SEBE6710A03 SIOW IM TA INTOAN Ls KOMATSU-CUMMINS N-$55 series DIESEL ENGINE ENGINE MODEL APPLICABLE MACHINE N-855-C PC300-1 PC300-2 PC300LC-1 PC300LC-2 NT-855-C D80A,E-18 D85A,E,P-18 D80F-18 D95S-2 PC400-1 PC400LC-1 W170-2 W180-1 NTA-855-C HD320-2 HD320-3 WS16S-2 WS23-1 Printed in Japan 09-84(01)1043101 11 12 13 14 15 19 00-2 @ CONTENTS GENERAL STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD REPAIR AND REPLACEMENT OTHERS No.of page 01-001 11-001 12-001 13-001 14-001 15-001 19-001 N8SS SERIESLIST OF REVISED PAGES The affected pages are indicated by the use of the following marks. It is requested that necessary actions be Mark Indication ‘Action required taken to these pages according to the table below. | Page to be newly added Add @ | Page to be replaced Replace (}] Page to be deleted Discard Pages having no marks a made additions. those previously revised or LIST OF REVISED PAGES wre Pome Tanest| wo re Tot] mak eon Timect | mark rape Tings [wae rae in oi @)s om @ le cm @ |e nos @|o ume @ Soe @| > war @ fe orm @ | 107 @ | o 108 © eT, ————_——_———_=_==E=_==_E Beer glo Se oleae 6 (sols im 6 ee ose gle ose) oo @ Pee gloss slo as olin ol ie o 0 Os = @ 2 01028 = @ |o 012 @ |o 11082 @ 00- 5 @® © (01-029 @ ° -013 @ fo 11-043, @ © 00-6 @ 01-001 @ @ 01-030 @ co (11-014 @ oO 11-044 @ © 00-7 @ 01-003 @ @ 01-031 @ 11-015 @ 11-045, @ so 8 oO 01-008 @ (01-031-1) o 1016 «@ 11.068 @ 9 08 @® 01-005, 01-032 @ co 11-017 @® o 11-047 @ [ee 6 ae rr rsrs=—=sésCQ¥CC Cor ote a | ser |e oe 6 |e a 6 cco = | ore @ | roa | o m0 @ |o 1080 © _—_—--_—===["===--=___ eetss:~—«s:«=i‘ésésSOCS [eso |e can | —rs—SC”sésECZ’ Pee Go|. oleae oO): 6]. eo Bee Glos glo an o|o ee 6): a 6 Se Glos elo as ol) acs 61: ie 6 | _—_—_-__E___ S20 «@ |e oro @|o orn @|o m0 @ fo m0 @ 5 Si6c 6 3 ¢|o a o fee oe soe o| on ol ae 6 |e 6 Soe Go |o soe Glo um o| 4 6 |. ie o ee, ——C=E™"’ Cea gona ol eee | S| eo Noss sentes &LIST OF REVISED PAGES vee row TET en rae Tenet] wan roe sat eae Fens] mam rae Tet o 11-066 @ (21) (11-503) © 12023 @ | o 12068 @ See | ee a Se oi eS Sao] ase ee Sa oo Soe oS) tae fc coe ol ae al ae ee Se ol ae 6 ° 11.07% @ (11.216) (11-508) eo 120% =@ |o 1200 © oe S| ace oa (gee a | eG [op aes ae [a ol eG Se | foe cn [aso co (11-078 @ (11-308) (11-601) © 12-035 @ @ 13-001 @ Se ae a a ol es aa ao | mas oe 6) as Cie 6 | aan Sc os Ste | ae foe |e ee 11083 @ (rsa © 12003 @ 12.040 = @ 13.008 Se S| ce ee le eo) en oe Gg se Go| eee Seo) fe eee ee | ea (11-101) (11-403) (12-007) 12-045, @ 13-012 (11-102) (11-404) (12-007-1) 12.086 @® 13-013, a oe eee | ee | ee ie oe |e |e ol cas (11-108) (11-410) @ 12-012 @ oO 12-063 @ 13-019 (11.201) 1-411) © 12-013 ® 12-084 @ 13-020 (11-202) (11-412) © (12-014 @ 12-085, @® 13-021 (11-203) (11-412-1) © 12-015 @ 12-056 @ 13-022, (i200 fe ee |e eee | ae a eg eee | aes a ee i ee | ee a ees ge a | ee a 00-2-2 ®LIST OF REVISED PAGES ark Pane THEFT mark oa Tet ark wage Tim ot| ark page Time] hark page meat * 4001 «@ 15010 @ «14003 @ wor @ 14008 @ wor 2 405 @|o 02 @ © 14008 @ | o 104 @ 2 4007 @|o 1505 @ o 14008 @ 1018 @ © 14000 @ 15017 @ 2 wow @|o 0% @ 2 wor @|o 09 © 2 wor @| 0 1502 @ 2 uo @|o 507 © o] + wou @|]o 102 @ 2 uo @| 0 1802 @ e wow @|o 10% @ 2 uo @|o 102 © 2 woe @|o 108 @ «uo @ | o 15027 @ 2 020 =@ | o 102% @ 2 14021 @ © 14022 @ o 40 @ fe 201 @ © 402 =@ | — 19.009 (14.0281 19.008 14.026 198-008 v4o2n 19.008 (n4-020 14.029 scan v4.02 o 1600 @ o 16.003 @ o 16-008 @ o 15.005 @ o 15-00 @ 15.007 @ 15.008 =@ 15.008 @ NBS SERIES 8 ° - &A\ IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols /f\ and cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. are used to mark safety pre- A\ SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1.Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. « Always wear safety glasses when hitting parts with a hammer. «Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them, 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and {lock the wheels or tracks to prevent the machine from moving, 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11, When removing the oil filler cap, drain plug ‘or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. ‘Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hi ting any other part. Do not work with any Part still raised by the hoist or crane. 15.When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fires, 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘© When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the trackFOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of ‘components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting, TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE ications contained in this shop manual are subject to change at any Contact your KOMATSU distributor for the The spe time and without any advance noti latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as 2 guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models, Electrical volume Attachments volume These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page umber. Example 1 (Chassis volume) 21-3 Unit number (2. Power train) Item number (1. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12-410 Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No, (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen () and number after the page number. File asin the example. Example: 21-4 12-203 21-4-1 12-203-1 21-4-2-}— Added peses—[_ 12.7032 21-5 12.204 00-6 REVISED EDITION MARK (O@@-~) When @ manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical Use, important places for safety and quality are marked with the following symbols. Symbol | em Remarks Special sofety precautions ore a ecessory when performing ihe - Safety Extra special safety precautions, are necessary when performing ‘the work because itis under internal pressure, ‘Special technical precautions or other precautions for | Caution | preserving standards are necessary when performing the work. Weight of parts or systems, Caution necessary when Weight | selecting hoisting wire, or when working posture is important, ete. Places that require special ng torque torque during assembly. Places to be coated with Coat | adhesives and lubricants etc. Places where oll, water or fuel il, water | must be added, and the [capacity os Gm | Tighten: | attention for the tightening ™ Places where oll or water must Drain | be drained, and quantity to be drained.HOW TO READ THE SHOP MANUAL NETWORK (Disassembly and assembly rela- tionship drawings) In the shop manual the following network draw- ings show relationship between work items and se- quence for assembly and disassembly. : 2 7 a 8 : : > as'y E Fas'y 80001 In this network the sequence of disassembly is ‘marked on the top right of each work item so that handling can be easily understood. For example, when taking D of the Ass'y follow the sequence A — BD, when removing E follow the sequence A —E. [reir Joints» further spate danse biy and indicates the existence of a previous work network For assembly the sequence is shown using the same kind of network TROUBLESHOOTING CHART ‘As shown below, the symptoms relating to a par- ticular trouble are described in the line designated “Problems”. The probable cause of the trouble is then marked under the “Causes” column, MAINTENANCE STANDARD Standard size, Tolerance The dimensions of finished parts each differ @ litle. Therefore, whon determining the finshed dimensions of parts, a dimension that will be stan- dard is determined provisionally, then the difference ‘allowed from itis indicated. The former is called the standard size, and the latter the tolerance. The way to show this is by a plus of a minus sign with the tolerance in smaller numerals to the right of the standard size. Example: 12079928 (itequals 119.874 — 119.978 mm) Moreover, when expressing the dimensions of a hole and the shaft that goes inside it, for the sake of convenience, the standard size for the hole and the shaft are usually taken as the same, and the toler- ances changed to indicate the tightness of the fit. For example, the fit of @ revolving shaft is indicated as follows, and is shown in the drawing, Shaft: 6079030 Hole: 60+9048 oo90 Example Symptom: Reduced tractive power or slow travel speed cous EB ila aE iit i Problems 2 lmaamngere = [elo Tenteaie=sisem meni || 30002 00-7HOW TO READ THE SHOP MANUAL Standard size This is the standard value at the time of design. This is the limit in dimensions which the part can be used. When parts exceed the repair limit, they ‘must be repaired or replaced as specified Example’ Unit: mm Ne. ‘Check tem ‘riteria Remedy Standard size Standard clearance This is the clearance between new parts after assembly. It is recorded as a range between minimum clearance and maximum clearance. The clearance is adjusted to this value. Clearance limit This is the maximum clearance allowed. When the clearance exceeds the clearance limit, the parts must be repaired or replaced as specified Example: Unit: mm No] Check item riteria Remedy Standaral__ Tolerance | standaral Clearance] Shen) wow feleorancel im 00-8PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 1. PREPARATIONS BEFORE DISASSEMBLY 1, Washing before taking a machine into the repair shop Thoroughly wash the machine to remove sand, mud and dust before taking it into the shop. Taking a dirty machine into the shop will decrease work efficiency, cause damage to parts, and in- crease the intrusion of dust and dirt into the ma- chine when itis reassembled. 2. Checking the machine before disassembly Before disassembly, study the entire disassembly procedure from beginning to end in the reference materials, and carefully check and record the items listed below. This will help to save unneces- sary disassembly and parts costs. It will also give clues on how to prevent recurrence of the trouble. ¢ Machine model, serial number and service ‘meter reading, ‘© Reason for disassembly. (Symptoms, locations, and cause of trouble) Any dirty air cleaner elements or air leakage. Properties of fuel used, clogging of fuel filter ‘elements, water mixed in fuel, and leaky or con- stricted fuel pipes. © Oil capacities, dirtiness of oils (viscosity, color, ‘and any impurities), water mixed in oil, oll eak- ‘age, and any clogging of oil filter elements. ‘Tension of the V-belt and tracks. Any damaged parts or loose bolts. 3. Preparation for disassembly Prepare the required facilities, tools, and space for the disassembly work and rack space for storing the disassembled parts. Make sure that they are all clean. 2. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 1. During disassembly 1) If the disassembly involves draining oil or lubricants, have containers of suitable capacity ‘on hand. Do not spill any oil or lubricants on the floor. 2) Mark the parts clearly to prevent confusion at the time of reassembly 3) For disassembly of certain designated parts, use only the special tool prescribed for that purpose. 4) When, after removal of fastening nuts and bolts, a part still can not be removed, never force it. Instead, investigate and correct the cause. 5) Maintain disassembled parts in good order for storage, paying special care not to confuse parts that appear similar. Tag them or mark with ink if necessary, 6) Store standard parts such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. 2. During reassembly 1) Thoroughly clean and examine all parts before reassembly. Repair any scratched or dented surfaces. ‘ Foreign matter is especially damaging to slid- ing surfaces, and will greatly decrease their service life. 2) Clean new parts to remove any rust preventa- tive coating, Solvent: Light oil or trichloroethane 3) Carefully align any match marks provided. 4) Use a press or press-fitting tool to assemble bearings, bushings and oil seals. 3. Checks and inspections during disassem- biy/reassembly 1) During disassembly, watch corefully for evi- dence of seizing, interference, or improper con- tact of sliding parts. 2)Measure and record end clearances, goar backlashes, protrusions, and the like during the disassembiy/reassembly. Quite often they cannot be measured afterwards.PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 3. DETERGENTS 1. Precautions for cleaning 1) Thoroughly clean disassembled parts and ‘group them by unit for storage. Be especially sure to remove sludge from oil holes and pipes. 2) Never use dirty solvents to clean important parts. 3) Take extreme care with special chemical agents. Observe the manufacturer's handling instructions and take measures to prevent the agent from coming into contact with your skin or eyes, 2. Selection of detergents Parts Detergents Ordinary parts light ol oF tichloroethane Finely machined parts] Clean kerosene or neutral (Bearings etc) dehydrated ight oi Large castings ‘Alkaline detergent, PHTO — 12 {Cylinder hese, immerse in 50 ~ 70°C detergent cylinder block ete) | for 5 ~ TO minutes. Then einse ‘thoroughly with water) 4.NUTS AND BOLTS Unless otherwise specified in the DISASSEMBLY AND ASSEMBLY, tighten all bolts to a torque of page 00-29. 1) Use bolts having the exact length req the parts they are to join. If too long, the bolt presses against the bottom of the tapped hole; this pressure makes proper tightening impossible. If too short, the bolt lacks the number of threads necessary to hold the parts together. 2) Tighten each nut and bolt to the specified torque. 3) Tighten bolts evenly and in order. fod for Tighten mutually opposing bolts alternately Oo & Tighten from the center outwards and on alternate sie. 3. Detergents for washing rubber parts (O-rings, oil seals etc) SE EES ES Detergents Ser Tacnooetane | Oo] oO | 0 | O reertoowtyan | o | x | x | 0 Gesoine ee lx |G hiner xe lx | x Light Cio] «| ° Steam Ox alo: lo (©: tmrson slowed fora shor two x: Beeget detent tier 00-10 SO00G08 Soe ue ee 4) The Template Method is prescribed for tightening bolts on certain specific parts of the engine. The Template Method obtains good fittings of bolts with their seats and of bearings with their races to ensure uniform overall tightening. The bolts are tightened in stages, then loosened, and then tightened once more. Tighten in ten on opposite sides.PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 5.HANDLING LOCKING DEVICES Nuts and bolts which cannot be checked visually from the outside or which are located in vital areas must be firmly locked into position with wires, cotter pins, and lock washers. Never reuse these locking devices. 1. Lock wire Bolt loosening direction y 7 The tension in the FP Wire'shoud oppose \_-—This wire serves b the bolt's tendency 4 ‘no useful purpose. 2. Cotter pin Match the holes Inthebott and nut while tightening eee Band the pins Crm, & & Conoet wrong 50005 Corset weone pe ‘© Bend the head and ends of the cotter pin up- wards as far as possible. [-- S : — 3. Lock washer eee ro Be 7 en (7 (OA sate i 80008 4, Thread tightener 1) Wesh and degrease the bolt and bolt hole with trichloroethylene and dry. Coat the bolt threads with two or three drops of thread tightener and tighten the bolts, 2) After an hour had passed, the bolt cannot be loosened or tightened any further. If retightening becomes necessary, the bolt must be completely removed, the old thread tightener removed, and a new coat applied 6. PRECAUTIONS FOR PRESS-FITTING ‘© Coat the surfaces of the parts to be press-fitted with anti-friction grease (molybdenum disulfide) — unless they are tapered ‘© For taper spline-to-serration fittings 1) Check that the splines and serrations are free from dust, burr, dents and indentations. 2) Insert and align the splines and serrations by hand before press-fitting the shaft into the hole. 3) If the spline-serration assembly is loose, dis- assemble and examine for wear. Replace worn parts with new ones, 00-11PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 7. PRECAUTIONS FOR ASSEMBLING THE 2, Push-puller PIN AND SHAFT When the screw of the push-puller does not reach the surface of the part to be pushed, insert a Before reassembling the pin and shaft, check the spacer. It is also a good idea to insert a plate to positions of the locking device and fastening prevent the head of the screw from damaging the device on the other side. This is especially impor- part. tant when the shaft is retracted from the inside of the hole as illustrated in the accompanying diagram. To ensure proper reassembly, make sure that the lock pin holes coincide. Push-puler Line up the lock pinholes Aen Fs0010 8. SERVICE TOOLS 3. Bearing coup! 1, Gear puller This can be used two ways: Fit the gear puller over the gear or bearing and 1) When the bottom 2) When the bottom tighten the bolt on the gear puller to remove the of the hole is of the hole is not part from the shaft. strong enough to strong enough to withstand the withstand the applied force. applied force. Push-puler ‘Adaptor Bearing couple 50011 50012PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 5. Hook wrench ‘A hook wrench has a claw which hooks into the turning sockets of round nuts. The wrench size is defined by the outer diameter of the round nut tured. The accompanying figure shows @ hook wrench designed for use with round nuts of two different sizes, Bearing separator k Fs0018 Fs001s Removal and installation of the Sprocket Wheel 00-13PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY 9.CLEARANCE ADJUSTMENTS 12, CENTERING Store each set of shims or washers so that they Centering is very important for interfaces in the can be installed in their original condition at the power train — for example, between the engine and the transmission and between the bevel gear shaft and the final drives. Incorrect centering only increases the stresses acting on the turning parts, so always make sure that the deviation is within the specified limit. time of reassembly, Engine 10.LINK RODS 1)If itis necessary to change the length of the link rod in order to remove it, first record the original length so that the rod can be easily reassembled in its original condition. 2) Remove the link rod at the pins. ‘Transmission od i correct f—9 af effet Conect i ——) 11.SHIMS AND WASHERS 1) Shims are used to center the engine and adjust the action of the bevel gears. Handle very carefully as they get deformed easily, 2) Record the numbers and positions to speed adjustment after reinstallation. 3) Do not reuse any shims or washers that are deteriorated, damaged, bent or deformed. 