Komatsu Engine Nt 855c Workshop Manuals 1

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 Foreword
This manual provides instructions for troubleshooting and repairing the NT 855 engine in the chassis. Component
and assembly rebuild procedures are provided in the NT 855 Engine Shop Manual. Refer to page 2 in the
Introduction for instructions on how to use this manual.
The manual is organized to guide a service technician through the logical steps of identifying and correcting
problems related to the engine.
This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for
repair procedures.
The repair procedures used in this manual are recommended by Cummins Engine Company, Inc. Some service
procedures require the use of special service tools. Use the correct tools as described.
The information, specifications, and recommended repair procedures in this publication are based on the infor-
mation in effect at the time this manual was printed. Cummins Engine Company, Inc. reserves the right to make
changes at any time without notice.
Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged.
Please send all suggestions and comments to:

CUMMINS ENGINE COMPANY, INC.

Box 3005
Columbus, Indiana 47202-3005
ATTENTION: NT 855 Product Service & Support
Mail Code - 80206
 Table of Contents
Section Page

Introduction................................................................................... I 1

Engine Identification ................................................................... E 1

- General Engine Specifications ............................................... 3

- Engine Diagrams ................................................................... 5

Troubleshooting .......................................................................... T 1

- Procedures and Techniques .................................................. 1

- Symptoms List ....................................................................... 2

- Symptoms Cause and Corrections Charts .............................. 3

Engine Systems Repair ...............................................................

- Cooling .................................................................................. 1 1

- Lubricating Oil ....................................................................... 2 1

- Combustion Air ...................................................................... 3 1

- Compressed Air ..................................................................... 4 1

- Fuel ....................................................................................... 5 1

- Electrical................................................................................ 6 1

- Base Engine Components...................................................... 7 1

Engine Testing (″In-Chassis″) .................................................... 8 1

Engine - Remove and Install ....................................................... 9 1

Engine Component Specifications ............................................. 10 1

Alphabetical Index....................................................................... 11 1

Additional Service Literature ...................................................... 12 1

Accessory Component Manufacturers ....................................... 13 1

Section I - Introduction Table of Contents
NT 855 Page 1

Section I - Introduction
Table of Contents
Page No.
About the Manual.............................................................................................. 2
How to Use the Manual ................................................................................... 2
Symbols ........................................................................................................... 3
Illustrations...................................................................................................... 7
Definition of Terms.......................................................................................... 8
General Repair Instructions ............................................................................ 9
General Cleaning Instructions......................................................................... 10
About the Manual Section I - Introduction
Page 2 NT 855

About the Manual

This NT 855 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. The procedure numbers describe specific repair pro-
cedures and are referred to in the Troubleshooting Logic Charts.
How to Use the Manual
The manual is organized to provide an easy flow from problem identification to problem correction. A list of
troubleshooting symptoms containing the most common engine problems is on page 2 in the Troubleshooting
Section. Complete the following steps to locate and correct the problem:

(STEP 1.) Locate the symptom on the list.

Reference is made to the page number where the″Troubleshooting Logic Chart″ is found.
(STEP 2.) The left column of the ″Troubleshooting Logic Chart″ indicates a probable cause, starting at the
top with the simplest and easiest to repair, and continuing downward to the most difficult.
The right column provides a brief description of the corrective action with a procedure number
reference for the repair procedure.
(STEP 3.) Locate the probable cause in the left column, and then turn to the procedure referenced in the right
column.
The repair procedures are listed by system (cooling, lubricating oil, combustion air, compressed
air, fuel, electrical, and base engine components).
(STEP 4.) The Troubleshooting Logic Charts are based on the following assumptions:
1. The engine has been installed according to the manufacturer’s specifications.
2. The easiest repairs are done first.
3. ″Generic″ solutions to cover problems with the most common applications and OEM’s (Original
Equipment Manufacturer).
Section I - Introduction Generic Symbols
NT 855 Page 3

Generic 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.

CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged
if the caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.
Simbolos Usados En Este Manual Section I - Introduction
Page 4 NT 855

Simbolos Usados En Este Manual

Los símbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando
aparece uno de estos símbolos, su significado se especifica en la parte inferior.

ADVERTENCIA - Serios daños personales o daño a la propiedad puede resultar si las instrucciones
de Advertencia no se consideran.

