www.too1s.com Specifications Manual Big Cam IV, New Big Cam IV, and 88 Big Cam IV NT 855 Series Engines CopyrightR 1989 Cummins Engine Company, Inc. All rights reserved Bulletin No. 3810434-00 Printed 3/89 www.too1s.com Foreword This manual contains complete assembly and rebuild specifications for the Big Cam IV, New Big Cam IV, and 88 Big Cam IV engines and all associated components manufactured by Cummins Engine Company, Inc. This manual is intended as a quick reference guide for an experienced technician who is familiar with our product. Various accessory and component suppliers can be contacted directly for any information not covered in this manual. A series of specific Cummins Engine Company, Inc. service manuals (Troubleshooting and Repair, Specifications, Alternative Repair, etc.) are available and can be ordered by filling out and mailing the Literature Order Form located at the end of this manual. Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged. Please use the postage paid, self-addressed Literature Survey Form at the end of this manual for communicating your comments. The latest technology and the highest quality components are used to manufacture the products of Cummins Engine Company, Inc. When replacement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts. These parts can be identified by the following trademarks: The specifications in this manual are based on the most current information at the time of publication. Cummins Engine Company, Inc. reserves the right to initiate any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location, a Cummins Division Office, or the factory. CUMMINS ENGINE COMPANY, INC. Box 3005 Columbus, IN 47202-3005 ATTENTION: NT855 Product Service & Support Mail Code - 80206 www.too1s.com Specifications Manual Table of Contents Additional Service Literature .......................................................................................................................... 0-73 Air Compressor Inspection Specifications............................................................................................................................... 0-64 Cam Follower Assembly Rebuild Specifications................................................................................................................................... Fixed Injection Timing .............................................................................................................................. MVT Injection Timing ................................................................................................................................ Torque Values............................................................................................................................................... 0-45 0-45 0-45 0-50 Capscrew Markings and Torque Values ......................................................................................................... 0-71 Capscrew Markings and Torque Values - U.S. Customary ........................................................................ 0-71 Cooling System -Torque Values ..................................................................................................................... 0-60 Cylinder Block Rebuild Specifications................................................................................................................................... 0-29 Torque Values............................................................................................................................................... 0-37 Cylinder Head Rebuild Specifications................................................................................................................................... 0-38 Torque Values............................................................................................................................................... 0-42 Decimal and Metric Conversion Factors......................................................................................................... 0-69 Drive Belt Tension Specifications................................................................................................................... 0-67 Engine Assembly Capscrew Torque Values .............................................................................................................................. 0-14 Specifications.................................................................................................................................................. 0-9 Engine Diagrams ............................................................................................................................................... 0-2 Engine Identification ......................................................................................................................................... 0-1 Engine Testing Test Specifications ........................................................................................................................................ 0-65 Fan Hub Inspection Specifications............................................................................................................................... 0-57 Fuel Pump Rebuild Specifications................................................................................................................................... 0-51 Fuel Pump and Compressor Drive Rebuild Specifications................................................................................................................................... 0-62 Torque Values............................................................................................................................................... 0-63 General Engine Specifications.......................................................................................................................... Cooling System........................................................................................................................................... Electrical System ........................................................................................................................................ Exhaust System .......................................................................................................................................... Fuel System................................................................................................................................................ General Engine Data .................................................................................................................................. Intake System ............................................................................................................................................. Lubrication System ..................................................................................................................................... 0-5 0-6 0-6 0-6 0-6 0-5 0-5 0-5 Injection Timing Codes ................................................................................................................................... 0-66 Injectors Rebuild Specifications................................................................................................................................... 0-51 Lubricating Oil Pump Inspection Specifications............................................................................................................................... 0-52 Lubricating Oil System Capacities ..................................................................................................................................................... 0-52 Torque Values............................................................................................................................................... 0-54 Newton-Meter to Foot-Pound Conversion Chart ............................................................................................ 0-70 Pipe Plug Torque Values................................................................................................................................. 0-72 www.too1s.com Rocker Lever Housing Assembly Rebuild Specifications................................................................................................................................... 0-43 Torque Values............................................................................................................................................... 0-44 Service Literature Ordering Location ............................................................................................................. 0-74 Specifications General Information ........................................................................................................................................ 0-4 Thermostat Housing Assembly Rebuild Specifications................................................................................................................................... 0-58 Thermostat (Reserve Flow Cooling) Operating Temperature ................................................................................................................................. 0-59 Turbocharger Inspection Specifications............................................................................................................................... 0-64 Valve and Injector Adjustments*...................................................................................................................... Crosshead Adjustment ................................................................................................................................ Cummins Engine Brake .............................................................................................................................. Injector Preload (Top Stop) ......................................................................................................................... JacobsW Engine Brake............................................................................................................................... Valves......................................................................................................................................................... 0-7 0-7 0-7 0-7 0-7 0-7 Vehicle Braking Rebuild Specifications................................................................................................................................... 