Komatsu Engine Nt 855c Workshop Manuals 1

Foreword

ThismanualprovidesinstructionsfortroubleshootingandrepairingtheNT855engineinthechassis.Component andassemblyrebuildproceduresareprovidedintheNT855EngineShopManual.Refertopage2inthe Introductionforinstructionsonhowtousethismanual.

Themanualisorganizedtoguideaservicetechnicianthroughthelogicalstepsofidentifyingandcorrecting problemsrelatedtotheengine.

Thismanualdoes not covervehicleorequipmentproblems.Consultthevehicleorequipmentmanufacturerfor repairprocedures.

TherepairproceduresusedinthismanualarerecommendedbyCumminsEngineCompany,Inc.Someservice proceduresrequiretheuseofspecialservicetools.Usethecorrecttoolsasdescribed.

Theinformation,specifications,andrecommendedrepairproceduresinthispublicationarebasedontheinformationineffectatthetimethismanualwasprinted.CumminsEngineCompany,Inc.reservestherighttomake changesatanytimewithoutnotice.

Reportingoferrors,omissions,andrecommendationsforimprovingthispublicationbytheuserisencouraged. Pleasesendallsuggestionsandcommentsto:

CUMMINSENGINECOMPANY,INC. Box3005 Columbus,Indiana47202-3005

ATTENTION:NT855ProductService&Support MailCode-80206

AbouttheManual

ThisNT855TroubleshootingandRepairManualisintendedtoaidindeterminingthecauseofengine-related problemsandtoproviderecommendedrepairprocedures.Themanualisdividedintosections.Somesections containreferencenumbersandprocedurenumbers.Thereferencenumbersprovidegeneralinformation,specifications,diagrams,andservicetools,whereapplicable.TheprocedurenumbersdescribespecificrepairproceduresandarereferredtointheTroubleshootingLogicCharts.

HowtoUsetheManual

Themanualisorganizedtoprovideaneasyflowfromproblemidentificationtoproblemcorrection.Alistof troubleshootingsymptomscontainingthemostcommonengineproblemsisonpage2intheTroubleshooting Section.Completethefollowingstepstolocateandcorrecttheproblem:

(STEP1.)Locatethesymptomonthelist.

Referenceismadetothepagenumberwherethe″TroubleshootingLogicChart″ isfound.

(STEP2.)Theleftcolumnofthe ″TroubleshootingLogicChart″ indicatesaprobablecause,startingatthe topwiththesimplestandeasiesttorepair,andcontinuingdownwardtothemostdifficult.

Therightcolumnprovidesabriefdescriptionofthecorrectiveactionwithaprocedurenumber referencefortherepairprocedure.

(STEP3.)Locatetheprobablecauseintheleftcolumn,andthenturntotheprocedurereferencedintheright column.

Therepairproceduresarelistedbysystem(cooling,lubricatingoil,combustionair,compressed air,fuel,electrical,andbaseenginecomponents).

(STEP4.)TheTroubleshootingLogicChartsarebasedonthefollowingassumptions:

1.Theenginehasbeeninstalledaccordingtothemanufacturer’sspecifications.

2.Theeasiestrepairsaredonefirst.

3. ″Generic″ solutionstocoverproblemswiththemostcommonapplicationsandOEM’s(Original EquipmentManufacturer).

GenericSymbols

Thefollowingsymbolshavebeenusedinthismanualtohelpcommunicatetheintentoftheinstructions.When oneofthesymbolsappears,itconveysthemeaningdefinedbelow:

WARNING -Seriouspersonalinjuryorextensivepropertydamagecanresultifthewarning instructionsare not followed.

CAUTION -Minorpersonalinjurycanresultorapart,anassembly,ortheenginecanbedamaged ifthecautioninstructionsare not followed.

Indicatesa REMOVALorDISASSEMBLY step.

Indicatesan INSTALLATIONorASSEMBLY step.

INSPECTION isrequired.

CLEAN thepartorassembly.

PERFORM amechanicalortime MEASUREMENT.

LUBRICATE thepartorassembly.

Indicatesthata WRENCHorTOOLSIZE willbegiven.

TIGHTEN toaspecifictorque.