4) Insert thin shims between thicker ones. @ ell Fs0o1eMEASURING INSTRUCTIONS MEASURING INSTRUCTIONS PREPARATIONS BEFORE CHECKING 1. Cleaning of parts ‘Wash parts to be checked. Special care should be paid to thoroughly remove dust and dirt from the ‘surfaces on which measurements are to be made so that possible errors can be eliminated 2. Minor repair of part surfaces Remove scratches, dents and rust from parts to be checked. If the surface are rough, the measure ments will be inaccurate. When smoothing any surface, be careful not to use an oilstone or sand paper coarser than the finished surface. Clean the tools and thoroughly remove dust and dirt from the surfaces which contact parts. Check ‘the tools for proper function and zero-point adjustment. Remedy any abnormality 4. Maintenance of measuring tools Handle all tools with sufficient care and do not subject them to unreasonable force or shocks which can affect their delicate construction. Peri- odically check the tools for accuracy and, if necessary, calibrate them. Put the tools back into their cases and return them to their fixed storage locations whenever not in use. It is recommended to assign a person to be responsible for the proper storage of measuring tools. MEASURING TOOLS ‘© Repeat each measurement two or three times to eliminate possible errors. Further repetition willbe necessary, if there is a large variation in the readings. ‘¢ When measuring the inside or outside diameter of 2 cylindrical object, take two readings with the measuring device put in two directions at right angles to each other. Repeat this at several points along the overall length of the object. «# Along eye-measurement below the unit of a scole may be used for making a comparison between two approximately equal measurements, the accu- racy of such eye-measurements should not be considered as reliable. ‘© At the start of each measurement, select 2 measuring device having an accuracy appropriate for judging whether the measurement reaches its allowable limit BLOCK GAUGES '* To bring two blocks into contact, wash each block with benzene to remove rust-preventing oil and wipe with a clean cotton cloth. Put one block on. the other, causing a sliding or twisting movement between the two. ‘* If the contact between two blocks feels rough, apply a fine-grade oilstone to the blocks along their edges. (Do not try to rub the contact surface of the blocks) ‘* Do not leave the blocks in contact for a long time. Long-time contact will make the blocks difficult to separate or cause black rust to appear on the con- tact surfaces. ‘* When separating two blocks, slide or twist them, Do not try to pull them apart, by force or strike them with a mallet. ‘¢ When storing a block gauge, wipe off moisture, dirt and fingerprints, coat with a rust-preventing lubricant such as vaseline, and put the gauge back inits case. VERNIER CALIPERS ‘© At the start of measurement, close the jaws and ccheck that there is no clearance (due to wear) be- tween the jaws and that the “zero” point of the graduation is in exact alignment with the “zero’ point of the vernier scale. ‘¢ Measuring an outer diameter Corect Wrong, com tS wrong Correct 30019 00-15MEASURING INSTRUCTIONS ‘¢ Measuring an inner diameter wrane Cconect ‘ron comet +020 ‘© Measuring a depth Y u iA = VORA wor Conect fsooat MICROMETERS ‘© Put the anvil onto an object at a right angle and turn in the spindle until it comes into contact with the object. Rotate the ratchet stop until there are two or three idle rotations, then read the ‘measurement. ‘¢ When reading a measurement, keep your eyes at a right angle to the graduation on the sleeve. © To turn back the spindle, rotate the thimble with your fingers. Orer edto Comect Wrong 50022 ‘* When storing a micrometer, leave a slight clear- ance between the anvil and the spindle. 00-16 DIAL GAUGES © Carefully put the gauge contact-point on a surface to be measured to protect the delicate gauge against shock. ‘# Set the zero-point of the gauge with care to keep the movement of the contact-point within its stroke during measurement. '* Careless setting of the zero-point may cause the spindle to retract or extend to its limit, thus ‘making measurement impossible. ‘¢ The measurements of the dial gauge are accompanied by relatively large errors because minute variations of the contact-point (and accompanying errors) are indicated by the dial Pointer through an expanding mechanism using ‘gears. The reliability of eye measurements can not be assured below the minimum unit on the scale. ‘© Measuring protrusions, depressions or steps Set the zero-point so that vertical movement of the probe does not exceed its stroke limits, and slide the base of the gauge on a flat surface. 50023 50024 Read the Total Indicator Reading (TLR) while moving the object back and forth or vertically Turn the object one complete rotation and read the difference between the maximum and ‘minimum indications of the gauge pointer.MEASURING INSTRUCTIONS ‘© Measuring end play, looseness or deviation = 50028 Read the TLR. while moving the object back and forth or vertically, ing face runout or rat 80026 1) Read runout at six or more positions during one ‘complete rotation of the object. 2) At the start of each measurement, set the zero- point at the middle of the assumable range of the spindle movement. Be careful not to con- {fuse positive and negative readings of runout. Face Radial runout | runout ‘When the pointer is = to the right of “0” When the pointer is e = to the left of “0” 3) When measuring face runout, place the contact-point on the object along a circle 2 or 3 mm smaller in diameter than the outside diame- ter of the object. Fs0027 1) Fully mesh one of two gears and place the dial ‘gauge contact-point on a tooth of the other ‘gear. Swing the free gear within the limits of its play in the rotational directions, and read the TAR 2) Use of the lever and fulcrum type dial gauge is recommended for this purpose as the contact- point placed on the gear is moved tangentially to the gear pitch circle. 3) The lever and fulcrum type dial gauge is suitable for use in @ narrow space or for a special measurement which requires placing the ontact-point on an object at an angle to the spindle of the gauge. Since the contact-point of this type of gauge has a very narrow measuring range (usually 3 mm or less), the contact-point should be care- fully checked for contact with the object during measurement, CYLINDER GAUGES '* Install a contact-point having a length approxi- mately equal to the cylinder bore to the measured. fon the cylinder gauge. Set the zero-point of the test indicator to the bore diameter of the standard cylinder measured with a reference ring gauge or ‘a micrometer. “Tost ingicator Contact-point Measuring point 50028 00-17PARTS CHECKING INSTRUCTIONS ‘# Insert the gauge into the bore to be measured and read the minimum indication of the test indicator while giving swings to the gauge about the tip of the detachable rod used as the fulcrum. ¢ When the minimum reading is obtained on the Fight side of the zero point of the test indicator, and the reading to the standard value to which the zero point is set When the minimum reading is obtained on the left side of the zero point, subtract the reading from the standard value. PARTS CHECKING INSTRUCTIONS ‘© Check disassembled parts to see if they are reusa- ble or need repair. I the part failed due to an exter- nal source, determine the cause and correct before assembly. 1.GENERAL PRECAUTIONS + Visually inspect parts for cracks, pitting, cor- rosion, scoring, ridging ete. To ensure proper inspection, every part should be clean before inspection «I the cause of the defect can be found, it willbe a great help to analyze the part condition; whether the defect will progress or not. and the possibilty of future trouble Knowing the cause of the defect, the service man can give good advice to the customer to prevent him from having the same trouble again ‘+ Visual inspection can not find minute or hidden damage. Other methods of inspection are as follows: a) Water-pressure or sr-pressure test ) Color check or magnetic damage test 2. CRACKS If the part is found to be cracked by visual inspection, it should be replaced or repaired. ‘¢ If the length or depth of crack exceeds 1/3 of the thickness of the part, it should be replaced instead of rep: ‘¢ Apart having an internal crack should be replaced. 00-18 3. PITTING 1) Pitting by cavitation In most cases, cavitation is accompanied by chemical corrosion. After removing rust or scale, carefully inspect the depth of pitting, © When the pitting can not be repaired within the allowable limit, replace the part. «@ If pitting is not deep, resurface the part after removing the rust and scale. 2) Pitting due to removal of surface « if ball bearing is pitted, replace it. @ If more than 1/3 of the contact face is pitted, the part should be replaced. ‘# If pitting is not serious, resurface the part.PARTS HANDLING PARTS HANDLING 1.01L SEALS A rection Be careful to install the oil seal with its lips facing in the proper direction, as shown in the figure below. Oil pressure side Main is Busttip 50029 2. Inspection prior to installation 1) Keep the oil seals free from dust, rust and scratches. Take special care to prevent rust or scratches on the lips. 21 To check the oil seal lip for smoothness, gently slide 8 wire across its surface. If the wire catches, replace the oil seal with a new one, ‘* Make sure that the wire used for this test does not scratch the lip surface. 3} Do not use the oil seal on a shaft where it ‘would come into contact with rust or scratches on the shaft surface. 4) When removing the oil seal, take care not to damage the housing or shaft surfaces. 3. Installing the oil seal 1) Coat the surface to which the oil seal is to be applied with a lubricant or grease. + If the lip should double over as the oil seal is being fitted over the shaft, return it to its proper place by rotating the shaft and pulling the oil seal sightly backwards. 2) When installing an oil seal on a shaft machined with a keyway, splines, or threads, use a suitable jg to protect the lip. Lp protection jig 3) Use a suitable press to press fit the cil seal into the housing. ‘© When installing the oil seal flush with the housing surface .. it seat nominal outside 4 diameter 415 ~ 10lmm Press ig 80031 © When installing the oil seal inside the housing Oil seat nominal ouside diameter al nominal outside diameter + (0.5 — 1.0)mm = (05 — 101mm st 011 seat nominal outside diameter 05 ~ 10lmm 80022 Fs0023 4) After press-fitting the oil seal, check that it has. not been installed at an angle to the housing ‘Max. permissible oi eal slant H,— Hy/2-= 11400 50034 00-19PARTS HANDLING ‘4. Applying grease to the lips Before installing an oil seal, coat it with grease according to the following procedure to prevent friction from burning the seal surfaces while the ‘machine is being started, 1) Single-lp oil seal Place a flat, uniform coating of grease on the surface away from the sealing surface. ‘Grease 50038 2) Double-tip oil seal Coat the entire surface between the two lips with grease in the manner shown in the accom- panying figures. Fs0036 5. Applying adhesives ‘Take special care when applying adhesives. to the outer surface of oil seals. Adhesive on the surface Of the lip or shaft leads to oil leakage. + Since any adhesives on the surface of the press jig will soon transfer to the oil seal lips, clean the jig before use. 00-20 2. FLOATING SEALS 1, Handling floating seals 1) Keep each pair of floating seals bundled together with tape to avoid mix-ups when they are reinstalled. 2) Discard the old O-rings. Always use new ones when installing the floating seals. 3) Replace a floating seal if its contact surface rusted installing floating seals 1) Remove all rust and dust from the mounting surfaces of the seal, Use sandpaper to remove any rust that might come into contact with the O-ring. 2) When installing the floating seal, coat the ‘mounting surfaces with oil, Then install the O-ring, taking care not to twist it + Do not coat the O-ring with oil ‘* The floating seal has been correctly installed if the seal ring rotates. 3) After installing the O-ring and seal rings in both housings, mate the two together. > \ | Housing Seating 50097 4) An installer is recommended for inserting the O-rings. + Using a screwdriver or other pointed object risks scarring the O-ring 5) Attempting to mote the two housings together without the O-rings and seal rings in place can damage the O-rings and lead to oil leakage. o-ing \ / Housing Seal eng 50098PARTS HANDLING 3.0-RINGS 1. Handling 1) Discard any O-ring that has been in storage too Jong or has hardened. 2) Use only the O-rings prescribed for the part in the PARTS BOOK. This is especially important for those rings used with high-temperature engine parts, where heat-resistant and durable materials such as silicon are required. 3) ALWAYS USE NEW O-RINGS. 2. O-ring types KOMATSU O-rings are marked with colored dots {as shown in the accompanying chart. Maring | PartNumber] —Mateiat | Application For One ue spot | 07000-0 | Ndersober | assum Two biue spots | 07000-1 | Nite rubber | FOF high-pressure For ‘One green spot | 07000-3.~| Furie rubber] TO srg Two ts] 07000-2-.|Fuorine eubber| FO" bed edeats ber] igh-pressure For One red spot | 0700-4. Nite uber | low-pressure in cola weather For Twored spots | 07000-5.-|Nitnlerubber | high-pressure in cola weather For Orange spot | 07000-6.|sticonrubber | low-pressure inhot weather 3. Inserting O-rings After coating the O-ring with oil, insert carefully 50 as not to damage it. Silicon rubber O-rings require special care since they tear easily. 4. GASKETS 1. Handling gaskets 1) Always replace packings, gaskets and copper packings with new ones, 2) Make sure that there are no scratches or burrs, (on the contact surfaces of the gasket. 2. Installing gaskets 1) Make sure that the holes in the gasket match those in the mating part. 2) Apply gasket sealant to the joints so specified in the SHOP MANUAL. 3. Precautions for using liquid gasket 1) Remove all scratches, dirt, paint, grease and old ‘gasket sealant before applying a new coat. 2) Coat the specified area evenly and let dry for several minutes. 3) Assemble the mating parts when the gasket sealant is stickly to the touch. 5. BEARINGS. 1, Handling bearings 1) Shield the bearings from dust and dirt; even the tiniest speck rapidly accelerates wear. + Leave the bearings in their protective Packaging until just before they are to be installed. 2) Protect a bearing from excessive force and shocks. * Never dry 2 bearing with compressed air after cleaning, 1) Never drive a bearing onto a shaft by pounding fon the outer race or into an opening by pounding on the inner race. Such pounding produces dents in the tracks in the races. 2) When a bearing must be fitted onto a shaft with some interference, press-fit the inner race with the jig shown in the accompanying figure. Jia Press it Fs0029 00-21PARTS HANDLING 3)If the shaft of opening has considerable inter- ference, heat the bearing before installing. + Donot heat above 120°C. 4) When a non-separable bearing must be fitted with interference for both races, press-fit with ‘the jig shown in the accompanying figure. ie a CaS SONG Press ft 80040 5) Thoroughly coat the bearing with oil before installing 6) Install the bearing, spacer or washer with its chamfered surface facing the step on the shaft. comet Wrong Fs0041 00-22 6. PRESS FITTING BUSHINGS Do not drive in a bushing directly with a hammer. Use a press so that pressure is uniform over the entire circumference. 1) If no press is available, hammer in the bushing using a driving tool so that the force is distributed evenly. 80082 2) If the bushing has an oil hole, bring the hole into exact alignment with the oil hole in the housing, Rear face of Bushing SYindorbigek Oilhole Toinjocton pumo Oithole Ina single pine & 50083 3) When a bushing has been removed, remove all burrs and foreign matter from the mounting hole, and then clean, 7. REMOVING SNAP RINGS 1) Use snap ring pliers to remove or install snap rings. Do not overexpand them especially the smaller ones. 2) After installing, check to make sure that the snap ring is firmly in place within its groove.PARTS HANDLING 8. HYDRAULIC PIPING AN Precautions for servicing the work equip- ment hydraulic system 1) Lower the work equipment to the ground and turn off the engine. 2) Loosen the oil filler cap to relieve pressure in the hydraulic ol tank 3) Operate the control levers 2 or 3 times to eliminate hydraulic pressure remaining in the Piping to be disassembled 4) Support the work equipment on a stand to Prevent it from falling when the piping is removed and the hydraulic pressure is released. 1, Removing the hydraulic piping 1) Disconnect hydraulic tubes from hoses or other tubes by holding the nut on the spigot (the male side of the joint) with a wrench while loosening the one on the socket (the female side). ! soo 2) Seal the ends of the disconnected tubes and hoses and the oil ports to the hydraulic ‘equipment with blind plugs to keep out foreign matter. For the same reason, seal the ports of the hydraulic tank with adhesive tape. 3) Have appropriately-sized containers under- ‘neath to catch the hydraulic fluid that will flow ‘out when the piping is disconnected. Clean up all spills immediately. 4) When working under the machine, position yourself out of the way of the oil shower. 5) Tag the ends of all piping removed as well as the ports to which they were attached. 2. Installing the hydraulic piping 1) Thoroughly clean each piece of piping with a suitable detergent (for example, light oil, kerosene, trichloroethane) and remove all traces of detergent with compressed ar. 2) Repair the sealing faces or, ifthe scratches and dents are too large, replace. 3) Do not use gasket sealant for hydraulic piping! 4) install the piping so that all the identification tags match. 5) When 2 pipe must be joined at both ends, tightening only one end at a time may make it too short. First fit both ends by hand and then tighten the ends by turns. (See figure) ge — 7 Tighton gradually and alternately ‘the both ends, Fs0048 6) To ensure tight-fitting seals, tighten the nuts to 80% of the specified torque, loosen 90°, and then tighten to the full torque 7) After completing all connections, run the engine at idling speed and operate all the control levers of the hydraulic attachments. Then check the oil level in the hydraulic tank ‘and add oll as necessary. 00-23PARTS HANDLING 3. Handling high-pressure hos: 1) Do not try to shorten the hose. A hose shorter than the specified length is subject to the defects shown in the accompanying figures. ‘Shorting under pressure increases the tension Fs008e 2) Make sure the hose is not twisted after itis installed, ‘Theletters printed onthe hose soon reves any twists Fs0088 3) Similarly, the hose must not twist as it moves. Fs0oae Improper connection causes the hose to twist a6 the pipe moves 80080 4) The last figures on this page are examples of poor connections. Crimping 7Z_— The hose must have sufficient play to.aiow ito contract under pressure vwthout crimping, 50081 80082 Rubbing Fs008a 00-24PARTS HANDLING 4, Handling hoses with self-seal couplings 1)Do not attempt to connect or disconnect or coupling without first relieving the internat hydraulic pressure. + The gushing hydraulic fluid will not only soil the surroundings, but the high flow rate may also damage the O-ring of the coupling. 2) Never use a hammer to tighten or loosen a coupling + Such sharp blows can deform the coupling, leading to oil leakage or cracking of the coupling, 3) Protect the disconnected piping from the intrusion of dust and dirt! If it is to remain disconnected for some time, seal by con- necting to another coupling or by fitting a dust cap or a blind plug to each end. Fs0084 During storage Fs008s 5. Handling split flanges 1) Follow the bolt tightening sequence given in the figure. 80088 2) Press the two halves completely together and tighten them uniformly. If they are not held tightly together, they will separate by @ distance equivalent to the clearance between the fastening bolts and their holes, forming a pathway for oil leakage. 30087 6. Using sealing tape 1)To prevent oil leakage, wind sealing tape around the tapered thread before inserting the plug into the plug hole. 2) Wrap all but the first 1.5 threads at the tip and then force the tape into the threads with a fingernail. Wind the tape in the same direction as the threads. Sealing tpe ‘ eT i Leave 1.5 threads bare, Fso05e 00-25PARTS HANDLING 9.SPRING WASHERS Judging suitabi 1) Discard the spring washer if the overlapping portion is worn or damaged, ep Missing dd Ww) oor 2) Discard if the distance P is more than 21/3. J ert i ee T _ — 10.SPRING (ROLL) PINS Handling spring pins 1) A spring pin performs somewhat better when the split is placed facing the load instead of at 2 right angle to the load, £55 +5 80061 00-26 11. PUMP 1) After assembly and before installation, fill the pump with oil through the intake port to provide intial lubrication, 2) Before installing the pump, turn the drive shaft by hand to make sure that it tums smoothly without any catching. 