PRECAUCION - Daños menores pueden resultar, o de piezas del conjunto o el motor puede
averiarse si las instrucciones de Precaución no se siguen.

Indica un paso de REMOCION o DESMONTAJE.

Indica un paso de INSTALACION o MONTAJE.

Se requiere INSPECCION.

LIMPIESE la pieza o el montaje.

EJECUTESE una MEDICION mecánica o del tiempo.

LUBRIQUESE la pieza o el montaje.

Indica que se dará una LLAVE DE TUERCAS o el TAMAN

x O DE HERRAMIENTA.

APRIETESE hasta un par torsor específico.

EJECUTESE una MEDICION eléctrica.

Para información adicional refiérase a otro emplazamiento de este manual o a otra publicación
anterior.
Section I - Introduction Symbole
NT 855 Page 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 erhöhte Unfall- und
Beschädigungsgefahr.

VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und
Beschädigungsgefahr.

AUSBAU bzw. ZERLEGEN.

EINBAU bzw. ZUSAMMENBAU.

INSPEKTION erforderlich.

Teil oder Baugruppe REINIGEN.

DIMENSION - oder ZEITMESSUNG.

Teil oder Baugruppe O

} LEN.

WERKZEUGGRO
} SSE wird angegeben.

ANZUG auf vorgeschriebenes Drehmoment erforderlich.

Elektrische MESSUNG DURCHFU

} HREN.

Weitere Informationen an anderer Stelle bzw. in anderen Handbüchern.

Symboles Utilises Dans Ce Manuel Section I - Introduction
Page 6 NT 855

Symboles Utilises Dans Ce Manuel

Les symboles suivants sont utilisés dans ce manuel pour aider à communiquer le but des instructions. Quand l’un
de ces symboles apparaît, il évoque le sens défini ci-dessous:

AVERTISSEMENT - De graves lésions corporelles ou des dommages matériels considérables

peuvent survenir si les instructions données sous les rubriques ″Avertissement″ ne sont pas
suivies.

ATTENTION - De petites lésions corporelles peuvent survenir, ou bien une pièce, un ensemble
ou le moteur peuvent être endommagés si les instructions données sous les rubriques ″Atten-
tion″ ne sont pas suivies.
sécurité p
Indique une opération de DEPOSE.

Indique une opération de MONTAGE.

L’INSPECTION est nécessaire.

NETTOYER la pièce ou l’ensemble.

EFFECTUER une MESURE mécanique ou de temps.

GRAISSER la pièce ou l’ensemble.

Indique qu’une DIMENSION DE CLE ou D’OUTIL sera donnée.

SERRER à un couple spécifique.

EFFECTUER une MESURE électrique.

Se reporter à un autre endroit dans ce manuel ou à une autre publication pour obtenir des
informations plus complètes.
Definition of Terms Section I - Introduction
Page 8 NT 855

Definition of Terms
The following is a list of guidelines for each procedure in the ″Repair Sections″ of the Troubleshooting and Repair
Manual. The procedure will be given first, followed by a definition of the step or steps involved.
Check - Examine a component or system for damage, excessive wear, accuracy, safety, or performance.
Inspect - Examine a component or dimension to make sure it meets the required specifications.
Test - Check or compare the performance of a component or system to established specifications.
Adjust - Complete the necessary steps to set or adjust the component, assemblies, or system in the required
setting or position.
Visually Inspect - Look for any obvious damage or problem.
Remove - Take off a component or assembly.
Clean - Remove dirt, grease, or other contamination.
Disassemble - Take apart the component or assembly.
Repair - Restore a component or assembly to a serviceable condition within the established specifications.
NOTE: Only the easiest and simplest repairs will be made to a component or assembly. If a component or assembly
must be rebuilt, it must be replaced with a new or Cummins Diesel ReConW, Inc. replacement or be rebuilt at a Cummins
authorized repair location.
Replace - Install a new, correctly rebuilt, or Cummins Diesel ReConW, Inc. component or assembly in place of
the one which is removed.
Install - Place a component or assembly in the correct position.
Star Pattern Torque Sequence -
Section I - Introduction General Repair Instructions
NT 855 Page 9

