-tn^nt'htioítínii&lmion,: • .: • • .

nm.imr.^.iAm^eiibih6«¿Jas,;• . .,' -
 IMPORTANT m J E C t O R INFORMATION

T h e endoseá Premium E x c h a n g e S T C (step-timing control) injectors are

o f t h e h i g h e s t q u a l i t y b e c a u s e t h e y a r e re^manufactured and have beeii
íested a n d conformto new injector specifications.

Improper installation o f the S T C injector m a y lead t o premature injector

failuré a n d e n g i n e d a m a g e . A c o m m o n error is over-setting the
plunger-ío-cup torque resulíing in b r e a k a g e ofthé injector's cup (spray-
tip) a n d is not covered under t h e manufactureras warranty for íhis
product

P r o t e c t y o u r i n v e s t m e n t . C o n s u l t t h e f o l l o w i n g injector installation
p r o c e d u r e a n d setting specifications w h e n i n s t a l l i n g the injectors. Itis
v i t a l t o tile n o r m a l o p e r a t i o n a n d l o n g e v i t y o f t h i s p r o d u c t . B e s u r e S T C
control valve is in proper operating c o n d i t i o n i n c l u d i n g a l l o i l Unes a n d
o 'rings t o a s s u r e p r o p e r o p e r a t i o n o f t h e i n j e c t o r i n t h e S T C s y s t e m .
 Service Bulletin
subjeci • • ; :
N T / N I 4 S T C P e r f o r m a n c e D e g r a d a t l o n T r o u b l e s h o o U n g P r o c e d u r e ( O B C O v e r h e a d S e t t i n g Procedui
BuIl«Un No. 3 6 6 6 0 0 6 - 0 1
Background
In 1 9 8 6 , t h e step t i m i n g c o n t r o l ( S T C ) i n j e c t o r w a s
introduced. Since itsIntroduction, extensive studies
have s h o w n that internal injector S T C tappet wear and
external injector t r a l n w e a r c a n resutt I n e n g i n e per-
formance degradation, Internal a n d external wear
causes a loss o finjector plunger t o c u p crush which
leads t o plunger carbon|ng, d e c r e a s e d injector fuel
flow, a n d m o r e retarded Jnjection t i m i n g .
It i s ' r e c o m m e n d e d t h a t v a l v e s a n d i n j e c t o r s b e . a d -
j u s t e d e v e r y 9 6 , 0 0 0 l<m [ 6 0 , 0 0 0 mi], 1 , 5 0 0 h o u r s , o r
once a y e a r (whichever c o m e s f irst). I n j e c t o r s t h a t have
opérated s i g n i f i c a n t l y h i g h e r m l l e a g e s b e t w e e n a d -
¡ustments c a n h a v e i n t e r n a l w e a r a n d / o r carbón d e -
posits. i n t e r n a l i n j e c t o r v/ear t h a t r e s u l t s i n i n c r e a s e d
t o t a l t r a v e l c a n b e c o m p e n s a t e d f o r b y u s i n g a n Cúter
B a s e C i r c l e (OBC) o v e r h e a d s e t v/ith t h e i n j e c t o r s i n
t h e e n g i n e . C a r t j o n depúsits c a n b e c l e a r i e d f r o m t h e
injectors through t h e u s e o f a P r e m i u m P l u s Flash
f o l l o w e d b y a n O B C o v e r h e a d s e t v/ith t h e i n j e c t o r s still