80062 3) Test run the installed pump and check for ‘unusual noises and leakage. 12. SEAL RINGS 1) Seal tings are very delicate, so handle and store carefully. 2) Do not reuse rubber seal rings. 3) Avoid excessive stretching when fitting 2 seal ring over a shaft; it decreases the ring’s performance. 4) Remove all sharp edges before fitting a seal ring into a slot on an abutment. Check for sharp edges snd scratches Shatt 80069HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AN Heavy parts (25 kg oF more) must be lifted with 8 hoist etc. in the Disassembly and As- sembly section, every part weighing 25 kg, or ‘more is indicated clearly with the symbol r=") 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: © Check for removal of all bolts fastening the part to the relative parts ‘© Check for existence of another part causing interference with the part to be removed, 2. Wire ropes. 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S" twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 10 12 14 128 16 14 22 16 28 18 36 20 44 224 56 30 100 40 180 50 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, ‘and 2 serious accident can result. Hooks have maximum strength at the middle portion, ee fso0ee 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on tothe load. AR, Siinging with one rope may cause turning of the load during hoisting, untwisting of the rope, of slipping of the rope from its original winding position on the load, which can resultin a dangerous accident. 4) Do not sling @ heavy load with ropes forming a ‘wide hanging angle from the hook When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling @ load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes ‘make @ 120° hanging angle, On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. kg An eee} fase) _gr009 z 3 o00| 8 3 = ao Liting angle + 50085HOISTING INSTRUCTIONS ‘¢ Approximate reduction of allowable load for wire ropes at various hanging angles. Hanging angle Reductionin % 30° orless 10% 31° 60° 20% ~er— oo | 30% 91° — 120° 50% AN Honsing anges should not exceed 150° 8) When hoisting several parts as a unit, be careful not to allow any part of the unit to fall. Use a suitable container when hoisting many ‘small parts at a time. 6) Select the most suitable sling device when hoisting a specially-shaped object. ‘Speciathook TT. csc 7) When using @ hoist to turn over a heavy part, ‘observe the following instructions: ‘@ Clear as much of the area surrounding the part as possible. ‘¢ When turning the part over, take special care to prevent the ropes from slackening and the part from slipping when the center of gravity changes. ‘© Gradually slacken the. wire ropes after making sure that the part is completely turned ov Slackening the ropes before complete turning of the part may cause the part to fall back to its original position 00-28 3. Hanging bolts q J PartNumber | d | Pitch | L atte 04530-0815] 8 | 125 | 15 80. 04530-1018] 10 | 18 | 18 150 04530-1222] 12 | 1.75 | 22 220 04530-1628] 16 | 20 | 28 | 450 04530-2030] 20 | 28 | 30 | 630 04530-2438] 24 | 30 | 38 | 950 04530-3045] 30 | 30 | 45 | 1500 04530-3655] 36 | 30 | 55 | 2300 04530-4625] 46 | 30 | 25 | 3400 04530-4870] 48 | 30 | 70 | 4500 + The allowable load in the table means the maximum static load which the bolt can withstand. The values of allowable load given in the table should be reduced, taking the necessary safety factors into consideration, as these bolts will be subjected to shocks during ‘actual hoisting operation. The allowable loads in the table are applicable to the bolts slung vertically from a hoist.STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1, STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS ‘The following charts give the standard tightening torques of bolts and nuts, Exceptions are given in sections of “Disassembly and Assembly’. ‘Thread diameter Width of bolt across flat (mm) (eam) kgm Nm 6 10 1,350.15 13.2214 8 13 3.2403 31.4429 10 7 67407 65.7468 12 19 115210 112498 14 22 18.0420 17719 16 24 28.53 | 27929 18 27 3944 383+39 20 30 566 549+58 22 32 76+8 745+78 24 36 94.5410 927498 27 4a 135+15 1320140 30 46 17820 1720190 33 50 225+25 2210240 36 55 280+30 2750290 39 60 335435 3280+340 ‘This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, of which require tightening to otherwise specified torque. 4% Nm (newton meter): 1Nm 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque ‘of bolt across fats : (mm) (rom) kgm Nm 10 14 6.7407 65.7+68 12 7 11.541 112498 16 22 28543 27929 00-29STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED aoa Use these torques for nut part of flared. Thread diameter Width across flats, =... Tightening torque of nut part ‘of nut part (om) (mm) kgm Nm 14 19 25408 | 245449 18 24 542 | 494196 22 27 B2 785+196 24 32 1443 137.3294 30 36 1823 17654294 33 a 20+5 196.1249 36 46 2545 245.2449 42 55 305 294,249 7d) ‘The recommended coating materials preseri COATING MATERIALS bed in Komatsu Shop Manuals are listed below. Nomenclature Komatsu code ‘Applications ural Used o apply rubber pads, rubber gaskets, and cork pgs ae Use apy malic and- oe ron-mtate parts wena fart strong sels needed. ure Preventing bots nuts nd plas rom loosening and leaking of Provides aniright, lectically insulating seal 3 Used for aluminum surfaces. em ‘Used with gaskets end packing 1olncease sealing fect. 163 Heat-resistont gost fr precombustion chambers nd exaust piping Liqua gasket {seb tel on mounting sufoces onthe final rive and anamisson case. oe (Thickness after tightening: 0.07 — 0.08 mm) ae Used by sso to eal grease fitngs, tapered screw fitings ad tapered sorew ingen hyoaute ects oes than SO mn ama ‘anireton compound aa ‘Apple to Bestngs and taper sats to facta pres-fiting and to event sng, rng oF uring. molybdenum disulfide) - = = Grease pied 10 Bearings, sing pats and ol sal forubricaton ash oT “Applied 10 bearings sing parts on ol seals for (itrium grease) prevention and facitation of assemising work vee Used for protecting battery electrode terminals from corrosion, 00-30 “LT-2is also called LOCTITE in the shop manualELECTRIC WIRE CODE ELECTRIC WIRE CODE eH In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: O5WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Topper wire Nominal pret cableo.0. | Curent rating ‘Applicable cuit ‘number Number | Dia ofstrands | Grose section | mm) « stands tr ‘re or " 02 08s 2a 2 ing, iting, signal ete o2 26 0.32 209 3a 20 Lighting, signa te 05: 65 032 523 46 37 Charging and signal 15 a8 05, 13.36 70 59 Starting (Glow plug) 40 85 0.80 4273, 14 135 Starting 60 127 080 0208 136 178 Starting 100 27 080 109.1 178 230 Starting ——1____| CLASSIFICATION BY COLOR AND CODE Printy oo sioring | charging | Uarting | signat | tnstumenr | omer code 2 w ® < Y v + | Primary cater ack we ed Green Yelow Bue ooo ow we aw ow ve ow . Color | Black & White | White &Red | Red & White |Green& White | Yellow & Red | Blue & White code ey we 7 a ve ia : Color | Black & Yellow | White & Black | Red & Black Yellow & Black | Blue & Red — Code BR WL RY cy Ys uy : Color Black & Red | White &Blue | Red & Yellow |Green & Yellow |Yellow & Green | Biue & Yellow Code : wr ae @ we : Color - |White & Yellow | Red & Green | Green & Black | Yellow & Biue | Blue & Black Cove . we a a Ww : Color - White & Green | Red & Blue | Green & Blue |Yellow & White 00-31SHOP NAVAN UY N-SSS SERIES Engine Serial No. 26100001 and up ENGINE OI GENERALCONTENTS General view 01-004 Specifications 01-007 Assembly drawing... ceeeeees 01-012 Performance curve «1... 6seseeceeeeeeee testes esse eeeeeeee 01-032 Weight table - 01-041 N55 SERIES 01-003GENERAL VIEW GENERAL GENERAL VIEW NN-855-C (For PC300-1, 2 and PC300LC-1, 2) 1. Fan 2. Alternator 3. Intake manifold 4. Fuel fitor 5. Oil filter 6. Flynheet housing 7. PT fue pump 8, Oi! pump 9, Aiccompressor 10, Vibration damper 6710P008-1 11, Starting motor 12, Exhaust manifold 1, Brea 16, Fan belt 6710P004-2 01-004 855 SERIES oGENERAL GENERAL VIEW NT-855-C (For D80, 854-18) Alternator Air leaner 1 2 3, Fue filter 4. Bypass Filter 5 PT fuel pump 6710P001 Mutter Corrosion resistor Turbocharger Oil cootee Starting motor in fter Vibration damper 87 10P002 NB5S SERIES 01-005GENERAL VIEW GENERAL NTA-855-C (For HD320-2) ‘Air compressor PT fuel pump ‘Aneroid control valve Attercooler Vibration damper | pum Ful fier 8. Turbocherger 9 Oileooter 10, Water pump M1. Starting motor 12, Corotion reistor 13, Fullfiow fiter 14, Oilpan 15, Alternator 01-006 N855 SERIESSPECIFICATIONS. GENERAL SPECIFICATIONS Engine model e550 NTas6e Pe3007,2 Deon, E78 Appliable machine model eect? | GBA Ee e0F-18 a . cae inde wore enim) @— 190.7 1624 6 — 1907x1824 a 14010 14010 Firing order feerererer| tee ce vera enth 1.676 1661 1.691 se | Overall width (om 357 110 1.110 3 | overa height £ Le {Excluding exhaust pipe} (mm) 1,279 1,953 1,953 {including exhaust pipe) (mm) " s i Flywheel horwpower—(HP/rpm) | ‘180/150 220/1,800 260/1,950 8 Maximum torque (kgm/rpm) 83.5/1,300, 105/1,250, 118/1,400, Ehsan ses trom) 1985-2085 | 1900-2000 | 2100-2200 é Low idling speed (rpm) 550 — 600 600 — 650 600 — 650 Minimum fel consumption gop) 175 175, 175 Dry weight tka 1.480 1.780 1.780 Fue pump cummins PT fuel pum] Cummins PT fuel pump Cummins VS governor i Governor Teenntga Cummins VS governor all-speed type} (Centrifugal, all-speed type) Tabiatng a capacity ie 3 6 iret capacity oy a Cooling water eapacty @ 28 78 79 Alternator DAV, 254 2aV, 258 DAV, 258 Starting motor av, 11kW ay, 1k Dav, 11kW battery tav,170anx2 | ravivoanxe | 12v 170ahx2 Turbocharger ii Cummins 5150 | Cummins ST-60 Attercooler : : : others if 7 : N855 SERIES 01-007SPECIFICATIONS. GENERAL Engine model NT-855-¢ epabe marine ode oa8s2 oo wiro2 amber oF a 6 1307x1824 Total piston asplacement (ce) 14910 Firing order 1-5-3-6-2-4 Overal length (mm) 1,680 1676 ans | Overall wiath (ram) 110 968 955 & 5 | (excluding exraust pipe) (mm) 1a 1263 1943 (including exhaust pipe) (mm) - 7 2.545 Flywheel horsepower (HP irom) 288/1,860 239/1,800 235/2,200 g | Maximum torque (kgeniepm) | 112/1,200 116/1,200 100/1,400 E | Hii iting speed (rom) 2,000 ~ 2,100 1,980 — 2,050 2,350 — 2,450 | Low idling speed (rpm) 600 — 650 1600 — 650 670-730 Minimum ful consumption grip +70 1% . Dry weight (ks) 1,750 1800 1485, Fuel pump ‘Cummins PT fue! pump Governor Cummins VS governor (Centrifugal, all-speed type) Labricating ol capacity a 3 e ra (Refill capacity) (38) 8) (3a) Cooling water capacity ® %0 67 8 ‘Alternator 2AV, 258 2aV, 258 24V, 358 Starting motor 2a, kW 2av, 11KW 24v, 11kW Battery 12v2008nx2 | 12v170Anx2 | 12V200Ahx2 Turbocharger ‘Cummins $T-50 | Cummins sT-50. | Cummins ST-50 Attercooler 7 - - others . . - Nass SERIES 01-008 @GENERAL SPECIFICATIONS NTa55-¢ NTABESC wis0-1 ng. Novsb102754 ~ | Eng. Novzotes009 | H0920.9 ws165-2 yeis0008 sidup 6 — 1397x1524 6 ~ 190.7 x1524 14910 14910 1-5-3-6-2-4 6-2-4 1.680 1,688 1.735 1,680 1687 955 976 998 998 970 1845 1.962 1352 1382 1.282 2s . . i . 790/2,200 408/2,200 406 /2,300 364/2,100 16/1600 42/1700 142/1,700 140/1,500 2430 ~ 2.590 2430 ~ 2.530 2as0-2590 | 2,250-2,350 600 - 700 600 ~ 650 675-725 610-650 170 175 175 175 1485 1,700 1.570 1570 1570 Cummins PT fuel pump Cummins VS governor (Centrifugal, ‘Cummins PT fuel pump Cummins VS governor (Centrifugal, Cummins PT fuel pump Cummins MVS governor [Cummins PT fuel pump ‘Cummins VS governor (Centrifugal, all-speed type) all-speed type! (Max. and min, speed type) all-speed type) 43 43 3 43 43 (38) (38) (38) (38) (38) Ea 125 125 128 128 24V, 358 24V, 358, 24V, 358, 24V, 244, 24V, 358 24V, 11kW 2av, 11k 24V, 11KW 24v, 11kW. 24V, 11kW 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200A x 2 Cummins $T-50 Komatsu KTR:130 | Komatsu KTR:130 | Komatsu KTR-130 | Cummins ST-60 ~ With with With with 855 SERIES 01-009 3SPECIFICATIONS. GENERAL Enna model NTASSEC penlabe rachis mad wana Tambor oF nda ~ ewan tm) | 6—1907 x1624 Tora pitonclaplecemant foe Mow ee 1-5-3-6-2-4 Overs eng ‘wm | ove wietn om 3 Z| Overall height = lea (Excluding exhaust pipe) (mm) (Including exhaust pipe) — (mm) Flywheel horsepower (HP/rpm) (364/2,100 | Maximum trae tkariromi| 14071500 2) ston ising soe tom | 2250-2900 : @ | Lowidling speed (rpm) 610 — 650 Him meen gen - Dry wig to 19 Fro Ful pump mins PT fe pune cummins VS governor Gomer ‘aves sae Tae aT aa a ‘a (Refill capacity) (38) Cooling water capacity (ae) 125 ‘erator 2.354 oe ev, re savory 12v 20080 «2 Turow Canmins 780 teecooe wih omnes - 01-910 N855 SERIESASSEMBLY DRAWING GENERAL, ASSEMBLY DRAWING N-855-C LEFT SIDE VIEW (For PC300-1) 17 Flywheel housing Fuel =a Tachometer ut or erent 736.7 Fuel return inlet Oil caution amp outlet cranishat From By-pas filter 6710F 1068 0191 i. NB5S SERIESGENERAL ASSEMBLY DRAWING NN-855-C RIGHT SIDE VIEW (For PC300-1) Flyutee! housing rear face a9 {Ul be 7 i ileal oorte cee : ial G7I0F 1078 N855 SERIES ESEASSEMBLY DRAWING GENERAL, N-855-C FRONT VIEW (For PC300-1) Cylinder center @ 1 CGrankahaft center 232.2 6710F 1084 1-914 IN855 SERIESGENERAL ASSEMBLY DRAWING NN-855-C REAR VIEW (For PC300-1) Crankshaft cantar 6710F 1098 NS55 SERIES 01-015 ®ASSEMBLY DRAWING NT-855-C LEFT SIDE VIEW (For D80, 85A-18) eo GENERAL Toradstor id ; © | i Wind ! q ‘| i |] From tot nk | || =D lene : = lal Crankaat cantar From aor | PIN aD aaron PS / se 01-016 @ 6710F050 N85S SERIESGENERAL ASSEMBLY DRAWING NT-855-C RIGHT SIDE VIEW (For D80, 85A-18) Flywheel housing reer foce [eo Crankshaft conte N8SS SERIES s & “ a > Wind B 0 4 Tat E ! I ow « 6710F0s1 01-017 @ASSEMBLY DRAWING GENERAL NT-855-C FRONT VIEW (For D80, 85A-18) 2380 vlinder Cente, Crankahett center e710F0s2 01-018 NB5S SERIES oGENERAL, ASSEMBLY DRAWING NNT-855-C REAR VIEW (For D80, 854-18) Crankhate center 6710F053 N855 SERIES 01-019ASSEMBLY DRAWING GENERAL NT-855-C LEFT SIDE VIEW (For D95S-2) { 1680 \ Fives! Housing To radiator . ‘Grankshate 6710F002 01-020 N855 SERIES ®GENERAL ASSEMBLY DRAWING NT-855-C RIGHT SIDE VIEW (For D95S-2) Fiywhee! housing Crankshaft conter owe 6710F00! N@55 SERIES 01-92101-022 @GENERAL, ASSEMBLY DRAWING NT-855-C REAR VIEW (For D95S-2) Covlinder center Crankehaft center 6710F004 N85S SERIES 01-023 ®ASSEMBLY DRAWING. GENERAL, NTA-855-C LEFT SIDE VIEW (For HD320-2 Engine No. 26102754 — 26155098) i i i 6710F005 01-024 N855 SERIES @GENERAL, ASSEMBLY DRAWING NTA-855-C RIGHT SIDE VIEW (For HD320-2 Engine No. 26102754 — 26155098) i : Ee j th i i if } : atu _ | TANT yey, cw } Se A ! 4 ; tells po 7 my of L| a! «o_o oe N@55 SERIES 01-025 @ASSEMBLY DRAWING GENERAL NTA-855-C FRONT VIEW (For HD320-2 Engine No, 26102754 — 26155098) 6710F007 01-026 N855 SERIES @GENERAL, NTA-855-C REAR VIEW (For HD320-2 Engine No, 26102754 — 26155098) N85 SERIES Cylinder center 76 ASSEMBLY DRAWING Crankshaft center 6710F008 01-027 @ASSEMBLY DRAWING GENERAL NTA-855-C LEFT SIDE VIEW (For HD320-2 Engine No. 26155099 and up) Crankshafs center it pressure gauge outlet 8710F 113 01-028 NB55 SERIES ®GENERAL ASSEMBLY DRAWING NTA-855-C RIGHT SIDE VIEW (For HD320-2 Engine No. 26155099 and up) = Toradiator g oa ) z a Crankshatt Rk From by-pass filter, 1431.6 e710F 12 N855 SERIES 01-929ASSEMBLY DRAWING GENERAL NTA-855-C FRONT VIEW (For HD320-2 Engine No. 26155099 and up) ‘Cylinder Genter “7 = Crake cantar 1) sees) Ci x0 20 6710F 110 N@S6 SERIES 01-030 ®GENERAL, ASSEMBLY DRAWING NTA-855-C REAR VIEW (For HD320-2 Engine No. 26155099 and up) Crankshaft center S ‘Thread dia, 12:mm, pitch 1.76 mm, 12 points S ‘Thread dla. 12 mm, piteh 1.75mm, 18 points 67I0F 111A N85S5 SERIES 01-031 @PERFORMANCE CURVE PERFORMANCE CURVE N-855-C (For PC300-1, 2 and PC300LC-1, 2) Flywheel horsepower Maximum torque 180HP/1,850 rpm 83.5 kgm/1,300 rpm Minimum fuel consumption ratio : 175 g/HP.h Cutout {HPP 01-032 ® 200. 1 GENERAL Torque “Toraue (kom) 10. 120: 100. 40 Fuel consumption ratio, Fuel consumption ratio (g/HPsh} i600 1001400 —«1600 Engine speed (rom) 102000) 2200 6710F 1148-0 NSSS SERIESGENERAL, PERFORMANCE CURVE NNT-855-C (For D80A, E-18 and D85A, E, P-18) Flywheel horsepower 220HP/1,800 rpm. Maximum torque 105kgm/1,250 rpm Minimum fuel consumption ratio : 175 g/HP.h S 0 Tove 10 Eoaeecs Felis! z o § 6 8 i oor 2 =. ‘ a a» ios 3 “0 1 - zo # 20 S % m 0 § : ut consumption rt _ = B: 1 10 Q ao alo Tein do ibe) abo abo ao Engine ped (om) . 6710FOOSA-O N855 SERIES 01-033PERFORMANCE CURVE. GENERAL NT-855-C (For D80F-18) Flywheel horsepower 260 HP/1,950 rpm Maximum torque 118 kgm/1,400 rpm Minimum fuel consumption ratio : 175 g/HP.h 7 118 kgm/1400 rpm 120 “ue 110 t 10 3 300 £ 260 HP/1950 rom 8 ‘Output (HP w 3 ul consumtion wa =| 5 mo Tb 00 70 cy B00 B00 Eine od emt ervorsas ee N855 SERIESGENERAL PERFORMANCE CURVE NT-855-C (For D95S-2) Flywheel horsepower 245HP/1,850rpm ‘Maximum torque 112kgmn/1,200rpm ‘Minimum fuel consumption ratio: 169g/HP.h 12 ms Torgue no Zeaw | peceaece 100 20 0 | ry a 2s 2 | 7 o § E 2 50 a «0 g vs 5 x » 150 0 ° 125 - 100 8 . os i: wo f wm op et ws . le | m3 8 10 3 ° voce tao ~—~00~—~«so~«aO~C«OO COD Engin seed (om) e710F010 NB55 SERIES OreGENERAL PERFORMANCE CURVE NT-855-C (For PC400-1, PC400LC-1) Flywheel horsepower : 233HP/1,800 rpm ‘Maximum torque 5 116kgm/1,200 rpm Minimum fuel consumption ratio : 175g/HP.h 1% Toray a 10 = % ey ws ‘0 o ‘0 2 15 : 7 ¥ : E wo 7 i ° 8 1s. 10 220 60 1% 1 » ze conamoton ap a 160 0 ao 000 Tato ano Teo a8 ato Engine speed (rom) “Torque (kgm) io (g/HPt) Fuel consumption 6710FO10-1 01-036 855 SERIES @GENERAL, PERFORMANCE CURVE NT-855 (For W170-2) Flywheel horsepower + 235HP/2,200rpm Maximum torque + 100kgm/1,400rpm Minimum fuel consumption ratio : 168g/HP.A : aaa je : : : . 5 | o £ 260 J} 4 30 : ; = 20 3 j | . 180 + : : i aa 10 | j Fas! consumption rata ? PS m0 o me | ieercce: oe ss dena S7IOFOIO-2 N855 SERIES 01 937PERFORMANCE CURVE GENERAL NT-855 (For W180-1) Flywheel horsepower 280HP/2,300rpm Maximum torque 116kgm/1,600rpm Minimum fuel consumption ratio: 170g/HP.h re Torave 120 Bisaes | 100 x0 0 C 275 40 20 20 ° us zm Boos 150 1 100 mz 20 78 0g é m0 § ere = 0 1 E Foal consumption 2 7 m 2 ~ 10 3 160 ° 1001200 —«1400~—«600~—«ao0 000 ago 2600 Engine weed (rent 6710F 116-0 Ness SERIES 01-038 ®GENERAL, PERFORMANCE CURVE NTA-855-C (For HD320-2 and HD320-3) Flywheet horsepower 40SHP/2,300r0m Maximum torque 2 142kgm/1,700rpm Minimum fuel consumption ratio: 1759/HPth 160 Torave 1% a 129 10 E o % oof “0 ~ 0 0 a. ontia| 0 Ex. 1 ow. 0. 20 20S 10 a mo 100 sumption ratio 1g m3 © mo ¢ 1 © ° rT Cn eC OT eo) Engine speed (rpm) S710FOI1A N855 SERIES 01-039 ®PERFORMANCE CURVE GENERAL NTA-855 (For WS16S-2 and WS23-1) Flywheel horsepower ‘364HP/2,100rpm Maximum torque + 140kgm/t,500rem Minimum fuel consumption ratio : 176 g/HP.h 0 120 1 | o & o F 40 2 0 co 0 \ 2 =m é ™ m 5 a0 & 1 20 3 10 -E i wo Fuel consumpt = m € % 1 | 10 A 1 oo 1000 150010060010 2000 700-2400 Ensne sed om) 8710F1 17-0 01-940 N855 SERIESGENERAL WEIGHT TABLE a This weight table is @ quide for use when transporting or handling components WEIGHT TABLE ae cara waese [NraneChTAGSeC] tame arnt] oem aren 7 2S) one AL —-++-F 3 | Owider Feed Cvindartoad vate abesacig | 405 | aos | 40s Sine onaraae anne! 7 assembly ‘main bearing cap fa tae ca poops, arcane, 2 ee ao a PC400-1, PC400LC-1 ae 5 | Fywheelamanbty | Fite sng ger ~ | os| - [pas woe a 5 te W180-1 as ea ee a WS16S-2, WS23-1 Pom. 3 PemDOLET- 2 | eee sea | aes ol ac, Se ann ~ [ao | - fomse ~ |. | 7 [Tina sree att oan tea 2 [tpn ai oon |saae B eisastar stan] cancer oa pe ae eerie oan econo ae] | AO | aise | Pon aaa . rod assembly connecting rod, connecting rod cap a on A Whole weights a exe ee re TD sa saa aot ania re ee (nea Wee Bsc oe 01-041 ®SHO NVA N-SSS SERIES Engine Serial No. 26100001 and up ENGINE 1 1 STRUCTURE NBS5 SERIES AND FUNCTIONGENERAL STRUCTURE .. INTAKE AND EXHAUST SYSTEM .. Turbocharger Aftercooler .. ENGINE BODY Cylinder head Valve system Cylinder block Main circulation system ‘Timing goar ‘Camshaft, cam follower and push rod, Injection timing, valve timing . . . Flywheel and flywheel housing LUBRICATION SYSTEM Lubrication system chart. it pump. . il filter and oil c Full-flow filter By-pass filter Oil cooler . . 