0-65 Water Pump Assembly Rebuild Specifications................................................................................................................................... 0-56 Weights and Measures Conversion Factors ....................................................................................................................................... 0-68 Engine Serial Number (E. Horsepower and RPM Rating The model name provides the following engine data: N T C 400 Maximum Rated Horsepower Custom Rated Turbocharged Four Valve Head .) 2. The information on the dataplate is mandatory when sourcing service parts: 1.com Specifications NT855 Engine Identification Page 1 Engine Identification The engine dataplate provides the model identification and other important information about the engine.too1s. Model 4.N.S. Have the following engine data available when communicating with a Cummins Authorized Repair Location. Control Parts List (CPL) 3.www. . drain points.www. filter locations.too1s. The information and configuration of components shown in these drawings are of a general nature. and access locations for instrumentation and engine controls. Some component locations will vary depending on applications and installations.com Engine Diagrams Page 2 Specifications NT855 Engine Diagrams The following drawings contain information about engine components. too1s.www.com Specifications NT855 Engine Diagrams Page 3 . Capscrew Markings and Torque Values. Customary dimensions.www. Customary. If a torque value is not listed.General Information Page 4 Specifications NT855 Specifications . Refer to the Table of Contents. and 88 Big Cam IV NT855 Series Engines Shop Manual.S. Capscrew torque values are listed in newton meters and foot pounds.50 mm [0. fit properly. in this manual. .S. and are secured with the correct torque value. The minimum and maximum tolerance limit specifications are listed in both metric and U.com Specifications . Bulletin No. followed by the U. Customary dimension in brackets. use the standard torque value for the capscrew. All capscrews used on the NT engine are U.too1s.S. for example: 0. New Big Cam IV. unless otherwise specified. 3810395-00. The metric dimension is given first. The assembly and rebuild specifications and torque values are provided to make sure the parts are assembled correctly.General Information The specifications in this manual are organized in the same sequence as the Big Cam IV.020 inch]. ........................................0 liters [855 C..................................... H20] Maximum Allowable Intake Restriction with Dirty Air Filter Element ..........................................] Compression Ratio ............... 3.... 35 to 30 liters [9...... 1800 or 1900 Bore & Stroke ............0 in.............................D....................] • Oil Pan Capacity (high-low) ....................www.S... 2............ 14...5 in..... 64 cm H20 [25 in...................S....................................... Customary] Horsepower (Refer to the engine dataplate) Engine speed @ Maximum Output: • Standard Rating (RPM) .....................I..................................................... 240 to 310 kPa [35 to 45 psi] Oil Capacity of Standard Engine: • Bypass Filter ....................................... 140 mm [5.................................................... 70 kPa [10 psi] At No Load Governed Speed: • Automotive ...............................................................................................................5 liters [0..........] ...................] Total System Capacity Including Bypass Filter ... 30 cm H20 [12 in........... Gal.............................................................................] X 152 mm [6........................7:1 Firing Order ... 1153 to 1194 kg [2540 to 2630 lb.................75 U...............................] Displacement .8 liters [0............................93 U............................ Gal...S......................................................................................... 14............5 to 8..................................Low Idle (Minimum Allowable) ......................................0 to 16............... H20] • Medium Duty Dry Type Cleaner ...............................................................S..............................] Intake System Maximum Allowable Intake Restriction with Clean Air Filter Element: • Normal Duty Dry Type Cleaner .......S.............................................. 38 cm H20 [15 in.................................. 42 liters [11 U.................................. Gal....................too1s................................ H20] Lubrication System Oil Pressure ........ 2100 • Formula Rating (RPM) ......... 1208 to 1249 kg [2660 to 2750 lb......0 U........ 25 cm H20 [10 in..............] • Full Flow Filter Capacity ............. 1-5-3-6-2-4 Engine Weight (With Standard Accessories): • Dry Weight .......................................................................................................................................... Gal....... H20] • Heavy Duty Dry Type Cleaner ........] • Wet Weight ...........................................com Specifications NT855 General Engine Specifications Page 5 General Engine Specifications General Engine Data Metric [U................................................................ .www....................... 200 mm Hg [8 in..5 in...... 100°C [212°F] Minimum Recommended Top Tank Temperature ....................... ** CCA ratings are based on two 12-volt batteries in series..................................................... Maximum Allowable Restriction to Pump: • With Clean Filter .] Standard Modulating Thermostat Range: • Conventional Aftercooling .............. 1000 mm [40 in..........S.................................................................................. Reserve capacity determines the length of time sustained cranking can occur................................................................... 350 kPa [50 psi] Maximum Allowable Top Tank Temperature . 70°C [158°F] Minimum Recommended Pressure Cap .................................................................................................. 100 mm Hg [4 in.... Hg] Maximum Allowable Return Line Restriction without Check Valves ............................... 75 mm [3 in........................................] Fuel System NOTE: For performance and fuel rate values................................................... 64 mm Hg [2........................................................................................................too1s.................................................................................................. 127 mm [5 in..........................................................] • H20 ........................................................ Hg] • With Dirty Filter ... Hg] Electrical System Minimum Recommended Battery Capacity Battery 12 Volt 24 Volt ** Cold Cranking Amperes 1800 900 Ambient Temperatures -18°C [0°F] Reserve Cold Capacity Cranking *Amperes Amperes 640 1280 320 640 0°C [32°F] Reserve Capacity Amperes 480 240 * The number of plates within a given battery size determines reserve capacity.....5 in........................................................................... refer to the engine data sheet or the fuel pump code for the particular model involved................... 165 mm Hg [6.......................... ..................................... 21 liters [22 U................... 82 to 93°C [180 to 200°F] • Optimized Aftercooling ............ Hg] Maximum Allowable Return Line Restriction with Check Valves and/or Overhead Tanks ........ Customary] Coolant Capacity (engine only) .. qt................... 50 kPa [7 psi] Exhaust System Maximum Allowable Back Pressure Created by Piping and Silencer: • Hg ..............S....................... 79 to 91°C [175 to 195°F] Maximum Coolant Cylinder Block Pressure (Pressure Cap Removed) Closed Thermostat .........com General Engine Specifications (Continued) Page 6 Specifications NT855 General Engine Specifications (Continued) Cooling System Metric [U..........................................] Exhaust Pipe Size (Normally Acceptable Inside Diameter) ....................... .....45mm[0.....................................................................................46 to 0.........002 in] Crosshead Adjustment Rocker Lever Clearance ... 0................. Refer to the table below....... 0..................53mm[0..........................................................................................................................030 in] Adjusting Screw Lock Nut Torque (Valves and Injectors): With Part No................................................com Specifications NT855 Valve and Injector Adjustments* Page 7 Valve and Injector Adjustments* Valves Initial: Intake ................. 35 N•m [25 ft-lb] Without Part No..........................34 in] NOTE: The JacobsT Model 425 engine brake is not approved for engines with Mechanical Variable Timing (MVT)............... ST-669 .....011 in] Exhaust . 0.. 45 N•m [35 ft-lb] Without Part No................... ST-669 .....6 to 0...................................................................... and 88 Big Cam IV JacobsT Slave Piston Adjustment Engine Model Big Cam IV Big Cam IV New Big Cam IV New Big Cam IV 88 Big Cam IV 88 Big Cam IV Single Entry Turbocharger Divided Entry Turbocharger Fixed Timing Step Timing Fixed Timing Step Timing 401B XXXX 0...018 in] Adjusting Screw Lock Nut Torque: With Part No......000 to 0............018 in] XXXX 0.................too1s..00 in-lb] Recheck Limit ...........018 in] XXXX XXXX XXXX 430 XXXX XXXX XXXX XXXX 0....... 24 N•m [18 ft-lb] Without Part No....................45mm[0..www...00 mm [0.............................................. Step Timing Control (STC)...018 to 0....05 mm [0... ST-669 .................................. 0..........45mm[0...... ** The correct adjusting screw must be used............ .....10 to 0........28 mm [0. 40 N•m [30 ft-lb] Cummins Engine Brake **Adjusting Screw Clearance (Use Dial Indicator) .............................016 in] Exhaust ................... 0....7 N•m [5........................................023 in] Recheck Limit: Intake . or 88 Big Cam IV engines........86mm[0.......................................................... NOTE: The JacobsT Model 430 can only be used on 88 Big Cam IV engines........................ New Big Cam IV......................46 mm [0..........021 in] XXXX XXXX XXXX Brake Model 420 XXXX XXXX XXXX 0......... Big Cam IV..018 in] XXXX XXXX 425 0.......................................................................00 to 0......................... 60 N•m [45 ft-lb] Injector Preload (Top Stop) Initial . * Adjustments must be made when the engine is cold (any stabilized coolant temperature at 60°C [140°F] or below).............018 in] XXXX XXXX XXXX XXXX 401C 0........................ 0...............41 mm [0.................................................................................. ST-669 .............. 27 N•m [20 ft-lb] JacobsT Engine Brake Caution: The JacobsT Brake slave piston clearance is not the same for all engine models... 0..45mm[0.......................................018 in] 0.00 to 6..................004 to 0............................030 in] XXXX 0.....76mm[0.............................58 mm [0.........................................45mm[0................ ST-669 ........................................... 0.......................................... Use the correct clearance and correct feeler gauge for the particular engine model................ ST-669 ........................76 mm [0..000 in] Adjusting Screw Lock Nut Torque: With Part No... ................................too1s.. 30 N•m [22 ft-lb] Without Part No................................ 35 N•m [25 ft-lb] Injector and Valve Adjustment Sequence .......................www.......................... ST-669 ......... ST-669 .....................................................com Valve and Injector Adjustments* Page 8 Specifications NT855 Adjusting Screw Lock Nut Torque: With Part No............................... 10 0.20 MAX MAX MAX MAX MAX MAX 0.012 0.13 SAE No.25 0.Specifications Page 9 Ref. 00 0 1/2 1 2 3 787.8 409.004 0.010 0.010 0.002 0.008 0.com Specifications NT855 Part or Assembly Engine Assembly .012 0.20 0.007 0.20 MAX MAX MAX MAX MAX MAX 0.Specifications Cylinder Liner Protrusion 0.25 0. 00 0 1/2 1 2 3 0.008 0.30 0.05 MAX 0.45 MIN MAX 0.002 Crankshaft End Clearance 0.13 17.008 0.20 0. Point mm in Engine Assembly .008 SAE No.01 25.R.20 0.006 Cylinder Liner Out of Round 0.www.D.I.3 447.25 0.25 0.30 0.63 16.007 Cylinder Liner to Lower Cylinder Liner Bore Clearance 0.20 0.018 SAE No.7 648.008 Flywheel Housing Bore I.010 0.18 MIN MAX 0.01 20.05 0.008 0.15 MIN MAX 0.51 23. Flywheel Housing Face Alignment T.4 511.7 MAX MAX MAX MAX MAX MAX 31.010 0. 00 0 1/2 1 2 3 0. .too1s.0 584.18 0.I. Flywheel Housing Bore Alignment T.R. Refer to Group 00.Specifications Page 10 Part or Assembly Specifications NT855 Ref. page 0-89.43 MIN 0.0045 0.019 0.08 mm [0.74 MAX 0.027 • Second 0. Engine Assembly.48 MIN 0.03 mm [0.030 • Third 0.114 0. Injection Timing. .76 MAX 0.020 Injection Timing To verify the correct injection timing for a particular engine refer to the engine dataplate. Point mm in Piston Ring Gap Piston • Top 0.025 Note: Add 0. 3810395. Rotate the rings to position the gaps as shown. Engine Timing Note: The timing marks on the camshaft gear must align with the timing marks on the crankshaft gear to make sure the engine timing is set correctly.020 0. for complete instructions.com Engine Assembly .68 MAX 0. Piston Ring End Gap The ring gaps must not be aligned with the piston pin bore. Bulletin No.010 0.001-inch] wear in the cylinder liner wall. in the NT855 Shop Manual. Connecting Rod Side Clearance 0. Backlash Between the Camshaft and the Crankshaft Gear 0.003-inch] to the maximum limit for each 0.33 MIN MAX 0.51 MIN 0.25 MIN 0.50 MIN MAX 0.002 0.029 • Oil 0. Oil Control Ring End Gap The two-piece oil ring must be installed with the expander gap 180 degrees from the oil ring gap.www.05 0.017 0.too1s.64 MAX 0.13 Note: The rod must move freely from side-to-side. 0.R.10 MAX 0.016 Flywheel Bore Runout T. Point mm in Accessory Drive Assembly Timing Position the accessory drive shaft dowel pin at the 12:00 o’clock position. Backlash Between the Accessory 0.020 Camshaft Gear Note: If the backlash is not within specifications.50 MAX 0.I.05 MIN 0.com Specifications NT855 Part or Assembly Engine Assembly .Specifications Page 11 Ref. the gear must be replaced.127 MAX 0.I. Vibration Damper Eccentricity T.020 Backlash Between the Lubricating 0.012 0. the lubricating oil pump drive gear must be replaced.203 0.www.008 0.356 0.50 MAX Note: If the backlash is not within specifications.R. Radius mm 203 254 305 356 406 (A) in 8 10 12 14 16 .002 Oil Pump Drive Gear and the 0.R.254 0.002 0. Flywheel Face Runout T.05 MIN Drive and the Camshaft Gear 0.I.18 MAX 0.014 0.406 MAX MAX MAX MAX MAX 0. Align the timing mark on the accessory drive gear with the timing mark on the camshaft gear.0050 0. 0.010 0.305 0.004 Vibration Damper Face Alignment (‘‘Wobble’’) T.too1s.007 0.R. 0.I. Align the ‘‘A’’ valve set mark on the accessory drive pulley with the pointer on the gear cover. Bulletin No. 3810395. . in the NT855 Shop Manual. Group 00.www. in the NT855 Shop Manual. Intake Valve Lash Specifications Exhaust Valve Lash Specifications 0. Bulletin No. 3810395. page 0-133.Specifications Page 12 Part or Assembly Specifications NT855 Ref.023 Air Compressor to Accessory Drive Timing Position the air compressor crankshaft timing mark at the 10:00 o’clock position. page 0-129. PTD Top-Stop Injector Adjustment. Group 00.011 0.28 0.58 MIN MIN 0. PTD STC Injector Adjustment. Point mm in PTD Top-Stop Injector Adjustment Refer to Engine Assembly. PTD STC Injector Adjustment Refer to Engine Assembly.too1s.com Engine Assembly . Point Belt Tension Water Pump Belt (Big Cam IV and New Big Cam IV) • New Belt Tension • Used Belt Tension Ref. Point Belt Tension Alternator Belts • New Belt Tension • Used Belt Tension Ref.www. Point mm in Newtons Pounds Force 710 290-580 160 65-130 Newtons Pounds Force 620 270-490 140 60-110 Newtons Pounds Force 620 270-490 140 60-110 Newtons Pounds Force 620 270-490 140 60-110 . Point Belt Tension Fan Belts • New Belt Tension • Used Belt Tension Ref.too1s.com Specifications NT855 Engine Assembly . Point Belt Tension Water Pump Belt (88 Big Cam IV) • New Belt Tension • Used Belt Tension Ref.Specifications Page 13 Part or Assembly Ref. too1s.www.Capscrew Torque Values Page 14 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Engine Assembly .Capscrew Torque Values Adapter Plate to Rebuild Stand 100 Mounting Plate Adapter to Rear Water Header.com Engine Assembly . Main Bearing Capscrews (3/4-inch Diameter Capscrews) Note: Tighten in the sequence shown. if Removed 9 75 7 Adapter Plate Mounting Capscrews • 3/8-inch 40 • 1/2-inch 100 • 5/8-inch 100 Note: Tighten all the adapter plate mounting capscrews in the sequence shown. Liner Force Plate Screw Main Bearing Capscrews (1 inch diameter capscrews) Note: Tighten in the sequence shown. Rear Cover Mounting Capscrews 136 30 75 75 100 1 2 3 4 5 6 7 150 285 415 110 210 305 150 285 415 110 210 305 1 2 3 4 5 6 7 120 230 345 90 170 255 Loosen all Loosen all 120 230 345 90 170 255 45 35 . Accessory Drive Mounting Capscrews Lubricating Oil Pump Gear Cover 60 45 55 40 70 50 . and 3 to install each cylinder head. 2.com Specifications NT855 Part or Assembly Flywheel Housing Note: Tighten in the sequence shown. Tighten the center cam follower housing first. Cylinder Head Note: Tighten in the sequence shown.www. the three housings of the MVT cam followers must be installed to the engine as an assembly.Capscrew Torque Values Page 15 Step Connecting Rod Capscrews Note: Tighten the connecting rod capscrews in alternating sequence.too1s. 1 2 3 Torque Values N•m 205 ft-lb 150 100 230 75 170 35 135 385 25 100 285 Cam Follower Housing (Without Mechanical Variable Timing) 20 15 Note: Tighten in the alternating 45 35 sequence shown. Engine Assembly . Note: With mechanical variable timing. Repeat steps 1. 8 260 190 Flywheel 270 200 45 35 Part or Assembly Camshaft Bearing Support Step Accessory Drive Pulley Front Engine Support Bracket Note: Tighten the capscrews in a star pattern.com Engine Assembly . Water Manifold Assembly Injectors (PTD-Top Stop) • Big Cam IV engines 18 156 in-lb Note: For Big Cam IV engines (5/16-inch .www.18 capscrews). 6 N•m [48 in-lb] torque one at a time. SAE grade No.too1s. to a final torque of 18 N•m [156 in-lb].Capscrew Torque Values Page 16 Specifications NT855 Torque Values N•m 25 ft-lb 20 420 310 70 50 Vibration Damper Capscrew Size: 5/8-inch. . tighten the capscrews alternately and evenly. .www. With adapter. Less adapter 35 40 25 30 30 35 22 25 Rocker Housing Mounting Capscrews Engine Brake Mounting Capscrews Note: Tighten the capscrews in the sequence shown.56-0.Lock Nut • Less JacobsW Brake: .Capscrew Torque Values Page 17 Step • New Big Cam IV and 88 Big Cam IV Torque Values N•m 34 ft-lb 25 Note: For New Big Cam IV and 88 Big Cam IV engines (3/8-inch ... 80 95 60 70 STC External Oil Manifold 11 95 in-lb 0.com Specifications NT855 Part or Assembly Injectors (PTD-Top Stop) Engine Assembly . ST-669 .. Part No. Less adapter • With JacobsW Brake Model 401 adjusting screw (exhaust crosshead only) .16 capscrews). Part No. With adapter. tighten the capscrews alternately and evenly. Injectors (PTD-STC) Fuel Crossovers 54 4 40 35 in-lb Crossheads .68 5-6 in-lb Injector Adjusting Screw . 11 N•m [8 ft-lb] torque one at a time to a final torque of 34 N•m [25 ft-lb].too1s. ST-669 . too1s. Part No.com Engine Assembly .www. 669 • Without adapter . Part No.68 ft-lb 35 45 6 in-lb Valve Lock Nut • With torque wrench adapter. 90 65 30 35 22 25 Note: Tighten the C Brake nuts in the sequence shown. ST-669 • Without adapter 45 60 35 45 Cummins C Brake Nuts 90 65 Cummins C Brake Lock Nut 24 18 JacobsW Hold Down Nuts Note: Tighten the nuts in the sequence shown. Part No.Capscrew Torque Values Page 18 Part or Assembly Injector Lock Nut Specifications NT855 Step • With torque wrench adapter. JacobsW Lock Nut • With torque wrench adapter. ST-669 • Without adapter Valve Lash Clearance (Torque Wrench Method Using Specified Feeler Gauge) Torque Values N•m 45 60 0. www. Engine Assembly .Capscrew Torque Values Page 19 Step Torque Values N•m ft-lb 20 16 15 12 25 20 70 50 • First. tighten the two capscrews (1) at the oil pan.too1s.com Specifications NT855 Part or Assembly Rocker Housing Covers • Big Cam IV/New Big Cam IV • 88 Big Cam IV Note: Tighten in the sequence shown. 