Inspection

  Turbocharger Replacement (3-08) Section 3 — Combustion Air System Page 3-18 Loosen the clamp on the discharge elbow. Remove the elbow and discard the o-ring. Cleaning and Inspection Clean the turbocharger and the exhaust manifold gasket surfaces. Inspect the turbocharger casings and replace if through cracks are found in the outer walls.

• Page 295
  Section 3 — Combustion Air System Turbocharger Replacement (3-08) Page 3-19 Cracks on the turbocharger mounting flange must not reach the mounting holes. Two cracks on the turbocharger mounting flange must be separated by 6.4 mm [0.25-inch]. Through cracks at the dividing wall are acceptable and can be any length.

• Page 296: Installation

  Turbocharger Replacement (3-08) Section 3 — Combustion Air System Page 3-20 Visually inspect the turbocharger compressor V-band out- let and the discharge elbow V-band connection for dents or fretting. Replace the turbocharger or discharge elbow if damaged so that the compressed air will not leak. Installation Apply a film of high temperature anti-seize compound, Part No.

• Page 297
  Section 3 — Combustion Air System Turbocharger Replacement (3-08) Page 3-21 Install a new o-ring seal, the clamp, and the discharge elbow to the turbocharger. Tighten the clamps. Torque Value: 8.5 N•m [75 in-lb] Install a new gasket, oil drain tube, and capscrews. Tighten the capscrews.

• Page 298: Removal

  Exhaust Manifold (3-09) Section 3 — Combustion Air System Page 3-22 Install the intake and exhaust pipes to the turbocharger and tighten the clamps. Torque Value: 8.5 N•m [75 in-lb] Operate the engine and check for air and oil leaks. Exhaust Manifold (3-09) Removal Remove the turbocharger.

• Page 299
  Section 3 — Combustion Air System Exhaust Manifold (3-09) Page 3-23 Cleaning and Inspection Use a 240 grit emery cloth to remove carbon deposits from the sealing surfaces. Steam clean, and dry with compressed air. Visually inspect for cracks or damage. Visually inspect the manifold seal bore for wear.
• Page 300
  Exhaust Manifold (3-09) Section 3 — Combustion Air System Page 3-24 Special capscrews with spacers are required for this par- ticular manifold. Do not use short capscrews. Warning: Because this assembly weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the exhaust manifold assembly to avoid personal injury.
• Page 301
  Section 3 — Combustion Air System Intake Manifold (3-10) Page 3-25 Operate the engine and check for leaks and engine operation. Intake Manifold (3-10) Removal Disconnect the intake air piping from the CAC to inlet air connector. Disconnect the air supply line from the air compressor to the intake manifold.
• Page 302
  Intake Manifold (3-10) Section 3 — Combustion Air System Page 3-26 Remove the four capscrews that attach the intake air connector to the intake manifold. Remove the nine capscrews and remove the intake manifold. Cleaning and Inspection Visually inspect the intake manifold for cracks, fretting or other damage.
• Page 303
  Section 3 — Combustion Air System Charge Air Cooler (3-11) Page 3-27 Install the intake air connector and tighten the four cap- screws. Install the intake air piping from the CAC to the air con- nector on the intake manifold and tighten the clamp. Torque Values: •…
• Page 304
  Charge Air Cooler (3-11) Section 3 — Combustion Air System Page 3-28 Install the other end of the manometer to the 1/8 inch pipe tap in the intake manifold. Operate the engine at the maximum advertised horse- power and correlating RPM. Record the readings on the manometer.
• Page 305
  Section 3 — Combustion Air System Charge Air Cooler (3-11) Page 3-29 Operate the engine at the maximum advertised horse- power and correlating RPM. Record the readings on the two gauges. If the differential pressure is greater than 102 mm Hg [4.0 in.
• Page 306
  Charge Air Cooler (3-11) Section 3 — Combustion Air System Page 3-30 If the temperature differential is greater than the speci- fications, check the CAC for dirt and debris on the fins and clean as necessary. If the problem still exists, check the CAC for debris in fins or between the CAC and ra- diator.
• Page 307
  Section 3 — Combustion Air System Charge Air Cooler (3-11) Page 3-31 If the pressure decay is caused by a leaky connection, repair the connection and repeat the test. If the leak is within the CAC, repeat the test to verify the accuracy of the pressure decay measurement.
• Page 308
  Charge Air Cooler (3-11) Section 3 — Combustion Air System Page 3-32 After the CAC has been thoroughly cleaned of all oil and debris with solvent, wash the CAC internally with hot soapy water to remove the remaining solvent. Rinse thor- oughly with clean water.
• Page 309
  Section 4 — Compressed Air System Page 4-1 Section 4 — Compressed Air System Section Contents Page Air Compressor …………………………. 4-21 Inspection …………………………4-22 Installation …………………………4-22 Removal………………………….. 4-21 Air Compressor, Cylinder Head ……………………4-16 Inspection …………………………4-17 Installation …………………………4-19 Removal…………………………..
• Page 310
  The compressed air system normally consists of a gear driven air compressor, an air governor, air tanks and all necessary plumbing. The Holset and Cummins single and two cylinder air compressors are engine-driven piston-type compressors which supply compressed air to operate air activated devices.
• Page 311
  Section 4 — Compressed Air System Compressed Air System General Information Page 4-3 E-Type System With Air Dryer Vehicles equipped with air dryers vented to the atmo- sphere during unloaded compressor operation, using the Holset E-Type air compressor, require the installation of an econ valve to prevent excessive oil consumption.
• Page 312
  Compressed Air System Flow Diagrams Section 4 — Compressed Air System Page 4-4 Compressed Air System Flow Diagrams…
• Page 313
  Section 4 — Compressed Air System Compressed Air System Specifications Page 4-5 Compressed Air System Specifications 13.2 CFM Single Cylinder Air Compressor (SS 296) Cylinders ……………………………1 Compressor Swept Volume @ 1250 RPM …………..6.2 L per sec. [13.20 CFM] Piston Displacement ………………….296 cc [18.06 C.I.D.] Bore ……………………..92.08 mm [3.625 in.] Stroke ……………………..44.45 mm [1.750 in.] Speed……………………….Engine Speed…
• Page 314
  Compressed Air System Specifications Section 4 — Compressed Air System Page 4-6 30.0 CFM Two Cylinder Air Compressor (ST676) Cylinders ……………………………2 Compressor Swept Volume @ 1250 RPM …………..14.2 L per sec. [30.00 CFM] Piston Displacement………………….676 cc [41.3 C.I.D.] Bore ……………………..92.08 mm [3.625 in.] Stroke ………………………50.8 mm [2.00 in.] Speed……………………….Engine Speed Cooling ……………………….Engine Coolant…
• Page 315
  Section 4 — Compressed Air System Compressed Air System Specifications Page 4-7 Compressor Spring Force Specifications Load Required to Com- press Spring to Measure- ment Length Approx. Free Number Wire Measurement Spring Length Diameter Length Minimum Maximum Part Number Spring Use mm [inch] Coils mm [inch]…
• Page 317
  Carbon Buildup, Air Compressor (4-01) NOTE: The illustrations shown will be of the single cylinder air compressor. Differences in procedures for one and two cylinder Holset or Cummins air compressors will be shown where necessary. Shut off the engine. Open the draincock on the wet tank to release com- pressed air from the system.