in the engine.
O v e r h e a d Set Procedure
T h e preferred m e t h o d o fp e r f o r m i n g n o r m a l valve and
S T C injector overhead a d j u s t m e n t isto.use the O B C
m e t h o d w h e r e the c r u s h of t h e injector plunger-to-cup
Is set b y t i g h t e n i n g t h e I n j e c t o r r o c k e r l e v e r a d j u s t i n g
screv/ t o a p r e s c r i b e d t o r q u e . T h e O B C m e t h o d c a n b e
used w i t h - o u l r e m o v i n g the S T C i n j e c t o r s ' f r o m the
engine for recalibration. This procedure does cause
the S T C tappet t o u n s e a t f r o m the tappet top stop
eff ectively m a k i n g t h e t a p p e t t o p s t o p i n o p e r a t i v e . T h i s ,
h o v / e v e r , i s acóeplable a s t h e l i g h l forcé o f t h e t a p p e t .
s p r i n g v/ill n o t i m p a i r i n j e c t o r t r a i n l u b r i c a t i o n . T h e
O B C overhead a d j u s t m e n t procedure d o e s a g o o d job
of r e s l o r i n g t h e Inj e c t o r t r a v e l a n d r e m o v i n g e x t e r n a l
train l a s h w i t h o u t r e m o v i n g t h e S T C injectors f r o m the
engine. T h i s procedure c a n b e p e r f b r m e d b y a n y ser-
v i c e l o c a t i o n a s it d o e s n o t r e q u i r e i n j e c t o r r e m o v a l o r
the use of the T o p S t o p stand.
if t h e S T C i n j e c t o r s h a v e b e e n r e m o v e d f o r c l e a n i n g
a n d c a l l b r a t l o n ór i f n e v / o r R e C p n i n j e c t o r s a r e b e i n g
i n s l a l l e d , it i s a c c e p t a b l e t 0 4 j s e e i t h e r t h e I n n e r B a s e
C i r c l e (1B C ) o r t h e O B C o v e r h e a d s e t p r o c e d u r e . W h e n
using the IBC m e t h o d , a d j u s t t h e Injector r o c k e r lever
to zero lash while r e t a i n i n g the t a p p e t i n t h e full upv/ard
position using tappet a d j u s t i n g too!, P a r t f^o. 3 8 2 3 3 4 8 ,
a n d a p p l y 0 . 6 7 N«m [ 6 in-ib] a d j u s t i n g screv/ torque..
Oimm Enaine Company, Inc.íCoIumbus. Indiana 47202-3Q05
C u m m i n s E n g i n e C o m p a n y L t d . ^ D a v a n t r y . N o r t h a n t s , Enfliand N N I I S N U
p«glst«fe<l omc«: 4».50 Coombe Road.iNew Malden. Surr«y KTi 40L
.'RMbtered Na S73951 England
CopyrlohtO 1992
Cummins Pnnin* 1»» .
— —— —— — — —
Date:
August, 1992
S e t t i n g v a l v e s a n d i n j e c t o r s v / i t h t h e I B C m e t h o d v/il
out injector recalibration will n o t r e s t o r e v/orn S I
injectors a n d m a y notcompletety r e s o l v e p e r f o r m a m
probléms.
Onnon-STCenglnés,theOBCmelhod m u s t n o t l
u s e d . U s e o f O B C o n f i x e d t i m e éngínes c a n u n s e
t h e injector p l u n g e r from t h e injector t o p s t o p . T h e st
plunger spring will excessively load t h e injector tra