50 Air Compressor 65 50 Fuel Pump 45 35 . Use only grade 8 capscrews. Lubricating Oil Transfer Tube 120 in-lb Aftercooler • Big Cam IV Unitized Aftercooler 70 Note: Tighten the nine capscrews in the sequence shown. • Thirty-two 7/16-inch capscrews Note: Tighten in the sequence shown. • Second. 45 35 45 35 DFC Signal Line Tube Nuts 15 Oil Pan • Four 5/16-inch capscrews in rear of the oil pan. tighten the capscrews (2) at the lubricating oil pump. 4 No.com Engine Assembly . .www. 6 No.too1s.Capscrew Torque Values Page 20 Part or Assembly Support Bracket to Cylinder Block Mounting Capscrews Specifications NT855 Step Fuel Tubing Tube Size 1/4-inch 5/16-inch 3/8-inch 1/2-inch STC Oil Control Valve STC Oil Control Valve Hoses Hose Size No. 8 Torque Values N•m 45 15-20 20-25 25-35 35-40 25 14-16 20-35 40-55 ft-lb 35 10-15 15-20 20-25 25-30 20 120-140 in-lb 15-25 30-40 Wiring Harness Mounting Clip to Cylinder Block 45 35 Wiring Harness Mounting Clips to Water Manifold Mounting Studs • Mounting Nuts 20 15 15 30 45 10 20 35 Water Pump (Big Cam IV and New Big Cam IV) Note: Tighten the capscrews in the sequence shown. Part or Assembly Water Pump (88 Big Cam IV) Idler Pulley Support Bracket Coolant Transfer Tube Hose Clamp (Big Cam IV and New Big Cam IV Only) Air Compressor Coolant Tubes Tube Nuts (Big Cam IV and New Big Cam IV) Air Compressor Air Inlet Fitting Into the Aftercooler Air Compressor Air Inlet Tube Hose Clamps (88 Big Cam IV) Step 5 40 in-lb 20 15 15 10 5 40 in-lb Water Pump Belt (Big Cam IV and New Big Cam IV) • New Belt Tension 710 N 160 lbf • Used Belt Tension 290-580 N 65-130 lbf Note: A belt is considered used it if has been in operation for more than 10 minutes. If used belt tension is below the minimum. .Capscrew Torque Values Page 21 Torque Values N•m ft-lb 15 10 30 20 45 35 Note: The two capscrews which mount the idler pulley support bracket are longer than the other four water pump capscrews.too1s. If used belt tension is below the minimum. Idler Pulley Shaft Lock Nut (Big Cam IV and New Big Cam IV) 70 50 620 N 270-490 N 140 lbf 60-110 lbf Water Pump Belt (88 Big Cam IV) • New Belt Tension • Used Belt Tension Note: A belt is considered used if it has been in operation for more than 10 minutes. tighten to the maximum value.com Specifications NT855 Engine Assembly . tighten to the maximum value.www. com Engine Assembly . Fan Hub 110 80 • Hexagon Head • Slotted Head 15 10 140 in-lb 95 in-lb Hand Hole Cover 45 35 Piston Cooling Nozzles . If the belt tension is below the minimum.Capscrew Torque Values Page 22 Part or Assembly Idler Pulley (88 Big Cam IV) Specifications NT855 Step Torque Values N•m 45 ft-lb 35 Fan Hub Support Bracket 100 75 Brace to Fan Hub Bracket Brace to Rocker Housing 70 80 50 60 Fan Drive Belts • New Belt Tension 620 N 140 lbf • Used Belt Tension 270-490 N 60-110 lbf Note: A belt is considered used if it has been in operation for more than 10 minutes. tighten to the maximum value.www.too1s. com Specifications NT855 Part or Assembly Coolant Filter Head (88 Big Cam IV) Engine Assembly .too1s. New Big Cam IV. New Big Cam IV. and NTC-444 Clamps 5 40 in-lb Thermostat (Reserve Flow Cooling) Front Hold Down Strap Capscrew 45 35 Thermostat (Reserve Flow Cooling) Rear Hold Down Strap Capscrew 110 80 . and NTC-444 Only 12 110 in-lb Thermostat (Reserve Flow Cooling) Big Cam IV.Capscrew Torque Values Page 23 Step Torque Values N•m 45 ft-lb 35 Thermostat Housing (Big Cam IV and New Big Cam IV) 45 35 Thermostat Housing (88 Big Cam IV) 45 35 Thermostat (Reserve Flow Cooling) Big Cam IV.www. www.too1s.com Engine Assembly - Capscrew Torque Values Page 24 Part or Assembly Oil Cooler Assembly (Big Cam IV and New Big Cam IV) Specifications NT855 Step Torque Values N•m ft-lb 45 35 Cooler Brace 10 8 Oil Cooler Assembly (88 Big Cam IV) 45 35 Support Bracket to Cylinder Block (2) Support Bracket to Rear Oil Cooler Cover (1) 45 35 45 35 Water Header Covers 12 110 in-lb 5 40 in-lb 25 20 Water Transfer Hose* Clamps *On engines equipped with a single pass oil cooler. Water Transfer Tube (Big Cam IV and New Big Cam IV) • Retaining Clip www.too1s.com Specifications NT855 Part or Assembly Water Transfer Housing to Thermostat Housing Engine Assembly - Capscrew Torque Values Page 25 Step Torque Values N•m 25 ft-lb 20 Water Transfer Tube (88 Big Cam IV) Hose Clamps 45 5 35 40 in-lb Water Fill Tube (88 Big Cam IV Only) 45 35 5 40 in-lb 12 110 in-lb 5 40 in-lb 5 40 in-lb Aftercooler Coolant Inlet and Outlet Tubes (Big Cam IV and New Big Cam IV) • Clamps Aftercooler Coolant Inlet and Outlet Tubes (Big Cam IV and New Big Cam IV) • Capscrews Aftercooler Coolant Inlet and Outlet Tubes (88 Big Cam IV) • Clamp Aftercooler Coolant Inlet and Outlet Tubes (88 Big Cam IV) • Hose Clamps (1) and (2) www.too1s.com Engine Assembly - Capscrew Torque Values Page 26 Part or Assembly Aftercooler Coolant Inlet and Outlet Tubes (88 Big Cam IV) • Capscrew Specifications NT855 Step Torque Values N•m ft-lb 12 110 in-lb 5 40 in-lb • Steel Tube Nuts 12 110 in-lb Aftercooler Vent Tube (88 Big Cam IV) • Tube nuts 12 110 in-lb 45 80 35 60 Turbocharger Mounting Nuts Turbocharger Hose Clamps 45 8 35 70 in-lb Air Crossover Tube Support Clamp(s) 20 15 Aftercooler Vent Tube (Big Cam IV and New Big Cam IV) • Rubber Hose Clamps Aftercooler Vent Tube (Big Cam IV and New Big Cam IV) Exhaust Manifold Note: Tighten in the sequence shown. www.too1s.com Specifications NT855 Part or Assembly Turbocharger Engine Assembly - Capscrew Torque Values Page 27 Step Torque Values N•m ft-lb • Capscrews • Hose Clamps 45 5 35 40 in-lb Turbocharger Oil Supply Hose Swivel Nuts 35 25 Bypass Oil Filter Return Tube Swivel Nuts 35 25 5 40 in-lb 12 110 in-lb 45 35 620 N 270-490 N 140 lbf 60-110 lbf Hose Clamps Note: Tighten the hose clamps on Big Cam IV engines which have the bypass oil filter return tube plumbed into the turbocharger oil drain tube. Bypass Oil Filter Return Tube Support Clamp Capscrew Note: Only on new Big Cam IV and 88 Big Cam IV engines with the single pass oil cooler. Alternator Mounting Bracket Alternator Belts • New Belt Tension • Used Belt Tension Note: A belt is considered used if it has been in operation for more than 10 minutes. www.com Engine Assembly .too1s.Capscrew Torque Values Page 28 Part or Assembly Adjusting Link Capscrews (Grade 5 or Higher) Bolt Size 5/16 7/16 1/2 Threads/Inch 18 14 13 Specifications NT855 Step Torque Values N•m ft-lb 20 35 65 15 25 50 40 90 110 35 65 80 45 35 175 130 Alternator to Alternator Support Capscrew and Nut (Grade 5 or Higher) Bolt Size 3/8 7/16 1/2 Fan Starting Motor Threads/Inch 16 20 13 . 6.170 .894 6.842 .D.5635 6.741 .6.5615 .167.6. (Installed) Note: If one of the bushings exceeds the maximum specifications.159.102 0.D.893 160.713 167. all of the bushings must be replaced.004 0.632 Upper Press Fit Design Counterbore Diameter • Standard • Oversize Lower Press Fit Design Counterbore Diameter 166.5700 6.096 .457 63.166.54 155.160.Rebuild Specifications Cylinder Block Height 421. .010 120.3070 None • Standard • Oversize 159.2950 6. Point mm in Cylinder Block .7485 4.909 6.2930 .6040 .609 16.45 MIN MAX 16.858 .167.878 167.197 None 6.5023 Cylinder Block to Main Bearing Cap Press Fit/Side Clearance • Press Fit • Clearance *Measured between the block and either side of the cap.6100 • Standard • Oversize Lower Press Fit Design Upper Liner Bore Diameter 160.6.558 MIN MAX 2.254* MIN MAX 0.5640 .5835 • Standard • Oversize 166. Camshaft Bushing I.com Specifications NT855 Part or Assembly Cylinder Block .160.725 .3030 .Rebuild Specifications Page 29 Ref.124 6.5815 .4983 2.D.6.166.662 .3350 Upper Press Fit Design Upper Liner Bore Diameter Cylinder Liner Lower Bore I.too1s.7505 63. Main Bearing Bore I.220 6.6.www.60 MIN MAX 6.663 MIN MAX 4. 155.3330 .612 120.6.126 0.87 422. 007 Counterbore Sealing Ring Thickness • Standard Lower Press Fit or Upper Press Fit Liners • Oversize Lower Press Fit Liners Cylinder Liner I.74 167.53 0.237 68.72 166.77 167.www.too1s.606 Liner O.604 6.020 0.79 1.D.004 0.D.262 MIN MAX 2. 0.031 0.566 6.007 0.566 6.020 0.72 166.10 0.77 167. (Upper Press Fit Area) Upper Press Fit Design • Standard • . Cylinder Liner Protrusion Specifications NT855 Ref.23 0.019 0.018 0.46 0.D.com Cylinder Block .23 167.694 139.79 MIN MAX MIN MAX 6.Rebuild Specifications Page 30 Part or Assembly Cylinder Block Camshaft Bore I.18 0.28 MIN MAX MIN MAX 6.51 0.020 Oversize Liner O.021 0.6875 0.D. Point mm in 68.4998 5.586 166.022 139.827 MIN MAX 5.48 0.56 0.57 0.5050 166.009 0.6865 2.040 Oversize . (Upper Press Fit Area) Lower Press Fit Design • Standard • .584 6.062 0.564 6.20 0.564 6.18 MIN MAX 0.008 0.51 0. 01 9.375 0.29 MIN MAX MIN MAX 0.366 9.31 139.299 6.040 Oversize Cylinder Liner Flange Thickness Upper Press Fit Design • Standard • . Piston Skirt Outside Diameter (A) (B) 139. (Lower Press Fit Area) Lower Press Fit Design • Standard • . If the feeler gauge enters the oil ring groove without resistance.98 MIN MAX MIN MAX 6.too1s.34 139. ST-560-6.D.356 0.355 0.294 6.86 159.96 160.006 inch] feeler gauge.99 MIN MAX MIN MAX 6. Part No.91 159.020 Oversize Cylinder Liner Flange Thickness Lower Press Fit Design • Standard • .299 159.355 0.01 9.040 Oversize Piston Compression Ring Grooves Width Use piston ring groove wear gauge.298 6.294 6.47 139.336 6.27 9.491 5.52 MIN MAX MIN MAX 5.Rebuild Specifications Page 31 Ref.296 6.04 9.486 5.485 5.020 Oversize 159.365 0.338 9. Piston Oil Ring Groove Width Use a new oil ring and a 0.99 159. Point mm in Liner O. (Lower Press Fit Area) Upper Press Fit Design • Standard • .152 mm [0.www.356 0.D.86 159.493 .52 9.com Specifications NT855 Part or Assembly Cylinder Block . The piston must be replaced if the widest part of the gauge touches the piston. the piston must be replaced.55 MIN MAX MIN MAX 0.04 9.93 160.376 Liner O. 7600 3.07 92. .7607 Crankshaft Front Oil Seal Area O.9990 Piston Pin O.001-inch] out of round. Crankshaft Connecting Rod Journal O.000 79. 1. 152.35 152.40 MIN MAX 5.122 3.998 6.D.625 3.D.775 MAX Note: Discard the piston pin if it is more than 0.504 95. Crankshaft Oil Seal Wear Groove 0.D.too1s. 92.9985 2.626 Crankshaft Rear Oil Seal Area O.125 Crankshaft Gear Fit Area O.www. Point mm 50.38 MIN MAX 3.10 MIN MAX 3.D.9985 1.762 MIN 50.D.30 79.0000 50.com Cylinder Block .522 MIN MAX 3.800 in MIN MAX 1.03 mm [0.762 50.25 MAX 0.Rebuild Specifications Page 32 Part or Assembly Piston Pin Bore Specifications NT855 Ref.010 95. D.626 3. .7600 3.com Specifications NT855 Part or Assembly Crankshaft Main Bearing Journal O.522 MIN MAX 3.394 95.5000 76.001 3.013 35.10 92. page 1-87.too1s. 95. 