PERFORM anelectrical MEASUREMENT

Refertoanotherlocationinthismanualoranotherpublicationforadditionalinformation.

SimbolosUsadosEnEsteManual

Lossi´mbolossiguientessonusadosenestemanualparaclarificarelprocesodelasinstrucciones.Cuando apareceunodeestossi´mbolos,susignificadoseespecificaenlaparteinferior.

ADVERTENCIA -Seriosdan˜ospersonalesodan˜oalapropiedadpuederesultarsilasinstrucciones deAdvertencia no seconsideran.

PRECAUCION -Dan˜osmenorespuedenresultar,odepiezasdelconjuntooelmotorpuede averiarsesilasinstruccionesdePrecaucio´n no sesiguen.

Indicaunpasode REMOCION o DESMONTAJE.

Indicaunpasode INSTALACION o MONTAJE.

Serequiere INSPECCION.

LIMPIESE lapiezaoelmontaje.

EJECUTESE una MEDICION meca´nicaodeltiempo.

LUBRIQUESE lapiezaoelmontaje.

Indicaquesedara´una LLAVEDETUERCAS oel TAMANODEHERRAMIENTA.

APRIETESE hastaunpartorsorespeci´fico.

EJECUTESE una MEDICION ele´ctrica.

Parainformacio´nadicionalrefie´raseaotroemplazamientodeestemanualoaotrapublicacio´n anterior.

Symbole

IndiesemHandbuchwerdendiefolgendenSymboleverwendet,diewesentlicheFunktionenhervorheben.Die SymbolehabenfolgendeBedeutung:

WARNUNG -WirddieWarnung nicht beachtet,dannbestehterho¨hteUnfall-und Bescha¨digungsgefahr.

VORSICHT -WerdendieVorsichtsmassnahmen nicht beachtet,dannbestehtUnfall-und Bescha¨digungsgefahr.

AUSBAU bzw. ZERLEGEN.

EINBAU bzw. ZUSAMMENBAU.

INSPEKTION erforderlich.

TeiloderBaugruppe REINIGEN.

DIMENSION -oder ZEITMESSUNG.

TeiloderBaugruppe OLEN.

WERKZEUGGRO } SSE wirdangegeben.

ANZUG aufvorgeschriebenesDrehmomenterforderlich.

Elektrische MESSUNGDURCHFU } HREN.

WeitereInformationenanandererStellebzw.inanderenHandbu¨chern.

SymbolesUtilisesDansCeManuel

Lessymbolessuivantssontutilise´sdanscemanuelpouraidera`communiquerlebutdesinstructions.Quandl’un decessymbolesapparaiˆt,ile´voquelesensde´finici-dessous:

AVERTISSEMENT -Degravesle´sionscorporellesoudesdommagesmate´rielsconside´rables peuventsurvenirsilesinstructionsdonne´essouslesrubriques ″Avertissement″ ne sont pas suivies.

ATTENTION -Depetitesle´sionscorporellespeuventsurvenir,oubienunepie`ce,unensemble oulemoteurpeuventeˆtreendommage´ssilesinstructionsdonne´essouslesrubriques ″Attention″ ne sont pas suivies.

se´curite´p

Indiqueuneope´rationde DEPOSE.

Indiqueuneope´rationde MONTAGE.

L’INSPECTION estne´cessaire.

NETTOYER lapie`ceoul’ensemble.

EFFECTUER une MESURE me´caniqueoudetemps.

GRAISSER lapie`ceoul’ensemble.

Indiquequ’une DIMENSIONDECLE ou D’OUTIL seradonne´e.

SERRER a`uncouplespe´cifique.

EFFECTUER une MESURE e´lectrique.

Sereportera`unautreendroitdanscemanueloua`uneautrepublicationpourobtenirdes informationspluscomple`tes.

DefinitionofTerms

Thefollowingisalistofguidelinesforeachprocedureinthe ″RepairSections″ oftheTroubleshootingandRepair Manual.Theprocedurewillbegivenfirst,followedbyadefinitionofthesteporstepsinvolved.

Check -Examineacomponentorsystemfordamage,excessivewear,accuracy,safety,orperformance.