• Page 318
  Carbon Buildup, Air Compressor (4-01) Section 4 — Compressed Air System Page 4-10 Warning: The air discharge line must be capable of with- standing extreme heat and pressure to prevent personal injury and property damage. Refer to the manufacturer’s specifications. Continue to check for carbon buildup in the air discharge line connections up to the first connection, or wet tank.
• Page 319
  Checking NOTE: The illustrations shown will be of the single cylinder air compressor. Differences in procedures for one and two cylinder Holset or Cummins air compressors will be shown where necessary. Shut off the engine. Open the draincock on the wet tank to release air from the system.
• Page 320
  Remove the unloader valve cap and the unloader valve spring. NOTE: Disassembly of the center unloader valve on Cummins two cylinder air compressors is similar to the single cylinder unloader valve. Remove the intake valve seat and valve. Remove the intake valve spring.
• Page 321
  Replace the unloader spring if it does not meet the spec- ifications shown, or the wrong spring has been used. NOTE: For Holset or Cummins two cylinder air compres- sors, check both cylinder and center unloader springs. Cummins Engine Company, Inc., recommends that new springs be installed during rebuild.
• Page 322
  Checking NOTE: The illustrations shown will be of the single cylinder air compressor. Differences in procedures for one and two cylinder Cummins air compressors will be shown where necessary. Remove the air governor or air governor line from the air compressor unloader body.
• Page 323
  Section 4 — Compressed Air System Air Governor (4-05) Page 4-15 If the air compressor does not stop pumping (air pressure continues to rise) at the governed air pressure, connect a regulated shop air pressure line to one of the following: •…
• Page 324
  Removal NOTE: The illustrations shown will be of the single cylinder air compressor. Differences in procedures for one and two cylinder Holset or Cummins air compressors will be shown where necessary. NOTE: On Holset or Cummins two cylinder air compressors, complete the disassembly and assembly steps for the valve assemblies on both cylinders.
• Page 325
  Remove the unloader valve cap and the unloader valve spring. NOTE: Disassembly of the center unloader valve on Cummins two cylinder air compressors is similar to the single cylinder unloader valve. Remove the intake valve seat and valve. Remove the intake valve spring.
• Page 326
  • Measure the flatness of the intake and exhaust valves. Both valves must be flat within 0.03 mm [0.001-inch]. NOTE: Cummins Engine Company, Inc. recommends that new valves be installed. • Apply a bluing compound to the exhaust valve seat- ing surface.
• Page 327
  Use valve spring tester, Part No. 3375182, to check the intake, exhaust and unloader valve springs. Replace any springs that do not meet specifications. NOTE: Cummins Engine Company, Inc. recommends that new springs be installed. NOTE: A compressor spring force specifications chart is shown on Page 4-6.
• Page 328
  Tighten the cylinder head capscrews of the Holset or Cummins two cylinder compressor in the sequence shown. NOTE: Be sure the center unloader valve assembly has been installed before tightening the head capscrews.
• Page 329
  NOTE: The illustrations shown will be of the single cylinder air compressor. Differences in procedures for one and two cylinder Holset or Cummins air compressors will be shown where necessary. Use steam to clean the air compressor. Dry with com- pressed air.
• Page 330
  Air Compressor (4-07) Section 4 — Compressed Air System Page 4-22 Remove the air connections from the air compressor. Remove the air compressor support bracket and cap- screws. Remove the four capscrews, the air compressor, and splined coupling. Inspection Visually inspect the compressor housing for cracks or damage.
• Page 331
  Section 4 — Compressed Air System Air Compressor (4-07) Page 4-23 NOTE: If rubber grommets are used on the coolant lines, be sure they are installed carefully to prevent cuts or tears to the grommets which will cause coolant leaks. When flexible tubing is used make sure that it does not rub any other surfaces.
• Page 332
  Air Compressor (4-07) Section 4 — Compressed Air System Page 4-24 Whenever the CELECT™ fuel pump is removed, it is nec- essary to prime the pump after installing it on the engine to remove any trapped air. NOTE: If the fuel pump is dirty, clean the outside of the pump.
• Page 333
  Section 5 — Fuel System Page 5-1 Section 5 — Fuel System Section Contents Page AFC No-Air Check ……………………….5-82 Air in Fuel Testing……………………….5-71 Air Actuated Road Speed Governor ………………….5-75 Fuel Suction Line (Gear Pump Drain)………………….5-71 Fuel Suction Line (Sightglass) ……………………5-74 Cylinder Misfiring/Smoking Location………………….
• Page 334
  Section 5 — Fuel System Page 5-2 Page Installation — STC Injectors ……………………..5-57 Removal — STC Injectors ……………………..5-56 Lubricating Oil Dilution by Fuel Testing………………….5-77 Black Light Method (Preferred)……………………5-77 Fuel Passage Pressurize Method (Optional) ………………..5-77 Operating in Normal Timing……………………..5-97 Power Check…………………………
• Page 335
  ‘‘pressure-time’’. The PT Fuel System consists of the fuel pump, supply lines, drain lines, fuel passages and injectors. The STC system is used on Cummins Diesel Engines to advance the injection timing under idle or light load conditions. The STC system includes fuel pump, supply lines, drain lines, fuel passages, oil passages, check valves, STC…
• Page 336
  The PT, or Pressure Time, fuel system derives its name from the two main variables that affect the amount of fuel metered per cycle in the Cummins fuel system. ‘‘P’’ stands for pressure at the inlet of the injectors. It is con- Fuel Pressure at the trolled by the fuel pump.
• Page 337
  The calibration flow rate of the injectors is determined by the size of an adjustable orifice. Each injector in the engine is calibrated to the same flow rate. The flow rate adjustment must be done by a Cummins Authorized Fuel Systems Location.
• Page 338
  Fuel System General Information Section 5 — Fuel System Page 5-6 The time available for fuel to flow into the cup is deter- mined by the time which the metering orifice in the barrel is uncovered by the plunger. The metering orifice is un- covered while the cam follower roller is on the inner base circle of the cam.
• Page 339
  Section 5 — Fuel System Fuel System General Information Page 5-7 Since more fuel is metered per cycle, more fuel is injected per cycle, and more torque is produced. Theory of Operation — STC Step Timing Control, commonly referred to as STC, con- trols the engine timing in an effort to minimize white smoke at cold engine start-up and meet Federal emis- sions standards.
• Page 340
  Fuel System General Information Section 5 — Fuel System Page 5-8 During NORMAL injection timing, STC: • Controls cylinder pressures Normal Timing • Reduces nitrogen oxide emissions • Controls Cylinder Pressures • Reduces Nitrogen Oxide Emissions The STC system consists primarily of: •…
• Page 341
  Section 5 — Fuel System Fuel System General Information Page 5-9 In ADVANCED timing, the tappet is filled with oil as the injector is metering fuel. As the camfollower starts up the cam injection ramp, the injector lever begins to force the inner piston downward.