General Repair Instructions

The NT 855 engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair
practices performed to quality standards.
Warning: Cummins Engine Company, Inc. does not recommend/authorize any modifications or repairs
to engines or components except for those detailed in Cummins Service Information. In particular,
unauthorized repair to safety-related components can cause personal injury. Below is a partial listing of
components classified as safety-related:

Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter
Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing
Turbocharger Oil Drain Line(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
• Follow All Safety Instructions Noted in the Procedures.
- Follow the manufacturer’s recommendations for cleaning solvents and other substances used during the
repair of the engine. Always use good safety practices with tools and equipment.
• Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
- The engine and its components must be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
• Perform the Inspections Specified in the Procedures.
• Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
• Use Genuine Cummins New or ReConW Service Parts and Assemblies
- The assembly instructions have been written to use again as many components and assemblies as
possible. When it is necessary to replace a component or assembly, the procedure is based on the use
of new Cummins or Cummins ReConW components. All of the repair services described in this manual
are available from all Cummins Distributors and most Dealer locations.
• Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Complete rebuild instructions are available in the NT 855 Engine Shop Manual, which can be ordered or purchased
from a Cummins authorized repair location. Refer to page 1 in the Additional Service Literature Section for ordering
instructions.
General Cleaning Instructions Section I - Introduction
Page 10 NT 855

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]. A cleaning tank that provides a constant mixing and
filtering of the cleaning solution will give the best results.
Remove all the gasket material, O-rings, and the deposits of sludge, carbon, etc., with a wire brush or
scraper before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When
possible, steam clean the parts before putting them in the cleaning tank.
Warning: The use of acid can be extremely dangerous to personnel and can damage the machinery.
Always provide a tank of strong soda water as a neutralizing agent.
Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The
rustproofing compound must be removed from the parts before installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good
way to clean the oil drillings.
Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat.
Do not steam clean the following parts:
1. Electrical Components
2. Wiring
3. Injectors
4. Fuel Pump
5. Belts and Hoses
6. Bearings
Glass or Plastic Bead Cleaning
Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The
cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the
cleaning time.
Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts or ring grooves. Small
particles of glass or plastic will embed in the aluminum and result in premature wear. Valves, turbocharger
shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.
Follow the equipment manufacturer’s cleaning instructions. The following guidelines can be used to adapt to
the manufacturer’s instructions:
1. Bead size: Use U.S. size No. 70 for piston domes.
Use U.S. size No. 60 for general purpose cleaning.
2. Operating Pressure: Use 620 kPa [90 psi] for general purpose cleaning.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic
beads after cleaning. Rinse with hot water. Dry with compressed air.
4. Do not contaminate the wash tanks with glass or plastic beads.
Engine Identification Section E - Engine Identification
Page 2 NT 855

Engine Identification
The model name provides the following engine data:

N T C 400 N T C C 400

= Maximum Rated Horsepower

= Maximum Rated Horsepower = California Certified
= Custom Rated = Custom Rated
= Turbocharged = Turbocharged
= Four Valve Head = Four Valve Head

Engine Dataplate
The engine dataplate shows specific information about
your engine. The engine serial number (1) and the Con-
trol Parts List (CPL) (2) provide information for ordering
parts and service needs.

Always record the serial number (1) of the engine, the

CPL (Control Parts List) number (2), and the engine model
number (3) on all orders for parts. This information is
important for fuel pump calibration and correct identifi-
cation of parts.
NOTE: The engine dataplate must not be changed unless
approved by Cummins Engine Company, Inc.

Fuel Pump Dataplate (Nameplate)

The fuel pump dataplate is located on the top of the fuel
pump. It provides information for fuel pump calibration.
Section E - Engine Identification Engine Specifications
NT 855 Page 3

Engine Specifications
General Engine Data
Horsepower ...................................................................................... 179 kw (240 BHP) to 354 kw (475 BHP)
Engine Speed@ Maximum Output
Standard Rating (RPM) ...................................................................................................................... 2100
Formula Rating (RPM)........................................................................................................................ 1800
Bore and Stroke ..................................................................................... 140 mm [5.5 in.] X 152 mm [6.0 in.]
Displacement .............................................................................................................. 14.0 liters [855 cu. in.]
Compression Ratio ................................................................................................................ 13.5:1 to 17.2:1
Firing Order................................................................................................................................... 1-5-3-6-2-4
Engine Weight (With Standard Accessories)
Dry Weight.................................................................................... 1126 kg [2480 lb.] to 1221 kg [2690 lb.]
Wet Weight ................................................................................... 1180 kg [2600 lb.] to 1276 kg [2810 lb.]