Inspect -Examineacomponentordimensiontomakesureitmeetstherequiredspecifications.

Test -Checkorcomparetheperformanceofacomponentorsystemtoestablishedspecifications.

Adjust -Completethenecessarystepstosetoradjustthecomponent,assemblies,orsystemintherequired settingorposition.

VisuallyInspect -Lookforanyobviousdamageorproblem.

Remove -Takeoffacomponentorassembly.

Clean -Removedirt,grease,orothercontamination.

Disassemble -Takeapartthecomponentorassembly.

Repair -Restoreacomponentorassemblytoaserviceableconditionwithintheestablishedspecifications.

NOTE: Onlytheeasiestandsimplestrepairswillbemadetoacomponentorassembly.Ifacomponentorassembly must berebuilt,it must bereplacedwithaneworCumminsDieselReCon ,Inc.replacementorberebuiltataCummins authorizedrepairlocation.

Replace -Installanew,correctlyrebuilt,orCumminsDieselReCon ,Inc.componentorassemblyinplaceof theonewhichisremoved.

Install -Placeacomponentorassemblyinthecorrectposition.

StarPatternTorqueSequence -

GeneralRepairInstructions

TheNT855engineincorporatesthelatestdieseltechnology;yet,itisdesignedtoberepairedusingnormalrepair practicesperformedtoqualitystandards.

Warning:CumminsEngineCompany,Inc.doesnotrecommend/authorizeanymodificationsorrepairs toenginesorcomponentsexceptforthosedetailedinCumminsServiceInformation.Inparticular, unauthorizedrepairtosafety-relatedcomponentscancausepersonalinjury.Belowisapartiallistingof componentsclassifiedassafety-related:

AirCompressor

AirControls

AirShutoffAssemblies

BalanceWeights CoolingFan

FanHubAssembly

FanMountingBracket(s)

FanMountingCapscrews

FanHubSpindle Flywheel

FlywheelCrankshaftAdapter

FlywheelMountingCapscrews

FuelShutoffAssemblies

FuelSupplyTubes

LiftingBrackets

ThrottleControls

TurbochargerCompressorCasing

TurbochargerOilDrainLine(s)

TurbochargerOilSupplyLine(s)

TurbochargerTurbineCasing

VibrationDamperMountingCapscrews

• FollowAllSafetyInstructionsNotedintheProcedures.

-Followthemanufacturer’srecommendationsforcleaningsolventsandothersubstancesusedduringthe repairoftheengine. Always usegoodsafetypracticeswithtoolsandequipment.

• ProvideACleanEnvironmentandFollowtheCleaningInstructionsSpecifiedintheProcedures

-Theengineanditscomponents must bekeptcleanduringanyrepair.Contaminationoftheengineand componentswillcauseprematurewear.

• PerformtheInspectionsSpecifiedintheProcedures.

• ReplaceallComponentsorAssembliesWhichareDamagedorWornBeyondtheSpecifications

• UseGenuineCumminsNeworReCon ServicePartsandAssemblies

-Theassemblyinstructionshavebeenwrittentouseagainasmanycomponentsandassembliesas possible.Whenitisnecessarytoreplaceacomponentorassembly,theprocedureisbasedontheuse ofnewCumminsorCumminsReCon components.Alloftherepairservicesdescribedinthismanual areavailablefromallCumminsDistributorsandmostDealerlocations.

• FollowTheSpecifiedDisassemblyandAssemblyProcedurestoAvoidDamagetotheComponents.

CompleterebuildinstructionsareavailableintheNT855EngineShopManual,whichcanbeorderedorpurchased fromaCumminsauthorizedrepairlocation.Refertopage1intheAdditionalServiceLiteratureSectionforordering instructions.

GeneralCleaningInstructions

SolventandAcidCleaning

Severalsolventandacid-typecleanerscanbeusedtocleantheengineparts. CumminsEngineCompany, Inc.doesnotrecommendanyspecificcleaners.Always followthecleanermanufacturer’sinstructions. Experiencehasshownthatthebestresultscanbeobtainedusingacleanerthatcanbeheatedto90to 95degreesCelsius[180to200degreesFahrenheit].Acleaningtankthatprovidesaconstantmixingand filteringofthecleaningsolutionwillgivethebestresults.