• Page 342
  Fuel System General Information Section 5 — Fuel System Page 5-10 The STC control valve uses fuel pressure and spring force to control the position of an AFC style plunger. The position of the plunger dictates whether the oil passage to the hydraulic tappets is open or closed.
• Page 343
  Section 5 — Fuel System Fuel System General Information Page 5-11 Internal oil tubes connect the oil manifold connectors to each STC injector in the rocker housing. Fuel pressure to the STC valve is provided by a hose (1) between the fuel pump shut-off valve and the STC valve. The internal spring cavity of the valve is vented to the engine crankcase by the crankcase vent line (2) in order to allow the plunger to cycle freely.
• Page 344
  Fuel System Flow Diagrams Section 5 — Fuel System Page 5-12 Fuel System Flow Diagrams…
• Page 433
  Section 6 — Electrical System Page 6-1 Section 6 — Electrical System Section Contents Page Alternator Belt …………………………6-7 Adjustment…………………………6-7 Alternator Replacement ………………………. 6-9 Installation …………………………6-9 Removal …………………………… 6-9 Batteries …………………………..6-5 Checking ………………………….. 6-5 Battery Cables and Connections ……………………6-6 Checking …………………………..
• Page 434
  Electrical System General Information Section 6 — Electrical System Page 6-2 Electrical System General Information The basic heavy-duty electrical system consists of: • Batteries and cables (1) • A starting motor (2) • An alternator (3) • A magnetic switch (4) •…
• Page 435
  Section 6 — Electrical System Starting System Specifications Page 6-3 Starting System Specifications Minimum Battery Capacity 12-volt starter ……….. 400 ampere hour — 1800 cold cranking amps @ -18°C [0°F] 24-volt starter ………… 200 ampere hour — 900 cold cranking amps @ -18°C [0°F] Maximum Starting Circuit Resistance 12-volt starter ……………………
• Page 437
  Section 6 — Electrical System Batteries (6-01) Page 6-5 Batteries (6-01) Checking If conventional batteries are used, remove the cell caps or covers and check the electrolyte, water and sulfuric acid solution, level. NOTE: Maintenance-free batteries are sealed and do not require the addition of water.
• Page 438
  Starter Connections (6-03) Section 6 — Electrical System Page 6-6 Remove and inspect the battery cables and connections for cracks or corrosion. Replace broken terminals, connectors or cables. If the connections are corroded, use a battery brush or wire brush to clean the connections until shiny. Make sure all debris is removed from the connecting surfaces.
• Page 439
  Section 6 — Electrical System Alternator Belt (6-04) Page 6-7 Inspect the starter for loose connections or broken ter- minals. Replace the starter if a terminal is broken. Tighten loose connections. For stacked eyelet connections, tighten the nut for the inner-most connection first.
• Page 440
  Alternator Replacement (6-05) Section 6 — Electrical System Page 6-8 Use Part No. ST-1138 (Borroughs) or 3822524 (Click- Type) Belt Tension Gauge to measure the 1/2-inch width V-belt tension. New Belt Tension Used Belt Tension 620 N [140 lb] 270 to 490 N [60 to 110 lb] NOTE: A belt is considered used if it has been in operation for 10 minutes or longer.
• Page 441
  Section 6 — Electrical System Alternator Replacement (6-05) Page 6-9 Loosen the alternator to alternator support nut and cap- screw. Loosen the adjusting link capscrew. Push the alternator toward the engine to release tension on the alternator belt, and remove the belt(s). Remove the adjusting link capscrew and the adjusting link.
• Page 444
  Section 7 — Base Engine Components Page 7-1 Section 7 — Base Engine Components Section Contents Page Accessory Drive Pulley Replacement………………….7-164 Inspection …………………………7-165 Installation …………………………7-165 Removal …………………………7-164 Accessory Drive Replacement ……………………7-170 Cleaning…………………………7-172 Inspection…………………………7-173 Installation …………………………
• Page 445
  Section 7 — Base Engine Components Page 7-2 Page Inspection for Reuse ……………………….. 7-69 Cylinder Head Capscrew Hole ……………………. 7-73 Block Preparation to Prevent Contamination from Machining Debris …………. 7-73 Repair Procedure ……………………….7-74 Salvaging …………………………7-73 Cylinder Head Capscrew Holes ……………………7-73 Checking ………………………….
• Page 446
  Section 7 — Base Engine Components Page 7-3 Page Injection Timing ……………………….7-106 Timing Tool Installation ……………………..7-107 Injection Timing (General Information)………………….7-105 Main and Thrust Bearings Replace…………………… 7-115 Cleaning and Inspection ……………………..7-117 Installation …………………………7-118 Removal …………………………7-115 Overhead Adjustment ……………………….
• Page 447
  Section 7 — Base Engine Components Page 7-4 Page Vibration Damper ……………………….7-176 Cleaning and Inspection ……………………..7-177 Installation …………………………7-178 Removal …………………………7-176 Wear Sleeve, Accessory Drive Pulley Replacement ………………7-166 Cleaning and Inspection ……………………..7-167 Installation …………………………7-167 Removal …………………………
• Page 448
  Section 7 — Base Engine Components Base Engine Components General Information Page 7-5 Base Engine Components General Information The base engine components section consists of the removal, cleaning, inspection, testing, and assembly of all internal and external components not previously cov- ered in the troubleshooting and repair of the various en- gine systems.
• Page 449
  Base Engine Components Service Tools The following special tools are recommended to perform procedures in Section 7. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
• Page 450
  Section 7 — Base Engine Components Base Engine Components Service Tools Page 7-7 Tool No. Tool Description Tool Illustration Water Tester Adapter Plate Used with hydrostatic tester, Part No. ST-1012. ST-1013 Valve Spring Compressor Stand Used to compress all the springs on a cylinder head at the same time.
• Page 451
  Base Engine Components Service Tools Section 7 — Base Engine Components Page 7-8 Tool No. Tool Description Tool Illustration Drill Ream Fixture Used to accurately drill and ream holes in cylinder blocks and flywheel housing for the installation of standard oversized dowel ST-1232 pins.
• Page 688
  Section Contents Page Chassis Dynamometer Operation ……………………8-39 Definition of Terms On Engine Performance Curve………………8-3 Cummins N14 Heavy Duty Engine Operating Curve Definitions: …………..8-3 Dynamometer Worksheet……………………..8-38 Engine Dynamometer — Install Engine ………………….8-9 Air Compressor ……………………….. 8-15 Air Inlet Restriction……………………….
• Page 689
  However, light load/high rpm operation must be avoided during the run-in period. The following in-service run-in guidelines are recommended for N14 engines after a repair involving replacement of one or more of the piston ring sets, cylinder liners or cylinder kits where engine or an engine dynamometer and/or chassis dynamometer run-in can not be performed.
• Page 690
  Definition of Terms On Engine Performance Curve Page 8-3 Definition of Terms On Engine Performance Curve Cummins N14 Heavy Duty Engine Operating Curve Definitions: 1. Peak Torque (N•m [ft-lb]) — Maximum torque that the engine will produce. Also, sometimes referred to as COMMAND TORQUE.