855 SERIES CONTENTS 11-004 11-006 11.014 11.016 11.017 11.018 11.020 11-022 11-023 11-024 11-025 11-026 11-034 11-036, 11.039 11-042 11-043 11-044 FUEL SYSTEM Fuel system chart PT fuel pump . PT fuel pump drive Injector. Fuel filter . Water separator ‘Aneroid control valve COOLING SYSTEM Cooling system chart ‘Water pump Fan drive .. Tension pulley ‘Thermostat Corrosion resistor ‘ACCESSORY Air compressor ELECTRICAL SYSTEM Alternator Starting motor... 2. Electrical intake air heater 11.045 11-048 11-088 11-060 11-081 11-063 11-084 11-066 11-068 11.071 11.075 11.077 11.078 11.079 11-080 11-083 11-085 11-003 ®GENERAL STRUCTURE GENERAL STRUCTURE Fan spacer Fan Fan pulley Water pump Liner se ing Cylinder block oylindortnar 8. Piston 10, Piston pin 11, Injector 12, Compression release shaft 13. Rocker arm housing 11-004 ® 14 15, 16. 7, 18 19. 21 2, 2 2s, eeune we \\ Rocker arm housing Focker arm shaft Push rod (Exhaust) Rocker arm (Exhoust) Rocker arm (Injector) Push rod (Injector) Rocker arm (Intake) Push rod (tata) Valve guide Valve (intake Valve (Exhoust) Cylinder hess PTO gear an 32, 33, 34 36, 27, 28, 39, PTO gear shaft Gear ease 1 Vibration damper Crankshaft pulley Crankshaft Front ol sea Crankshaft gear Main besring cap ‘Connecting rod Connecting rod cap Oil pon Connecting rod beating Main bearing 40, a 42, 4a, 4s. 46, 46, 47, 48. 49. 50, 51 52, STRUCTURE AND FUNCTION en0F012 Rear cover plate Fear ol sel Seat cotsinor PTO drive geer Fig gear Flywheo! PTO ister gear PTO ial shaft ‘Thermostat housing Exhaust manifold Turbocharger it pipe (to turbocharger) 01 pipe (from turbocharger) N8SS SERIESSTRUCTURE AND FUNCTION GENERAL STRUCTURE NT-855-C (With turbocharger) NTAS55.C {With turbocharger and after-cooler) Type: Inline, 6-oylinders, water-cooled, direct fuel injection, 4-cycle diesel engine. N8S5 SERIES 11-005 @INTAKE AND EXHAUST SYSTEM STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM N-855.C (For PC300-1, 2, PC300LC-1, 2) INTAKE SYSTEM 1 1. Intake manitola 2, Intake connector pipe 3. Aircleaner AL intake 67104001 EXHAUST SYSTEM i Za F6710A002 11-006 855 SERIES @STRUCTURE AND FUNCTION NT-855-C (For D80, 85-18, D95S-2) INTAKE SYSTEM EXHAUST SYSTEM B N855 SERIES e710F 054 e710F 086 INTAKE AND EXHAUST SYSTEM 1. Turbocharger 2. Air cleaner 3. Intake manifold A 1. Exhaust manifold 2, Turbocharger 3. Mutter 8. Exhaust 11-007 @INTAKE AND EXHAUST SYSTEM STRUCTURE AND FUNCTION NT-855-C (For PC400-1, PC400LC-1) INTAKE SYSTEM Air cleaner Turbocharger Intake connector pipe Electrical intake a heater 1 2, 3 4, Intake manifold 5 6. Intoke connector pipe A loake 67108003, 1 Muffin 2. Exhaust connector pipe 3. Exhaust manifold 4, Turbocharger 8. Exhaust 67104008 11-008 N55 SERIES ®STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM NT-855-C (For W170-2, W180-1) INTAKE SYSTEM Turbocharger Intake connector pipe Precieaner Air cleaner Intake manifold Incake connecter pipe px Peo eens Intake 67108005 EXHAUST SYSTEM Exhaust manifold “Turbocharger Exhaust connector pipe ster Exhaust pipe Exhoust 67108006 855 SERIES 11-009 ®STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM NTA-855-C (For HD320-2) INTAKE SYSTEM A x 1. Airleaner 2. Turbocharger 2. Aftercooler A. Intake e710F 055 mutter 1 2. Turbocharger 3. Exhoust manifold 8. Exhaust 6710F087 11-010 N855 SERIES ®STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM NTA-855-C (For HD320-3) INTAKE SYSTEM .Preleaner ‘ir leaner Intake connector pipe Intake connsctor pipe 1 2 3. 4. Turbocharger 6 6. aftercooler A Iotoke Exhaust manifols 1 2. Turbocharger 3. Exhaust pipe 8. Exhaust 67108008 N855 SERIES 1 1911INTAKE AND EXHAUST SYSTEM STRUCTURE AND FUNCTION NTA-855-C (For WS16S-2, WS23-1-FRONT ENGINE) INTAKE SYSTEM 67108000 67104010 11-gi2 N855 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM NTA-855-C (For WS23-1-REAR ENGINE) INTAKE SYSTEM Intake connector pipe Air cleaner Intake connector pipe Turbocharger pe eere Intake 3 4 Fe7I0A011 Exhaust pipe 1 2. smuttler 3, Turbocharger 4, Exhaust connector pipe 8 Exhaust Fe7104010 NB5S SERIES 1 ior 3‘TURBOCHARGER STRUCTURE AND FUNCTION ak TURBOCHARGER at” < ‘CUMMINS ST-50 (NT-855-C and NTA855.¢) 1 2 3 4 5 6 qT a 9 10 6710F0598 1. Blower housing 9. Turbine impellr ‘Turbocharger specifications 2. Blower impeller 10. Turbine housing Mode! Cummins $7-50 Length x Width x Height 334mm x 278mm x 308mm 3, Sleeve AL Airinlet Weight: 27.59 4. Shiold 8. Airoutlet (Continuous rotation 70,000 rpm Maximum charging 31.2kg/min, Lane eee Maximum temperature (At inlet) 708°C and below 6. Center housing 1D. Exhaust outlet Diraction of rotation (viewed from blower: Clockwise Lubrication method: Forced lubrication with engine oi 7. Clamp , Lubricating oll inter, 8. Shield F. Lubricating oil outlet 11-014 N855 SERIES ®‘STRUCTURE AND FUNCTION KOMATSU KTR-130 (NTA-855-C) foc 10 " 1. Blower housing 10. stinger 2. Blower impeller 11, Insert 3. Clamp 12, Thru bearing 4, Bearing housing A. Airinlet 5, Journal bearing 8. Airoutlet 8 Clamp Exhaust init 7. Shisle Exhoust outer 8, Turbine impolier From ol itor 9, Turbine housing To oll pan drain N855 SERIES TURBOCHARGER / —_D =A F 6710F058 ‘Turbocharger specifications Model Komatsu KTA:190 Length x Width x Height 325mm x 298mm x 344mm Weight: 20k5 Continuous rotation: 170,000rpm Maximum charging 31.Bkg/min Maximum temperature (At inlet) 780°C ond below Direction of rotation (viewed from blower: Clockwise Lubrication method: Force lubrication with engine ci 11-015 @AFTER-COOLER, STRUCTURE AND FUNCTION AF TER-COOLER NTAB55-C Seetion XX 6710F 060 1, Gore cover Housing Worer outlet (To thermostat) Air intake (From turbocharger) Water intake (From cylinder block) Air outiet (To intake manifold) roof > Compressor outlet, 11-016 NB5S SERIES oSTRUCTURE AND FUNCTION CYLINDER HEAD ENGINE BODY CYLINDER HEAD % 83} peex 6710F 096-1 Water pump Fan Radiator From oil pump fot) To main galery (oi), 85S SERIESSTRUCTURE AND FUNCTION COOLING SYSTEM CHART NT-855-C 6710F097A 1. Corrosion resistor 8. Oil cooler A. From oil pump foil) 2, Thermostat 7. Water pump 8. To main gallery (ot) 3. Water manifola 8 Fan From machine ches (it) 4. Piston 9. Radiator . To machine chasis (ol) 5. Cylinder tinee N855 SERIES 11-067, ®WATER PUMP. STRUCTURE AND FUNCTION WATER PUMP N-855-C NT-855-C NTA-855-C (WS16S-2, WS23-1) 1 6710F098A Pulley (0.0.: 118.5 mm) A. From radiator Ball bearing B. Toil cooler Pump housing Impaler uu 968 N855 SERIESSTRUCTURE AND FUNCTION WATER PUMP, NTA-855-C (For HD320-2) 8 138 14 15 16 17 tater puttey eztonoeen, 1 ler housing 8. Idler pulley bracket 15, Ball bearing 2, Pump housing 8. Ball bearing 16. ler pulley 3. Pump shaft 10. Wear soove 17, Plug 4, Oita 11, Oil seat 5, Water sea! 12, Pump pulley (0.0.: 142mm) A. From radiator, thermostat 6. Pump seat 13. Oi seat 8, To oll cooler, eylinder block 7. Impeller 14, ler pulley shaft N855 SERIES. 11-069 ®WATER PUMP STRUCTURE AND FUNCTION NTA-855 (For HD320-3) 6710F099-3 1. Impeller 8. Pump pulley 2. Inlet housing 9. Wear sleeve 3, Water seat 10, Oil sot 4, Olt seat 11, Pump set 5. Pump housing 12, Oil seat 6. Pump shaft 13, ler pulley shate 7. Idler palley bracket 14 tae pulley 11-070 N855 SERIES @STRUCTURE AND FUNCTION FAN DRIVE N-855-C N855 SERIES FAN DRIVE vebett Fen driveshaft Fen pulley (0.D.: 262 mm) Vibration damper Witer pump pulley (0.0: 118.5 mm) 6710F099-18 ‘Tension pulley (0.D.: 125 mm} Alternator pulley (0.0.: 95mm) Vbete ‘Accessary drive pulley (0.D.: 222:3 mm) |. Crank pulley (0.0. 183 mm) 11-071 ®STRUCTURE AND FUNCTION FAN DRIVE NNT-855-C (For D80, 85-18, D95S-2) 6710F 100A, 1. Fen 7. Alternator pulley (0.D.: 95mm) 2. Ball bearing 8. Water pump pulley (0.0.: 118.8mm) 3. Viele 8. vibett 4, Ball bearing 10. Accessary drive pulley (0.0.: 222 mm) 5. Fan spacer 11, Crankpulley (0.0.: 169 mm) 6. Fanpulley (0.0.: 262mm) 12, Vibration damper 11-072 ® “Tension pulley (0.0.: 120 mm) 85S SERIESSTRUCTURE AND FUNCTION NT-855-C (For PC400-1, PC400LC-1, W170-2, W180-1) NTA-855-C (For WS16S-2, WS23-1) 1. Fan pulley (0.0) (0.0. for PCA00-1: 262 mm 1702, w180-1: 315mm, WS165-2: 336 mm) 2. Fan 3. Fandrive sate 4, Bal bearing N85S SERIES 5. Fan spacer 6. Tension pulley (0.0. for Pe400-1, w1702, W180: 120 mm, WS16S-2: 118 mm) 7. Crank pulley (0.0. for PC400-1: 194 mm, 1702, W180-1: 180mm, Ws16s2: 192mm) FAN DRIVE 67 10Fos9-4 Water pump pulley (0.0.: 118mm) ‘Ateroaor pulley (0.0.: 118mm) Vote ‘Accesary driv pulley (0.D.: 222 mm) Vebeit Vibration damper 11-073 ®FAN DRIVE NTA-855-C (For HD320-2, HD320-3) 1. Fan 2, Vibett 2. Roller bearing 4, Fan pulley (0.0.: 228 t0 247 mm) 5. Ball bearing 6. Spacer 2, Cover 8. Fan spacer 9. Brocket 11-074 @ 10, 1" 12, 13, 14, 18, 16. ”. Fan bracket it sest Fon drive shott Lock nut Water pump support Water pump cover tater pulley (0.0.: 101.5 mm) ‘ater pump pulley (0.D.: 118 mm) STRUCTURE AND FUNCTION 6710F 1018 18, Accessary drive pulley {alternator drive 0.0.1 Change 155 mm to 238 mm) (Fan drive 0.0.: 185:mm) 19. Vbett 20. Vibration damper 21. Crank pulley (Water pump drive 0.0. ‘change 238 mm to 260.5 mm) (Alternator drive 0.0.2" 260.5 mm) 22, Vibe 23, Alternator pulley (0.0.: 120 mm) SSS SERIESSTRUCTURE AND FUNCTION TENSION PULLEY TENSION PULLEY N-855-C 1, Tension pulley bracket 2. Spacer ©. Cover 4. Oil seal 5, Tension pulley 6 ‘Tension pulley shoft 6710F099-2A “Torsion pulley shaft / 2. Oil seat ‘Tension pulley Spacer Pulley cover “Tension pulley bracket ~eepee Needle besring 6710F0S9-5 11 N855 SERIES 975TENSION PULLEY. STRUCTURE AND FUNCTION NT-855-C (For PC400-1, W170-2, W180-1) NTA-855-C (For WS16S-2, WS23-1) 1, Bracket 2, Oil seal 3. Tension pulley 4. Spocer 5 Cover 6710F099-6 11-076 N@55 SERIES @STRUCTURE AND FUNCTION THERMOSTAT THERMOSTAT NT-855-C 1. Spring 2, Thermostat cate A. From water manifold 8 To radiator upper tank ©. Towater pump Opening temperature : 75.5~78.5°C Full opening : temperature :90°C Fall opening ft: 10mm 6710F 102 NTA-855-C 1. Spring 1 2 2, Thermostat A, From water manifold 8, Toradiator upper tank .Toradiator upper tank 1D. Towater pump Opening temperature : 74.5~78,5°C Full opening ‘temperature 90°C 6710F 103, Full opening lift: 10mm N855 SERIES 11-977CORROSION RESISTOR STRUCTURE AND FUNCTION CORROSION RESISTOR CARTRIDGE TYPE B Bracket A. Water init cartridge 8. Water outlet 2 3. Element (Paperl 4. Elomont (Chemicals a Soring _ 1.978 N855 SERIESSTRUCTURE AND FUNCTION ACCESSORY AIR COMPRESSOR (For N-855-C, NTA-855-C) 5 > neces 3—___ 2— Cylinder nese Cylinder head cover Unlosder valve spring Unioader valve cap Unloader vale body Inte valve spring Outlet valve seat Outlet vate 11, Outer valve spring 85S SERIES N en AIR COMPRESSOR 2 13. 14 18, 16. 17. 18, 19, 20. a Wear plate Piston Connecting rod Crankease CCrankease bushing Crankshaft Support Hai coupling Thrust washer Support bushing Thrust washer 6710F 105, Paton pin ap ring Ot ring Piston ring (No.2) Piston ring (TOP) From air tank Tosir tank Cooling water outlet Cooling water inlet From intake manifold 11-079 @ELECTRICAL SYSTEM STRUCTURE AND FUNCTION ELECTRICAL SYSTEM ALTERNATOR 2 pute Eraine model] Applicable chine 08 Spesitenion | 15,02. [gh Peo, 8 Wako DEN NB56C | pc300Lé-1,2 Type: Sealed ee a “ O86. FF besa: Matar: NIKKO DENK D96S-2 Type: Sealed eave cen. ted a wrasse | peso, potco.e. Tater NIKKO DENK W702 ilar: RIK mwv.sa | a0 |e oss serves 11-080 ®STRUCTURE AND FUNCTION ELECTRICAL SYSTEM aoe Engine model] _ Appisble machine Tye sowifiation] PHe¥ OT weight) z Moker, NIKKO BENKI ote wressc | wisos Maker NIK nav.35a | (oathle | 178 720 wowo , 18 ee Maker: NIKKO DENKI 2av, 354 |(Single pulley) ‘WS16S-2 ‘Type: Sealed (wecbt 178 eee pulley) i N55 SERIES 11-981ELECTRICAL SYSTEM STRUCTURE AND FUNCTION ” FE7100014 Engine mode] Apptialemechine Tyee Speciation] Pele”. [ weinc w) Tokar NRO BEN wrasse | Hoa ake SK vavaca | v0 | as oss series 11-082 ®STRUCTURE AND FUNCTION STARTING MOTOR WITHOUT SAFETY RELAY Rotating direction 1. Pinion 2. Magnetic switch 3. Staring motor B,C, M: Terminal ELECTRICAL SYSTEM 67104015, Engine node] Applicable machine Type specication] AMET T weight ka) wa8s.e | allmacine Waker IKKODENKT [aay rw | 11 “5 wr8560 | allmacine Waker NIKKODENKT aay, yew | 14 us wrasise | WBies2 Makar NIKKO DENK! | cay, sua] 11 us a Leet NB55 SERIES a 1-983ELECTRICAL SYSTEM STRUCTURE AND FUNCTION WITH SAFETY RELAY {rosaing rection \ 8 Fertoa01 1. Pinion 8,6,€,M,R, 5: Termiral 2. Sefety rly 3. Magnet siteh 4. Startingmotor : Number of| Engine model | Applicable machine Type Specification} Number of | Weight (ka) wi702 Makers NIKKO DENKI nressc | MI207 eee zav, kw | om 45 11-084 N855 SERIES aSTRUCTURE AND FUNCTION ELECTRICAL SYSTEM ELECTRICAL INTAKE AIR HEATER RIBBON TYPE © SMALL SIZE (For PC300-1, 2, PC300LC-1, 2) 1. Heater coi 2, Heater boay 3. Earth wie 4. Terminal 67108017 © SMALL SIZE (For PC400-1, PC400LC-1, W170-2, W180-1) 855 SERIES 1. Heater col 2. Heater body 2, Terminal Fe710A018 11-085 ®ELECTRICAL SYSTEM STRUCTURE AND FUNCTION © LARGE SIZE (For PC400-1, PC400LC-1, W170-2, W180-1) 1. Heater coi 2. Hester body 3. Terminal a |, Fe710A019 COIL TYPE (For D80, 85-18, D95S-2) 1. Heater coil 2 Tube 3. Heater boey 67108020 11-986 N855 SERIESSOP MAA UAY N-SSS SERIES Engine Serial No. 26100001 and up ENGINE TESTING AND I 2 ADJUSTING 855 SERIESCONTENTS Testing and adjusting injector and valve clearance .............. 12004 Measuring compression pressure 12-008 Measuring blow-by pressure 12.010 Measuring oil consumption. 12.012 Measuring fuel pressure 12.014 PT pump calibration data 12.015, PT fuel pump parts specification 12.027 Injector specification ........ 12.037 Rur-in standard . 12.038 Performance test criteria .... 12.040 Testing and adjusting tool list 12.045 Testing and adjusting data 12.046 Troubleshooting ....... 12-052 12-00. NSSS SERIES o 3TESTING AND ADJUSTING INJECTOR AND VALVE CLEARANCE TESTING AND ADJUSTING TESTING AND ADJUTING INJECTOR AND VALVE CLEARANCE * When testing and adjusting the injector and the valve clearance, work in the same cranking position and adjust the injector first. 4% Test and adjust the injectors and valve clearances in the following engine firing order: Firing order: 1-§-3-6-2-4 ADJUSTING INJECTORS Special tools Part Number Partname [Q'ty 795-630-1803 | Torque wrench set__| 1 B | 795-130-2103 | Torque wrench set | 1 + Remove the rocker arm housing cover. * When adjusting No.3 and No. 4 injectors, remove crossover pipe. 1, Rotate the crankshaft in the normal direction and, while watching the valve movement, align stamp '"1.6VS" (on accessory pulley (1) with pointer (2) on the gear case, ‘When stamp “1.6VS" is aligned with the pointer, either No. 1 or No. 6 cylinder should be in com pression TDC position. If the valves for No. 1 cylinder is stil in motion at this stage, the cylinder is not in the compression. TDC position. In this case, rotate the crankshaft, ‘one complete turn in the normal direction. 2. Loosen locknut (4) for adjustment screw (3). 3, Screw in the adjustment screw until the injector plunger comes into contact with the cup. Then, screw in the adjustment serew about 15° to drive the fuel out of the cup. 4, Back off the adjustment scerw one complete turn. [207P 105.” 12-004 855 SERIES ®‘TESTING AND ADJUSTING INJECTOR TESTING AND ADJUSTING AND VALVE CLEARANCE 5. Tighten the adjustment screw to the specified torque with the torque wrench in tool A. REI Adjustment serew: Units kam TEI Engine No, | JOZEA, _[est85792 andup Cols (20°C) 058 0.83 ‘Warm (60°C) 069) 0.83 and 6, Hold the adjustment screw with screwdriver ( tighten the locknut with too! B. ZI Locknut: 4.80.7 kgm % After the valve clearance is tested and adjusted in the same eranking position, adjust the next injector in the firing order, use the same manner described above, N855 SERIES 1g c0eTESTING AND ADJUSTING INJECTOR AND VALVE CLEARANCE TESTING AND ADJUSTING TESTING AND ADJUSTING THE VALVE CLEARANCE Special tools Part Number PartName [arty 795-130-2103 | Torque wrench set_| 1 & | 795-562-1300 | Feeler gauge 1 ‘© Adjust the valve clearance in the same cranking position, after the injector is adjusted. ‘© “Testing” the valve clearance means checking to see if 2 feoler gauge of the specified clearance can slide lightly ‘when inserted between the rocker arm lever and the crosshead, * If the clearance deviates from the standard value, * Valve arrangement. adjust the clearance in the following manner. 00Yool|(oo“oo0|(o0oVoo Foe 9ejjo9 oojjoo oo © Intake valve © Exhaust valve 207F201 1. Loosen locknut (4) for adjustment serew (3). 2. Insert feeler gauge C between the rocker arm lever and the crosshead, and adjust the clearance with the adjustment screw just until the gauge can be sided lightly. ‘ ‘ 207° 108] 3. Hold the adjustment screw with serewdriver ( and tighten the locknut with wrench B. 2B Locknut: 4.8 ¢ 0.7 kgm * After the locknut is tightened, check the clearance again % Adjust the other valve clearances according to the firing order in the same way as described above. 12-006 N855 SERIESMEASURING COMPRESSION PRESSURE MEASURING COMPRESSION PRESSURE Special tools Part Number PartName [Q'ty H | 795-132-6401 | Injector puller 1 ' Adapter 1 T | 795-502-1203 | Compression gauge | 1 AS tren measuring te compresion res, bec ales ea fens ore ona por Caught in reviving prt ofthe engine ius the valve clearance tnfore mesurng aero ety, tr TESTING. AND ADJUSTING THE VALVE CLEARANE 1, Loosen the locknut for injector lever (1) and remove the adjustment screw. 2." Remove push rod (2). 3. Remove mounting bolt (3) and clamp (4) 4, Pull out injector assembly (6) with injector puller H. 12-008 reer, TESTING AND ADJUSTING Ls N8SS SERIESTESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE 5. Install adapter I and tighten clamp (4) with bott (3) HE) Bolt: 1.55+0.55 kgm 6. Connect the hose and gauge J 7. Disconnect wiring (6) for the shutoff valve. QD Tote care not t tet the daconnected wring Someiote contact withthe machine bo. 8, Crank the engine with the starting motor and measure ‘the compréssion pressure. * Read out the pressure from the compression gauge when the gauge hand has come to a stand stil ‘# When measuring the compression pressure, measure the engine speed as well and confirm that the engine speed is within the specified range in the measure- ‘ment conditions N855 SERIES 12-009MEASURING BLOW-BY PRESSURE TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE * Measure blow-by after the engine has warmed up (oil temperature at least 60°C or water temperature at least 70°C) 1. Remove the rocker arm housing cover, * Unnecessary in the case on an engine fitted with a turbocharger. 2. Block up the air vent holes of each rocker arm housing. * When taking blow-by measurements, block up the air vent holes in order to prevent the pas sage of air from the cylinder head to the air intake side, ‘* In the case of an engine fitted with a turbo- charger, the air vent holes are plugged up. 3. Install the rocker arm housing cover Install blow-by check tool (1) over the oil filler or breather port using the adapter provided with the check tool. 5. Connect the check tool to U-tube manomenter (3) oF a pressure gauge by means of tubing, 6. Block up all openings (breather, oil filler, oil level gauge guide, etc.) except the one over which the blow-by check tool is mounted, in order to prevent leakage. 