Air Induction System

Maximum allowable turbocharged intake restriction .................................................. 64 cm H2O [25 in. H2O]
Maximum allowable naturally aspirated and Fleet 270 intake restriction .................... 51 cm H2O [20 in. H2O]

Lubrication System
Oil pressure at idle (minimum allowable) ................................................................. 70 kPa [10 psi] minimum
At no load governed speed ....................................................................................... 240-310 kPa [35-45 psi]
Oil capacity of standard engine:
Bypass filter ......................................................................................................... 2.8 liters [0.75 U.S. gal.]
Full flow filter ....................................................................................................... 3.5 liters [0.93 U.S. gal.]
Combo filter ......................................................................................................... 3.9 liters [1.04 U.S. gal.]
Oil pan capacity (high-low)............................................................................ 36-28 liters [9.5-7.5 U.S. gal.]
Total system capacity including filters ....................................................................... 42 liters [11.0 U.S. gal.]
Engine Specifications Section E - Engine Identification
Page 4 NT 855

Engine Specifications (Cont’d.)

Cooling System
Coolant capacity (engine only) ................................................................................. 21 liters [22 U.S. quarts]
Standard modulating thermostat range
Conventional aftercooling .......................................................................................... 82-93°C [180-200°F]
Optimized aftercooling............................................................................................... 79-91°C [175-195°F]
Maximum coolant cylinder block pressure (pressure cap removed)....................................... 350 kPa [50 psi]
Maximum allowable operating temperature ............................................................................. 100°C [212°F]
Maximum allowable operating temperature for NTC-444 ......................................................... 104°C [220°F]
Minimum recommended operating temperature ........................................................................ 70°C [158°F]
Minimum recommended pressure cap...................................................................................... 50 kPa [7 psi]

Exhaust System
Maximum allowable back pressure imposed by piping and silencer ....................... 1000 mm H20 [40 in. H20]
Maximum bending movement to turbocharger flange........................................................... 27 N•m [20 ft-lb]
Exhaust pipe size (normally acceptable inside diameter except NTC 475) .............................. 127 mm [5 in.]
NTC 475.............................................................................................................................. 152 mm [6 in.]

Fuel System
Maximum allowable restriction to pump:
With clean filter ........................................................................................................ 100 mm Hg [4 in. Hg]
With dirty filter.......................................................................................................... 200 mm Hg [8 in. Hg]
Maximum allowable fuel return line restriction
Without check valves .............................................................................................. 64 mm Hg [2.5 in. Hg]
With check valves and/or overhead tanks.............................................................. 165 mm Hg [6.5 in. Hg]
Minimum fuel tank vent capability ................................................................................... 0.85 m3/h [30 ft3/hr]

Electrical System
Battery Size Ambient Temperatures
-18°C (0°F) 0°C (32°F)
Cold Reserve Cold Reserve
Cranking Capacity * Cranking Capacity
Amperes Amperes Amperes Amperes
12 Volt 1800 640 1280 480
24 Volt ** 900 320 640 240

* The number of plates within a given battery size determine reserve capacity. Reserve capacity determines the
length of time sustained cranking can occur.
** CCA ratings are based on two 12-volt batteries in series.
Komatsu Engine Nt 855c Workshop Manuals 1
Full download: http://manualplace.com/download/komatsu-engine-nt-855c-workshop-manuals-1/
Procedures and Techniques
NT 855 Page 1

Section T - Troubleshooting
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 3 are organized so that a problem can be located
and corrected by doing the easiest and most logical things first. Complete all steps in the sequence shown from
top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts should stimulate
a thought process that will lead to the cause and correction of the problem.
Follow these basic troubleshooting steps:
• Get all the facts concerning the complaint.
• Analyze the problem thoroughly.
• Relate the symptoms to the basic engine systems and components.
• Consider any recent maintenance or repair action that may relate to the problem.
• Double-check before beginning any disassembly.
• Solve the problem by using the logic charts and doing the easiest things first.
• Use CompuchekW where applicable to diagnose a problem.
• Determine the cause of the problem and make a thorough repair.
• After repairs have been made, operate the engine to make sure the cause of the problem has been
corrected.

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