• Page 691
  General Run-In Procedures Engine Testing Page 8-4 General Run-In Procedures Caution: Refer to General Engine Test Specifications in this section before operating the engine to avoid internal component damage. NOTE: The amount of time specified for the following engine run-in phases are minimums. The engine can be operated for longer periods of time at each operating range or phase with the exception of engine idling which must be kept to 5 minutes or less.
• Page 692
  Engine Testing General Run-In Procedures Page 8-5 Caution: Do not shut off the engine immediately after the run-in is completed. Allow the engine to cool by operating at low idle for a minimum of 3 minutes to avoid internal component damage.
• Page 693
  General Engine Test/Run-In Specifications Engine Testing Page 8-6 General Engine Test/Run-In Specifications Maintain the following limits during the engine test/run-in procedures: Due to variations in ratings of different engine models, refer to the specific ‘‘Engine Data Sheet’’ for the particular engine model being tested.
• Page 694
  Engine Testing — Service Tools The following special tools are recommended to perform procedures in Section 8. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description…
• Page 695
  Part No. ST-435-1 is the hose 3375932 and Part No. ST-435-6 is the pressure gauge. Fuel Measuring Device Measure the rate of fuel consumption of a Cummins diesel engine. 3376375 Digital Optical Tachometer Used to measure engine speed (RPM).
• Page 696
  Engine Testing Engine Dynamometer — Install Engine (8-01) Page 8-9 Engine Dynamometer — Install Engine (8-01) NOTE: Be sure the dynamometer capacity is sufficient to permit testing at 100 percent of the engine rated horse- power. If the capacity is not enough, the testing procedure must be modified to the restrictions of the dynamometer.
• Page 697
  I.D. neoprene hose. Testing has shown the 12 GPM city water flow is required (6 GPM per aftercooler core) to adequately cool the intake air for the N14 460E engine. A typical garden hose is not suitable for this flow due to the excessive restriction.
• Page 698
  Engine Testing Engine Dynamometer — Install Engine (8-01) Page 8-11 The air flow piping requires 4 inch I.D. aluminized steel piping. The flow circuit must have as few bends as pos- sible maximizing the length of straight sections. How- ever, when bends are required, use long elbows. Do not use mitered elbows, or anything that changes the air flow direction quickly.
• Page 699
  Engine Dynamometer — Install Engine (8-01) Engine Testing Page 8-12 Air Inlet Restriction Install a water manometer to the air inlet pipe of the turbocharger to measure inlet restriction. NOTE: The manometer adapter must be installed at a 90 degree angle to the air flow in a straight section of pipe, one pipe diameter before the turbocharger.
• Page 700
  Engine Testing Engine Dynamometer — Install Engine (8-01) Page 8-13 Intake Manifold Pressure Remove the pipe plug in the intake manifold just below the inlet air connection and install the intake manifold pressure gauge. Engine Blowby Install the Part No. 3375150, Engine Blowby Tool, to the breather on the rocker lever cover to measure engine crankcase pressure.
• Page 701
  Engine Dynamometer — Install Engine (8-01) Engine Testing Page 8-14 Fuel Inlet Restriction Measure the fuel inlet restriction. Install a vacuum gauge, Part No. ST-434, between the fuel pump inlet and the gear pump inlet. NOTE: Do not measure fuel inlet restriction with the fuel measuring device installed.
• Page 702
  NOTE: The gauge will not measure the correct pressure if the gauge is not held at the same level as the connection. Air Compressor NOTE: All air compressors manufactured by Cummins En- gine Company, Inc. must be operating during the engine run-in. During the performance check, all air compressors must be in the unload or non-operating mode.
• Page 703
  Engine Dynamometer — Install Engine (8-01) Engine Testing Page 8-16 Starting Motor NOTE: Inspect the voltage rating on the starting motor be- fore installing the electrical wiring. Install the electrical wiring to the starting motor and bat- teries, if used. NOTE: If another method of starting the engine is used, follow the manufacturer’s instructions to make the neces- sary connections.
• Page 704
  Engine Testing Engine Dynamometer — Install Engine (8-01) Page 8-17 Connect the dynamometer test OEM wiring harness pin connector to the actuator harness power connector (shroud). To save, adjust, and write parameters to and from the ECM, refer to the CELECT™ Compulink™ Cartridge Manual, Bulletin No.
• Page 705
  Engine Dynamometer — Install Engine (8-01) Engine Testing Page 8-18 Connect the keyswitch panel datalink cable to the Compulink™. Depress the ‘‘POWER ON’’ button on the Compulink™. If the ‘‘Progressive Shift Feature’’ is turned ‘‘ON’’, it must be turned ‘‘OFF’’ during the engine test to allow the engine to accelerate through its RPM range.
• Page 706
  Engine Testing Engine Dynamometer — Install Engine (8-01) Page 8-19 Depress the active key to cancel or back up to the screen showing the ‘‘Main Menu Option’’. The ECM is equipped with a tamperproof system that limits engine speed when the vehicle speed signal is lost. This parameter must either be bypassed with the Compulink™…
• Page 707
  Below is a description of the fuel measuring device, available from Cummins En- gine Company, along with installation and operation rec- ommendations. The fuel measuring device, Part No.
• Page 708
  Engine Testing Fuel Flow Measurement on Engine or Chassis Dynamometer (8-02) Page 8-21 Operation This is a schematic of the fuel measuring device, Part No. 3376375. The device con- sists of the following components: • Fuel Filter • Flowmeter • Float Tank •…
• Page 709
  Fuel Flow Measurement on Engine or Chassis Dynamometer (8-02) Engine Testing Page 8-22 Note: On CELECT™ engines, the engine fuel inlet line must flow through the ECM cooling plate to ensure proper cooling of the ECM dur- ing engine operation. The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet.
• Page 710
  Engine Testing Intake Manifold Boost Pressure Correction Factors (8-03) Page 8-23 Intake Manifold Boost Pressure Correction Factors (8-03) Boost pressure measured in the intake manifold is di- rectly related to the ambient temperature, the tempera- ture rise across the air cleaner and turbocharger, and the pressure drop across the charge air cooler.
• Page 711
  Intake Manifold Boost Pressure Correction Factors (8-03) Engine Testing Page 8-24 2. Measure the intake manifold temperature at the 1/8 inch NPT tap near the air horn connection with the intake manifold. Measure this temperature as close as possible to the inlet of the intake manifold. Alternately, intake air temperature can be measured by using Compulink™…
• Page 712
  Engine Testing Intake Manifold Boost Pressure Correction Factors (8-03) Page 8-25 TEST DATA FOR BOOST CORRECTION CHART Altitude: Engine Horsepower: Date: Customer: Truck Unit: Vehicle Make/Model: ESN: CPL: Mileage: Fuel Rate Turbo Outlet Intake Mfd Turbo Comp Intake Mfd lb/hr Press (in Hg) Press (in Hg) Inlet Temp (°F)
• Page 713
  Intake Manifold Boost Pressure Correction Factors (8-03) Engine Testing Page 8-26 Next, find the curved line in the graph (B) closest to the measured intake manifold temperature recorded during the test. If the measured intake manifold temperature is for example 130°F, put a mark in the middle of the curved lines representing 49°C and 60°C [120°F and 140°F] intake manifold temperature.