Removeallthegasketmaterial,O-rings,andthedepositsofsludge,carbon,etc.,withawirebrushor scraperbeforeputtingthepartsinacleaningtank.Becareful not todamageanygasketsurfaces.When possible,steamcleanthepartsbeforeputtingtheminthecleaningtank.

Warning:Theuseofacidcanbeextremelydangeroustopersonnelandcandamagethemachinery. Alwaysprovideatankofstrongsodawaterasaneutralizingagent.

Rinseallofthepartsinhotwateraftercleaning.Drycompletelywithcompressedair.Blowtherinsewaterfrom allofthecapscrewholesandtheoildrillings.

Ifthepartsare not tobeusedimmediatelyaftercleaning,diptheminasuitablerustproofingcompound.The rustproofingcompound must beremovedfromthepartsbeforeinstallationontheengine.

SteamCleaning

Steamcleaningcanbeusedtoremovealltypesofdirtthatcancontaminatethecleaningtank.Itisagood waytocleantheoildrillings.

Warning:Wearprotectiveclothingtopreventpersonalinjuryfromthehighpressureandextremeheat. Do not steamcleanthefollowingparts:

GlassorPlasticBeadCleaning

Glassorplasticbeadcleaningcanbeusedonmanyenginecomponentstoremovecarbondeposits.The cleaningprocessiscontrolledbythesizeoftheglassorplasticbeads,theoperatingpressure,andthe cleaningtime.

Caution:Donotuseglassorplasticbeadcleaningonaluminumpistonskirtsorringgrooves.Small particlesofglassorplasticwillembedinthealuminumandresultinprematurewear.Valves,turbocharger shafts,etc.,canalsobedamaged.Followthecleaningdirectionslistedintheprocedures.

Followtheequipmentmanufacturer’scleaninginstructions.Thefollowingguidelinescanbeusedtoadaptto themanufacturer’sinstructions:

1.Beadsize:UseU.S.sizeNo.70forpistondomes.

UseU.S.sizeNo.60forgeneralpurposecleaning.

2.OperatingPressure:Use620kPa[90psi]forgeneralpurposecleaning. 3.Steamcleanorwashthepartswithsolventtoremovealloftheforeignmaterialandglassorplastic beadsaftercleaning.Rinsewithhotwater.Drywithcompressedair. 4.Do not contaminatethewashtankswithglassorplasticbeads.

EngineIdentification

Themodelnameprovidesthefollowingenginedata:

N T C 400

N T C C 400

=MaximumRatedHorsepower

=CustomRated

=Turbocharged =FourValveHead

=MaximumRatedHorsepower =CaliforniaCertified =CustomRated =Turbocharged =FourValveHead

EngineDataplate

Theenginedataplateshowsspecificinformationabout yourengine.Theengineserialnumber(1)andtheControlPartsList(CPL)(2)provideinformationforordering partsandserviceneeds.

Always recordtheserialnumber(1)oftheengine,the CPL(ControlPartsList)number(2),andtheenginemodel number(3)onallordersforparts.Thisinformationis importantforfuelpumpcalibrationandcorrectidentificationofparts.

NOTE: Theenginedataplate mustnot bechangedunless approvedbyCumminsEngineCompany,Inc.

FuelPumpDataplate(Nameplate)

Thefuelpumpdataplateislocatedonthetopofthefuel pump.Itprovidesinformationforfuelpumpcalibration.

EngineSpecifications

GeneralEngineData

Horsepower......................................................................................179kw(240BHP)to354kw(475BHP) EngineSpeed@MaximumOutput

StandardRating(RPM)......................................................................................................................2100

FormulaRating(RPM)........................................................................................................................1800

BoreandStroke.....................................................................................140mm[5.5in.]X152mm[6.0in.] Displacement..............................................................................................................14.0liters[855cu.in.]

CompressionRatio................................................................................................................13.5:1to17.2:1

FiringOrder...................................................................................................................................1-5-3-6-2-4

EngineWeight(WithStandardAccessories)

DryWeight....................................................................................1126kg[2480lb.]to1221kg[2690lb.] WetWeight...................................................................................1180kg[2600lb.]to1276kg[2810lb.]