3810395.7565 Crankshaft Gear Fit Area O.300 MIN MAX 4.D.23 76.629 35.4975 4.415 MIN MAX 3. Bulletin No. 95.7607 92.Rebuild Specifications Page 33 Ref.003 Crankshaft Gear Bore I.3785 1.237 114.052 MIN MAX 1.28 MIN MAX 3. in the NT855 Shop Manual.www.Group 01.D.504 95. Point mm in 114. Cylinder Block .7557 3.17 MIN MAX 3.3800 Crankshaft Thrust Face Width Crankshaft Adapter Inside Pilot Diameter Crankshaft Adapter Outside Pilot Diameter Note: The instructions for performing a magnetic crack inspection and the limits of acceptance for open and subsurface indications are provided in Cylinder Block . Refer to Crankshaft Magnetic Crack Inspection (01-10). 0022 Connecting Rod .25 0.405 MIN MAX 0. 50.99 MIN MAX 0.2445 0.010 0. 84.0947 Connecting Rod Capscrew O.1215 0.086 3. Point mm in Main Bearing Shell Thickness (Standard) 3.004 Connecting Rod .0930 0.145 MIN MAX 0.D.10 MAX MAX 0.583 0.210 6.too1s.Rebuild Specifications Page 34 Part or Assembly Specifications NT855 Ref.000 0.856 MIN MAX 2.D.www.3157 3.244 MIN MAX 3.2475 Connecting Rod Bearing Thickness (Standard) 2.D.75 304.590 Connecting Rod Crankshaft Bore I.998 12.81 14. 14.Alignment: • (Without Bushing) • (With Bushing) .0010 2.1238 Thrust Bearing Thickness 6.3167 Piston Pin Bushing I.825 50.286 MIN MAX 0.com Cylinder Block .Length 304.362 2.80 MIN MAX 11.219 84. 662 45.7985 44. Refer to Camshaft . Point mm in Connecting Rod .7510 1.Magnetic Inspection (01-15). Camshaft Thrust Washer Thickness 63.50 0.42 MIN MAX 2.090 0.745 MIN MAX MIN MAX 1. 3810395. page 1-118 and Camshaft Gear . • Flanged Camshaft • Flangeless Camshaft Camshaft Gear Press Fit O.455 44.010 The instructions for performing a magnetic crack inspection of the connecting rod is provided in Group 01.Magnetic Inspection (01-18).D.497 2. page 1-123. in the NT855 Shop Manual.37 63. Bulletin No.7530 1. in the NT855 Shop Manual. page 1-109.682 MIN MAX MIN MAX 1.8010 Camshaft Gear Bore I.too1s.7535 1.475 45. • Flanged Camshaft • Flangeless Camshaft The instructions for performing a magnetic crack inspection of the camshaft and camshaft gear is provided in Group 01.49 MIN MAX 0. Refer to Connecting Rods .020 0.098 44.29 2.7977 1. .526 44.8005 1.733 45.Magnetic Inspection (01-19). Camshaft Bushing Journal O. Bulletin No. 3810395.539 45.7502 1.D.www.D.Rebuild Specifications Page 35 Ref.495 2.Twist: • (Without Bushing) • (With Bushing) 0.25 MAX MAX 0.com Specifications NT855 Part or Assembly Cylinder Block . .125 inch] from the outside diameter.com Cylinder Block .7485 4.D.18 mm [0.010 inch].D. Accessory Drive Seal Bore I.too1s. 39.1905 120.D.07 43.D.962 81.10 MIN MAX 1.75 39.565 1.25 mm [0.380 1. The difference between any two of the four measurements must not exceed 0.696 1.Rebuild Specifications Page 36 Part or Assembly Crankshaft Pulley I.90 MIN MAX 1. 80.10 in MIN MAX 1.038 MIN MAX 3.05 35.688 MIN MAX 4.611 120. Specifications NT855 Ref.D.697 Crankshaft Seal Bore I. 43.571 Accessory Drive Bushing Bore I.7515 Accessory Drive Bushing I.382 Vibration Damper Thickness Measure the thickness in four places 90 degrees apart approximately 3.www.1875 3. Point mm 35. com Specifications NT855 Part or Assembly Cylinder Block . Connecting Rod Capscrews NOTE: Tighten the capscrews in alternate sequence.Torque Values Page 37 Step Torque Values N•m ft-lb Cylinder Block . Main Bearing Capscrews (3/4-inch diameter) Note: Tighten the main bearing capscrews in the sequence shown.Torque Values Cylinder Block Pipe Plugs • 1/4-inch • 3/8-inch 20 25 15 20 25 15 20 10 20 25 15 20 90 65 1 2 3 4 5 6 7 150 285 415 Loosen All 150 285 415 110 210 305 1 2 3 4 5 6 7 120 230 345 Loosen All 120 230 345 90 170 255 100 230 75 170 Cylinder Block Pipe Plugs • 3/8-inch • 1/8-inch Cylinder Block Pipe Plugs • 1/4-inch • 3/8-inch Cylinder Block Pipe Plug • 7/8-18 Straight Threaded Plug Main Bearing Capscrews (1 inch diameter) Note: Tighten the main bearing capscrews in the sequence shown.too1s. 110 210 305 90 170 255 .www. 85 111.449 0.0008 0.7 lbf 0. Valve Guide I.D.685 2.Rebuild Specifications Cylinder Head Flatness Per 25.00 in.Rebuild Specifications Page 38 Part or Assembly Specifications NT855 Ref.114 11.5 lbf • Valve Spring Part No. 3035996 Valve Spring Working Height: • Valve Spring Part No.D.too1s.44 Nominal Nominal 1.7 lbf 92.90 MIN 0. 211999 • Valve Spring Part No.635 43.020 0.4 mm [1.671 • Valve Spring Part No. 211999 295 N 326 N MIN MAX 66.40 11.5 lbf 73.www. Point mm in Cylinder Head . Valve Head Thickness at O.325 4.46 MIN MAX MIN MAX 85.79 42.724 1.D.com Cylinder Head .380 68.4550 Cylinder Head Thickness Valve Spring Free Height: A • Valve Spring Part No.557 MIN MAX 0. (Installed) 1 .08 MAX MAX 0.506 11.] of Length Cylinder Head Flatness (Total Overall Length) 0. 211999 • Valve Spring Part No. 3035996 381 N 412 N 11.003 109. 3035996 Load for Working Height: B C Valve Stem O.4530 0.20 66.25 MIN MAX 4.451 2.93 Nominal Nominal 2. 085 Crosshead Guide O.67 4.063 0.4321 0.51 MIN MAX 1.18 MIN MAX 0.975 11.too1s.070 Valve Seat to Valve Guide Concentricity (Per 360 Degrees) 0.280 10.880 1.060 0.26 32.Rebuild Specifications Page 39 Ref.16 MIN MAX MIN MAX 0.25 47.78 MIN MAX 0.D. Point Valve Guide Height (Installed) mm in 32.19 1.09 MAX 0.4335 47.165 0.52 1.60 3.055 0.75 MIN MAX 1.011 MIN MAX 0.105 0. Crosshead Guide Height (Installed) Valve Seat Area Width 1 Valve Protrusion • Pre-88 NT • 88 NT .40 2.860 1.0035 2.www.270 1.125 Injector Tip Protrusion 1.com Specifications NT855 Part or Assembly Cylinder Head . 24 7.D.285 0.Rebuild Specifications Page 40 Part or Assembly Specifications NT855 Ref.7520 7.4310 0.D.813 MIN MAX 1.91 1.9995 2. Valve Seat Insert Bore Depth (Standard Insert) Valve Seat Insert Bore I. Point mm in Valve Seat Width Limit 1. (Standard Insert) Crosshead Guide Bore I.37 MIN MAX 0.D.972 MIN MAX 0.4320 11.D.101 MIN MAX 0.com Cylinder Head .787 50.947 10. 19.088 19.0005 10.469 0.www.too1s.290 50.063 0.751 19.60 3.05 19.750 0.52 Approx.07 MIN MAX 0.060 Valve Guide O.7515 0.125 Valve Guide Bore I.18 MIN MAX 0. Injector to Injector Sleeve Seat Pattern: • Distance from Cylinder Head Surface • Pattern Width 1 2 . MIN 0. 434 0.03 11.380 0.too1s.17 MIN MAX 0. Point mm in Valve Seat Leakage (Hg) 508 MIN 20 635 MAX 25 Note: Refer to Cylinder Head . page 2-38. Bulletin No.www.400 . 3810395. 1 2 3 11.Vacuum Testing Valve Seating For Reuse (02-10).D.65 10.440 Valve Crosshead Stem Pocket to Pad Face 1 9.16 MIN MAX 0. in the NT855 Shop Manual. Valve Crosshead Stem Bore I.Rebuild Specifications Page 41 Ref.com Specifications NT855 Part or Assembly Cylinder Head . 3810395. in the NT855 Shop Manual. Injector Sleeve Expander Mandrel Injector Sleeve Holding Tool Capscrews Note: This torque value is for pressure testing the cylinder head. in the NT855 Shop Manual. Bulletin No. page 2-33. page 2-17. 3810395. 3810395. Bulletin No.too1s. and Cylinder Head .www. Bulletin No.Rebuild (02-02).Torque Values Page 42 Specifications NT855 Part or Assembly Step Torque Values N•m ft-lb Cylinder Head . in the NT855 Shop Manual. Refer to Cylinder Head Replacing the Injector Sleeves (02-07). 1 2 3 . page 2-35. Refer to Cylinder Head-Pressure Testing (02-08).Torque Values Install the Injectors into the Cylinder Head Capscrew Timing Size Fixed 5/16 6 12 18 14 24 34 48 4 9 13 10 18 25 35 Injector Sleeve Puller Small Nut 65 50 Injector Sleeve Holding Tool Nut Note: This torque value is for installing new injector sleeves. page 2-30. 60 45 8 75 in-lb 5 10 15 45 in-lb 90 in-lb 130 in-lb Fixed 3/8 1 2 3 1 2 3 1 STC 3/8 Note: Refer to Cylinder Head .com Cylinder Head .Replacing the Injector Sleeves (02-07). • Pre-88NT • 88NT .188 1.too1s.17 36.D.3735 1.50 MIN MAX MIN MAX 1.630 0.1286 1. (Internal Cup Plug Design Only) Rocker Lever Bore I.988 MIN MAX MIN MAX 1.D.052 MIN MAX 0.437 Rocker Lever Shaft O.886 34.www.Rebuild Specifications Rocker Lever Bushing Bore I.D.187 1.1215 1.562 28.Rebuild Specifications Page 43 Ref.1245 1.15 30.D.666 34.810 34.860 MIN MAX MIN MAX 1. (Installed) • Pre-88NT • 88NT 28.1235 1.3725 16.002 16.490 28.540 34.com Specifications NT855 Part or Assembly Rocker Lever Housing Assembly .47 36.632 30.3705 1.3775 28. Point mm in Rocker Lever Housing Assembly .436 1. • Pre-88NT • 88NT Rocker Lever Shaft I. Part No. Spray nozzles must be aligned with valve spring spray nozzle locator.too1s.com Rocker Lever Housing Assembly . ST-1182. Rocker Lever Shaft Threaded Plugs 95 70 .Torque Values Page 44 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Rocker Lever Housing Assembly .Torque Values Rocker Lever Shaft Set Screw 11 100 in-lb Note: The 80-degree tilt engines use spray nozzles instead of set screws in the rocker lever housings.www. 23 0.003 0.024 Cam Follower Roller to Pin Clearance 0. 19.009 0.7520 Cam Follower Shaft O.D.Rebuild Specifications Fixed Injection Timing Cam Follower Roller Side Clearance 0.20 MIN MAX 0.02 19.748 0.024 Cam Follower Roller to Pin Clearance 0.Rebuild Specifications Page 45 Ref.61 MIN MAX 0.052 19.23 0.08 0.009 0.D.61 MIN MAX 0. MVT Injection Timing .com Specifications NT855 Part or Assembly Cam Follower Assembly .7501 0.00 19.20 MIN MAX 0.749 Cam Follower Shaft Bore I.749 0.02 MIN MAX 0.05 MIN MAX 0.100 MIN MAX 0.003 0. Point mm in Cam Follower Assembly .008 Cam Follower Lever Bushing I.750 Cam Follower Roller Side Clearance 0.www.D.008 19. 19.too1s.08 0. Cam Follower Shaft Bore I.113 MIN MAX 0.15 MIN MAX 0.055 MIN MAX 0.3740 1.750 0.Rebuild Specifications Page 46 Part or Assembly Specifications NT855 Ref.D.748 Injector Cam Follower Lever Eccentrics O.029 19.920 MIN MAX 1.900 34.7502 19.3765 1. 18.3784 1 34.746 0.7525 Actuator Shaft Bore I.D.05 19.D.www.02 MIN MAX 0.D.D.963 35.3748 2 19.748 0.7505 0.00 19.7520 Injector Lever Bushing I.D.011 MIN MAX 1.com Cam Follower Assembly .7501 0.749 19. Cam Follower Shaft O.062 19. Point mm in Valve Lever Bushing or Bore I.7492 0.too1s.100 MIN MAX 0.D.052 19.95 19.00 MIN MAX 0. 34.754 Actuator Shaft O. . 19. 19. 405in] 31.81 4.225in] 37.960 Timing Spacer Length Part No.002 .D.60 49.215in] 37.150 0.D.www.996 2.11mm [1.759 0.28 19.920 Spring Tester Working Height C D 67.76 Nominal Nominal Load for Working Height C 391N 480N 578N 711N MIN MAX MIN MAX 50.72mm [1.D.495in] MIN MAX 0. Point mm in Actuator Shaft Guide I. 49.Rebuild Specifications Page 47 Ref.05 48.762 Actuator Plunger O.43mm [1.160 105.38 Nominal 4.35 MIN MAX 0.68mm [1.97mm [1.149 2.640 1. 