7. Run the engine and read off the blow-by pressure. % After completion of the above measurements, open up the air vent holes. NaSS SERIES‘TESTING AND ADJUSTING DETERMINATION OF RESULTS OF BLOW- BY MEASUREMENT AND REMEDY * The blow-by standard is specified as the value ob- tained at the rated output of the engine. At high idling, it is possible to obtain about 80% of the blow-by obtained at rated engine output. For this, reason, the blow-by standard is sometimes specified at high idling + When it is difficult to operate the engine at rated ‘output during field measurements, for example, take measurements under full stall operation or the previously mentioned high idling condition in order, to obtain a value similar to that obtained at rated engine output, + The blow-by standard is specified for an engine installed in a new machine. The actual measured value will thus vary depending upon the operating ‘time and maintenance condition of the machine, The measured blow-by value may sometimes abrupt- ly inerease depending upon the degree of overlap of the piston ring gaps or may vary depending upon the operating condition of the machine. It is thus dangerous to assume that an abnormality in the blow-by reference value is related to a fault in the engine, + If a measured blow-by value is considered to be abnormal, it is necessary to thoroughly investigate the following items which are related to blow-by. 1 Oil consumption 2 Exhaust color 3 Starting performance 4 —Oildeterioration % The main causes of abnormal blow-by area 1. Worn piston rings and liners 2 Worn valve stems and guides 3 Blocked breather 4 Abnormal combustion OF these, it is possible to check 1 and 2 by meas: treing the compression pressure. N85S SERIES MEASURING BLOW-BY PRESSURE 12-011 @MEASURING OIL CONSUMPTION TESTING AND ADJUSTING MEASURING OIL CONSUMPTION ‘Measuring oil consumption * Measure the oil consumption using oil level gauge (1) in terms of the amount of oil required to main tain a constant oil level ‘* In order to do this, itis necessary to perform the oil level inspections accurately. % In order to eliminate errors due to changes in oil temperature and oil circulation, inspect the oil at ‘the stop level at the commencement of operation. In the case of an engine in which the oil is poured in from the cylinder head, inspect the oil level after a lapse of at least 30 minutes from the time the ol is poured in, Oil consumption ‘* The oil consumption will vary greatly depending upon the size of the engine, whether or not a turbo: charger is fitted, and the operating conditions, etc. % It will also vary depending upon the operating hours, temperature and external pressure (high alti tude work), ete # In addition, the oil consumption will also increase ‘momentarily when the piston ring gaps overlap, Oil consumption rate * Because the oil consumption will vary considerably depending upon the type of machine and operating conditions, etc., it is very difficult to determine whether or not the oil consumption is normal simp ly by saying that it is X@ per day. Because of this the OIL CONSUMPTION RATE is used, This ex presses the amount of oil consumed for a given amount of fuel, after compensating for change due ‘to machine type (engine size) and operating condi tion, Oil consumption uel consumption Oil consumption rate = x 100% 12-012 N855 SERIES ®TESTING AND ADJUSTING MEASURING OIL CONSUMPTION Determination of oil consumption rate + In order to determine the oll consumption rate, itis necessary to accurately measure the fuel consump- tion in addition, of course, to accurately reading the oil level so as to accurately derive the oil consump- tion, Because the oil consumption will vary depending upon various conditions itis necessary to determine the oil consumption rate on the basis of measure ments taken over as long a period as possible (one ‘month is necessary). + If the oil consumption is quite large, take ap- propriate action as soon as possible. + Oil consumption on a new machine {one which has been run for no more than 500 hours) tends to be igh owing to the fact that the sliding surfaces are ‘not properly worn in (oil consumption tends to be 0.3 to 1.0% greater than the oil consumption on a ‘machine that is already run in. %* The oil consumption of an engine fitted with a turbocharger will tend to be high because of oil circulation to the turbocharger, etc. (oil consump: tion tends to be 0.3 to 1.0% greater than the oil consumption on a machine not fitted with a turbo- charger). ‘The oil consumption on a vehicle which has been run for a large number of hours will be high due ‘to wear of piston rings and liners, etc. % If an engine is run at high speed on a light load, oil ‘consumption will be high despite the low fuel con- sumption because of the fact that the oil circulation ‘quantity will remain constant and also on account Of the increase of raising oil from the piston rings due to the combustion pressure remaining the same. ‘When determining the oil consumption rate, it is necessary to take into consideration the aforemen tioned various conditions. It must be borne in mind, that a simple numerical determination will result in incorrect remedial measures. AAs a general guide, if oil consumption is 0.6 to 1.0% ‘greater than other similar type machine ~ exercise cca; if itis 1.0 to 2% greater -> consumption high; . if it 2% or greater > consumption very large or ex- 85S SERIES 12.013MEASURING FUEL PRESSURE TESTING AND ADJUSTING MEASURING FUEL PRESSURE * Check and measure the fuel pressure using a test bench, + This section describes a simple method of inspect ing and measuring the fuel pressure, which can be performed even in the field 1, Remove the fuel pressure outlet plug from the PT pump shutoff valve 2. Screw in the nipple, and connect up the hose and fuel pressure gauge (1) 3. Warm up the engine for a period of § to 10 minutes, % Continue engine warm-up until the water and oil temperatures enter the specified operating range (green region). 4, Read off the maximum indication on the fuel pros- sure gauge when the fuel control lever (2) is abrupt: ly pulled from the low idling position to the high idling position. # Because the maximum value is only maintained, for 0.3 to 0.5 seconds, confirm the reading by repeating this test 2 or 3 times. %* By carrying out the above simplified inspection and meaturement procedure, it is possible to obtain a value of about 90 to 100% of the fuel pressure ‘corresponding to rated output. % The results of this simplified inspection and meas- Uurement procedure can be determined as satis: factory if they are within about 85 to 105% of the fuel pressure at rated output (test bench standard) ‘taking into account measuring errors and measuring accuracy, etc. N8SS SERIESTESTING AND ADJUSTING PT PUMP CALIBRATION DATA NOTES: 1. Some calibration data show two or more set stand- ards. Setting to either standard is acceptable, but setting to the latest standard will facilitate adjustment of engine output after installing 2 pump to the angine. In other words, a pump preset to the standard in parentheses in the application column should be set, to the standard without parentheses at the time of overhaul. PT PUMP CALIBRATION DATA 2. If the pump sets to a different pump code, the code number punched on the pump nameplate should also be changed, 1,_MACHINE MODELS AND PT PUMP CODE NUMBERS Machine Engine able Engine No. | PT Pump . rah Specifications Noel Applicable Engine N Bari Pag 26139838 to 26155378 | GRI41 12017 D80A-18 Standard NT-855-¢ 26155979 and up Grui73 12021 26139849 to 26185897 | GRIT 12017 D85A18 ‘Standard NT@65¢ |} 26155898 and up GRut73 12021 Da0F-18 Standard NT-855-¢ Gr.s207 12024 oss-2 Standard NT-865-¢ | 26153623 and up Grstet 12019 PC300-1, 2 a 7 Peaooucs,2 | Standard 955.6 | 26162054 and up Grigg 12018 Po4oo-t Standard NT-855-C | 26163093 and up GRs203 12022 103202 teas ‘Standard NTA855 | 26198580 t0 160361 | GRWI38 12016 H3203 Standard NTA-855 | 26169352 and up Griz 12.020 wst6s-2 Standard NTAS55-¢ | 26164237 and up GRW217 12.028 wi702 Standard NT-855-¢ | 26178483 and up GR241 12026 wrgo Standard NT-865-¢ | 26169968 and up GR205 12.023 NB6S SERIES 12-015 @Sere ec] | ‘sarin |e i g sno a= — moment I . 2 sensenes [of eer ay SET eae ‘emma eto ss oe gan fe I a {stequinu apoo duind 14 Jo 10p40 oup u! pobuenty) W1VG NOILWUSIIVO -Zeuudg somanon SAN [41] ae : sen evs aamaer | i 7 angones fe [2 anateiemmeo [| sontegin [of ‘tardy ousnan | \ ye i en c ee 12-017 ® N85S SERIESail eae a0 oxrwae | sanpeats-oumen [s | f [- == ! zz wena ends inane |p : ames czar |e S| osomeoeee |, = == ‘S802 6 566i Sonreuta | = sa N85S SERIES 12-018| saa] sons fe i Aare | weer [al ene aortas fe] F ™ ‘603 103 i vesouv | 1 Naomi oadewnoos [o| F ~ a q ronan [i was — eas sense fo f aos | Sooner emesis oe wes aaewse | Samavrade wren | caine 12-019 855 SERIESun weoven [al asian | 2 ou ae aeavin | momma N85S SERIES 12-020e — ina omeawoes |» |¥] e | nave | emotes | comasettn |e |g r | “ waramsvmnvovon [ol f Nan i toca “ eons] senamsan |e “ eonesgine | ‘ao | amace |i waimoatay omens |e a oe | a ezoricis | wacunal wc arb fe 2-9981N | epon mats 12-021 N855 SERIESTansee meentom fo aceinnevvaon [a voce want | guecen = NSS5 SERIES 12-022 fo[= Te Pusan rd a senven |i nny veo | 8 = ; 12-023 ® 85S SERIESco ? wuts aay | en] i ee N8S5 SERIES 12-024— venom Jol | = : : 4 a marco 3 waren | - area | =m 0) ‘suds souasoy |» : 12-025 NBSS SERIES5 cum an ro le N855 SERIES 12-026‘TESTING AND ADJUSTING PT FUEL PUMP PARTS SPECIFICATION PT FUEL PUMP PARTS SPECIFICATION IDLE PLUNGER Code No. | mention B |omarsu Parts No.} CUMMIME — Code No, | Dimension B |comatsy Parts No. | Summins 3 [530-837 | esto-7iesi0 | 41623 1s | 938-004 z 745959 7 [saa—sso | scio7i-e%20 | vaieze 187 | 940-056 = 145954 10 [sss—ses | soro7ee00 | 1si625 700 | 9si—o09 eS 746965 12 [668-575 | se1o716000 | 1ai626 192 | o7—oa2 . 145066 15 [80-586 | so0716450 | 120000 105 | oa7—008 S 145957 a7 [892-601 | e610716000 | 140sr7 197 | 999-1007 = "45950 20 [608-613 | e610716070 | 191620 200 | 1032— 10.20 7 145959 22 [619—626 | es10716000 | 141600 202 | 1025-1039 7 7465960 26 [631650 | est07re000 | _ra1691 208 | 10.38 — 1046 7 745967 27 [eaa—es2| estorresio | 141692 207 | 1050-1088 7 145962 30 [657-664 | 610716520 | iatex9 210 | 1063-1071 7 145963 32 [660-777 | esio71e30 | ra1604 212 | 1076-1088 . 145964 36 [6a2—600| esio71e540 | 140022 215 | 1088— 10.96 . 145065 37 [e94—702 | esio7ie550 | va0se 27 | i101 1109 7 145966, ao [707718 | eo107-6600 | 197570 20 aae— nt . 145967 a2 [720-728 | e61071-66570 | 140020 a) 7 145968, a5 [733-740 | os10-710580 | 198862 2s | i1390— 147 = 146969 @7_[746—753 | co10710590 | _ 1a08ze za | 1152-1160 = 148970 30 | 758-766 | eo10710610 | 140025 20 | 168-1472 = 145971 2 [77-779 | eerie | 129618 Ee = 145972 6 [7aa—7or | esio71e600 | 129610 235 | 1190-1198 148973 57 [796-804 | esi0716600 | 140026 a ee = 145974 0 [0o—e17 | sei0710050 | 140027 2 [ez2—az0| ssi0716060 | 191636 8 _[as4—ea2 | eo10710070 | 141697 67 _|[sa7—ass | esio710000 | 141008 17 |a60-867 : 145947 1m [a72—e80 = 145948 175 | ea6—a93 . 145949 177 [98-906 | = 145950 10 [911-918 7 145951 1a [ozs—oa1 = 145952 NOS5 SERIES 12-027 @PT FUEL PUMP PARTS SPECIFICATION GOVERNOR SPRING TESTING AND ADJUSTING Komatsu Part No. {CumminsPart Wo. | Golorcode | Fregtenath | Springrate | Wire dla. | Number | Remarks TOG | OrangehWte var | 58 7o71+H | Le Blue/Orange 1a? | 6s 7o711d | Le. Green/wite 130 | 62 70711 | Orange/Lt. Groen aes | ~6610-71.5510 143247 ‘| Yellow 3777 oss | 200 | ta 6610-71-5520 143248 | Yetlow/Green 377 os | 20 | 79 worn 6610-71-5690 142249 | Yellowwnite 3797 ose | 208 | 7a 6510-71-5540 143260 ‘| Rearwmite a7 0.46 218 1 707114 (6610-71-5560 143251 | Bive/Purpe 377 oat 210 | 8a 707118 (6610-71-5560 149252 | Rea 3777 oss | 203 | 76 (6610-71-5570 143253 | Rea/Yetlow a7 030 | 203 | 86 ore (6610-71-5580 143254 | ReaiPurote 3777 0.25 1 | 78 136158 6510-71-5590 143255 | Red/Green “an 020 10 | 78 707110 6610-71-5610 143256 | white/Bive 37.77 014 fey |e someF (610-71-5620 140073 | White aan2 as [218 77 6610-71-5630 140479 | Green aan2 oat zie | ea (6610-71-5640 144490 | Orange 3142 Oe oe re (6610-71-5650 r4ae1 | Light tue 3142 oso | 203 | 36 16610-71-5560 147202 | Pome 35.68 Ger oles (6510-71-5870 147293 | Orenge/Yotlow 33.58 ova | :230 | ea (6610-71-5590 147204 | white/Purole 31.62 om | 250 | 83 (6610-71-5580 147295 | Orange/Red 3142 ose | 230 | 60 6610-71.5710 147296 | Purple/Green 31.42 os | 200 | 58 152232 | Bue 31.42 2 [7a 6610-71720 159235 | Green/Orange 3450 oso | 203 | a6 6610-71-5730 153236 | Green/3ive 3459 oas | 208 | 79 6610-71.5740 152237 | siue/Yellow 3459 oat 213 | 86 (6610-71-8750 153238 | siue/Red 3459 oss | 203 | 76 157059 | Biue/Orange 3777 ors | 204 | 63 177629. | Purple/Orenae 32.28 wat 20 | 61 3000032 | Purple/Le. Blue 442 oss | 203 | 78 3000033 | Furple/Orenge 442 oso | 203 | a6 N855 SERIES 12-028 ®TESTING AND ADJUSTING PT FUEL PUMP PARTS SPECIFICATION Komatsu Part No color code | Freetenatn | Soaneraw | muecia | Number | Romar 3000834 | Ble/Le Bue “| om | i | 78 7 3000935, Green/Lt. Blue 44.12 0.20 183 90 soos | veliowtiaue | ara2 | 073 | 2a | 07 3000037 | WhierLe tue aa | oes | 2m | 70 3000838 | ea/Le Bue aia | ose | 2 | 74 3000839 | White/Orange aa | os | 29 | 79 sooo | orngertiawe | sraz | a7 | 218 | 77 3000081 | Greonmmite wa | om | 2 | 04 2001146 | Yelow/Purpie wos | 020 | 10 | 90 2001147 | Brown woos | ozs | 19 | 07 2001148 | Brown/Green woos | 030 | 203 | 07 z 3001149 Brown/ White 40.64 0.36 2.03 7 e 3001150 Brown/ Yellow 40.64 O41 248 85 ~ 3001151 Brown/Red 40.64 0.46 248 1 2001182 __| Brown/lue wos | ose | 21 | 73 aoortss | Gey wos | os7 | 25 | 80 3001184 Brown/Orange 40.64 063 2.34 74 2001185 | Brow/txeue | 3450 | 052 ma 3001186. Brown/Purple : 34.59 057 234 73 : 3001157 | Grey/Yetiow 3459 063 234 74 2001188 | Grev/Green sso | oss | 20 | 70 oo 3001159 Grey/Wnite 34.69 0.73 234 67 001160 | Grey/ned sia | oss | 2% | 55 a001161 | Grey/oue sa | to | 2m | 54 2001162 | Grev/8rown ee ee 2001163 | Grey/Orange aia ee teen |oce N8SS SERIES 12-029 @PT FUEL PUMP PARTS SPECIFICATION TESTING AND ADJUSTING TORQUE SPRING Komatsu Part No. [Cummins PartNo. | Color code | Fregimath | Spararate | wire. | Number Remarks 16610-71-5100 138768 | Red 1626-1676] 0.18 142, 65 6610-71-5110 138769 | Bue 1626-1676] 0.21 112 87 6610-71-5120 138780 | Green 1626-1676] 0.25 112 62 6610-71-5130 198781 Yellow 16.26-16.76| 0.29 1.19 56 6610-71-5140 198782 | Rea/Biue 16.26- 16.76] 0.32 1.19 52 6610-71-5160 198783 | Red/Green 1626- 16.76] 0.36 1.30 59 6610-71-5160 138784 | RediYellow 16.26 16.76] 0.39 1.30 55 6610-71-5200 198785 | Red 1499-1549] 0.18 ae 65 6610-71-5210 198786 | Blue 1499-1549] 0.21 112 87 6610-71-6220 138787 | Green 1499-1549] 0.25 112 52 6610-71-5230 13878 | Yellow 1499-1649] 0.29 119 56 6610-71-5240 138789 | Red/Bive 1499-1649] 0.32 113 52 .6610-71-5250 138790 | Red/Green vag9— 1649] 0.36 1.30 so 6610-71-5260 198791 Red/Yellow 1499-1549] 0.99 1.30 85 (6610-71-5270 138792 Blue/Green 1499-1549] 0.43 1.30 82 £6610-71-5300 198793 | Red 13.72~1422| 0.18 a2 65 6610-71-5310 138794 | Blue 13.72-14.22| 0.21 112 87 6610-71-5320 138795 | Green 19.72-1422| 0.25 12 82 6610-71-5330 198796 | Yellow 1372-1422] 0.29 1.19 56 6610-71-5340 198797 | Red/Purpie 1372-1422| 0.92 118, 52 6610-71-5360 138798 | Red/Green 1372-1422| 0.96 1.30 59 6610-71-5360 138798 | Red/Yellow 1372-1422] 0.39 1.30 5s 6610-71-5370 198800 | Bive/Green 1372-1422] 0.43 1.30 52 8610-71-5380 198801 Blue} Yellow 13.72- 1422] 0.48 1.30 47 6610-71-5390 198802 | Greeny/Yetlow | 12.45- 12.95] 060 137 54 6610-71-5400 198803 | Red 1245-1295] 0.18 1.12 65 6610-71-5410 138804 | Biue 1245-1295] 0.21 112 87 6610-71-5420 138805 | Green 1245-1295] 0.25 1.12 52 (6610-71-5430 138993 | Yellow 1245-1295] 0.29 1.19 86 18610-71-5440 138004 | Red/Bive 1245-1295] 0.92 1.19 52 6610-71-5450 199995 | Red/Green 1245-1295] 0.36 1.30 59 6610-71-5460 138996 | Red/Yellow 1245-1295] 0.39 1.30 55 12-930 N55 SERIES.‘TESTING AND ADJUSTING PT FUEL PUMP PARTS SPECIFICATION Koma Part No, [cumminsPart No. | Color code | Free lenatm | Springraw | Wiredia, | Number | Remarks wororves | 198007 | BueiGeen [1245-1205] 043 | 130 | 82 coio7vea0 | teem | awervenow | 1245-1205] 048 | 120 | a7 e510 71500 | 198000 | Geen/velow | 1245-1205] 050 | 137 | 54 25107-5170 1a08ee | ewerGren | te20—s078| oma | 190 | 52 61071-5180 120505 [euervenow | 1626-1676; 046 | 190 | 47 610715100 | 190688 | Geenivelow | t626-1676| 050 | 137 | sa es107rs290 | 129687 | Bueivelow | taov—15a0| 04s | 130 | 47 esio7rsm0 | 10052 | Geen/veuow | 1490-1540| 050 | 127 | 54 ‘42008 | wniwave [1626-1676] ora | 108 | 63 42007 | wmierveiow [1626-1676] om | 108 | 77 ‘42600 | wmiwiGwon [1626-1676] 007 | 089 | 67 142009 | wniw/ave [rase—tsa9] ora | 104 | 6a 142700 | wniervenow | 1499-1540] 011 | 10a | 77 vazie1 | wmiterGmen | tag0—1549| 007 | o@9 | 67 vazr02|wniwrave | 1a72—vaze| ora | 104 | 63 142703 | wmiervetow | 1a7a—vaze] on | 104 | 77 142704 [wniwiGeen | 1372-1422] 007 | o@ | 67 142705 [wnneieue | 1245-1205] ora | 108 | 63 142706 | wnieivelow | v2as— i205] on | 100 | 77 v42107 | wniteiGren | 1245-1205] 007 | 099 | 67 142043 [wwiweue | 2iaa—anea| or | 108 | 69 142804 | Red aiae—aree| ore | az | 68 142005 | Blue visas] or | 19 | oe vaza0e | Green aise—aiee] 025 | ise | 6a 142350 [wmiwoue | 2007-2057| 014 | 10a | 62 waza | Rea zo7—20s7| ore | 12 | 65 420582 | ave z007-2087| 02 | 119 | 68 va2esa | Green 2007-2087| 028 | 149 | 6a vaaase | Yetow z007-2087| 028 | 139 | 86 va2ass | Rea/owve zoor-2s7| 032 | 190 | 63 va2as7 | wniwrove | 100-1930] 018 | 104 | 63 vazase | rea veeo-1920| 027 | 12 | 65 N855 SERIES 12-031 @PT FUEL PUMP PARTS SPECIFICATION TESTING AND ADJUSTING Komats PartNo. |cumminsPare no. | Coiorcoge | Fes rath ‘agar | Moh ‘number | Remarks vaa080 | ave weao— vos} anv | 170 | ea 142060 | Green weao-wea0] ozs | 119 | 6a va2001 | Yalow vea0- 1000 028 | 110 | 86 2082 | meseive west] om | 100 | 63 aeca | raGwen | 860-1050) 036 | 130 | 50 vaece | wniwraue | s7sa-r803] ora | 10a | 63 va2065 | Rea vea- wos] oar | aaa | 86 vw2066 | Bue w7sa— eos} oat | 109 | es 147867 | Grn 7a 1803] oa | 110 | en 2868 | Velow v7sa—1e03] ozo | 110 | 66 ‘2869 | Redeive w7s0- asl 0a2 | 130 | ea va2e70 | aediGren [72-1803] 030 | 100 | 50 ao020«7 | wie weae-1676] 058 | 137 | 52 soazos | wninitea | v628-1676| 087 | 127 | 0 a02049 | Brown 1626-1676 081 | tar | 40 soozis0 | srownimed | 1626-1076] 084 | iso | se "3002081 Brown/Blue 1626-16.76| 0.68 1.50 55 aaoz0s2 | erowignen | 1628-1076| 07 | 180 | sa 002083 | vite vaso 16a0] ose | 137 | 62 souzise | vmiwitea | v490-1640| 087 | 137 | 80 2002085 | Brown vaoo- 1500) oer | 137 | as ee Ce 3002087 [eromiowe | r490-1640| 068 | 150 | 35 3002086 | srown/Gren | 1499-1540/ 071 | 180 | 59 +—___l 12-032 N55 SERIES ®TESTING AND ADJUSTING PT FUEL PUMP PARTS SPECIFICATION MVS GOVERNOR SPRING ewmmirarno,] comes | aie [RGact | “inal” | MESir” [renee cones (een [na seers) usa | sass |e SS aceecaner| Slaoe | aon [Eos scion ffs jaws) oa oo ao Ser ee ce sone eel [en ieee Soe ame are (6610-71-6210 110460 ‘Orange 38.05 40.08] 0.20 1.60 4 So ssio7 a0 So ie N85S SERIES 12:933PT FUEL PUMP PARTS SPECIFICATION TESTING AND ADJUSTING MVS GOVERNOR PLUNGER Komawurar io. | cummnsParno, | case | colorcade lamer (nt emer 6560-7950 e080 ° Pee 7910— 7014 86 Q ea 79107914 14462 5 aie 79167910 aes 1 ue 7916 — 7910 76806 2 Gren 7.930 7.936 7008 2 Gree 7.900 7.996 168007 a Yelow 7938-7942 160908 3 Yeliow 79067942 AFC SPRING Komatsu Par No. [cummins PartNo. | Color