a n d w i l l i m p a i r l u b r i c a t i o n t o t r a i n compónents l e a d i r
.to a c c e l e r a t e d w e a r a n d s c u f f i n g o f t h e b a l l a n d s o c k i
; jolnts.'"
C a u t l o n : D o n o t a t t e m p t t h e O B C o v e r h e a d s e l pr<
cedure o n L 1 0 S T C engines, as d o l n g ? o wlll result i
e n g i n e d a m a g e . Püiley m a r k s a n d cámshaft g e o m e t r
o n the LIO e n g i n e s d onot a c c o m m o d a t e t h i s proct
dure al this time. "
Troubléshooting
W h e n troubléshooting N T S T C p e r f o r m a n c e d e g r a d a
tíon c o m p i a i n t s , f o l l o w t h e s t e p s o u t l i n e d i n t h e t r o L
bleshpoting s y m p t o r h charts I n t h i s S e n / i c e P u b l i c a
• tion. t h e s e p r o c e d u r e s are u p d a t e d v e r s i o n s o f th(
s y r n p t o m c h a r t s i n t h e N 1 4 Troubléshooting a n d R e
p a l r M a n u a l , 3 8 1 0 4 5 6 a r i d w l l l l e a d t h e méchame te
c h e c k i l e n n s k n o w n t o b e p b t e n t i a l . c a u s e s f o r péríor
m a n e e degradation. The primary d i f f e r e n c e f r o m the
Troubléshooting a n d R e p a i r M a n u a l p r o C e d u r e s ' a r e
t h e r e f e r e n c e s t o P r e m i u m P l u s Fíush a n d t h e O B C
overhead set.
B e f o r e troubléshooting a p e r f o r m a n c e C o m p l a i n t , i t i s
important to thoroughiy understand t h e coniplaint. Re-
f e r t o the"Dríveability - G e n e r a l I n f o r m a t i o n " s e c t i o n
a t t h e e n d o f t h e Troubléshooting s e c t i o n i n t h e N 1 4
E n g i n e Troubléshooting a n d R e p a i r M a n u a l , B u l l e t i n
N o . 3 8 1 0 4 5 6 a n d o n P a g a 1 1 of t h i s S e r v i c e P u b l i c a -
t i o n . F i n o u t t h e dríveability c h e c k i i s t s l o c a t e d t h e r e .
1 . If a r o u g h i d i e o r e x c e s s i v e v / h i t e s m o k e a t i d i e i s
presentí w i t h a l o w pov/er c o m p l a i n t t r o u b l e s h o o t
t h e r o u g h i d l e ór e x c e s s i v e w h i t e s m o k e a t i d i e f i r s t .
T h i s v/ill léad t o résettiñg t h e o v e r h e a d a n d i n j e c t o r
total travel early intheprocess. T h i s will b e d o n e b y
u s i n g t h e O B C sét m e t h o d . T h i s m e t h o d v/ill c o r r i -
•pensaie f o r tnternar injector w e a r a n d t r a i n l a s h
w i t h o u l r e m o v i n g the Injectors. S e e t h e O B C O v e r -
h e a d S e t P r o c e d u r e o n P a g e 4 f o r Instructíons.
2 . If a l o w povi/er c o m p l a i n t t s e n c o u n t e r e d . f o l l o w t h e
L o Y / P o Y / e r Troubléshooting S y r n p t o m - D y n a m o m -
 N T / N I 4 S T C P e r f o r m a n c e D e g r a d a t i o n Troubléshooting P r o c e d u r e ( O B C S e t t i n g
Pag.e 2 .