3021515 3024029 3024030 MIN 35. 19.953 1.395in] 30. 88 108 130 160 lbf lbf lbf lbf 1.too1s.85 MIN MAX D Actuator Housing Cylinder Sleeve I.86mm [1.06 Actuator Spring Free Length MAX 35.78 MIN MAX 1.485in] Timing Spacer Flange Thickness 3.com Specifications NT855 Part or Assembly Cam Follower Assembly .69 50. 687 MIN MAX 0.881 MIN MAX 0.246 2.2485 1. 31.772 MIN MAX 0. 56.www. 17.02 MIN MAX 2.too1s. Point mm in 23.05 57. 17.776 12.40 MIN MAX 0.711 31.D.4990 0.5030 0.25 23.245 Actuator Housing Cylinder Sleeve O. 57.759 17.711 31.75 MIN MAX 0.D.D.801 MIN MAX 0.762 MIN MAX 1.935 25.915 0.30 25. 31.Rebuild Specifications Page 48 Part or Assembly Cam Follower Shaft From Housing Extension Dimension Specifications NT855 Ref.97 57.15 MIN MAX 2.4995 Injector Lever Roller Pin Bore I.000 Actuator Housing Cylinder Bore I.996 1. 12.856 17.7030 0.2505 Crowned Injector Roller O.D.674 12.5040 Injector Lever Roller Bore I.D.2485 1.D.7040 Crowned Valve Roller O.D.D.6992 0.243 2.762 MIN MAX 1.2505 The Shaft End Opposite the Actuator Must Have a Depth in the Housing as Follows: Dimensions .com Cam Follower Assembly . 12.6997 Valve Lever Roller Bore I.250 Valve Lever Roller Pin Bore I. 772 17.013 0. 12.050 MIN MAX 0. 19. Point mm in Valve Roller Pin O.0025 Cam Follower Roller Side Clearance Press Fit Between Lever and Socket .064 MIN MAX 0.700 MIN MAX 0.0005 0.7505 0.088 MIN MAX 0. 17.7490 0.Rebuild Specifications Page 49 Ref.7000 0.6997 0.61 MIN MAX 0.024 (1) Cam Follower Socket O.com Specifications NT855 Part or Assembly Cam Follower Assembly .025 19.780 MIN MAX 0.692 12.www.009 0.7500 0.too1s.7515 (2) Cam Follower Lever Bore I.D.5000 Injector Roller Pin O.D.D.063 19.4997 0.23 0. 19.D. Torque Values Page 50 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Cam Follower Assembly .Torque Values Cam Follower Shafts Locking Screws 2 15 in-lb Note: The heads of the locking screws must be flush or below flush with the gasket surface of the cam follower housing.www.com Cam Follower Assembly .too1s. Eccentric Set Screws 70 50 Solenoid Valve Jam Nut 5 45 in-lb Air Filter Adapter 3 25 in-lb Air Filter Elbow 3 25 in-lb Air Filter 3 25 in-lb Actuator Shaft Capscrews 25 20 Actuator Shaft Retaining Capscrew 60 45 . Injectors . inspection.Rebuild Specifications The disassembly. For Top-Stop Injectors: • Shop Manual PT (type D) Top Stop Injectors.too1s. 3379084. Bulletin No.Rebuild Specifications The disassembly. inspection.com Specifications NT855 Part or Assembly Spring Retainer Lock Nut Fuel Pump . repair and calibration procedure for the injectors are covered in the following bulletins: For STC Injectors: • Shop Manual PT (type D) Step Timing Control Injector. 3810344. 3810313.Rebuild Specifications Page 51 Step Actuator Cap Torque Values N•m 45 40 ft-lb 35 30 Fuel Pump .www. Bulletin No. . assembly and calibration procedures for the fuel pump are covered in PT Fuel Pump Rebuilding and Calibration Instructions. repair. Bulletin No. Point U.com Lubricating Oil System .D.www.73 MAX 1.S. 6.8725 22. Gallons Liters Lubricating Oil System .D.005 Lubricating Oil Pump Body and Cover Bushing I. the drive gear must be replaced.5 High Refer to Lubrication System Specifications. Lubricating Oil Pump Drive Shaft O.0 9.877 22.22 MIN MAX 0.5 22.Inspection Specifications Lubricating Oil Pump Drive Shaft End Clearance 0.D.the bushings must be replaced.28 MIN 0.874 0.7 Low 26.161 MIN 0.33 MAX 0. Valve Seat Depth 46. Main Drive Gear Bore I.877 22.Capacities Page 52 Part or Assembly Specifications NT855 Ref. 22.13 MIN MAX 0.875 22. .too1s.20 22. the bushings must be replaced.8735 Note: If the main drive gear bore is worn beyond the maximum limit. 22.0 • Industrial Part or Assembly Ref. page 5. for additional specifications.840 Note: If the valve seat depth is greater than the maximum specifications given. Lubricating Oil Pump Driven Gear Bushing I.879 Note: If the bushings are worn larger than the maximum given. the oil pump body must be replaced.05 0.002 0. 22.187 MAX 0.D.0 7.33 MAX 0.Capacities Oil Pan Capacity: • Automotive 30 35 Low High 8. Point mm in Lubricating Oil Pump .879 Note: If the bushings are worn larger than the maximum given.28 MIN 0. Inspection Specifications Page 53 Ref.387 MIN 0. Driven Shaft Press Fit Area O.8780 0.877 0. the gear must be replaced.20 MIN 0.8740 Note: If the bore inside diameter is not within specifications.too1s.D. 22. Driven Shaft Bore I.874 22. Point mm 25.301 22. 22.289 MAX 0. Drive Shaft O. 22.387 25.8785 . Lubricating Oil Pump .314 MIN MAX 0.www.D.875 Note: Shafts that are damaged or worn smaller than the minimum given must be replaced.9995 1. (New) 22.0005 Driven Gear Bushing Bore I.0005 Note: If the bushing bore inside diameter is not within specifications.413 in MIN MAX 0.22 MAX 0.30 MIN MAX 0.D.8735 22.D.8765 22. Bushing I. 22.8775 Note: If the shaft bore diameter is not within specifications.com Specifications NT855 Part or Assembly Lubricating Oil Pump Body and Cover Bushing Bore I.D.D.878 Drive Gear Bore I.D.263 MIN 0.9995 25. the pump body must be replaced.187 MIN 0.200 MAX 0. 25.413 MAX 1. the gear must be replaced.28 22. com Lubricating Oil System .705 0.www.735 ft-lb Lubricating Oil System .90 18.67 Step in MIN MAX Torque Values N•m 0.Torque Values Page 54 Part or Assembly Specifications NT855 Ref.Torque Values Sending Unit Capscrew (Big Cam IV and New Big Cam IV) 15 120 in-lb Filter Head Capscrews (Big Cam IV and New Big Cam IV) 45 35 45 35 Bypass Valve Capscrews (Big Cam IV and New Big Cam IV) 40 30 Oil Cooler Support Self-Tapping Screws (88 Big Cam IV) 12 110 in-lb Oil Cooler Support to Cooler Housing Capscrews (Big Cam IV and New Big Cam IV) .too1s. Point Driven Shaft Protrusion Part or Assembly mm 17. com Specifications NT855 Part or Assembly Oil Cooler Connection (Housing) to Support Capscrews (88 Big Cam IV) Lubricating Oil System .Torque Values Page 55 Step Torque Values N•m ft-lb 45 35 45 35 6 50 in-lb 25 8 20 75 in-lb 20 15 Lubricating Oil Pump Cover to Body Capscrews 25 20 Oil Pressure Regulator Retainer Plug Capscrew 25 20 DFC Signal Line Adapter Elbow 11 100 in-lb Rear Cover to Oil Cooler Connection (Housing) Capscrews (88 Big Cam IV) Oil Cooler Core Holddown Clamp Nuts and Capscrews (88 Big Cam IV) Tighten the nuts and the capscrews in the following sequence: • Nuts Note: Tighten the nuts alternately in 3 N•m [25 in-lb] increments: • Capscrews • Nuts Oil Filter Head to Connection (Housing) Capscrews (88 Big Cam IV) .www.too1s. D.9847 3 15. (88 Big Cam IV) Water Pump Impeller Vane To Body Clearance .020 0.9847 0.436 15.6696 2 25.001 25.010 0.011 25.6267 1 15.918 MIN MAX 0.905 15.D.25 0.85 15.47 MIN MAX 1.88 MIN MAX 0.905 15.Rebuild Specifications Page 56 Part or Assembly Specifications NT855 Ref.008 MIN MAX 0.85 15. 61.6262 0. Water Pump Drive Pulley Bore I.949 MIN MAX 0.too1s.625 16.www.com Water Pump Assembly .D.9843 0.011 MIN MAX 0.51 MIN MAX 0.040 Water Pump Body Seal and Seat Assembly Bore I.918 MIN MAX 0.6663 0.D.D.624 0.02 MIN MAX 0.51 1.022 MIN MAX 0.918 MIN MAX 0.45 36.D.6267 • Phenolic 0.Rebuild Specifications Water Pump Body Bearing Bore I. Point mm in Water Pump Assembly .6673 15.6693 0.4416 36.4406 2.924 16.88 MIN MAX 0.624 0.435 1.9851 3 15.625 1 17. Water Pump Impeller Bore I. • Pre-88 NT • 88 NT Water Pump Shaft Journals O.6267 2 25.000 17.905 15.6262 0.991 62.6262 0.017 MIN MAX 2. (Big Cam IV and New Big Cam IV) Water Pump Shaft Journals O.020 • Cast Iron 0. 78 50.82 MIN MAX 1.D.75 MIN MAX 1.67 50.D.999 2.075 MIN MAX 2.986 MIN MAX 0.961 51.D.3745 1.D.0467 Bearing Spacer O. (Big Cam IV and New Big Cam IV) 61.4408 2.Inspection Specifications Inner Bearing Spacer Length (1) 50.9847 Idler Pulley Bearing Bore I.9838 0. 65.001 Outer Bearing Spacer Length (2) 50.9817 0.too1s.996 62.3750 Fan Hub Bore I.935 24.4414 Idler Shaft O. Point mm in Water Pump Idler Pulley Bearing Bore I.998 .011 MIN MAX 0.D. (Big Cam IV and New Big Cam IV) 24.0457 2.5605 2.925 MIN MAX 1.012 MIN MAX 2.D.038 65.www. (88 Big Cam IV) 24.986 MIN MAX 2.912 34.com Specifications NT855 Part or Assembly Fan Hub .995 1. (88 Big Cam IV) 51.Inspection Specifications Page 57 Ref.9837 Fan Hub Shaft O. 34.989 25.5620 Fan Hub . www.D.462 44.08 0.Rebuild Specifications Radiator Thermostat Seat Height (Big Cam IV and New Big Cam IV) 38.503 1.115 0.70 5.com Thermostat Housing Assembly .185 0.507 • 49 State Engine (EPA Certified) 3.010 Thermostat Housing Assembly .003 0.18 38.25 in MIN MAX 0.386 44.125 0.125 Bypass Thermostat Seat Protrusion (Big Cam IV and New Big Cam IV) Bypass Thermostat Seat Counterbore Depth (Big Cam IV and New Big Cam IV) .513 MIN MAX 1. Point mm 0.7475 1.437 MIN MAX 1.7505 1.D. (Big Cam IV and New Big Cam IV) 44.386 44.7525 Bypass Thermostat Seat Bore I. (Big Cam IV and New Big Cam IV) 44.7475 1.00 MIN MAX 0.28 MIN MAX 1.17 MIN MAX 0.18 3.too1s.197 Radiator Thermostat Seat Bore I.140 • 50 State Engine (EPA and CARB Certified) 4.D.Rebuild Specifications Page 58 Part or Assembly Fan Hub End Clearance Specifications NT855 Ref.92 3.56 MIN MAX 0. (Big Cam IV and New Big Cam IV) 44.7495 Radiator Thermostat Seat O.7495 2.437 MIN MAX 1. 250 0.513 MIN MAX 1.255 • 50 State Engine (EPA and CARB Certified) 7.140 • 50 State Engine (EPA and CARB Certified) 4.Operating Temperature Optimized Aftercooling Thermostat: • Initial Opening Temperature • Fully Open Temperature • Maximum Open Distance Part or Assembly Ref.7505 1.630 • Bypass Thermostat 66.202 Thermostat Rectangular Seal Bore Depth .35 6. (Big Cam IV and New Big Cam IV) mm in 44.198 0.03 5.462 44.630 • Radiator Thermostat 5.70 5.125 0. • Radiator Thermostat 66.200 in.185 0.56 MIN MAX 0.310 0.48 MIN MAX 0.312 • 49 State Engine (EPA Certified) 3.00 MIN MAX 0.92 MIN MAX 0.18 3.13 MIN MAX 0.55 66. Point Degree °C Degree °F Thermostat (Reserve Flow Cooling) .08 mm MAX MAX 200°F 0.55 66.87 7.D.198 0. mm in Thermostat Rectangular Seal Bore I.7525 • 49 State Engine (EPA Certified) 6.80 MIN MAX 2.www.03 5.80 MIN MAX 2.620 2.13 MIN MAX 0. Point Bypass Thermostat Seat O.too1s.com Specifications NT855 Part or Assembly Thermostat (Reserve Flow Cooling) . Point 87°C 89°C MIN MAX 188°F 192°F 93°C 5.Operating Temperature Page 59 Ref.D.202 • Bypass Thermostat 5.620 2.197 Bypass Thermostat Seat Thickness (Big Cam IV and New Big Cam IV) Bypass Thermostat Seat Protrusion (Big Cam IV and New Big Cam IV) Part or Assembly Ref. too1s.www. Water Transfer Tube Clamp Capscrews (Big Cam IV and New Big Cam IV) 45 35 Thermostat Cover Capscrews (88 Big Cam IV) 45 35 .com Cooling System -Torque Values Page 60 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Cooling System -Torque Values Assembly of the Water Pump Idler (Flat Head Capscrew) 40 30 205 150 Filter Head Adapter in the Housing (Big Cam IV and New Big Cam IV) 45 35 Water Transfer Cover to Thermostat Housing (Big Cam IV and New Big Cam IV) 25 20 Bypass Thermostat Seat Cover (Big Cam IV and New Big Cam IV) 45 35 Fan Hub Lock Nut Note: Tighten the cover capscrews alternately so the seat enters the bore correctly. www.too1s.com Specifications NT855 Part or Assembly Coolant Transfer Tube Clamp Capscrew (88 Big Cam IV) Cooling System -Torque Values Page 61 Step Torque Values N•m ft-lb 45 35 Coolant Filter Head Retaining Capscrew 20 15 Coolant Filter Element Adapter 45 35 . 