• Page 714
  Engine Testing Intake Manifold Boost Pressure Correction Factors (8-03) Page 8-27 Consider another example: The turbocharger compressor inlet temperature measured between the air cleaner and the turbocharger is 70°F and the intake manifold temperature is 49°C [120°F]. At the intersection of the 49°C [120°F] intake manifold temperature curve (B), and the vertical line (A) for 21.1°C [70°F] compressor inlet temperature, draw a horizontal line (C) to the vertical axis and record the boost correction factor.
• Page 715
  Intake Manifold Boost Pressure Correction Factors (8-03) Engine Testing Page 8-28 N14-310E…
• Page 716
  Engine Testing Intake Manifold Boost Pressure Correction Factors (8-03) Page 8-29 N14-330E…
• Page 717
  Intake Manifold Boost Pressure Correction Factors (8-03) Engine Testing Page 8-30 N14-350E…
• Page 718
  Engine Testing Intake Manifold Boost Pressure Correction Factors (8-03) Page 8-31 N14-370E…
• Page 719
  Intake Manifold Boost Pressure Correction Factors (8-03) Engine Testing Page 8-32 N14-430E…
• Page 720
  Engine Testing Intake Manifold Boost Pressure Correction Factors (8-03) Page 8-33 N14-460E…
• Page 721
  Engine Run-In Procedure — Engine Dynamometer (8-04) Engine Testing Page 8-34 Engine Run-In Procedure — Engine Dynamometer (8-04) Measurements from these indicators and gauges must be observed closely during all phases of the engine run-in period. Engine measurements taken are: •…
• Page 722
  2. Injector Parts Flow and Cross Reference, Bulletin No. 3379664. 3. Engine Data Sheets. 4. N14 Engine Shop Manual, Bulletin No. 3810487. 5. N14 Specification Manual, Bulletin No. 3666010. If a sudden increase in blowby occurs, or if blowby ex- ceeds the maximum allowable limit during any run-in step, return to the previous step and continue the run-in.
• Page 723
  Engine Run-In Procedure — Engine Dynamometer (8-04) Engine Testing Page 8-36 Move the throttle lever to its fully opened position, and increase the dynamometer load until 100 percent rated fuel pressure or 100 percent fuel flow for CELECT™ en- gines is developed. Operate the engine at this condition and load level for 5 minutes, or until the blowby becomes stable within specifications.
• Page 724
  Engine Testing Engine Run-In Procedure — Engine Dynamometer (8-04) Page 8-37 Shut off the engine. Make sure all instrumentation is removed before remov- ing the engine from the engine dynamometer.
• Page 725
  Dynamometer Worksheet Engine Testing Page 8-38 Dynamometer Worksheet Date Repair Order No. Operator Fuel Pump Code Complaint SC Code PARAMETER CODE SPECIFICATIONS ACTUAL READING Fuel Pressure (psi @ RPM) Fuel Rate (lb/hr) Check Point 1 (psi @ RPM) (Reference Only) Intake Mfd.
• Page 726
  Engine Testing Chassis Dynamometer Operation (8-05) Page 8-39 Chassis Dynamometer Operation (8-05) The performance of an engine installed in ‘‘on-highway’’ vehicles can be tested on a chassis dynamometer. NOTE: Due to driveline inefficiencies and engine-driven accessories, the rated horsepower will be reduced by ap- proximately: •…
• Page 727
  Chassis Dynamometer Operation (8-05) Engine Testing Page 8-40 • Make sure the tires are inflated to the manufactur- er’s specifications. • Remove all rocks or other material from the tread of all tires that will be rotating on the dynamometer rollers.
• Page 728
  Engine Testing General Test Procedure — Chassis Dynamometer (8-06) Page 8-41 • Make sure there is proper overhead clearance for exhaust stacks, air deflectors, or other attachments above the cab. General Test Procedure — Chassis Dynamometer (8-06) Check the engine coolant level to be sure it is filled to the proper level.
• Page 729
  General Test Procedure — Chassis Dynamometer (8-06) Engine Testing Page 8-42 To properly monitor engine performance, record the fol- lowing parameters. To limit dynamometer operating time, instrument the engine to make as many checks as pos- sible. • Engine speed rpm with a verified tachometer •…
• Page 730
  Engine Testing General Test Procedure — Chassis Dynamometer (8-06) Page 8-43 Fuel Rate Use fuel measuring device, Part No. 3376375, to mea- sure the rate of fuel consumption. For more information, refer to Procedure 8-02. Install the fuel measuring device as follows: •…
• Page 731
  General Test Procedure — Chassis Dynamometer (8-06) Engine Testing Page 8-44 Operate the engine at maximum horsepower RPM and Advertised Horsepower. Observe the reading on the gauge. NOTE: The maximum fuel inlet restriction is as follows: CELECT™ (plus ECM Cooling Plate) Clean fuel filter: 102 mm Hg 127 mm Hg [4 in Hg]…
• Page 732
  Engine Testing General Test Procedure — Chassis Dynamometer (8-06) Page 8-45 Intake Manifold Pressure Measure the intake manifold pressure (turbocharger boost). Install pressure gauge, Part No. ST-1273, in the intake manifold as shown. Observe the reading on the pressure gauge. NOTE: Intake manifold pressure (turbocharger boost) must be corrected for variances due to intake air temperature.
• Page 733
  General Test Procedure — Chassis Dynamometer (8-06) Engine Testing Page 8-46 Non CELECT™ Engines: Lock the cooling fan in the ‘‘ON’’ mode. This can be done by installing a jumper across the temperature switch, or by supplying shop air to the control valve. Refer to the fan drive manufacturer for the recommended procedure.
• Page 734
  Engine Testing General Test Procedure — Chassis Dynamometer (8-06) Page 8-47 NOTE: When measuring the pressure drop, operate a dy- namometer at the rpm that delivers the maximum horse- power of engine tested. Engine speed will be 1600-1700 rpm on most engines. Intake Air Restriction Measure the inlet air restriction.
• Page 735
  General Test Procedure — Chassis Dynamometer (8-06) Engine Testing Page 8-48 Operate the engine at maximum horsepower RPM and advertised horsepower. Observe the gauge or manometer. NOTE: Pressure must not exceed 75 mm Hg [3.0 inches Hg]. Engine Blowby Measure the engine crankcase pressure. Use blowby checking tool, Part No.
• Page 736
  Engine Testing Engine Run-In Procedure — Chassis Dynamometer (8-07) Page 8-49 Lubricating Oil Pressure Use Pressure Gauge, Part No. 3375275, to measure lu- bricating oil pressure. Install the pressure gauge to the main oil rifle and observe the oil pressure. Low Idle (minimum allowable) 80 kPa [10 psi] At 1300 RPM (minimum allowable) 205 kPa [30 psi] At Advertised RPM 241 to 310 kPa [35 to 45 psi]…
• Page 737
  1. Fuel Pump Calibration Values, Bulletin No. 3379352. 2. Injector Parts Flow and Cross Reference, Bulletin No. 3379664. 3. Engine Data Sheets 4. N14 Engine Shop Manual, Bulletin No. 3810487. 5. N14 Specifications Manual, Bulletin No. 3666010.