the overhead i s r e s e t b y the O B C method, the

- f u e ! r a t e ¡s l o w , r e m o v e t h e i n j e c t o r s a n d r e p a i r ~
'dccording t o 8 9 S I B 6 - 1 . This I n f o r m a t i o n i s a l s o
i n c l u d e d ¡h t h i s b u l l e t i n o n P a g e 2 8 .
j»3. if a m i s s o r w h i t e s m o k e a t - i d l e w i t h a v e r y h o t
engine is encountered, ireset t h e o v e r h e a d using
the O B C m e t h o d . C h e c k internal oil p l u m b i n g for
l e a k s . ' R e s e t the l o w idle s p e e d t o 7 0 0 R P M ± 5 0
RPM. • í

^ • If á m i s s o r w h i t e s m o k e a t I d l e w i t h a v e r y h o t
e n g i n e is e n c o u r i t e r e d a f t e r a n O B C r e s e t , m e a -
s u r e t h e i d l e o i l p r e s s u r e a t t h e m a i n o i l r i f l e . If t h e .
: mínimum r i f l e p r e s s u r e i s e q u a l t o o r l e s s t h a n 6 9
k P a [10 psi], t r o u b l e s h o o t for l o w o H p r e s s u r e . A n
. : i n c r e a s e i n . e n g i n e idle s p e e d w i l l i n c r e a s e oil
pressure t o t h e tappets a n d c a n resolve the
;;'.;problém., , . • •
• I f i d l e o U p r e s s u r e i s 6 9 kPá ( 1 0 p s i ] o r a b o v ' e .
r e m o v e tiie injectors a n d repair according t o
; 89SÍB6-1 a n d I n s t a l l n e w t a p p e t s .
Caution: D onot a t t e m p t the OBG overhead set pro-
cedure o n L10 S T C e n g I n e s , as dolng so wlll result In
e n g i n e damagé. P u l l e y miarícs ánd cámshaft g e o m e t r y
o n . t h e L I O e n g i n e s d o n o t accomnriódate t h i s p r o c e -
d u r e a t t h i s timé.
F o r f u r t h e r I n f o r m a t i o n a n d b a c k g r o u n d , v i e w t h e NT/
N14 S T C Overhead A d j u s t m e n t : O u t e r B a s e Circle
(OBC) Method videotape, Bulletin No. 3387796.
T h e " N T / N l 4 - S T C 0 u t e r B a s e Circle (OBC) Overhead
Set Procedure" (Page 4 ) can b e o r d e r e d a s a lami-
nated card, Bulletin N o . 3 6 6 6 0 0 7 - 0 0 .
 Pag
Hold the a d u s t i n g s c r e w a n d torque the lock nutto 5 4 ^ p x
N»m [4p ft-lb] o n N e w B i g C a m I V a n d 8 8 B i g C a m i V s [f \
?in.d'68 N«m [ 5 0 ft-lb] o n N 1 4 m o d e l s .
After setting t h e i n j e c t o r o n a given cylinder, s e tt h e
valves o n the s a m e cylinder. Notice that the O B C m e t h o d
,requires n e wvalve settings for N e w Big C a m I V a n d 8 8
Big C # m I V e n g i n e s . H o l d the adjusting screw and torque
the lock n u t t o 5 4 N»m (40 ft-lb] o n N e w B i g C a m IVa n d
8 8 B i g . C a m I V ' s ánd 6 8 N-«m [ 5 0 f t - l b ] ón N 1 4 m o d e l s .
Advance t h e accesspry drive pulley t othe nexl set m a r k
a n d a d j u s t t h e i n j e c t o r s a n d t h e v a l v e s . Continué t h r o u g h
t w o revolülions o f t h e e n g i n e t o c o m p l e t e a l l s i x c y l i n d e r s .

In setting t h e C - B r a k e , t h e O B C o r I B C . s e q u e n c e c a n b e
used. ..

H o w e v e r , t o elimínate confusión, ít w i l l b e e a s i e r t o u s e
the same s e q u e n c e t h a t w a s u s e d t o set t h e overhead. C-Brake Set Pósitlon -Sequence
Bar Ih Pulley Set Brake
Directlon Position IBC OBC
Start Aor1-6VS •5 • . • ^ •
Adv. To B or 2-5VS 3 5
Adv. To G or 3 ^ B S 6 . 3
Adv. To Acr1-6VS . 2 6 .
Adv. To B Of 2-5VS 4 2 .
Adv. To C or 3-4VS 1 4
Firing Order: 1-5-3-6-2-4 RightHandRotalion

I n t h e troubléshooting p r o c e d u r e s i n t h e f o l l o w i n g p a g e s ,
references t o procedures such a s 3 - 0 1 , 3 - 1 1 , 7 - 0 5 . Sec-
t i o n 8 , e t c . . p e r t a i n t o p r o c e d u r e s i n t h e N 1 4 Troublé-
s h o o t i n g ánd R e p a i r , M a n u a l . B u l l e t i n N o . 3 8 1 0 4 5 6 .
. N w m 4 t ) i ü Hertormance Degradation Trou&leshooting Procedure (OBC Overhead Setting Procedure)

NT/N14- S T C Outer Base Circte^^BC).