3752 1.D.5620 3 33.55 MIN MAX 1. Hub Coupling I.0030 1.30 MIN MAX 0.3100 1.930 34.316 1.D.29 2.3760 39.3120 4 25. Thrust Bearing Thickness Drive Shaft Journal O.too1s.0015 34.425 25.Rebuild Specifications Drive Shaft End Clearance 0.41 MIN MAX 0.0000 1.05 0. Drive Gear Bore I.012 33.674 MIN MAX 1.3770 2 39.095 1 34.com Fuel Pump and Compressor Drive .D.730 39.489 25.5642 1.400 25. Splined Coupling I.662 39.5650 Drive Housing Bushing Bore I.www.43 33.3765 1.5615 1.325 MIN MAX 1.976 MIN MAX 1.963 34.D.0010 1.002 0.0035 1.751 MIN MAX 1.0010 1.321 2.Rebuild Specifications Page 62 Part or Assembly Specifications NT855 Ref. Point mm in Fuel Pump and Compressor Drive . .438 MIN MAX MIN MAX MIN MAX 1.D.950 MIN MAX 1. Drive Pulley Bore I.090 0.425 25.274 33.476 25.D. 75 MIN MAX 1.5665 1.77 50.73 36.447 50.Torque Values Page 63 Ref.446 1.5675 Drive Housing Bushing Bore I. Point mm in Drive Shaft Gear Fit Journal O.82 MIN MAX 1.Torque Values Accessory Drive Housing Capscrew 45 35 Accessory Drive Housing Pipe Plug 8 75 in-lb .D.789 39.814 MIN MAX 1.www.999 2.D. Part or Assembly Step Torque Values N•m ft-lb Fuel Pump and Compressor Drive .001 Accessory Drive Pulley Wear Sleeve Fit Area O. 39.too1s.com Specifications NT855 Part or Assembly Fuel Pump and Compressor Drive . 36.D. 006 Note: Specifications and instructions for rebuilding the single cylinder air compressor are provided in the Air Equipment Rebuild Manual.05 0.13 MIN MAX MIN MAX 0.008 0.008 0.005 0.53 MAX 0. Use two mounting nuts locked together to tighten the studs.19 MAX 0.018 Turbocharger Turbine Wheel Radial Clearance Model No.15 0.021 BHT4C/HT4B 0.002 0.05 MIN 0.10 0. 3810242.20 MIN 0.too1s.46 MIN MAX MIN MAX 0.006 0.20 MIN 0.006 0. BHT3B/HT3B BHT4C/HT4B 0.www.Inspection Specifications Page 64 Part or Assembly Specifications NT855 Ref.004 0. Two Cylinder Air Compressor Crankshaft End Clearance 0.018 0. Bulletin No. .com Turbocharger . 3810230 or 3810241. Air Compressor .Inspection Specifications Turbocharger Shaft End Clearance Model No. 3810257.46 0. BHT3B/HT3B BHT4C/HT4B Turbocharger Compressor Impeller Radial Clearance Model No.15 0. Point mm in Turbocharger .002 0.53 MAX 0. Bulletin No.021 Note: Specifications and instructions for rebuilding the turbocharger are provided in the Turbocharger Component Shop Manuals. for Holset turbochargers.002 0. Bulletin Nos. Aftercooler Assembly Capscrews Torque Value: 40 N•m [30 ft-lb] Exhaust Manifold Flange To Turbocharger Mounting Stud Torque Torque Value: 40 N•m [30 ft-lb] Note: Apply a coat of anti-seize compound to the threads.03 0.008 Note: Specifications and instructions for rebuilding the two cylinder air compressor are provided in the Air Equipment Rebuild Manual.05 MIN 0.15 MAX 0. BHT3B/HT3B 0.Inspection Specifications Single Cylinder Air Compressor Crankshaft End Clearance 0.001 0. Refer to Vehicle Braking .Group 14. Bulletin No.com Specifications NT855 Engine Testing . page 14-1. Vehicle Braking . . Bulletin No.www.Group 20. 3810395.too1s. in the NT855 Shop Manual. 3810395. in the NT855 Shop Manual. page 20-1.Test Specifications Page 65 Engine Testing .Rebuild Specifications Note: The specifications and instructions for rebuilding the JacobsT Brake are provided in the JacobsT Brake Installation Manual.Test Specifications Note: The specifications and instructions for testing the engine are provided in Engine Testing . 54 to -2.80 -0.071 -1.42 -0.80 -0.102 -5.211 to -0.0185 0.00 0.’’ This travel represents the injection timing value.100 to -0. Timing Code* AX BU BY CD FI GG GH GJ GM GO GR GS HF HH HI HO HP Push Rod Travel Range mm in -1.68 -0.67 -0.19 -0.002 inch] indicator travel.14 to -4.37 to -1.00 0.054 to -0.00 * Refer to the Control Parts List Manual.086 -2.0255 0.05 mm [0.071 -2.056 -1.103 to -0.26 to -2.132 to -0.90 -0.44 -0.18 mm [0.096 -2.00 0.161 mm [0.0115 0.075 -1.40 -0.53 -0.41 -0.139 -3.31 -0. Read the push rod travel gauge counterclockwise from ‘‘0.089 to -0.48 to -3.64 -0.094 to -0.0185 0.00 0.128 Camshaft Key Part No.066 -1.39 to -2.59 -0.069 to -0.36 to -5.0255 0.137 to -0. 3021601 3021596 3021596 3021597 3021601 3022353 3022352 3021594 3021601 3021601 3021594 3021592 3022352 3021601 3022352 3021601 3021601 Amount of Offset 0.75 to -1.069 to -0.0310 0.0185 0.www. Bulletin No.com Injection Timing Codes Page 66 Specifications NT855 Injection Timing Codes Note: Injection timing is measured at 5.064 to -0.23 to -3.00 0.213 -3. . In the example shown. the value is 0.163 to -0.2032 inch] BTDC piston travel.63 to -1.18 -0.094 to -0.073 to -0.165 -3. Note: The injection timing can be changed by removing the cam follower housing and by increasing or decreasing the gasket thickness.13 to -2.59 to -2.58 mm [0.084 to -0.35 to -3.127 to -0.85 to -1.44 -0.too1s.62 to -2.091 -2.0185 0. for a complete up-to-date timing code list.25 -0.007 inch] of gasket thickness affects injection timing by approximately 0.096 -4.023 in].39 to -2.00 0.0390 0. Each 0.75 to -1.102 to -0.105 -2. 3379133.0185 0.104 -2.134 -2. If the belt tension is less than the minimum value. tighten the belt to the maximum value.380 3822524 N/A 620 140 270 490 MIN MAX 60 110 .too1s. . Click-Type Burroughs Belt Tension .com Specifications NT855 Drive Belt Tension Specifications Page 67 Drive Belt Tension Specifications SAE Belt Width in.Used* N lbf N lbf . Belt Tension Gauge Part No.New Belt Tension .440 3822524 N/A 620 140 270 490 MIN MAX 60 110 1/2 3822524 ST-1138 620 140 270 490 MIN MAX 60 110 11/16 3822524 ST-1138 620 140 270 490 MIN MAX 60 110 3/4 3822524 ST-1138 620 140 270 490 MIN MAX 60 110 7/8 3822524 ST-1138 620 140 270 490 MIN MAX 60 110 4 Rib 3822524 ST-1138 620 140 270 490 MIN/Rib MAX/Rib 60 110 5 Rib 3822524 ST-1138 670 150 270 530 MIN/Rib MAX/Rib 60 120 6 Rib 3822525 ST-1293 710 160 290 580 MIN/Rib MAX/Rib 65 130 8 Rib 3822525 ST-1293 890 200 360 710 MIN/Rib MAX/Rib 80 160 10 Rib 3822525 3823138 1110 250 440 890 MIN/Rib MAX/Rib 100 200 12 Rib 3822525 3823138 1330 300 530 1070 MIN/Rib MAX/Rib 120 240 * Adjust belts that are used again to the values in this column. A belt is considered used if it has been in operation at least 10 minutes.www. 113 8.4536 2.3769 0. liter l 3.too1s.www.264179 gallon (Imp*) gal.219976 cubic inch in3 liter l 0. millimeters m2 645.2488 4.01639 61.001550 Force pounds force lbf Newton N 4.3769 0.850756 gallon (U.546 0. CUSTOMARY METRIC FROM U.Conversion Factors QUANTITY U.4482 0.737562 pound force per inch lb-in Newton-Meter N•m 0.7853 0.29613 inches of mercury in-Hg kilopascal kPa 3.224809 Length inch in millimeters mm 25.40 0.) lb kilograms kg 0.039370 Pressure pounds force per sq. CUSTOMARY TO METRIC MULTIPLY BY Unit Name Unit Name Abbr.S. inch in2 sq.40 0.039370 pound force per foot lb-ft Newton-Meter N•m 1. inch psi kilopascal kPa 3.35582 0. FROM METRIC TO U.204623 Torque Volume: liquid displacement Weight (mass) * British measurement .S.039370 inches of water in-H20 millimeters of water mm-H20 25.16 0. CUSTOMARY MULTIPLY BY Abbr.) gal.S. liter l 4.S.29613 inches of water in-H20 kilopascal kPa 0.Conversion Factors Page 68 Specifications NT855 Weights and Measures .019299 inches of mercury in-Hg millimeters of mercury mm-Hg 25.02545 pound (avoir. Area sq.com Weights and Measures .40 0. 4375 7/16 23.15937 0.33437 0.890625 57/64 10.421875 27/64 23.9375 15/16 11.54062 0.44687 0.31875 0.57187 0.43125 0.08125 0.36562 0.328125 21/64 21.82812 0.21875 7/32 18.109375 7/64 15.59375 19/32 2.8125 13/16 8.Conversion Factors Metric mm Decimal in Fractions 0.46875 15/32 24.078125 5/64 14.1875 3/16 17.6875 11/16 5.09375 3/32 15.95312 0.796875 51/64 7.00 1/64 Metric mm Decimal in Fractions 13.203125 13/64 17.703125 45/64 5.77812 0.3125 5/16 20.015625 0.15625 5/32 16.50937 0.60625 0.11250 0.30312 0.12812 0.578125 37/64 2.28750 0.71875 23/32 5.734375 47/64 6.19062 0.65625 21/32 4.53125 17/32 1.85937 0.38125 0.484375 31/64 25.78125 25/32 7.01875 0.76250 0.40000 1.265625 17/64 19.25625 0.90625 29/32 10.27187 0.640625 41/64 3.765625 49/64 7.too1s.68437 0.89062 0.0625 1/16 14.62187 0.84375 0.98437 0.81250 0.03437 0.87500 0.921875 59/64 11.14375 0.125 1/8 15.70000 0.546875 35/64 1.35000 0.46250 0.96875 31/32 12.234375 15/64 18.375 3/8 22.58750 0.500 1/2 25.453125 29/64 24.390625 25/64 22.34375 11/32 21.28125 9/32 19.06562 0.03125 1/32 13.84375 27/32 9.73125 0.1750 0.63750 0.24062 0.66875 0.www.171875 11/64 17.93750 0.250 1/4 19.671875 43/64 4.49375 0.41562 0.52500 0.96875 0.984375 63/64 12.953125 61/64 11.625 3.com Specifications NT855 Decimal and Metric .Conversion Factors Page 69 Decimal and Metric .05000 0.22500 0.39688 0.859375 55/64 9.90625 0.92187 0.65312 0.71562 0.20937 0.875 9.296875 19/64 20.828125 53/64 8.40625 13/32 23.74687 0.79375 0.140625 9/64 16.046875 3/64 13.359375 23/64 21.609375 39/64 3.09687 0.750 6.5625 1.00312 0.55625 0.47812 0.515625 33/64 9/16 5/8 3/4 7/8 1 . divide Newton-Meters by 9.www.too1s.com Newton-Meter to Foot-Pound Conversion Chart Page 70 Specifications NT855 Newton-Meter to Foot-Pound Conversion Chart N•m ft-lb N•m ft-lb N•m ft-lb 5 44 in-lb 70 52 170 125 6 53 in-lb 75 55 175 129 7 62 in-lb 80 59 180 133 8 71 in-lb 85 63 185 136 9 80 in-lb 90 66 190 140 10 89 in-lb 95 70 195 144 12 9 100 74 200 148 14 10 105 77 205 151 15 11 110 81 210 155 16 12 115 85 215 159 18 13 120 89 220 162 20 15 125 92 225 165 25 18 130 96 230 170 30 22 135 100 235 173 35 26 140 103 240 177 40 30 145 107 245 180 45 33 150 111 250 184 50 37 155 114 55 41 160 118 60 44 165 122 65 48 NOTE: To convert from Newton-Meters to Kilogram-Meters. .803. 