Komatsu N-855 Series Diesel Engine Shop Manual SEBE6710A03 – PDF DOWNLOAD

Komatsu N-855 Series Diesel Engine Shop Manual SEBE6710A03 – PDF DOWNLOAD

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Komatsu N-855 Series Diesel Engine Shop Manual SEBE6710A03 – PDF DOWNLOAD

Language : English
Pages : 366
Downloadable : Yes
File Type : PDF
Size: 48.1 MB

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Komatsu N-855 Series Diesel Engine Shop Manual SEBE6710A03 – PDF DOWNLOAD

The Komatsu N-855 Series Diesel Engine Shop Manual, SEBE6710A03, is a comprehensive guide for the maintenance, repair, and overhaul of the N-855 engine series. This engine series is widely used in various types of heavy equipment, including mining, construction, and marine applications.

• The manual is divided into several sections, each covering different aspects of the engine. The first section provides an overview of the engine, including a description of its components and systems. This section also includes information on engine specifications, such as torque and horsepower ratings, as well as the procedures for checking and adjusting these specifications.
• The second section of the manual covers engine disassembly and assembly procedures. This section includes detailed instructions on removing and installing various components, such as the cylinder head, pistons, connecting rods, and crankshaft. It also provides instructions on how to measure, inspect, and repair these components, as well as how to install them correctly.
• The third section of the manual covers engine testing and adjustments. This section includes instructions on how to perform a variety of tests and inspections to determine the condition of the engine and its components. These tests and inspections include compression tests, oil pressure tests, and fuel injection timing tests. The section also includes instructions on how to adjust the engine’s components, such as the fuel injection pump, governor, and valve clearance.
• The fourth section of the manual covers engine troubleshooting and repair. This section includes a comprehensive list of common engine problems and their possible causes. It provides step-by-step instructions on how to diagnose and repair these problems, as well as how to identify when components need to be replaced.
• The manual also includes a section on safety precautions, which outlines the hazards associated with working on the engine and provides instructions on how to minimize these hazards. Additionally, the manual includes a list of tools and equipment required for engine maintenance and repair, as well as a detailed index and table of contents for easy navigation.
• Overall, the Komatsu N-855 Series Diesel Engine Shop Manual provides a detailed and comprehensive guide for anyone responsible for the maintenance, repair, and overhaul of these engines. The manual includes a wealth of information, ranging from basic engine specifications to detailed disassembly and repair procedures, making it an essential reference for mechanics and technicians working on this engine series.

TABLE OF CONTENTS:

Komatsu N-855 Series Diesel Engine Shop Manual SEBE6710A03 – PDF DOWNLOAD

COVER…………………………………………………. 1
CONTENTS………………………………………………. 2
01 GENERAL…………………………………………….. 37
CONTENTS…………………………………………… 39
GENERAL VIEW……………………………………….. 40
SPECIFICATIONS……………………………………… 43
ASSEMBLY DRAWING……………………………………. 48
PERFORMANCE CURVE…………………………………… 68
WEIGHT TABLE……………………………………….. 77
11 STRUCTURE AND FUNCTION……………………………….. 79
CONTENTS…………………………………………… 81
GENERAL STRUCTURE…………………………………… 82
INTAKE AND EXHAUST SYSTEM……………………………. 84
TURBOCHARGER……………………………………. 92
AFTER-COOLER……………………………………. 94
ENGINE BODY………………………………………… 95
CYLINDER HEAD…………………………………… 95
VALVE SYSTEM……………………………………. 96
CYLINDER BLOCK………………………………….. 98
MAIN CIRCULATION SYSTEM…………………………..100
TIMING GEAR……………………………………..101
CAMSHAFT, CAM FOLLOWER AND PUSH ROD………………..102
INJECTION TIMING, VALVE TIMING…………………….103
FLYWHEEL AND FLYWHEEL HOUSING……………………..104
LUBRICATION SYSTEM…………………………………..112
LUBRICATION SYSTEM CHART………………………….112
OIL PUMP………………………………………..114
OIL FILTER AND OIL COOLER…………………………117
FULL-FLOW FILTER…………………………………120
BY-PASS FILTER…………………………………..121
OIL COOLER………………………………………122
FUEL SYSTEM…………………………………………123
FUEL SYSTEM CHART………………………………..123
PT FUEL PUMP…………………………………….126
PT FUEL PUMP DRIVE……………………………….136
INJECTOR………………………………………..138
FUEL FILTER……………………………………..139
WATER SEPARATOR………………………………….141
ANEROID CONTROL VALVE…………………………….142
COOLING SYSTEM………………………………………144
COOLING SYSTEM CHART……………………………..144
WATER PUMP………………………………………146
FAN DRIVE……………………………………….149
TENSION PULLEY…………………………………..153
THERMOSTAT………………………………………155
CORROSION RESISTOR……………………………….156
ACCESSORY…………………………………………..157
AIR COMPRESSOR…………………………………..157
ELECTRICAL SYSTEM……………………………………158
ALTERNATOR………………………………………158
STARTING MOTOR…………………………………..161
ELECTRICAL INTAKE AIR HEATER………………………163
12 TESTING AND ADJUSTING…………………………………165
CONTENTS……………………………………………167
TESTING AND ADJUSTING INJECTOR AND VALVE CLEARANCE………168
MEASURING COMPRESSION PRESSURE………………………..172
MEASURING BLOW-BY PRESSURE……………………………174
MEASURING OIL CONSUMPTION…………………………….176
MEASURING FUEL PRESSURE………………………………178
PT PUMP CALIBRATION DATA……………………………..179
PT FUEL PUMP PARTS SPECIFICATION………………………191
INJECTOR SPECIFICATION……………………………….201
RUN-IN STANDARD……………………………………..202
PERFORMANCE TEST CRITERIA…………………………….204
TESTING AND ADJUSTING TOOL LIST……………………….209
TESTING AND ADJUSTING DATA……………………………210
TROUBLESHOOTING……………………………………..216
13 DISASSEMBLY AND ASSSEMBLY……………………………..239
CONTENTS……………………………………………241
GENERAL DISASSEMBLY………………………………….243
GENERAL ASSEMBLY…………………………………….267
WATER PUMP ASSEMBLY………………………………….302
14 MAINTENANCE STANDARD………………………………….309
CONTENTS……………………………………………311
INTAKE AND EXHAUST SYSTEM…………………………….312
TURBOCHARGER…………………………………….312
ENGINE BODY…………………………………………314
CYLINDER HEAD……………………………………314
VALVE, VALVE GUIDE……………………………….315
CROSSHEAD AND CROSSHEAD GUIDE……………………..316
ROCKER LEVER, SHAFT………………………………317
CYLINDER BLOCK…………………………………..318
CRANKSHAFT AND VIBRATION DAMPER……………………320
CYLINDER LINER…………………………………..322
CAMSHAFT………………………………………..323
CAM FOLLOWER AND PUSH ROD…………………………324
GEAR AND GEAR COVER………………………………325
CONNECTING ROD…………………………………..326
PISTON, PISTON RING, PISTION PIN…………………..328
FLYWHEEL, FLYWHEEL HOUSING, REAR COVER……………..329
LUBRICATION SYSTEM…………………………………..330
OIL PUMP………………………………………..330
COOLING SYSTEM………………………………………332
WATER PUMP AND IDLER PULLEY……………………….332
15 REPAIR AND REPLACEMENT………………………………..333
CONTENTS……………………………………………335
CYLINDER HEAD……………………………………….336
GRINDING AND CORRECTING CYLINDER HEAD MOUNTING FACE….336
REPLACING VALVE SEAT INSERTS………………………337
GRINDING AND CORRECTING VALVE SEATS SURFACE…………340
REPLACING INJECTOR SLEEVES………………………..341
REPLACING VALVE GUIDES……………………………344
REPLACING CROSSHEAD GUIDES………………………..345
GRINDING AND CORRECTING VALVES…………………….345
REPLACING ROCKER LEVER BUSHINGS……………………345
CYLINDER BLOCK………………………………………346
GRINDING AND CORRECTING TOP FACE OF CYLINDER BLOCK…..346
CORRECTING CYLINDER LINER COUNTERBORE………………347
REPLACING MAIN BEARING CAPS……………………….348
GRINDING AND CORRECTING CRANKSHAFT…………………352
CORRECTING SLEEVES AT CRANKSHAFT REAR SEAL………….356
REPLACING CAMSHAFT BUSHING………………………..357
REPLACING CONNECTING ROD BUSHING…………………..358
REPLACING CAM FOLLOWER LEVER BUSHING……………….359
REPLACING CRANKSHAFT GEAR…………………………360
REPLACING CAMSHAFT GEAR…………………………..360
REPLACING FLYWHEEL RING GEAR………………………360
19 OTHERS………………………………………………361
CONTENTS……………………………………………363
STANDARD TIGHTENING TORQUE……………………………364
ADHESIVE COMPOUND……………………………………366