Overhead SetProcedure \
Rotate t h e accessory drive i nt h e direciion o f engine
rotation. T h e a c c e s s o r y d r i v e will r o t a t e c l o c k w l s e . o n a
• r i g h t h a h d e n g i n e , w h e n looklñgattheírontof t h e e n g i n e .
, Aligh t h e " A " o r " 1 - 6 V S " m a r k o h t h ea c c e s s o r y drive
pulley w i t h t h e pointer o n ' t h e g e a r cover.
NOTÉ: I t ¡s i m p o r t a n t t o a d j u s t t h e i n j e c t o r fírst b e f o r e a d -
j u s t i n g t h e v a l v e s o n a c y l i n d e r w h e n u s i n g t h e O B C pvér-
head set procedure.

: - 7 - ^ — Check the valve rocker levers o n cylinder N O i 1t o seeif

O u t e r Basí.Cirtfré ( O B C ) r.*- both valves a r e closed.
Inlector a n dValve A d j u s t m e n t Sequence
Bar E n g i n e N O T E : Both t h e intake a n d exhaust valves ^re closed w h e n
In D i r e c i i o n Pulley Set Cylinder b o t h r o c k e r l e v e r s a r e loóse a n d c a n b e m d v e d f r o m s i d e ; t o
of R o t a t i o n Position Inlelítor Aalve s i d e . If b o t h v a l v e s a r e n o t c l o s e d , r o t a t e t h e a c c e s s o r y d r i v e
Slart 1 • :.í one complete revolution; a n dalign t h e " A " mark with the
Advance t o > • ^";B. • • ;•5 / pointer again.
Advance t o 3
Advance t o - A 6 If t h e v a l v e r o c k e r l e v e r a d j u s t i n g s c r e w s h a v e b e e n l o o s -
Advance t o , :B 2 • 2 • ened a n dn o tyet adjusted, w a t c h the valve p u s h tubes
Advanceto - c A ••• as t h e e n g i n e rolls u p o n t h e " A " m a r k , B o t h v a l v e push
F i r i n g O r d e r : 1-5-3-6-2r4r |> tubes will have m o v e d t ot h e d o w n w a r d (valve closed)
position ift h eengine I so n t h e correct stroke. , .

Injector Intake Exhaust

Engine Engine AdJ. S c r e w V a l v e Valve C-Brake
Model CPL Torque Lesh Lesh Lash
NBClí' 621, 833 12 N»m
903, 9 W 0.014 0.027 0.018
8 0 6 , 1215 [ 1 0 5 i n - l b ]
86BCIV 910, 5 2 7
1185
1186 10N»m
1210 0.014 0.027 : ; 0.018
1211 (90in^b]
1256
1280
NH 1374 •vi'
14 N«m 0.014 0.027 0.023 A 4
1395
1405 • (ISSIn^bJ
•••1507

U s e a d i a l t y p e t o r q u e w r e n c h t o tíghtert. t h e ' i n j e c ' \ o r

rocker lever a d j u s t i n g s c r e w s t o t h e specified t o r q u e . If
t h e s c r e w c a u s e s c h a t t e r i n g d u r i n g settinéj,-"repair t h e
s c r e w a n d l e v e r a s r e q u l r e d . .:.
Hold the torque wrench in a position t h a t a l l o w s y o u t o
look i na direct Une at t h e dial. T h i s Is t o m a k e s u r e that
you read t h e dial a c c u r a t e l y , ' , ; l
T h e t o r q u e w r e n c h muéttoé'cafibrated, h a v e a r e s o l u t i o n
o f 0 . 2 8 N«m [ 2 . 5 i n - l b ] , a n d h a v e a r a n g e o f 1 7 N » m [ 1 5 0
in-lb]. '^•'i^
O n n o n - b r a k e engiries,Tf t h e i n j e p t o r adjusting s c r e w i s
a slotted-head type, be carefut that the screw drlver does