24 7/16 .Grade 5 Capscrew Cast Iron Aluminum N•m ft-lb N•m ft-lb 9 7 8 6 12 9 9 7 20 15 16 12 23 17 19 14 40 30 25 20 40 30 35 25 60 45 45 35 65 50 55 40 95 70 75 55 100 75 80 60 135 100 110 80 150 110 115 85 180 135 150 110 210 155 160 120 325 240 255 190 365 270 285 210 490 360 380 280 530 390 420 310 720 530 570 420 800 590 650 480 8 Capscrew Torque .S. SAE capscrews are identified by: U. SAE capscrews are graded according to the strength of the capscrew.S.18 5/8 .8 .U.(Thread) 1/4 .24 3/8 .Grade 8 Capscrew Cast Iron Aluminum N•m ft-lb N•m ft-lb 15 11 12 9 18 13 14 10 30 22 24 18 33 24 25 19 55 40 40 30 60 45 45 35 90 65 65 50 95 70 75 55 130 95 100 75 150 110 120 90 190 140 150 110 210 155 170 125 255 190 205 150 290 215 230 170 460 340 365 270 515 380 410 300 745 550 600 440 825 610 660 490 1100 820 890 660 1200 890 960 710 .20 .11 .16 .18 3/4 .too1s.20 1/2 . always use a capscrew of the same measurement and strength as the capscrew being replaced.13 .com Specifications NT855 Capscrew Markings and Torque Values Page 71 Capscrew Markings and Torque Values Caution: When replacing capscrews.14 1. 2. 5 Capscrew Torque .20 9/16 .28 5/16 . Customary SAE Grade Number Capscrew Head Markings These are all SAE Grade 5 (3) line Capscrew Body Size (Inches) .14 Refer to the notes above.10 . Customary (5/16 X 18 X 1 1/2) 5/16 18 1 1/2 Major Number Length Thread Threads in Diameter per Inch Inches in Inches Notes: 1. Do not use the torque values in place of those specified in other sections of this manual. Capscrew Markings and Torque Values .9 . Using incorrect capscrews can result in engine damage. They are marked on the head so the correct strength and torque value are known.18 .12 . 3.16 7/8 .www. The torque values in the table are based on the use of lubricated threads. Always use the torque values listed in the following table when specific torque values are not available. It is important to use the correct torque values for SAE grade 5 and 8 capscrews. The table below lists the capscrew markings and the correct value for the capscrew.14 . 90 Torque In Aluminum Components N•m ft-lb 5 45 in-lb 15 10 20 15 25 20 35 25 45 35 60 45 75 55 85 65 Torque In Cast Iron or Steel Components N•m ft-lb 15 10 20 15 25 20 35 25 55 40 75 55 95 70 115 85 135 100 .85 26.54 17.1 0.7 0.05 33.7 1.com Pipe Plug Torque Values Page 72 Specifications NT855 Pipe Plug Torque Values Size Thread in 1/16 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 Actual Thread O.41 13.6 0.5 1.68 21.32 42.www.32 10.D.too1s.66 48.3 0.3 1.4 0.2 1. mm in 8. New Zealand. 3379000 Title of Publication Air For Your Engine 3379001 3379035 Fuel For Cummins Engines Alternative Repair Manual 3379039 3379071 Big Cam IV Cooling System Injectors PT (All Types) Rebuild Manual 3379084 Fuel Pump PT (Type G and R) Rebuild and Calibration Instructions 3379091 3379352 Turbochargers Rebuild Manual (T-18A.www. T-50. and Puerto Rico HT4B Turbocharger Shop Manual Single Cylinder Air Compressor Shop Manual HC5A Turbocharger Shop Manual Automotive Operation and Maintenance Manual NT 855 International C Brake Installation Manual ST677 Two Cylinder Air Compressor Shop Manual C Brake Troubleshooting and Repair Manual C Brake Master Repair Manual 3810298 3810306 3810313 NT 855 Troubleshooting and Repair Manual 444 Operation and Maintenance Manual PT Injector .com Specifications NT855 Additional Service Literature Page 73 Additional Service Literature The following publications can be purchased by filling in and mailing the Service Literature Order Form: Bulletin No. T-46.Step Timing Control Shop Manual 3810316 PACE Master Repair Manual 3810366 Troubleshooting and Repair Manual .A. VT-50. Canada. and 88 Big Cam IV NT855 Engines 3810387 3810395 3822017 Analysis and Prevention of Bearing Failures Shop Manual Big Cam IV.Big Cam IV. Australia. NT855 Series Engines Big Cam IV Parts Catalog 3884210 3884211 444 88 Big Cam IV Parts Catalog 88 Big Cam IV Fixed Time Parts Catalog 3884212 88 Big Cam IV Step Timing Control Parts Catalog 3379099 3379348 3810241 3810242 3810243 3810249 . T-35.too1s.S. New Big Cam IV. ST-50 Models) Wiring Diagrams Troubleshooting Non-Optimized Aftercooled Cooling System Fuel Pump Calibration Values 3379664 3387247 3387251 3387266 3387275 3387380 Injector Parts Flow and Cross Reference Mechanical Variable Timing Coolant Additives and Filtration Cold Weather Operation Low Flow Cooling Familiarization Step Timing Control Familiarization 3810230 3810238 3810255 3810257 3810260 3810265 HT3B Turbocharger Shop Manual NT 855 Automotive Operation and Maintenance Manual U. and 88 Big Cam IV.. New Big Cam IV. Inc. Inc. Literature Center 100-G Pasir Panjang Road Singapore 0511 Australia and New Zealand Cummins Diesel Australia Maroondah Highway. Mail Code 40700 1460 National Road Columbus. P. O.too1s. 16085 Northwest 52nd Avenue Hialeah.com Service Literature Ordering Location Page 74 Specifications NT855 Service Literature Ordering Location Order service literature from your nearest regional location. and Eastern European Countries Cummins Daventry Royal Oak Way South Northants.O. Australia All Regions (for Service Products Catalog only) Service Products Company. England NN11 5NU South and Central America (excluding Brazil and Mexico) Cummins Americas.. Inc. KY 40232-4470 U.B. 3400 Robards Court P. refer to the addresses listed below: Region Ordering Location United States and Canada Gannett Direct Marketing Services. Columbus. Box 34470 Louisville. Europe. 139 Ringwood 3134 Victoria. Africa. IN 47201 .K. FL 33104 Brazil and Mexico International Parts Order Dept.www. Inc. Mid-East. Mail Code 40931 Cummins Engine Company. IN 47202-3005 Far East (excluding Australia and New Zealand) Cummins Diesel Sales Corp. . 0-52 Lubricating Oil System ............................................................................... 0-42 Decimal and Metric .......................... 0-6 Electrical System ... Customary ........ 0-67 Engine Assembly .......... 0-29 Cylinder Block ... 0-71 Capscrew Markings and Torque Values ..............................................................................Capscrew Torque Values .....................................................................................Rebuild Specifications ...................................... 0-45 MVT Injection Timing ....................................................................www....................................Rebuild Specifications............................................................. 0-7 JacobsT Engine Brake .......................................................................... 0-51 Lubricating Oil Pump .. 0-68 Index Page 75 ...Conversion Factors.................................. 0-7 Crosshead Adjustment............................................ 0-65 Fan Hub ......................Torque Values ............. 0-6 Fuel System ........ 0-66 Injectors .........Torque Values .......................... 0-59 Turbocharger ..Rebuild Specifications .............................................................................. 0-65 Water Pump Assembly ....... 0-73 Air Compressor .. 0-45 Fixed Injection Timing ..........................................................................Torque Values .................................Rebuild Specifications ...............................................................................com Specifications NT855 Additional Service Literature .............................................Rebuild Specifications ... 0-7 Injector Preload (Top Stop) .................... 0-14 Engine Assembly ........Conversion Factors ...................... 0-6 Exhaust System.................... 0-1 Engine Testing .. 0-60 Cylinder Block ..............................Rebuild Specifications .......Torque Values ........................ 0-43 Rocker Lever Housing Assembly .................................... 0-6 General Engine Data ............................................................................... 0-5 Intake System.... 0-4 Thermostat Housing Assembly ...Test Specifications .............. 0-71 Cooling System -Torque Values.... 0-56 Weights and Measures .......................................... 0-72 Rocker Lever Housing Assembly ....... 0-58 Thermostat (Reserve Flow Cooling) ............................................................ 0-9 Engine Diagrams ......................U..................................................................................................Rebuild Specifications ............................................too1s.......General Information ............Inspection Specifications ............... 0-51 Fuel Pump and Compressor Drive ............................................ 0-50 Capscrew Markings and Torque Values ............ 0-54 Newton-Meter to Foot-Pound Conversion Chart ...................................Specifications ........ 0-64 Cam Follower Assembly ......................... 0-5 Cooling System ............ 0-44 Service Literature Ordering Location ...................................Torque Values...................................Rebuild Specifications........... 0-45 Cam Follower Assembly .... 0-5 Injection Timing Codes ..... 0-37 Cylinder Head .............Torque Values .......................................Operating Temperature.................... 0-7 Vehicle Braking ............................. 0-52 Lubricating Oil System ........Capacities... 0-69 Drive Belt Tension Specifications ......................................... 0-5 Lubrication System ........................ 0-62 Fuel Pump and Compressor Drive ...........Inspection Specifications........................... 0-7 Valves .........S............ 0-2 Engine Identification .............................. 0-7 Cummins Engine Brake . 0-57 Fuel Pump ....................................................................................................................... 0-63 General Engine Specifications .....................................................................................Inspection Specifications .............Rebuild Specifications ....... 0-64 Valve and Injector Adjustments* ................ 0-74 Specifications ......................Inspection Specifications ...................... 0-38 Cylinder Head ........... 0-70 Pipe Plug Torque Values.......Rebuild Specifications ...................... 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