cage springen | wide. | Number | Remar eri0-72:2820 | 179608 | white 036 267 62 eno7aze0 | 170000 | ave uae | om | 207 | aa ero722000 | 170000 | Pole uae | on | so | «6 eno7azee0 | t7aeie | Sielamite ame | oa | aos | aa erio7aas10 | _17a8ia | Bieldrange nae | ter | aa | a7 erio722920 | 170810 | Ble/Orenge Ee ee az | ia | am | aa enoraa0 | 179m eriovaasc0 | 179022 | whiwiGreon Pr ee eroraaeeo | 179800 eno7226m | 170824 | whieiRes vas | vat | ons | 38 erio7a200 | 178625 | white/Yelow wae | 1m | 276 | 4a ero7aaiz0 | 179828 | Grennes vas | 198 | am | «2 ero7aa10 | 170800 | GreniVeliow wae | 2% | ane | «0 erio7aaieo | 170002 | Orng/Purle uae | 2m | 3 | 30 eroreaice | t7aaaa | RediPurle sie | 250 | are | 97 eno7aaai0 | 179836 | Purl/Velow nae | 200 | so8 | «0 erio7zazs0 | 2000802 | Usm Gwen sas] 208 | ase | 38 12-034 B55 SERIES ®TESTING AND ADJUSTING WEIGHT ASSIST SPRING PT FUEL PUMP PARTS SPECIFICATION Komasu PartNo. [cummins art No. | Colorcode | Freelenatm | Springrate | wires, | Number | Remarks 143808 | ea 1590-1666] 047 0010712140 va3ee7 [ave vas—t5a1| 028 | 07 27 vase4e [wri v306-1987| 029 | 076 20 v43ee9 | Veiow vei9-v609| 014 | 076 | 10 143850 | Reaiveliow | 1765-1842] 0.08 vaaes1 | ReaiBrown | 1168 1245| 042 csorrrziao | 142052 | Aeaivelow [tiee—i2as| 02s | on | 05 42862 | RediBrowm | 1168-1245] 0.30 143064 | Bue/vetiow | 1168—1246| 026 143055 | wnterveiow | 1168-1245[ 012 | 056 | 100 eeio7va200 | 416020 ‘| whitened wes4—1740| 047 | a1 | 100 50662 | Green v7a5—1842| 009 | 086 75 2010.71-2190 wie yer-1790| 042 | 08 | 10 N85S SERIES oePT FUEL PUMP PARTS SPECIFICATION. TESTING AND ADJUSTING ADJUSTMENT SHIM ara Name Komatei Parts No. [Cummins arts No. Theknes Famarks wero7iaao | va2ire 076 eei0 71 1280 70760 02 “Trot adjustment sim e610-71-1280 7OrsOA on e510.71-41290 707608 008 eo10.714960 won oat Governor sexing shi w61071 600 Tora 035 e107 670 Torre or8 wero7isa60 | 10188 oat Torque soring shim eero7i1a70 | 01892 028 cer0-7i140 | 101888 er ‘Weight ait hin ceroriaie | 1ast70 081 | 038-064mm esiorraai0 | 188978 031 eeiorae20 | 163080 028 IMS governor eo aivstmen shim eororrae7o | 165081 078 wero 713400 . on8 510718310 70811 ost IVS governor adustment shim e51071 600 7081-8 028 3510.718990 7081-8 a8 12-036 B55 SERIES ®‘TESTING AND ADJUSTING INJECTOR SPECIFICATION INJECTOR SPECIFICATION DELIVERY VOLUME Tapeor AY Par Ef Giow porch] BEER [orrono [oom] ea” | Ma ge ct eriorrao10 | anaoose fir7—s76] 175 | 120 | 8-o005-xie | coco | oes” —o.020" errorrsor | s0oso90 [75178] — | 120 | 8-oone'xse | oa | ooze" 0.00" erzivson | s00se43 frar—vz2] — | 120 | e—ccoesxi7 | 00a | oo1e"—oore ADJUSTMENT ORIFICE ine donor Tae or Koma Paso, umm Parnes, enn Kama Par No. [Cumming PartNo fp curries wim [ ose | ors era 0 wees | 084 | 0038 eriotT 3410 amas | os | 001s erro tra820 vreaa | 088 | 00s e710 113420 wee | on | 001 eriotrae0 vss | 089 | 0038 erro 13480 7a | 04s | oot? ertosrseao vreaa8 | 001 | 0006 crorrasso | 177280 | oa | oot __ert0-i-0s0 vmesa7 | 094 | 00s? crorrseco | 77287 | oa | cov _@7t0-1-000 ves | 097 | 003s crorrsieo | 77288 | ost | 000 e7t0.1070 vme80 | 098 | 0000 crorrse7o | 77260 | oss | 00a 6710-1 90 i700 | 102 | 0040 o7io113460 700 | 086 | 002 ertorr000 ime 104 | 00m corso | 7701 | oss | 000 enoaari0 ime | 107 | 008 cnorasio | 77002 | ost | oa _erto1n 720 ime | 109 | 00 erorrasco | v7703 | ose | og _eniorva700 ease | 112 | 0088 cota | v7 | ose | cas enoarareo | veo | 144 | oo eroirsso | 17708 | cas | 0a entoramo moe | a7 | 0oes eriotrae60 | 177266 ‘| om | oom vmeee? | 140 | o0a7 e7i0-1-3560 77 | 074 | 007 veo | 122 | oom erie-13670 708 | 076 | 0000 ertoara7e0 wooo | tae | 00 e710-13660 i700 | 070 | 000 errotra7e0 vee | a7 | 0080 er10-13500 72 | ont | 00s N855 SERIES 12-037RUN-IN STANDARD TESTING AND ADJUSTING RUN-IN STANDARD ‘© Load are given for the case of the dynamometer arm length is 716 mm. This list shows the standard on condition that the fan is removed. Order Engine | Machine i model | "moda, 7 5 = zy j Running time [min] 10 20 20 10 Engine sees | cpm | 550 ~ 1000 | 1400 | 1880 oo les pm | 650 ~ 600 8 mes5¢ | pcso0us.,2 "2 oa ww} 0 37 at 108 Ourpur wl] oo 38 110 194 Running ime [min] 8 10 20 30 10 Engine speed | rpm | 600-650 | 1,100 | 1.4 1600 | 1,800 peoacre | Entinesoeed |e 100 804 ee ed s/o 33 6 98 131 Output we} 0 36 925 137 236 Punningtime [min] 8 10 20 30 10 Engine speed [rpm | 600-850] 1,200 | 1,550 | 1.750 | 1,950 e0F.18 Looe | 35 7 105 140 output we} 0 a 105 1s | 265 Funningtime —min.| 5 10 2 30 10 Engine speed —|rpm | 600-650 | 1,150 | 1480 | 1,700 | 1,260 9552 Load | 0 38 70 104 142 Output He | 0 39 935 m 255 Nres5-c Running time —|min.| 5 10 20 30 10 Enginespeed | pm 600-650] 1,100 | 1.400 | 1600 | 1.200 eee gine os Perea | ioe w| 0 35 70 106 141 ourpur wl oo 38 95 165 246 Funning time [min] 5 10 20 30 10 Engine speed — |p [670-730] 1300 | 1,750 | 2000 | 2.200 wr702 ood | 0 28 37 85 113 ouput He] oo 38 7 165 242 Funningsime min] 8 10 2 30 10 Engine peed | pm [670-730] 1400 | 1.000 | 2100 | 2200 wigoa ood w] 0 2 6 96 128 ourpue we} 0 “4 12 196 235 12-038 N86 SERIES ®TESTING AND ADJUSTING RUN-IN STANDARD Order Engine | Machine a ‘mose! | "mods! 7 z a 7 a % Running time min] 6 10 20 30 10 wogme |ereremms | mm e10-e80 | 1400 | 1900 | 2100 | 2200 Hos20% Lose | 0 45 ot 136 181 ourpur uw] oo os 164 rss | 416 NTABSS- Running time [min] 6 10 20 30 10 Engine rom | 610~: 1 a ine speed 610-680 | 1.400 800 | 1.900 | 2100 es) Load | 0 a 96 137 182 ouput we] oo 55 148 252 an N55 SERIES 1 2039PERFORMANCE TEST CRITERIA PERFORMANCE TEST CRITERIA TESTING AND ADJUSTING Engine | Machine aes Specitied value | Engine speed |Dynamometer load] Outout roca model el uly eauippea) trom) (HP Flywheel horsepower | 180HP/1,860rem | 1,845—1.865 | 1030-1132 | te05— 1985 sximum torave 300rpm | 1,200 - 1, 1189 126.1 = |i 85.5HP/1.300r0m | 1,200- 1.400 | 118.9~ 126. Nes5¢ | pesooLe-1.2 ? | igh iting spsea | 1,986 ~ 2,.085r0m | 1,985 - 2,085, ° ° Low iting spec 850 -600~pm | $50 ~600 ° ° Fiywhee! horsepower | 220HP/1,800rem | 1,795—1,805 | t278— 135.1 | 2300— 243.2 imum torque | 105kgm/1,250rpm | 1,180~1,350 | 149.3 ~ 158.1 : poate | dita = BBSAE Pt BSAEPB | sion ding speed | 1,900 2,000:0m| 1,900 ~ 2,000 ° o Low iting speed 600 -650%~m | 600-850 ° ° Fiyaheel norsenower | 260H°/1,950rem | 1.945 —1,955 | 1399-1481 | 2645 — 280.1 Maximum torque |118kpm/1400%pm | 1,300~1,500 | 168.2~173.0 - 80-18 High idling speed | 2,100 ~2,200%0m | 2,100 - 2,200 ° ° Low iting speed 600 -680%pm | 600-650 ° ° Flywheel horsepower | 245HP/1,860rpm | 1.845— 1,855 | 1379-1457 | 2550-2697 Maximum torque |112kgm/1,200¢pm | 1,100~1,300 | 158.7 — 168.0 - 9ss2 | High iting speeé | 2,000~2,100pm | 2.000 — 2,100 ° ° Low idling specs 600 850rm | 600-650 ° ° NT-855-¢ Flywheel horsepower | 233HP/1,800m | 1.705—1,805 | 1371-1451 | 2396-2536 imum torque | 116kgm/1,200rpm | 1,100 ~ 1, = 1704 = 1 ios on) 300 | 1606-1 Posaoues High iting spsed | 1,950 ~ 2,050%0m| 1,950 ~ 2,050 ° ° Low iting speed 600 650rm | 600-650 ° ° Flywheel horsepower | 288HP/2,200—em | 2195-2205 | 1135-1201 | 2423-2563 Maximum torque |100kgm/1,400rpm | 1,300~ 1,500 | 1428 -151.1 - wi702 High idling sseed—|2.380~ 2,480¢pm| 2,980 ~ 2.450 ° ° Low iaing peed 670—730rem | 670-730 ° o Flywheel horsepower | 220HP/2300—pm | 2.206205 | 1280-1384 | 2956-3023 Maximum torque |116kpm/1,600rm | 1,500-1,700 | 1609-1706 = wieo High istinaspecs ——|2.430-2,530:0m| 2,430 - 2,590 ° ° Low iting speed 600 700rpm | 600-700 ° ° 12-040 ® N8SS SERIESTESTING AND ADJUSTING PERFORMANCE TEST CRITERIA Torave Fusiprire | coolant ampere | Lubricating ot | Lubricating oi [Exes emma: tiont ‘isle ‘ure Cor | temperature Cc) | pressure tearm’) [We CC) (> or . a-95 70-90 mw 100 | 35-58 | wax650ra 981-903 . 70-90 20 - 100 S Max, 620+ 3¢ ° . 70-90 0-100 . . ° = 70-90 Min 80 Min. 1.0 . = 70-80 70-20 wo-100 | as—5s | Mex.co0+a 1069-112 . 70-90 0 ~ 100 . Max. 690+ 3 ° = 70-90 80 — 100 . . ° . 70-90 sin 20 Min. 1.0 - = 97-107 70-90 wo-10 | 35-55 | maxesora 1204-1239 . 70-90 80 — 100 . Sox. 080 +21 ° = 70-90 20-100 : = ° . 70-90 Min 80 Min. = . 75-87 70-90 wo-t10 | 35-85 | maxesora 1136-1203 . 70-90 0-110 . ox. 680 +21 ° 7 70-99 20-110 . = ° . 70-90 Min, 20 Min. 1.0 = = 75-90 70-0 wo | as—ss | Max osors H15—122 7 70-99 a= 110 7 Mx, 690+ 38 ° = 70-90 0-110 = . ° : 70-90 Min, 80 Min. 10 . = 96108 70-90 w-10 | 95-55 | mexesorar 1022-1002 7 70-90 80-110 7 Max. 680 43 ° 7 70-90 80-110 = . ° 7 70 90 Min. 80 Min. 1.0 . = Waa 128 70-90 wo-10 | sess | waxesorar 1152-1222 . 7-90 0-110 . Max, 650 +3¢ ° . 70-90 20-110 = . ° . 10-90 Min. 80 Min. 1.0 . N855 SERIES 12-041PERFORMANCE TEST CRITERIA TESTING AND ADJUSTING Engine | Machine Engine speed |Dynamometer loud] Output mode! model Aetl toe) ‘kal (HPI Flywheel horsepower | 408HP/2,300mm | 2295-2305 | 1760-1852 | 40874260 Maximum torque |142kgmn/1,700rpm | 1,600~ 1,800 | 193.7 — 203.9 - 0320.2 High iting speed [2-430 ~ 2,530 pm) 2,430 ~ 2,530 ° ° Low idling speed 600-650%pm | 600-650 o ° Flywheel horsepower | 408HP/2,3000m | 2.296- 2805 | 1760-1852 | 4087-4260 Maximum torque |142kgm/1,700%pm | 1,601,800 | 193.7 - 203.9 - NTasss.c| 403203 High iting speed |2-480-2,530mm | 2,430 — 2,530 ° ° Low iting speed 675 726%pm | 675-725 ° ° Flywheel horsepower | 364HP/2,100%~m | 2.005-2,105 | 1764-1874 | 3594—281.7 wstes2 | Maximum torque |140kam/1,500rm | 1,400—1,600 | 191.3 203.2 . (S231 7 High iting specs | 2.430 2,830rm | 2430 - 2,530 ° ° Low iting speed 610-650rm | 610-650 ° ° N8SS SERIES 12-042 ®‘TESTING AND ADJUSTING. PERFORMANCE TEST CRITERIA Tora] Faslpomere | Cooant meme | ubreainagit turning, Loree) fea emt iegiem') sure Pe” | cemperatae CC) | pres tgiem? = 146156 70-95 w= 10 35-55 1987-1480 ° 70-95 90-110 . Max. 700 +38 ° ° 70-95 80-110 7 7 ° ° 70-95 Win. 80 Min, 10 : = 146-158 70-95 10 35-55 | wax 7000 1987-1460 ° 70-95 e- 110 . Max 700 +3¢ ° ° 70-95 s0-110 - - ° ° 70-95 Min. 90 Min. 1.0 - ~ Wa 192 7095 3-10 35-55 | mec saorar tert ~ 1458 : 70-95 80-10 - Nox. 690 +3¢ ° 7 70-95 0-110 - . o . 70-95 Min. 80 Min. 1.0 = NB55 SERIES. 12-043 @TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST TESTING AND ADJUSTING TOOL LIST No. | Tering and acting item Fault finding to! list PartNo Remarks + | Ensine specs Mulisachometer 799-203-8000 | Depita eading: 60 ~ 20,000 rom 2 | eae ss. 1.300 ~ 1.300 Battery coolant tester 795-500-1000 | Fase enparatarefeaing eoeeere «arama = = 200'e z Thermisor temperature uae | 790-500-1300 3 | Exnust temperature 0-100" © | Loteieatng ol presure 0 10Kaiem* 7 | Feel presre (= 20 kalem*™ @ | tnakepresure, exhaust pressure | Engine pressure mesturing kt | 799-209-2002 | 0 — 7,500 mmHg | Blow-by pressure 01,000 mmis0 10. | Intake resistence =1,000 = O mms 0 11 | Compression presse Compression gouge 796-502-1203 | 0-70 kafem* 12 | Blow pressive Blowby checker 799-201-1603 | 0-500 mmHtiO 13 | Valve clearance Feeler gauge eee | eee 795-562-1300 | 0.36, 0.69 mm 14 | exroust gos eater Mandy smoke checker 7ae-201-9000 | Pitines 0 10% wit nanderd color 18 | woterana ue content not! | Engine oi checker 799-201-6000 | Moved wit 0.1 and 0.2 water 16. | Prpump tel presuce Fuel presure gauge 799-201-1200 | 0-25 kglem* 17 | Pr pump vacuum pressure | Vacuum gauge 799.201.1200 | 0-70 ka/em* 18 | Inisetor timing “Timing fixture 795-140-1608 19 | coolant quality Water quality teter 799.202.7001 | PH, nitrite ion concentration al | eee cere ee: Radistor cap tester 7992029001 | 0-2 kgiem* 21 | racator blockage wind somes) | Anemometer (Airspeed guge? | 799-202-2001 | 0 - 40.m/e 22 | Engine cranking ranking it 795610-1000 22. | electrical circuit Tester Commeriatv | Curent, Voltage, Resistance N8S5 SERIES 12-04: g45TESTING AND ADJUSTING DATA TESTING AND ADJUSTING TESTING AND ADJUSTING DATA Enuine model Ness Nrasse oo 9630052 Oa0Ae98 alert PC300LC-1,2 (DB5A,E,P-18 Tanderd | Ferman | —Siandard | Panne ‘acral ee eee value value value value High idling we ‘om | 1,5 — 2,085 | 1965 - 2086 | 100 - 2,000 | 1,00 - 2,000 | Ersine soma i Lon ing speed rom | ss0-600 | sso-eoo | coo—cs0 | so0-cso : & ve rom |Win 180 = in 180 = | Necenry staring = =20%e itn seating ssn | com | Min. 100 . in 100 - Intake ressance | Atrated ovout mmo] mux.e30 | 60 | woxcao | 560 Intokapremre | trata ouput mig} = - 7 . exnauetprine | Atened over mig} = 7 7 . E | exaust mperatore | ANSBHG gy | 2c | ox.ca0 | Max.c20 | tax.630 | Mex. 680 5 ls 2 | exaust gas color son | = ae : 3 At high iting inde | stax 25 36 Mow. 26 38 : rates [am | oss 0268 = a cols | = Exhaust valve mm 0.69 - 069, a Vive clorance | aioe | an | 098 ees eta = arm exnmuavere | mm | 089 . oso . : Oi temperature: 40 —60°C | kalem® | min. 92 2B Win 20 20 § | compresion sresure | : {asin weed trom | (230-260) | (220-260) | 1170-180) | (170-160) FT oiomby momue [ALMA cone mmtno| mox.t00 | 200 | Man t00 | 200 Ape At high iting oom | 5-65 | as-se | esse | aes 8 | atS0' oi mee 2 | ere! Mi 80°C |e tow iting raion? | Min. 1.0 07 into | mint. § [on wmpwewe | Allwaed (lin cil pan) 100 | 10 | 0-100 | 120 i 3 | oit consumption ratio | Acontinuous rated output | 4, | aan. 1.0 18 Max. 10 18 al At rd ouput rst? | 25-05 = 70-80 : BE] Pt pum tus pressure | 5 Cuick scsaraton kalem* . . ren ae: 70-90 100 70-90 100 ave opening wmperatue | ve | 705-785 | mazes | ms—yee | 145-705 Twermontet function | Full opening temperatuwe | °C 80 . 0 . Full opening it mm | 10x05 | t0s05 | tos0s | tos08 Radiator pressure vaio | Obeningereswre | tgiem= | 075201 | 0.75401 | 075201 | 078201 Fon see Acenaieratedspeed | wm [1at0-1970| 12m | oso-oo0 | 020 Fane wnson | Deets pied wih | Se page 12.040 12-046 855 SERIES o‘TESTING AND ADJUSTING TESTING AND ADJUSTING DATA wreeee aor.18 vss B90, wi7o2 Tagged] eqeae | Sagas | Pequioe | Saar] temas | Sangre] Page 2.100 - 2200 | 2100 2.200 | 2000 2.100 | 2000 - 2100 | 1.960 - 2080 | 1.980 - 2080 [2.980 2so [2360-2460 ca -6s0 | so0-cso | coo-eso | so0-eso | coo-eso | soo-sso | o70-r50 | 670-700 win 180 ~ tin 180 = win 180 = win 180 ~ win, 100 . tin 100 . win 100 . ta 100 . ioe 50] con Une so | nao soe (me ce se een wwox.680 | ox. 660 | wer.e90 | oxo | Mox.6e0 | ox690 | axe | ax. 680 ox as wes | 78 | mmos | 78 | mmes | 75 ox 25 mx2s | 35 | moze | 35 | moze | 35 036 = 036 . 038 . 036 . 069 - oo . oso . 09 . 036 = 036 = 038 = 036 = 069 | - 069 - 069 - 069 - win 28 * win 28 2 win. 20 ~ win 28 70 t170= 100) | 1170=1001 | a70—180 | r70—100) | cr70—100) | ar70—100) | (270—100) | «70~ 1001 Se ee eee ae-ss | as-es | as-es | as-es | os-es | ss-es | asses | sesso wint0 | into | ainro | 07 tin. 1.0 o7 winto | o7 Sa ee a eer wai | v8 | wnro | v8 | wnto | a8 | wmvo [vs 70-80 . 73 87 = 75-80 — [ee-we | mo-00 | 10 | w-e0 | 100 | vw-s0 | 100 | 70-0 100 745-788 | 745~785 | 745~785 | 75-705 | 725—7a5 | wes—705 | Teomves | TeS— 70 Py - % . * - so . tosos | ws0s | wxos | sso | weos | tor0s | s0s0s | 10205 a7e201 | o7sroa | ovssoa | ovsvor | o7svo1 | ovszor | ovevor | ovsvo iore— aaa) 1008 fraoo—1ae0] 1260 [isss—vei8) vase se pose 12040 No56 SERIES 12-047 ®TESTING AND ADJUSTING DATA TESTING AND ADJUSTING Enna moa nTesee NTAGGSe oma Agpliale machine mode wo (Emsne No aei02754 — Beis em Condition, ete Unit [Standard value [ Permisible [Standard [Permissible hing ned vom |2a00-2590 [240-2800 |2400 2500 | 2430-2500 | Erne oe } Lew iting sued rom | 600-700 | 90-700 | 600-680 | 600-650 : & ee vom | an. 180 = win-te0 | 2 | neceiry staring ed 20% twin tartng ia) | opm | mn 100 - Min, 100 Iwate resance | Avated utut mtv] wax sao | eo | mex sso] 0 Intake remure | aratedoutput | — | re00—100| xmas premure | Atetadoutpt Normal Problems 3-> Abnormal Problems 4+ Normal From the table of ex ample 1, the cause of the fault is b. Example 2: Not necessary yom table otex Se Problems 1+ Noma _ | Fremtheae of x Poblos 2 Abnormal | 2 he 4 in exon 2 ie evr th cae ine wrihut ourying ov tiene howe bo Slane 2 prone by way of tea nck 12-052 N855 SERIES‘TESTING AND ADJUSTING. Example 3: Problems 1 > Abnormal ) From the table of ex- Problems 2-> Normal | ample 3, the cause is Problems 3+ Normal | one of a, cand. Continue problems i Problems 4 ~ Normal Problems § + Normal From the table of ex: ample 3-1, the cause Example 4 Problems 1+ Abnormal Problems 2 > Normal From the table of ex. ample 4, the cause is one of a, bord. Continue problems i Problems 3» Abnormal | From the table of ex Problems 4» Abnormal | ample 4-1, the cause Problems 5~ Normal | is aor. ‘As can be seen from the above examples, itis not neces: sary to perform all of the problems. Also, looking at a particular cause, no matter how many ‘+ marks there are in the column corresponding to that cause, it will cease to be an actual cause if there is even ‘one @ mark in the same column, N855 SERIES TROUBLESHOOTING Example 3 a/bfe [aye Probient x/of 7 ooog 2 ele 3 ol Io} 4 lol {Io} 5 fol 1 Io) Example 3-1 roves — ee fue] 8]a] 3 o ‘ fe ott fe Example 4 [sfefefafe proven — IJ] ]n] x 7 elefefe 2 io] 3 lo} « fol {To} 5 for Is Example 41 Lh be fa fe] Problema xfe/e/A/* r nooo 2 | [9] 3 elle “ OmmO 5 jo[_| fe) 12-053 ®TROUBLESHOOTING TESTING AND ADJUSTING TROUBLESHOOTING TABLE 1. Starting defective or badness. 1) Engine does not turn, Questions to ask operator before starting trouble- shooting 1. Did machine stop suddenly during operation? > ‘Damage or seizure of internal parts, 2. Did machine make abnormal noise during opera- tion? -> Damaged parts. * Cause h: battery charging rate Charging ] fae | 100% | 90% | 20% | 25% | 70% 29 128 | 126 | 124 | 123 | 122 oe 120 | 127 | 125 | 124 | 129 =e 130 [128 | 1.26 | 1.25 | 124 + Specific gravity should be at least figure for 70% charging rate, + In cold weather, specific gravity must be at least figure for 75% charging rate. [epee ale tf wo. | —Protems Fematy xx x xf fx (When sting he starng switch to START, | . $1 'No sound of pinion moving out 1 [2 Pinion arate ° 3 Pinion engages but doesnot tum lof 0 Jol o folo When checking battery, elacvolvie lee or specitio 7 2 | Saye tew Ola When cranking evaine with Baring toa 11" Boer not move. ° 3 | 2) moves backlash only. } 3 Can be turned in reverse rection lof o Jo ‘Remove head cover. When checking valve cot, ti 4 | cuvot pce jo} 5 ° 3 lo) The following symbols are used to indicate the action tobe taken when a cause of failure is located X: Reploce a: Re As Adjust © 12-054 N855 SERIES ®TESTING AND ADJUSTING TROUBLESHOOTING 2) Engine turns but no exhaust gas is emitted. Check before troubleshooting 1, Is there any fuel in fuel tank? 2. Is fuel feed valve open? ‘tank and 4, Is fuel piping leaking or damaged between float tank and PT pump? 5. Is fuel piping leaking or damaged between PT pump and injector? 6. Is there any water, rust or sludge mixed with fuel drained from fuel tank or fuel filter? {PT pump or injector are frequent cause of failure.) 7. Did fuel be added in tank after replacing fuel filter. 8, Is compression release lever position sced in “RELEASE” No Probleme 1 | Resmagjon nT eampresion ss ris 7 2 | Engine ars when srning inthe nob of shart 7 3 | Nose comer out ven i lain rom fut S + | Reiuacomegaigenyt PT eume waters [5/5 ]o, «| Remove sie FT pum. No eetion own i dive 7 © | fafuelgomesoutmenittcarank outer hoes [oy The following symbols are used to indicate the action tobe taken when a couse of failure is located, X: Replace ‘4: Repair AL Adjust ©: Clean N85S SERIES 12-055 ®‘TROUBLESHOOTING 3) Exhaust gas is emitted but engine does not start. Check before troubleshooting 1, Is dust indicator red? -> cleaner element clogged. 2. Is SAE3O oil being used at temperatures below 0°C? (Oil viscosity is too high) -> at temperatures below 0°C, use SAETOW cil. 3. Is ASTM D975 No. 2 diesel fuel being used at ‘temperatures below — 10°C? (Clogging caused by precipitated parafin) > use ASTM D975 No, 1 at ‘temperatures below — 10°C, 4, Is fuel control lever bent? Is there any play? Is the pin out of place? 