• Page 738
  Engine Testing Engine Run-In Procedure — Chassis Dynamometer (8-07) Page 8-51 If a sudden increase in blowby occurs, or if blowby ex- ceeds the maximum allowable limit during any run-in, return to the previous step and continue the run-in. If blowby does not reach an acceptable level during the next step, discontinue the run-in and determine the cause.
• Page 739
  Engine Run-In Procedure — Chassis Dynamometer (8-07) Engine Testing Page 8-52 Operate the engine at nominal torque peak RPM, full load, wide open throttle, for 5 minutes. Check the gauges, and record the readings. NOTE: Refer to the engine ‘‘Data Sheet’’ for the torque peak RPM of the engine model being tested.
• Page 740
  Engine Testing Engine Run-In Procedure Without Dynamometer (8-08) Page 8-53 Engine Run-In Procedure Without Dynamometer (8-08) On-Highway Caution: Refer to General Information and General En- gine Test Specifications and Procedures at the front of this section before operating the engine to avoid internal component damage.
• Page 741
  Section 9 — Engine Remove and Install Page 9-1 Section 9 — Engine Remove and Install Section Contents Page Engine Installation ……………………….9-9 Engine Mounts Inspection ……………………..9-9 Engine Removal …………………………. 9-4 Engine Remove and Install General Information………………..9-2 Engine Remove and Install Service Tools ………………….9-3…
• Page 742
  Engine Remove and Install General Information Section 9 — Engine Remove and Install Page 9-2 Engine Remove and Install General Information The procedures required to replace an engine will vary with different engine models, the type of equipment, op- tional equipment, and the shop facilities. Use the follow- ing procedures as a guide.
• Page 743
  Engine Remove and Install Service Tools The following special tools are recommended to perform procedures in Section 9. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description…
• Page 744
  Engine Removal (9-01) Section 9 — Engine Remove and Install Page 9-4 Engine Removal (9-01) NOTE: Place a tag on all hoses, lines, linkage, and electrical connections as they are removed to identify their locations on the engine. Disconnect the battery cables. Drain the engine coolant.
• Page 745
  Most cab-over configuration vehicles will have the Cummins factory installed rear engine lifting bracket still installed. Installations such as short and medium nose conven- tional chassis, the factory installed rear engine lifting bracket are usually removed due to space constraints.
• Page 746
  Engine Removal (9-01) Section 9 — Engine Remove and Install Page 9-6 On STC engines, loosen the mounting clips from the external oil manifold at the No. 3 rocker housing. Remove the external oil manifold connector from rocker housing No. 3. Approximately 1/2-inch clearance is needed be- tween the oil manifold and the rocker housing for the engine lifting bracket installation.
• Page 747
  Section 9 — Engine Remove and Install Engine Removal (9-01) Page 9-7 Attach the right plate of the lifting bracket to the exhaust side of the rear rocker housing. Install the four 3/8-16×1 inch UNC (Grade mounting capscrews and washers. Torque Value: 75 N•m [55 ft-lb] Caution: If all fasteners are not installed and properly…
• Page 748
  Engine Removal (9-01) Section 9 — Engine Remove and Install Page 9-8 Conventional chassis configurations will require use of the portable rear lifting bracket. Attach lifting fixture, Part No. ST-125 or Part No. 3822512, to the engine mounted lifting brackets to remove the engine.
• Page 749
  Section 9 — Engine Remove and Install Engine Mounts Inspection (9-02) Page 9-9 Engine Mounts Inspection (9-02) Inspect all rubber-cushioned mounts for cracks or dam- age. Inspect all mounting brackets for cracks or damaged bolt holes. NOTE: Damaged engine mounts and brackets can cause the engine to move out-of-alignment, can damage the drive- line components in the equipment, and can result in vibra- tion complaints.
• Page 750
  Engine Installation (9-03) Section 9 — Engine Remove and Install Page 9-10 Warning: The engine lifting equipment must be designed to safely lift the engine and the transmission as an as- sembly. The dry weight of the standard engine with accessories is 1256 kg [2770 lbs.].
• Page 751
  Section 9 — Engine Remove and Install Engine Installation (9-03) Page 9-11 Make a final inspection to make sure all hoses, wires, linkages, and components have been correctly installed and tightened. Warning: Do not remove the radiator cap from a hot engine.
• Page 752
  Section V — Engine Component Specifications Page V-1 Section V — Engine Component Specifications Section Contents Page Capscrew Markings and Torque Values ………………….V-44 Capscrew Markings and Torque Values — Metric ……………….. V-45 Capscrew Markings and Torque Values — U.S. Customary …………….V-46 Component Specifications and Torque Values ………………..
• Page 753
  3379084 Injector Rebuild Manual 3379071 Single Cylinder Air Compressor Shop Manual 3810242 Turbocharger Rebuild Manual (H2B, H2C, and HC3) 3379461 N14 Shop Manual 3810487 N14 CELECT™ System Troubleshooting and Repair Manual 3810469 Refer to Section L for literature ordering information.
• Page 754
  82°C 180°F • Fully Open Temperature 93°C 200°F • Maximum Open Distance 9.52 mm 0.375 in Top Tank Temperature • N14-460E and N14-430E 104°C 220°F • All Other Ratings 100°C 212°F Coolant Alarm Activation Temperature • N14-460E and N14-430E 104±1°C 220±2°F…
• Page 755
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-4 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Radiator Shutter Operating Temperature 1-17 • Intake Air Temperature 66°C OPEN-MIN 150°F 99°C OPEN-MAX 210°F 49°C CLOSE-MIN 120°F 66°C CLOSE-MAX 150°F •…
• Page 756
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-5 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Water Filter Head Shutoff Valve Retaining Capscrew 1-29 20 N•m 15 ft-lb Water Filter Head Threaded Male Insert 1-28 47 N•m 35 ft-lb Water Pump Idler Pulley Shaft Lock Nut 1-25…
• Page 757
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-6 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Coolant Temperature Sensor (CELECT™ Engines) 1-30 N•m 25 ft-lb…
• Page 758
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-7 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Lubricating Oil System Specifications — Section 2 Lubricating Oil Pressure At Main Oil Rifle 2-01 • At Idle With Oil Temperature at 93°C [200°F] 69 kPa 10 psi…
• Page 759
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-8 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. High Oil Pressure Relief Valve Retainer 6.48 mm 0.255 in Plug Installed Depth 2-14 6.98 mm 0.275 in Lubricating Oil Pump Drive Shaft End Clearance 2-13 0.051 mm…
• Page 760
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-9 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Lubricating Oil Cooler Core-to-Transfer Housing Mounting Capscrews 2-19 27 N•m 20 ft-lb Lubricating Oil Cooler Transfer Housing-to-Support Mounting Capscrews 2-19 47 N•m 35 ft-lb Lubricating Oil Cooler Support Bracket…
• Page 761
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-10 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Lubricating Oil Pump Cover to Body Mounting Capscrews 2-13 27 N•m 20 ft-lb Lubricating Oil Pump DFC Signal Line Tube Nuts 2-16 14 N•m 120 in-lb…
• Page 762
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Viscosity Sensor Fittings 2-18 • Main Oil Rifle (1) 24 N•m 18 ft-lb • To Lubricating Pump Regulator (2) 18 N•m 13 ft-lb Viscosity Sensor Fitting 2-18…
• Page 763
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-12 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Combustion Air System Specifications — Section 3 Intake Air Restriction Measured With Water Manomometer 3-04 • Normal Duty Cleaner (Clean) 250 mm-H 10.0 in-H •…
• Page 764
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-13 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Combustion Air System Torque Values Exhaust Air Pipe Clamps 3-01 8.5 N•m 75 in-lb Exhaust Manifold Mounting Capscrews 3-09 • Step 1 47 N•m 35 ft-lb •…
• Page 765
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-14 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Turbocharger Turbine Housing V-Band Clamp Capscrew 3-01 8.5 N•m 75 in-lb Turbocharger Intake Air Pipe Clamps 3-01 8.5 N•m 75 in-lb Turbocharger Mounting Nuts 3-08 44 N•m…
• Page 768
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-17 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel System Specifications — Section 5 Testing, Measurement, Installation Procedures, Specifications, and Torque Values listed for the fuel system components and assemblies can be found in the following publication: CELECT™…
• Page 769
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-18 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel Gear Pump Flow (CELECT™ Engines) • 1200 RPM 236 Kg/Hr 520 lb/Hr • 2100 RPM 295 Kg/Hr 650 lb/Hr Fuel Gear Pump Outlet Pressure (CELECT™…
• Page 770
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-19 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. STC Oil Control Valve (Refer to the CPL Manual, Bulletin No. 3379133 for valve part number) Upper Shift Point Lower Shift Point Part No.