AirInductionSystem

Maximumallowableturbochargedintakerestriction..................................................64cmH2O[25in.H2O]

MaximumallowablenaturallyaspiratedandFleet270intakerestriction....................51cmH2O[20in.H2O]

LubricationSystem

Oilpressureatidle(minimumallowable).................................................................70kPa[10psi]minimum Atnoloadgovernedspeed.......................................................................................240-310kPa[35-45psi]

Oilcapacityofstandardengine: Bypassfilter.........................................................................................................2.8liters[0.75U.S.gal.] Fullflowfilter.......................................................................................................3.5liters[0.93U.S.gal.] Combofilter.........................................................................................................3.9liters[1.04U.S.gal.]

Oilpancapacity(high-low)............................................................................36-28liters[9.5-7.5U.S.gal.]

Totalsystemcapacityincludingfilters.......................................................................42liters[11.0U.S.gal.]

EngineSpecifications(Cont’d.)

CoolingSystem

Coolantcapacity(engineonly).................................................................................21liters[22U.S.quarts]

Standardmodulatingthermostatrange

Conventionalaftercooling..........................................................................................82-93°C[180-200°F]

Optimizedaftercooling...............................................................................................79-91°C[175-195°F]

Maximumcoolantcylinderblockpressure(pressurecapremoved).......................................350kPa[50psi]

Maximumallowableoperatingtemperature.............................................................................100°C[212°F]

MaximumallowableoperatingtemperatureforNTC-444.........................................................104°C[220°F]

Minimumrecommendedoperatingtemperature........................................................................70°C[158°F]

Minimumrecommendedpressurecap......................................................................................50kPa[7psi]

ExhaustSystem

Maximumallowablebackpressureimposedbypipingandsilencer.......................1000mmH20[40in.H20]

Maximumbendingmovementtoturbochargerflange...........................................................27N•m[20ft-lb]

Exhaustpipesize(normallyacceptableinsidediameter except NTC475)..............................127mm[5in.]

NTC475..............................................................................................................................152mm[6in.]

FuelSystem

Maximumallowablerestrictiontopump:

Withcleanfilter........................................................................................................100mmHg[4in.Hg]

Withdirtyfilter..........................................................................................................200mmHg[8in.Hg]

Maximumallowablefuelreturnlinerestriction

Withoutcheckvalves..............................................................................................64mmHg[2.5in.Hg] Withcheckvalvesand/oroverheadtanks..............................................................165mmHg[6.5in.Hg]

Minimumfueltankventcapability...................................................................................0.85m3/h[30ft3/hr]

Komatsu Engine Nt 855c Workshop Manuals 1

Full download: http://manualplace.com/download/komatsu-engine-nt-855c-workshop-manuals-1/

SectionT-Troubleshooting

ProceduresandTechniques

Athoroughanalysisofthecustomer’scomplaintisthekeytosuccessfultroubleshooting.Themoreinformation knownaboutacomplaint,thefasterandeasiertheproblemcanbesolved.

The ″TroubleshootingSymptomsCharts″ beginningonpage3areorganizedsothataproblemcanbelocated andcorrectedbydoingtheeasiestandmostlogicalthingsfirst.Completeallstepsinthesequenceshownfrom toptobottom.

Itis not possibletoincludeallthesolutionstoproblemsthatcanoccur;however,thesechartsshouldstimulate athoughtprocessthatwillleadtothecauseandcorrectionoftheproblem.

Followthesebasictroubleshootingsteps:

•Getallthefactsconcerningthecomplaint.

•Analyzetheproblemthoroughly.

•Relatethesymptomstothebasicenginesystemsandcomponents.

•Consideranyrecentmaintenanceorrepairactionthatmayrelatetotheproblem.

•Double-checkbeforebeginninganydisassembly.

•Solvetheproblembyusingthelogicchartsanddoingtheeasiestthingsfirst.

•UseCompuchek whereapplicabletodiagnoseaproblem.

•Determinethecauseoftheproblemandmakeathoroughrepair.

•Afterrepairshavebeenmade,operatetheenginetomakesurethecauseoftheproblemhasbeen corrected.