5. Is fuel tube damaged or leaking between PT pump TESTING AND ADJUSTING “The following symbols are used to indicat the action tobe taken when a cause of failure is locate. X: Replace 2: Repair AL Adjust ©: Clean and injector. tio] Probleme Remedy 1 | |x fox] x [oxi a fexfexpxayea Ti, aa do nbs warm + | (Gotd vente operation {Eosina th elo Intake ar heater.) 2] “Gow plug amp doe nt ght even I turn staring 2 | Sitch to HEATER, (Cold weather operation) lo. Fuel preure does nat raise when ope 3 | priming pump, or te reaction dos ‘then operating (Cold went operation. I || Wren starting switch urs to "HEAT, heeer mount Is warm but sng does nt sar o| Rotating weed of arting motor sto0 sow to war 5 | Sine © | nen checking battery lcrayis lvl or speaic Dratty too owe Tio reaction even compresion eens lover ls 7 | aerated jo & | Engine stars if ai ceaner element removed Oo Remove the injector, When checking, nection spay 8 | Conationeno vector ° 10 | Comprenion presure i 00 low blow-by i high ol 11 | vane clearance not proper vale O| erove the oyna heed Ger, THRCGE Tina 12 | Revamp potion ° 13 | Airclaner dos nt atpirate ir. (After maintenance) Ness SERIES 12-056 @TESTING AND ADJUSTING TROUBLESHOOTING Engine stopped during operation. Questions to ask operator before starting problems. 1, Did engine stop slowly? ~ fuel supply cut. 2. Did engine stop suddenly? ~ internal parts damag- ed or seized, 3. Did engine make abnormal nose?“ parts damag: ed. z 2 > Check before woubleshootng Jefe) [2 1. Is there any fue! in fuel tank? a] /E 2, Is fuel control lever bent? Is there any play? g} fs Is the pin out of place? 3. Is fuel piping leaking or damaged between fuel ‘tank and injector? 4, Is beed hole of fuel tank cap clogged? — No. Problems —————____ Remy fos x Jax faxes] ax fay x | x ‘tarting motor cranks engine, but engine stops If pear 1 | shit tever is moved to any speed postion ° ‘Starting motor does nat crank engine $7" Engine does not turn when cranking engine with lo) barring too 2) Engine turns backlash distance only. lo '3) Engine can be turned in reverse direction, No fvel comes out oven if felis drained from fuel fier ° | Engine warts when srewing in the knob of shutoff velve ° Remove the PT pump. No reaction even if drive halt sumed, ° ‘No fuel comes out even i float tank outlet hore ie Toorened | The following symbols are used to indicate the action tobe taken when cause of failure is located X: Replace 2: Repair AL Adjust ©: Clean NB5S SERIES 12-057 @TROUBLESHOOTING TESTING AND ADJUSTING 3. Engine runs abnormally. eae 1) Engine speed is too high. Cause Remedy Cause Remedy ersined opening 2 ‘cnaeaconetne | OX 77 governor oF MVS governor {ther thing ond rms | purgtrsesedorrated'or Axa Sajustmont defective, 5) Hunting, Engine speed does not increase. alee coe %* Hunting may be happened for several time ‘couse Remedy when air in circuit bleeds, after maintaing fuel system and replacing fuel filter element. Fuel return piping damaged or clog — ‘ged between injector and float tank, | 26% caus Remedy PG governor ar MVS governor | plunger seized or rusted or Ax, uel piping ar leaking into system lcjustment defective, 2 | betmeen float ank an fuel ax fier. 13) Engine deceleration time (over 15sec.) and stop time (over 10 80) ae long, © | Aictakngin pte rom oat | a, coe Remedy Fon pipinga ating into evsem . ‘iteraed ax Fuel return piping damaged ox cog ‘ged between injector and float tank. | S°X a | MogmentorPr6 somimor and | cq [MVS governor plunger detective Movement of PTG governor and > | MVS Bovernor plunger defective. on * In case of improper engine-running causes the trouble of PT pump (PTG governor or MVS governor plunger seized or rusted or adjustment defective), the mixed water and dirt and used non-specified fuel are considered. Check for the fuel drain tank or fuel filter. % Inspection, adjustment and repair of PT pump inside perform only the shop prepared test stand, Engine damages if PT pump pressure sets the higher than standard pressure and the pump for other modal is equipped in order to cover the lack of engine power. 4, Fuel consumption is more, ‘Ask the operator that you fell why fuel consumption is more, Symbol cause Remedy 2 | Fue eakage from fuel tank, fue iter, PT pump and ping. x | Eepietan rom inet and outro incor fel pasa in ead cover 004 | Foy probe ®, Ole ae © | Overinjection, worse fuel consumption, Problems "6. Exhaust gas i “The following symbols are used to indicate the action tobe taken when a cause of failure is located X: Replace 2 Repair AS Adj : Clean 12-058 NB55 SERIES @TESTING AND ADJUSTING 5. Lack of power. % If lack of power is accompanied by black exhaust 925, follow problems “6. Exhaust gas is black” ‘+ First troubleshoot whether the cause is in the en- gine or in the chassis as follows. Torque converter oi m- perature spprox. 70°C. Forward, Top speed ‘oly bakes fly oes not move. NG. i [Problem wits | [Prabiem with [snaine machine Judge mainly checking for track tension, brake func: tion, acceleration and engine high idling speed when mounting DIRECT transmission. Check before troubleshooting 1. Is fuel piping damaged between fuel tank and float, tank? 2. Is fuel piping damaged or leaking (air leaking into system) between float tank and PT pump? 3. Is fuel tube damaged or leaking between PT pump. and injector? 4. Is fuel control lever linkage bent? Is there any play? 5, Is bed hole of fuel tank cap clogged? 6. Is there any water, ust or sludge mixed with fuel drained from fuel tank? (PT pump or injector are frequent causes of failure.) (Check strainer clogged when no fuel comes out.) 7. Is incorrect fuel being used? No. Probieme Remedy TROUBLESHOOTING “The following symbols are used to indicate the action tobe taken winen a cause of failure is located X: Replace 2: Repair AS Adjust ©: Clean I xc fax! Ax fal ax | ¢ [Ax ax{ex 1 | it evel sss, (Fuel mixed with engine oil) ° 2 | Fuel pressure slack 3. | Excessive of vacuum pressure 4 | Lack of vacuum pressure (pressure isnot stationary 5 | Leck of vacuum pressure (pressure i stationary) 6 | check the injector ° N85S SERIES 12-059 ®TROUBLESHOOTING 6. Exhaust gas is black. Check before troubleshooting 1. Is dust indicator red? -> Air cleaner element clog- ged, 2. Is PT pump seal out of position? > Pump out of adjustment (excessive injection). 3, Is fuel return piping damaged of injector? 4. Is air leaking between turbocharger and cylinder head? 5. Is standard spec. machine operating at high alti- tude? TESTING AND ADJUSTING Exhaust gas color improves when ai elesner element is removed, 2 | Fuel pressure is too large, ‘Remove the injector and injection spray conditions 3 | sre defective when checking 4 | Blomby i excesive, | Compression pressure is ack. 6 | Vale clearance is to large or too small, 7 | exhaust gas color improves when mutter i removed 8 | Turbocharger is sluggish when turned by hands. 9 | jection viming is not matched. ° 12-060 ® The following symbols are used to indicate the action tobe taken when a couse of fallure is located. X: Replace ‘4: Repair As Adjust ©: Clean N8SS SERIES‘TESTING AND ADJUSTING. TROUBLESHOOTING 7. Exhaust gas is blue. (Combustion of engine oil) Check before troubleshooting 1. Has engine continued to run for over 20 ming at ow idling? > Oil coming up into cylinder, oil leak from seal at turbocharger turbine side. 2. Has engine continued to run for over 20 mins ‘at high idling? > Oil coming up or down into cylinder, oil leak from seal at turbocharger blower, side. 3. Is turbocharger oll return pipe damaged? - oil leak. from turbocharger seal ——— No. Probleme Remedy | x/ ¢/x/ x] x 1 | tnside of turbocharger intake pipe is coated with ol 2 | Turbocharger shat play is excessive ° 3 | Compression presure i ack. 4 | Blowby is excesve jo 5 | when checking breather element clogged with oi. | |) ‘Remove eylindar heed, When checking intake valve | ‘nd valve guide, the clearance of thems big L The following symbols are used to indicate the action tobe taken when a cause of fallure fs located, X: Replace ‘a: Repair A: Adjust, ©: Clean N855 SERIES 12-061 ®TROUBLESHOOTING TESTING AND ADJUSTING 8. Oil consumption too high, Before starting the diagnosis, ask the operator why the noticed the fuel consumption was too high, * If answer is: “Oil consumption was high and ex- hhaust gas was blue”, follow problems “7. Exhaust 2s is blue”. Check before troubleshooting Is engine or engine lower part coated with oil (Remove earth and sand and check.) Plog No. Problems oe Remedy ha x A] x0 [fax ax 1 | itteokine ou of enaine (check round eran. ° 2 | cootina water is mixed with eran oi ° 3 | Oijaman curchar FOROFLOW wammaion [cp Sr camper ners The following symbols ere used to indicate the action tobe taken when a cause of failure i located X: Replace ‘a: Repair AL Adjust ©: Clean 12.962 N55 SERIESTESTING AND ADJUSTING TROUBLESHOOTING 9. Oil level rises. (Mixed water or fuel) Check before troubleshooting + Is the cooler of engine oil dirt — white? > Mixed water. Problems 1 | water mixed with engine ol 2 | Fost mined with engine ot 3 | Oitin main clutch or TORGFLOW transmission or demper decreases ‘Seal or etal contact foes of hydraulic pump drive 4 | bhatt te worn or damaged, ° N855 SERIES “The following symbols are used 19 robe taken na of ‘the actionTROUBLESHOOTING 10. Oil quickly becomes dirty. Before starting the troubleshooting, ask the oper- ator the following questions. 1, Were oil and oil filter changed in accordance with the “Operation and Maintenance Manual’ 2, Was improper oil used? No, Probleme remedy px x 7 | Extoust gas is blue when engine ism at high speed } 2 | Compression pressure i ack 3 | Blonsy is excensive “4. | Alter running at high idling for approx, 10 mins, oi! fan be soon leaking from turbocharger turbine ote, 5 | Turbocharger shaft play is excessive TESTING AND ADJUSTING 4% If the above problems does not reveal the cause, a common secondary cause of dirty cil is carbon from incom: plete combustion mixing with the oil 12-064 @ In this case follow problems in "6, Exhaust ga black”. The following symbols are used to indicate the action tobe taken when a cause of fllue ie located, X: Replace ‘: Repair As Adjust ©: Clean NBS SERIESTESTING AND ADJUSTING TROUBLESHOOTING 11. Engine oil pressure gauge indicator fluctuates abnormally. No, Problems remedy [Ax] a Oi ive in 0 pant xoo low. 1_| Ghee whether oi consumption i excesive) ° 2 | Fuewation stone when gauge is enlace. jo ‘Moun in instrament panel ar oor 3 | (check directiy) ° j equator valve fe eathed, singe fatigued, valve 4 | or valve guide is damaged. (Check directly) JO. “The following symbols are used to indicate the action 1t0>be taken when 9 cause of failure is located. X: Replace 2: Repair A: Adjust ©: Clean N855 SERIES 12-065 ®TROUBLESHOOTING TESTING AND ADJUSTING 12, Lack of oil pressure. {At engine speed of over 700 rpm, indicator of engine oil pressure gauge is to left of “green range”) Question to be asked before starting trouble- shooting. | 10W oil being used at temperatures above 0°C? 2 rwoon [[efe Oil teak from hove or wube. (Check Yor signs of externa oil leakepe) 2 | wn or nt se wh ol 2 | ormaiomincctosmoteneniormam. | 11 | | | of | «| rome rue eromalt ane ep | eo) 8 | oarsrenys” me mee mili BE | lo | 7 | RSW" ShatteMhoer sonora lol | © | Eeeesel rave sos on wen song oni . 2 | Seoasttiemases™ veer Si] wo | Seminar ammnatisectaccnr | fo | 1] 2upime esirxaat oneomiracotmone [oy sed 10 indicate the ation ’a: Repair ©: Clean 12-066 N55 SERIES ®TESTING AND ADJUSTING TROUBLESHOOTING 13. Oil in cooling system. cause Fomeoy >] Babe broken ta oil oar a Oring damaged, | Head gesker damaged x © | eviinder head cracked x 4 | Cylinder Block cracked x 14, Water temperature does not rise, Water temperature gauge indicator is to left of ‘green range". + In cold weather operation, if reversible fan and radiator are not fitted, the engine may rot warm up. No.| Problems Remeay |x / x 1. | water temperature rises i gauge i replace. ° When thermostats vemowed its found to stay opens 2 | orpertormance tex shows eracking temperatures 100 | town The following symbols are used to indicate the action tobe taken when a cause of failure is located X: Replace AL Adjust N855 SERIES 12-067 ®TROUBLESHOOTING TESTING AND ADJUSTING 15, Water temperature rises excessively. (Water temperature gauge indicator goes to right of ‘green range", engine overheats.) Never remove the radiator cap when the tem perature is still high. Boiling water may spurt ‘out and cause serious burns. ‘* When the engine overheats, stopping the engine immediately means water is no longer sent out by the water pump. As a result the temperature of the parts being cooled rises sharply and this may cause cracking or other damage to the engine, Before starting the troubleshooting, ask the o tor the following questions. 1. Is antifreeze being used in summer? 2. Is water being supplied according to the “Opera- tion and Maintenance Manual” ‘Check before troubleshooting 1. Is machine being operated under excessive load?| 2. Is fan damaged or deformed? 3, Is belt groove of fan pulley or crank pulley worn? 4, Are radiator shutter and reversible fan being used properly? 1 | coolant tve is too low. 2 | Cooling water mixed with ol 2 | Fan ett loosens 5 4 | Radiator cove is domaged or clogged with mud or dus. lo | Difference in temperature tween upper and lower fis tanks is extreme, 6 | Radiator is only slightly warm ‘olo| 7. | Valve opens when testing thermostat ony water temperature gouge is replaced, it returns to | Hpeter temperature enue is epaced, lol (9 | Torque converter oil temperature t00 high o (with TORGFLOW transmission) i + Ifexhaust smoke is black, follow problems “6. Exhaust gas is black”, “The following symbols are used to indicate the action to-be taken when a cause of falure is located. X: Replace ’: Repair AL Adjust Ci Clean 12-068 N55 SERIES ®TESTING AND ADJUSTING. 16. Too much vibration. TROUBLESHOOTING ae x no.] Prooens —————_____ramewy fx x [nox Xx] a [x[x fs 1 | eneine mounting Bos are loose, (Check arecty) Oo Vibration deme no warm 10 vouch after oper 2 | Nonrduring operation, avr noise fa ences ie lo 2 | Extaust gris back, lof fo lO 14 | water temperature doesnot rior rise sowy. lo) 5 | Low ating speed oe tw lololo % | Planar doesnot move when checking the injector bterremening cyngor hed cover Injection sory condition defective when removing 7 | tnlctor and chee io | J Vacuum presi tow or or stationary, © | Foe preure i excessive Oo 10 | Ou pressure low at ow iio. o 1 | Remove the cam follower housing anit is abnormal, Temowe cylinder head. When desk Rho appet 2 | orintake and exhaust valves are abnormal ° “The wear and elesrance of front suppor pilot ae 13] ite O| BSS SERIES 12-069 @TROUBLESHOOTING TESTING AND ADJUSTING 17. Abnormal noise emitted, “he falling sbos ae wad Toate he action tobe taten whens cus of fi tocte, 4 When noises indicating internal damaged are be Xe Renter Rept ing emitted continuing to operate the machine A Ads : Clan may make the damage worse, As far as possible, classify the abnormal noise 0 Imake location ofthe cause easier. Type of noite + Interference + Abnormal combustion * Gears Interna, external + Engine, power tain wo.| Prion 7 | exena or rene erin nose oer o 2_| exo irc ° o 3 | combustion noi abnormal oll | lol lo 4 | at eer dos nr, o ‘Vion aoper is ot war 0 ouch afer option, 5 | uring operation, gear noise i also excossve. jo © | Fuel prs care prema) ih 56 SPR pee ace lo 7_ | companion pase ack, low y exc 3 @ | vv deracn i to re oreo sa Bl | Trectr futon kdfetve, (Planar dos pr 1 8 | now epsnd down) ™ ° ‘0 ion sry tein, Remove and a 7 | Bere giz, Wher ecto nea eae S 12 || remove gear cover Gear nok oosre 13 | Remove cam follower howing, Hebron we | eueperin end etna ea sei 865 SERIES 12-070 ®TESTING AND ADJUSTING TROUBLESHOOTING 18, Excessive wear of engine parts. Before starting the troubleshooting, ask the opera tor the following questions. 1. Is the specified oil being used? 2. Is the specified fuel being used? 43. Is the air cleaner element cleaned and replaced to the “Operation and Maintenance 4. Is the fuel filter element cleaned and replaced according to the “Operation and Maintenance Manual"? 5, Are the engine oil and oil filter element replaced according to the “Operation and Maintenance Manual"? 6. Has there been repeated rapid acceleration, or rapid gear shifting? 7. Is the machine warmed up before operation, ‘and left idling before stopping engine ac cording to the “Operation and Maintenance Manual"? No. Problems ————_ Remedy 1 | ire gets into engine, (Check directv) ° 2 | DRRAEp CK (Se oben "6 Eaters 7 3 | Fagipmerswit on, Gee rcbioms@, OF el iS a | Mass emreawim on (ee erosions, One | [TT 5 | Guage. (ee problems 10, Ol aie becomes lo § | Bixcgaer dainsoutwhenualiank dino | |) | 7 | Fuet titer is diny or damaged lo The following symbols are used to indicate the action tobe taken when a cause of falar is located X: Replace 1: Repair AL Adjust ©: Clean Ne6 SERIES 12-071 ®TROUBLESHOOTING TESTING AND ADJUSTING 19. Engine does not start because of fault in electrical system, (Check starting circuit) Ad wine checking, tke care no 10 be eau in fan or other rotating parts entine sare, Check before troubleshooting 1. Is battery electrolyte level or specific gravity too low? 2. Check starting circuit for broken or disconnected wires, loose terminals or short circuits (Visual check). Battery —> Safety relay —* Starting switch —> Battery relay switch <> Battery 3, Immediately after repair, mistaken wiring con- nection is possible cause. 4. When problems 1-1) “Engine does not turn” ives cause | “Electrical system defective”, use this problems No. Problems Remedy cf tr og 1 terminals (B) and (C) of starting motor are connected, pinion moves out. 1 | Sparks ste produced by this test, lolojojo ‘When pinion movement confirmed, discon nectterminats wmmeditely oe fe 2 [Seem geeleey emo e + [Karaeracimsnareemcten | | [o 7 | Seema stea ti otaeyarwvemens, | To ‘ator terminals (6) and (C] are connected, The following symbols are used 10 indicate the ection 0. taken when a cause of fllure is located X: Replace 2: Repair AL Adjust ©: Clean 12-072 NB55 SERIES ®TESTING AND ADJUSTING TROUBLESHOOTING 20. Battery does not charge. (Check charging circuit) “The following symbols ae used to indicate the setion tobe taken when 9 cause of 2 X: Replace When checking, take care not to be caught in fan or other rotating parts if engine starts. Take care also not to cause short circuits. Before starting the troubleshooting, ask the opera tor if the battery is old (in use for 2 or more years) Check before troubleshooting 1. Is alternator drive belt loose? 2. Chack starting circuit for broken or disconnected wires, loose terminals or short circuits. (Visual ‘check, continuity check). Battery —> Starting switch <> Ammeter —> Regulator <> Alternator Battery relay switch + Battery 3. Do lamps or heater exceed specified limit? Are they loft on? % When engine is stopped and charged lamp stays on, or ammeter indicator deflects to fone side, lamps are stil on, or there is a short circuit 4, Following repairs, mistaken wiring connection is possible cause. Probieme During operation, defection of ammeter end cherging lomp are normal | ° Continuity text using tester shoves 17 Little or ne continuity when terminals (AC) and (6 of starting smiteh ara Connected, with switch ON) ‘DV Whan tha starting awiteh i ON, continuity be {aueen them above 1] proper Out when being io BEET no contin. 3) Little or no continuity between (+) terminal and [Cterminal of ammeter or horging lama, ° Fun engine at medium speed (1,000 — 1,500 ror and ‘meesure charging voltage ith tester. 