• Page 771
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-20 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel Pump Regulator Spring Force (At 16.0 mm [0.631 in] Compressed Height (CELECT™ Engines) 3.63 Kg 8 lbf 4.44 Kg 10 lbf Fuel Pump Shutoff Valve Mounting Capscrew (STC and CELECT™…
• Page 772
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-21 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. STC Oil Control Valve Fittings • Fuel Pressure Sensing Line Fitting (1) 9.5 N•m 84 in-lb • Oil Outlet Fitting (2) 13.6 N•m 120 in-lb •…
• Page 773
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-22 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. ECM Mounting Capscrew (CELECT™ Engines) 7.3 N•m 65 in-lb Wiring Harness Amp Connectors to ECM (CELECT™ Engines) • OEM Harness 2 N•m 18 in-lb •…
• Page 774
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-23 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Electrical System Specifications — Section 6 Alternator Belt Tension 6-04 New Belts 620 N 140 lbf Used Belt 270 N 60 lbf 490 N 110 lbf…
• Page 775
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-24 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Starting Motor Mounting Capscrews 6-06 176 N•m 130 ft-lb…
• Page 776
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-25 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Base Engine Components Specifications — Section 7 Valve & Injector Adjustment Limits (STC Engines) 7-04 • STC Injector Preload (Top Stop) 0.56-0.68 N•m 5-6 in-lb •…
• Page 777
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-26 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Block Lower Press Fit Bore 7-27 159.842 mm 6.293 in Inside Diameter (For Standard Liner) 159.893 mm 6.295 in Cylinder Block Lower Press Fit Bore Inside Diameter 7-27…
• Page 778
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-27 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Head Capscrew Length 7-18 185.6 mm 7.130 in Crosshead to Valve Spring Retainer Clearance 7-18 0.65 mm 0.025 in Main Bearing Shell Thickness (Standard 7-23 3.086 mm…
• Page 779
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-28 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Crankshaft Gear Press Fit Area Outside Diameter 7-38 95.504 mm 3.7600 in 95.522 mm 3.7607 in Piston Skirt Outside Diameter 7-25 139.27 mm 5.4922 in…
• Page 780
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-29 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Connecting Rod Bearing Shell Thickness 7-24 2.362 mm 0.0930 in (Standard Bearings) 2.405 mm 0.0947 in Connecting Rod Side Clearance 7-26 0.1400 mm 0.0055 in…
• Page 781
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-30 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Liner Flange Outside Diameter 7-27 167.74 mm 6.584 in (Oversize Liner) 167.79 mm 6.586 in Cylinder Liner Flange Thickness 7-27 9.01 mm 0.355 in…
• Page 782
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-31 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Vibration Damper Eccentricity TIR 7-32 0.10 mm 0.004 in (Per 25.4 mm [1.0 in] Damper Outside Diameter) Vibration Damper Face Alignment (Wobble) TIR 7-32 0.18 mm…
• Page 783
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-32 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Camshaft Gear Bore Inside Diameter 7-40 45.662 mm 1.7977 in 45.682 mm 1.7985 in Camshaft Gear Press Fit Area Outside Diameter 7-40 45.733 mm…
• Page 784
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-33 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Flywheel Housing Face Alignment TIR SAE 00 7-44 0.30 mm 0.012 in SAE 0 0.25 mm 0.010 in SAE 1/2 0.25 mm 0.010 in SAE 1…
• Page 785
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-34 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Ambient Air Pressure Sensor Mounting Capscrews (CELECT™ Engines) — 30 N•m 22 ft-lb Cam Follower Housing Mounting Capscrews 7-20 • Step 1 20 N•m 15 ft-lb •…
• Page 786
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-35 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Head Mounting Capscrews 7-18 • Step 1 136 N•m 100 ft-lb • Step 2 298 N•m 220 ft-lb • Step 3 +90 degrees +90 degrees Engine Lifting Bracket Mounting…
• Page 787
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-36 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel Crossover Tube Mounting Capscrews 7-18 4 N•m 35 in-lb Gear Cover Inspection Hole Straight Thread Plug 7-31 27 N•m 20 ft-lb Gear Cover Mounting Capscrews 7-37…
• Page 788
  Section V — Engine Component Specifications Component Specifications and Torque Values Page V-37 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Rocker Housing Mounting Capscrews 7-10 • Capscrews (1/2 inch) 115 N•m 85 ft-lb • Capscrews (3/8 inch Grade 47 N•m 35 ft-lb Rocker Lever Shaft Mounting Capscrews 7-09…
• Page 789
  Component Specifications and Torque Values Section V — Engine Component Specifications Page V-38 Injection Timing Codes Note: Injection timing is measured at 5.161 mm [0.2032 inch] BTDC piston travel. To verify the correct injection timing for a particular en- gine, check the injection timing code on the engine dataplate.
• Page 790
  Section V — Engine Component Specifications Drive Belt Tension Page V-39 Drive Belt Tension SAE Belt Size Belt Tension Gauge Belt Tension Belt Tension Range Part No. Used* Click-type Burroughs .380 in. 3822524 270 to 490 60-110 .440 in. 3822524 270 to 490 60-110 1/2 in.