1) Tester does nox show charging voltage (26 — 30V) between terminal (E) of alternator and terminal (N)|© | of regulator. 2) Tester shows charging voltage betwoon terminals Aj and (eof dynamo, or between terminals (8) | |O and (E) of alternator, but des not show with above 3) Taner show charging ete wth 2}onty-—[ | N85S SERIES 12.073 @SHOP NAGY b Engine Serial No. 26100001 and up 13 Disassemety AND ASSEMBLY N8S5 SERIESSHOP NAAN U Yb N-SSS SERIES Engine Serial No. 26100001 and up ENGINE 14 MAINTENANCE STANDARD N55 SERIESCONTENTS INTAKE AND EXHAUST SYSTEM Turbocharger ........ 14-004 ENGINE BODY Cylinder head 14-006 Valve, valve guide 14-007 Crosshead and crosshead guide. cesses 14-008 Rocker lever, shaft cesses 14-009 Cylinder block 14.010 Crankshaft and vibration damper 14.012 Cyiindeline ve 14.014 Cmhet 14.015 Cam follower and push rod 14.016 Gear and gear cover 14017 Connecting rod... ...ee+ + 14.018 Piston, piston ring, piston pin .. : 14-020 Flywheel, flywheel housing, rear cover ...... 6660+ 14.021 LUBRICATION SYSTEM Oil pump .. ee tees COOLING SYSTEM Water pump and idler pulley... 14.024 855 SERIES 1 4-903TURBOCHARGER MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM TURBOCHARGER (kTR130 for NTA-855-C) 6710F023 14-004 N8S5 SERIES gMAINTENANCE STANDARD TURBOCHARGER Unt a No. Check tm rein Remedy standin Rep Repace 1 | nd pay of wet hat oe 0.08 - 0.13 0.18 ‘ania Rese 2 | adi pay of whee hat 025-043 060 Eee Tolanee Rep standard 8 | Sova tering centr nosing oe | shat | Hote 2000 | oom 20 200 | 9 ress | 2008 4 | sour bearing turbine sat 2» em | 2015 | isos | 2005 — Tolerance Roper iit ole cn Width Groove ‘Width Groove 5 | Theknas of rust bering 6 ee | || oo 6 | Wickes of ng a |e eee | are epics Cierane between blower housing jerance it oe 7 | snd impetter eee ee oa” Tee an) Range ean) | Tetening torque Bower Tilak a5 20-90 @ | Tomening torus ofa ote 128 10-18 Retahon 10 | lomening torque of V.bend tock mut 098 09-10 N855 SERIES 14-905CYLINDER HEAD. MAINTENANCE STANDARD ENGINE BODY CYLINDER HEAD e710Foz4 67 10F025, Unit: mm No. ‘check item Criteria Remedy Order ‘Target (kom) Range (kom) “Tightening toraue of cylinder head mounting bolts tstswp 35 7 1 | (coat ott threads and washers | — with ol and tighten in sequence 2nd step 128 4-138 ive in diagram abovel 3rd sep 40.41 387-415, C2 phe actineh erat 1.55 * 0.05 kgm (Tighten 0.5 kgm each in turn) “Tightening torque of injector . Pe oe ia 48 + 0.7 kam (Using adapter: 4.1 + 0.6 kom) Engine No. | Engine condition | Targa tkam) Range (kam) pero |_ 4 0") 058 26185791 ; 4 | Aajustment torque of injector Warm (60°) 0.69 cold (20°C) 083 126185792 and up oa ‘Cam profile gauge Engine | Crankin ‘Top gouge Rated side | Advance sige = | injector ining Nassc BTC 19° 516 0762 | -o71 | adjust nressc | BTOC 19° 5.16 -oses | —o864 ntasssc | sToc 19° 5.16 1105 | —1.003 jt 14-906 (N855 SERIESMAINTENANCE STANDARD VALVE, VALVE GUIDE VALVE, VALVE GUIDE 1 67 10F026 Unit: men No ‘Cheek ier criteria Remedy Standard size Repair iit 1 | Thickness of valve head : 267 Standard Tolerance Repair limit 2 | Valve seat angie : t 20° Standard sie Tolerance Repair iit 3. | Valve stem outside diameter = Py 118. yey nat — +0011 4 | atv guide inside ameter ns coat 1156 5 | Protrusion of valve guide 3353 20.13 . ‘Standard size Repair iit Free Tastaliod | Tostlied | Free | —tnetaied Valve sping length Tenth load length Toad | . 68.20 57.15 70.39 - 64.9k9 Squareness of valve spring Fair iit: within 2° N855 SERIES 1 4-007CROSSHEAD AND CROSSHEAD GUIDE CROSSHEAD AND CROSSHEAD GUIDE 6 MAINTENANCE STANDARD il e710F027 ne me We heck em citer Pemedy Sanaa Tae Fei 1 | bop ot crossed stm ese 3 3388 as 2 | tide hametr of contend 0 ae 18 uv dino aronead ae 3 | guard " 3 1097 4 | rowan of erohaad pe os 1028 : SS ee co a0 a. are oat oe 5 | Valve clearance eon Warm (60°C) 0.36 0.69 Adjust coe a0°e) 038 om 2e1ss702 dup | io (oe) 038 om «| Thenna oraue of eoeud 481507 kom (Using adept 4.15 +088 kam) “Thing ora of oka fo Ss 7 | rocker arm adjustment screw oe Ness SERIES 14-008 ®MAINTENANCE STANDARD ROCKER LEVER, SHAFT Section AA G7I0F 116. ROCKER LEVER, SHAFT 6710F029 Unit: om No. Check item cetera Remedy Standard size Tolerance Fepair limit 1 | Lavershatt note diameter is Inrocker housing 40.065 285 et 10.139 2. | Rocker lever bushing bore 285 aaa 2266 Replace 40.097 3 | Rocker lever shat diameter 285 oe 2850 “Tightoning torque of rocker arm housing mounting bats 4 | (coat bolt threads and washers with 8220.7 kam Fetighten cil and ghton in sequence given In diagram above) N865 SERIES 14-009 @CYLINDER BLOCK MAINTENANCE STANDARD CYLINDER BLOCK 10 2 yo \ Fe . \ 3 > : ag 7 6 9 & TT ‘oO a Hi@ A i ha © i ] . /- L') %| | a T 7 OF u Ry : Z aa = _ pay oe : i erior0s0 14910 IN855 SERIESMAINTENANCE STANDARD. CYLINDER BLOCK Units Criteria Remedy ‘Standard size Tolerance Fepair limit 1 | Counterbore depth +0058 ‘ pair by : “0.110 04s grinding replace. Inside diameter of counterbore Toor 2 | esr 8 mn rom 188.7 aon 166.77 Inside diameter of camshate 40.088 3 | bushing mounting hole bak 0.06 saat Reni Inside diameter of eamshatt 40013 Repisce 4 | pushing (When installed.) Lond “0025 5084 bushing Inside diameter of main bearing 40.050 5 | mounting hole 1206 +072 oe Height of evlinder block +0.050 © | (Feom main bearing center) ca 01002 49248 Height of cylinder block 40027 7 | (From necking rine) ea 0023 4 Replace Inside diameter of cylinder block ° 8 | icyinder liner inserted portion) 1556 0.050 Clearance between cylinder block earonce limit: 0.05 — © | anc evlinaer nee Cc 0.05 020 Distortion of cylinder head te pa Repair by 10 | mounting sure Lead a erat ringing Interferance between eylingar nterforence limit: 0.10 ~ 0.1 replace 11 | broek and main bearing cap tnvores O40 048 fae 42 | Tihtoning torque of ot pan Block portions 62703 Kam ‘mounting bolt Rear plate portion: 2.0 = 0.3 kgm 19 | Tiahtening torque of ot pan ae 3 | drain plus a Tightening torque of piston . "4 | cooling nozzle oe Order ‘Target (kam) ange (kam) steep 200 193-207 45 | Tihtening torque of main 2nd sep a 415429 cena Seastep Loosen completely ‘aihatep 202 193-207 Sth step 422 415-429 N85S SERIES 14-011 ®CRANKSHAFT AND VIBRATION DAMPER CRANKSHAFT AND VIBRATION DAMPER MAINTENANCE STANDARD eu 2, \ Bi Ee 1 7 7 T \ fe \ 4 10 e710F031 Units No, Check item citria Remedy Sie Siandardsze | Towwance | Papal sto 11400 19300 11422 o2sus. 11378 19.96 tae | ena by use diameter of in sue Mate! oso us. 113.50 som v9.72 | Srreptace” o7sus. 928 378 1348 so0us. 11300 so208 321 ole Nass SERIES 14-012 @MAINTENANCE STANDARD. CRANKSHAFT AND VIBRATION DAMPER Unit: am we chek tem crteria Remedy oe Sidardaze | Towne = sy Ba oasus 7078 a7 7008 2 | ouside mata ofc in jeune osous 7830 19387 ram | Urpin soko, Protas orsus 7025 19368 ase ie = a — 3 | Roundnes ot journal init: Within 0.13 (Tot instr reading "Sona dean ‘lewranc iit wena by 4 | End pley of crankshaft ~ sing over 0.18 -043 056 or replace se pease | ieee eae |e Sihpoe 8 | win ot jouma at has journal sige sro 7620 1392 reso | Seebee 6 | thickness of main bering sto a0 same 208 sro 620 22 a voce | Sxtermine by 1 thickness oF thst bering ozo eas 1398 | canton ona Sor owos 70 7908 Stand rane Ciesrane nie Cinrane ofan our api i 0025 —0.125 oe Singular aro ore Clearance of crank pa four e040 ~0.110 ore 2 | bend ot eranksate 0.09 Total instr reading) Fees runout of vibration damper epatiit: 0.25 (Tota iestoreding) — eating 2 Radial f vitor flange or: tedial runout of vibration a it otal indicator readin replace. fal eprint: 025 (Total ineator ein) Tahonng wraue of eenishah ae 17 | pulley mounting bott eer “Tanening rue of virion : 1 | damper mounting bolt icienamiaals Nass SERIES 14-013 @CYLINDER LINER, MAINTENANCE STANDARD CYLINDER LINER 6710F032 Unit: mm No. Check tem criteria Remedy Standard size Tolerance pair limit Inside diameter of eylinger liner 10.028 : 139.7 one 130.83, Replace Top of liner Repair iit: 0.08 ooundness of eyindor liner Tepetiner Renal Bog 2 | Protrusion of evlindr iner Tolerance 0.08 ~ 0.15 ‘Aust with Standard size Tolerance 3. | Outside diameter of evlinder = liner at top of counterbore 10.30 168.3 oa eam a Fopices side diameter of cylinder 40.19) 4 | ner at bottom of counterbore ae 20°03 ‘Outside diameter of eylinder 10.48) © | iner at One io 1037 14-014 N55 SERIES. ®MAINTENANCE STANDARD CAMSHAFT CAMSHAFT 3 O @ section A-A, section 8-8 RA pe 0 ean Coty aftr +H | “Aesth R ap He TOA La ke s 5 ie e71oroaaa Unt mm No. ‘Check Item i Remedy. Sonal a aa 1 | Outsiceciameter of camshaft tk 7 journal C3) 9049 (on 70.080 2 | Thickness of rut ate 2a at : eee Replace 3 | Va cam it 4 | tjstor eam itt Sanda drones Clarence it | Cerance ot camatt Reotsce Journal ae = Eine 6 | Bend ot camnate Repsirtimit: 0.10 Replece 7 | endpiey Standord: 0200.33 Gree Nass SERIES 14.015 @‘GAM FOLLOWER AND PUSH ROD_ MAINTENANCE STANDARD CAM FOLLOWER AND PUSH ROD 6710F034 6710F035 Unit: mm — No. chock tom criteria Romody ‘Standard size Tolerance Repair limit 1 | Outside siameter of eam follower - shaft ‘ 10.025 e so012 2 Inside diemeter of cam follower 0.062 ; 2 | bushing 2 30.037 9.09 ‘Outside diameter of cam roller 10.075 3 | tinieetor) ae 20.025 a ig. | Outside diameter of eam roller | 40.050 co) a 2388 3187 Inside diameter of cam roller 10.002 5 | injector) ie “028 12.88 Replace inside diameter of cam roller (Valve 7 0.038 | 6 | ins a cam rll (Valve) 12, oe 12.78 o 7 127 ape 1262 ‘Standard size Tolerance 8 | Radius of pushrod ball end 40.075 188 a tadius of push rod socket en 10.21 9 | Radius of push rod socket ond 13 a 10 | Bend of push rod Repair imit: 0154 (total deflection of indicator order 98 (kgm) ‘Range (kom? ‘Tightening torque of cam follower 1 | housing mounting bole Step 1 25 21-28 Retighten (Tighten in sequence given in sisgram) Step? 45 4a—48 14-016 N855 SERIES. ®MAINTENANCE STANDARD GEAR AND GEAR COVER a GEAR AND GEAR COVER 6710F036 Unit: No, check time. criteria Remedy ‘Standard size Tolerance Repair mit 1] tri oma of amt Replace support hole 40.082 445 oo 4483 Inside diameter of accessory 40.015 Replace 2 | gear bushing ou “2.086 | oo bushing 3. | Radiat runout of front sal hole FRopair limit: Within 0.25 Replace Ditference in level between gear cover 4 | case and eylinder Block Yoce eps limit: Within 0.05 “Tightening torque of gor case cover es ae 8 | Tahtening tor 6.55 + 0.35 ko Retighten N55 SERIES 14-017 ®CONNECTING ROD MAINTENANCE STANDARD CONNECTING ROD Section A-A 6710F038A 14-018 NB5S SERIES @MAINTENANCE STANDARD. CONNECTING ROD nt te nok han omer remedy coum Townes ae a, woe _ 1 | bearing and crankshaft ceeeate metal fete erat lad ear | aim | oom — 793 40.035 40.114 0.142] 0.48 Standard size Talon | Repeirlanit : Fin 19988 7 83.1 Replace setae ‘208 i cy on 98% ince betwen center of connect- | ry 3] ing rod holes. ‘ial -0.050 | nae i “e082 esos 1 | coma of connecting od bing 10 ae 120 pee Gonering ed bushing ine 72038 rence 5 | diameter 50.8 10.025 50.86 bushing | comecting ed bot - 9980 er fie 7 | comeing ro bot are ‘8 “9982 1588 — 8 | inside diameter 168 40.057 eee Congecing roca ol hole “2078 : are, ® | inside diameter 68 40,065 16.88 Fer int Bend of connecting rod ‘With bushing i 0.10 vou beta 028 tee We buhing a ars, Two coonoring ed ee Wout ating oat Eee of connected a 030 a Tot hom) faves ml Seo! vo o7=104 owe? . 342027 = ‘etn compe ss | igure ot coming a ee ea i sues 704 o7=104 se8 "ea ieaz07 12 | san vice ——————————— N855 SERIES 14-019 ®ISTON RING, PISTON PIN. MAINTENANCE STANDARD PISTON, PISTON RING, PISTON PIN 6710F037 nit: om No. Cheek item citer Remedy Standard size | Tolerance Repair iit 1. | Outside aiameter of piston | 0.008 1294 one 199.27 Applicable engine Number of ring Top ring Sepiston ring type No. 2, 3,4 rings 023-058 Oit ring 025-051 2 | Piston ring gap clearance Top ring 043 0.69 pleco ‘piston rng type No. 2,3 rings 048 0.74 iting 025 ~ 0.68 Standard size Tolerance pair iit 3. | Inside diameter of piston pin hole = T 0072 50.7 | one 60.77 Aside diameter of piston pin 39.075 4 | ouside ot 3 piston i 50.7 aoe 5075, 14-020 @ N8S5 SERIESMAINTENANCE STANDARD FLYWHEEL, FLYWHEEL HOUSING, REAR COVER, FLYWHEEL, FLYWHEEL HOUSING, REAR COVER 67100408 Unit: mm nena No. check item criteria Remedy 1. | Face runout of tiywhos! Limit: Within 0.19 (total detection of indicator) 2. | aca! runout of tywheet Limit: Within 0.13 (total detection of indiestor) 2 | Face runout of fiywheel housing Limit: Within 0.20 (total deflection of indicator) place 4 | Radia runout of flvwhee! housing Limit: Within 0.20 (total defletion of indicator) 5 | Radiat runout of rar cover Limit: Within 0.13 (total detletion of indleator) Difference in level between rear cover 3 © | god oi! pan mounting surface Lae Mie one Tightening torque of flywheel mount 7 | ingbore e 21.040.7 kam (Goat bot thread with engine ol) “Tightening torque of flywheel housing Peps re a | Tightoning tora 2071.3 kg Retioh “Tightening torque of rear cover mount- £0.25 kgm | Tantenin 3.78 + 0.25 ka N855 SERIES 14-021 ®‘OWL PUMP. LUBRICATION SYSTEM Mal INTENANCE STANDARD olL PUMP WITH SCAVENGING PUMP 1 ~ 10 3 e7ioroaia nit mn no eek tom criteria amy ‘Standard emma ‘Standard 4 | clearance benwsen shatt i Shaft Hole | imerfrenee Soden nm | 7 | wos | one SH | 32 ‘ee Imrfrnce beeen grr ozs | vore7 | 0025 2 | ond shaft a 40.212 40.162 | 0.063 iterference between ‘and shaft 0314 40.289 sada Re 3 | inimioence perwmentodyanastart| 22 | 19g | s02a9 2 es ole 7 | instr toen sata ee eee al ne oar SH | ih ‘se ‘Sandra ie Tokrance epic 5 | Inside diameter of cover bushing ce 0.04 2 oR nas Jutside diameter of shaft 28 8 | curse camera of set 2 | ae naa? aes 7 | eras teen ger and body - - os Sendra eva tin stor vate sri Fae] tated] —tonated | — Free | trated 8 | Grmertera mo length length oad length Toad | Replace exs0 a2 | s6801.0 0 | nase o sat Limit; 004 0.08 epace to | Tiateins torus ot cover mount 25:0540m atten 865 SERIES 14-022 @MAINTENANCE STANDARD ou pumP WITHOUT SCAVENGING PUMP 7 a 9 ree SS 5 2 a ; a 1 8 5 4 a -- 6710FO42A Unt: en te Check tm rica Remedy Toleanee Singers standard | Rapa tii 1 | Clearance between shaft and bushing eat oe Crane 025 | 0204 2 Bon Bie | eke aa Tratoreece ozs | 0187 2 | inmterence tetneengrarandshatt | 22 Som ee yo22 | 1.162 Ae Trereenen Interference between body and shaft 34 028 |e Bit | Bae | eos epee 4 | interference beeen gearand smart | 22 woz | so220 ‘Sandor size Totwanee 5 | nad tata of cover busing i : 2 a Renee 7 | cranes batonen gar and body . . os conor Soy Sanda ee eps Fes] Wad] —Trsaloa | — Free] trad equator vate sorng a en 8 | Repustor a seg | at ‘cad | ung | "iesd” | pecace oa.20 452 | ae6et.0 8 | End play of arive shat Limit: 0108 — 0.09 Tightoning torque of cover mount. 10 | ing bole N855 SERIES 14-023 @WATER PUMP AND IDLER PULLEY MAINTENANCE STANDARD COOLING SYSTEM WATER PUMP AND IDLER PULLEY (NTA-855-C) OAR® 6710F043, Unit: mm — SSS No (check iter criteria Remedy Standard ceeeee standara | Interference 1 | taterforence between pump shaft ‘lee = wow | interference | timit and impelier a Hs woos | 0.025 159 $918 | 9225 0033-0066] 0025 | Replace Interference between pump shaft +0.008 | -0.033 = 2 | andpulley 200 se0e | 23082 0.030 -0.069| 0.025 3. | Tigmening torque of ier pulley 4.18 + 0.15 kam Retighten 14-024 N856 SERIES ®SHOR NUANUANG N-SSS SERIES Engine Serial No. 26100001 and up 15 REPAIR_AND REPLACEMENT N@55 SERIESCONTENTS CYLINDER HEAD Grinding and correcting cylinder head mounting face ........ 15-004 Replacing valve seat inserts ......... 15-005 Grinding and correcting valve seats surface 15-008 Replacing injector sleeves... 15-009 Replacing valve guides .. 15-012 Replacing crosshead guides 15-013 Grinding and correcting valves . . 15-013 Replacing rocker lever bushings . . 15-013 CYLINDER BLOCK Grinding and correcting top face of cylinder block .......... 15-014 Correcting cylinder liner counterbore . 16015 Replacing main bearing caps. . 15-016 Grinding and correcting crankshaft. 15-020 Correcting sleeve at crankshaft rear seal 15.024 Replacing camshaft bushing 15.025 Replacing connecting rod bushing ........-..6ceee00ee20+ 15-026 Replacing cam follower lever bushing. 15-027 Replacing crankshaft gear... 15-028 Replacing camshaft gear 15-028 Replacing flywheel ring gear ...... 15.028 NB5S SERIES 15-003 ®GRINDING AND CORRECTING CYLINDER HEAD MOUNTING FACE REPAIR AND REPLACEMENT CYLINDER HEAD GRINDING AND CORRECTING CYLINDER HEAD MOUNTING FACE 1. ting 1) Romove the vale et nse 1 ZI For detail, sev REPLACING VALVE SEAT OF SE CLE INSERTS. H O a 0 For details, see REPLACING INJECTOR Go a SLEEVES, 3) Grind the cylinder head to remove deformation 67 10F501 fr rust, Do not exceed the repair limit of the cylinder head height H. % Repair limit of cylinder head height (H): 110.24 mm it for one time: - 0.10 0.15 mm Roughness of grinding surface: Within 6S Flatness (deformation): Within 0.05 mm Grinding limit: 0,3 mm Difference in head height per unit Within 0.15. * Grinding to wee 4) Prossefit the next oversize inserts. For details, see REPLACING VALVE SEAT INSERTS. 5) Press-ft injector sleeves. For details, see REPLACING INJECTOR SLEEVES, 2. Checking after grinding © Check that the protrusion of injectors is within the standard value. * Protrusion of injector Allowed range: 1.52 — 1.78 mm 15-904 N855 SERIESREPAIR AND REPLACEMENT. REPLACING VALVE SEAT INSERTS Special tools Port Number PartName [arty ‘A | 79500-4800 | Vaweseat puller | 1 8 | 795-100:3003 | Vatveseat cutter | 1 c Push tool 1 D | 795-134-1401 | Caulking too! 1 Di | 790-101-5821 _| Grip 1 % When repairing and correcting the valve seat without replacing the valve seat insert, correct the valve seat as described in GRINDING AND CORRECT: ING VALVE SEATS. N855 SERIES REPLACING VALVE SEAT INSERTS Removing valve seat inserts v Using the grinder for valve seat puller A, make a groove in the insert as described below 10 facilitate the removal. Working air pressure: 5 ~ 6 kg/cm? + When replacing the grindstone, be sure 10 cut off the air supply. AN aetore starting the grinding work, make 2 trial run of the grinder for a minute to confirm that it is in normal operating condition. © After the grindstone is replaced, make & trial run of the grinder for three minutes AA confirm that the grindstone is not damaged, then install it to the grinder shaft securely AA Use safety glasses when operating the ringer. i) Install grindstone @ to grinder @. ii) Align the groove on sleeve @) with holder @® and install the sleeve and the grinder Use set screw @ to adjust the grinder positon 3) 6162F508 15-005 @REPLACING VALVE SEAT INSERTS. REPAIR AND REPLACEMENT i) Adjust the grinder position so that the horizontal center tine of grindstone @ is located at the center of valve seat insert (1), then secure the grinder by tightening the set screw. iv) Fully open the grinder throttle valve and slowly move the rotating grindstone towards insert (1) until it comes into V) While pressing the grindstone lightly towards the inner surface of the insert, move the grindstone in a circle and make @ groove in the circumference of the inner surface to a depth of about 1 mm. 2). Using the puller head on valve seat puller A, remove the insert as follows: i) Press three claws (a) on puller head @ inside by hand and fit the puller head into insert (1, ii) Tighten screw @ so that the three claws will be pressed into the groove on the inside of the insert. + Stop tightening the screw as soon es the claws fit completely into the groove, If the screw is overtightened, the insert may get damaged and it willbe difficult to remove. ii) Place bridge @ around the outside of the puller head, put plates i and qj) on the bridge, and tighten nut until the insert is removed. 1 5-906 N855 SERIES