• Page 791
  Fraction, Decimal, Millimeter Conversions Section V — Engine Component Specifications Page V-40 Fraction, Decimal, Millimeter Conversions THS. THS. NDS. THS. INCHES THS. THS. NDS. THS. INCHES 0.0156 0.397 0.5156 13.097 0.0313 0.794 0.5313 13.494 0.0469 1.191 0.5469 13.891 0.0625 1.588 0.5625 14.288 0.0781…
• Page 792
  Section V — Engine Component Specifications Weight and Measures — Conversion Factors Page V-41 Weight and Measures — Conversion Factors QUANTITY U.S. METRIC FROM U.S. FROM CUSTOMARY CUSTOMARY METRIC TO U.S. METRIC CUSTOMARY MULTIPLY BY MULTIPLY BY Unit Abbr. Unit Abbr.
• Page 793
  Newton-Meter to Foot-Pound Conversion Chart Section V — Engine Component Specifications Page V-42 Newton-Meter to Foot-Pound Conversion Chart N•m ft-lb N•m ft-lb N•m ft-lb 44 in-lb 53 in-lb 62 in-lb 71 in-lb 80 in-lb 89 in-lb 48 NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
• Page 794
  Section V — Engine Component Specifications Capscrew Markings and Torque Values Page V-43 Capscrew Markings and Torque Values Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. SAE capscrews are graded according to the strength of the capscrew.
• Page 795
  Capscrew Markings and Torque Values Section V — Engine Component Specifications Page V-44 Capscrew Markings and Torque Values — Metric Commercial Steel Class 10.9 12.9 Capscrew Head Markings 10.9 12.9 Body Size Torque Torque Torque Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum…
• Page 796
  Section V — Engine Component Specifications Capscrew Markings and Torque Values — U.S. Customary Page V-45 Capscrew Markings and Torque Values — U.S. Customary SAE Grade Number Capscrew Head Markings These are all SAE Grade 5 (3) line Capscrew Torque — Grade 5 Capscrew Capscrew Torque — Grade 8 Capscrew Capscrew Body Size Cast Iron…
• Page 797
  Pipe Plug Torque Values Section V — Engine Component Specifications Page V-46 Pipe Plug Torque Values Size Torque Torque In Cast Iron or Thread Actual Thread O.D. In Aluminum Components Steel Components N•m ft-lb N•m ft-lb 1/16 0.32 45 in-lb 0.41 0.54 0.68…
• Page 798
  Section V — Engine Component Specifications Tap-Drill Chart — U.S. Customary & Metric Page V-47 Tap-Drill Chart — U.S. Customary & Metric NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60% and 75% of full thread depth.
• Page 799
  Section L — Service Literature Page L-1 Section L — Service Literature Section Contents Page Additional Service Literature ……………………..L-2 Service Literature Ordering Location ………………….L-3 Service Publications Order Form……………………L-4…
• Page 800
  Troubleshooting and Repair Manual — PT Pacer 3810443 PT Pacer Compulink™ Cartridge Manual 3810445 Operation and Maintenance Manual N14 Automotive Engines STC and CELECT™ Models. Worldwide, Excluding U.S.A., Canada, Aus- tralia, New Zealand and Puerto Rico 3810469 Troubleshooting and Repair Manual CELECT™ System N14 Engines…
• Page 801
  Jurong Industrial Estate Singapore Australia and New Zealand Cummins Diesel Australia Maroondah Highway, P.O.B. 139 Ringwood 3134 Victoria, Australia Obtain current price information from your local Cummins Distributor or (for U.S.A. and Canada) by calling Cummins Toll Free Number 1-800-DIESELS (1-800-343-7357).
• Page 802
  Quantity Each Amount Order Total Contact your Cummins distributor for prices and availability. For problems with literature orders, contact 1-800-DIESELS (1-800-343-7357) (for U.S.A. and Canada). Prices subject to change without notice. Please cut on dotted line — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — Literature Order Form Use this form for prompt handling of your literature order.
• Page 803
  Section L — Service Literature Service Literature Ordering Location Page L-5 Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor. FROM: Name: Street Address: City: State: Zip Code: Country: SHIP TO: (Name and address where literature is to be shipped)
• Page 804
  Section C — Component Manufacturers Page C-1 Section C — Component Manufacturers Section Contents Page Component Manufacturers’ Addresses………………….C-2 Air Compressors ……………………….C-2 Air Cylinders …………………………C-2 Air Heaters …………………………C-2 Air Starting Motors ……………………….C-2 Alternators …………………………C-2 Auxiliary Brakes ……………………….. C-2 Belts …………………………..
• Page 805
  Section C — Component Manufacturers Page C-2 Component Manufacturers’ Addresses NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers may be contacted directly for any specifications not covered in this manual. Air Compressors…
• Page 806
  Section C — Component Manufacturers Component Manufacturers’ Addresses Page C-3 Engine Protection Controls Filters Kabi Electrical and Plastics Cranborne Road Teddington Industrial Fleetguard International Corp. Potters Bar Equipment Cavalry Hill Industrial Park Herts Windmill Road Weedon EN6 3JP Sunburn on Thames Northampton NN7 4TD England Middlesex…
• Page 807
  Component Manufacturers’ Addresses Section C — Component Manufacturers Page C-4 Oil Heaters Fleetguard, Inc. P.O. Box 6001 Cookeville, TN 38502 Telephone: (615) 526-9551 Kim Hotstart Co. West 917 Broadway Spokane, WA 99210 Telephone: (509) 534-6171 Torque Converters Twin Disc International S.A. Chaussee de Namur Nivelles Belgium…
• Page 808
  Index Page 1 Accessory Drive Pulley Replacement……..7-164 Compressed Air System Service Tools……..4-8 Inspection …………….7-165 Compressed Air System Specifications ……..4-5 Installation …………….7-165 13.2 CFM Single Cylinder Air Compressor (SS 296) ….4-5 Removal …………….7-164 15.0 CFM Single Cylinder Air Compressor (SS 338) ….4-5 Accessory Drive Replacement ……….
• Page 809
  Fan Shroud Inspection …………1-42 Definition of Terms On Engine Performance Curve ….8-3 Fan Spacer and Pulley Inspection ……… 1-42 Cummins N14 Heavy Duty Engine Operating Curve Definitions:. 8-3 Filling the Cooling System …………. 1-22 Dipstick Calibration …………..2-26 Filling the Lubricating Oil System ………
• Page 810
  Index Page 3 Overhead Fuel Tank Requirements ……..5-23 Lubricating Oil Filter ………….. 2-19 Proper Use of Fuel System Gauges ……..5-24 Cleaning …………….2-19 Fuel System Specifications ………… 5-17 Installation …………….2-19 Basic Application Requirements ……….5-17 Removal …………….2-19 Fuel Oil Recommendations …………
• Page 811
  Index Page 4 Removal …………….7-44 Thermostat …………….1-69 Radiator and Charge Air Cooled Fins ……..1-37 Testing — In Chassis ………….. 1-69 Inspection …………….1-37 Testing — Out of Chassis …………1-70 Radiator Pressure Cap …………1-36 Thermostat Housing ………….. 1-65 Inspection …………….
• Page 812
  Cummins Engine Company, Inc. Box 3005 Columbus, IN, U.S.A., 47202-3005 Cable: CUMDIEX COLUMBUS Cummins Engine Company Ltd. 46-50 Coombe Road New Malden, Surrey KT3 4QL, England Cable: CUMEUR G Registration No. 573951 England Bulletin No. 3810456-01 Printed in U.S.A. 7/92…