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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

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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

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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

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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

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 . Model 4.too1s.S.N.com Specifications NT855 Engine Identification Page 1 Engine Identification The engine dataplate provides the model identification and other important information about the engine. Control Parts List (CPL) 3. The information on the dataplate is mandatory when sourcing service parts: 1. Engine Serial Number (E. Have the following engine data available when communicating with a Cummins Authorized Repair Location.) 2.www.

www. .com Engine Diagrams Page 2 Specifications NT855 Engine Diagrams The following drawings contain information about engine components. 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. filter locations. drain points.too1s.

www.com Specifications NT855 Engine Diagrams Page 3 .too1s.

in this manual.020 inch]. . 3810395-00. use the standard torque value for the capscrew. unless otherwise specified.S.too1s.General Information Page 4 Specifications NT855 Specifications .S. and are secured with the correct torque value. Customary. for example: 0.S. and 88 Big Cam IV NT855 Series Engines Shop Manual. If a torque value is not listed. The minimum and maximum tolerance limit specifications are listed in both metric and U.www. Customary dimensions. Capscrew Markings and Torque Values. Capscrew torque values are listed in newton meters and foot pounds. Refer to the Table of Contents.com Specifications . The assembly and rebuild specifications and torque values are provided to make sure the parts are assembled correctly.50 mm [0. Bulletin No. New Big Cam IV.General Information The specifications in this manual are organized in the same sequence as the Big Cam IV. fit properly. Customary dimension in brackets. followed by the U. The metric dimension is given first. All capscrews used on the NT engine are U.

................] • Full Flow Filter Capacity .......................... 2100 • Formula Rating (RPM) ........0 in.... 25 cm H20 [10 in............................. 64 cm H20 [25 in........ Gal...................0 U......................................93 U.................. 240 to 310 kPa [35 to 45 psi] Oil Capacity of Standard Engine: • Bypass Filter ..............................] • Oil Pan Capacity (high-low) ...............................] Compression Ratio ............................S.........com Specifications NT855 General Engine Specifications Page 5 General Engine Specifications General Engine Data Metric [U...................................................................................] Total System Capacity Including Bypass Filter ........................... 30 cm H20 [12 in...............................I......................................S.......................... H20] Lubrication System Oil Pressure ........................] • Wet Weight ......................................] ............................................................................S........................0 liters [855 C........................ 14........................................ 1800 or 1900 Bore & Stroke ...................................7:1 Firing Order ................S.............8 liters [0.....................................................0 to 16.....................S....... 42 liters [11 U........................................] X 152 mm [6...too1s.] Intake System Maximum Allowable Intake Restriction with Clean Air Filter Element: • Normal Duty Dry Type Cleaner .................. 35 to 30 liters [9.......................... Gal.................................. H20] Maximum Allowable Intake Restriction with Dirty Air Filter Element ..... 14...........................................................................................................................................................................www..................75 U...................... Gal...........D................................................................... 1153 to 1194 kg [2540 to 2630 lb.................5 to 8........... 1-5-3-6-2-4 Engine Weight (With Standard Accessories): • Dry Weight ..................................... 2........................................................... 70 kPa [10 psi] At No Load Governed Speed: • Automotive . 140 mm [5.....................] Displacement ............................... H20] • Heavy Duty Dry Type Cleaner .... 38 cm H20 [15 in............................... Customary] Horsepower (Refer to the engine dataplate) Engine speed @ Maximum Output: • Standard Rating (RPM) ............................................... 3..... 1208 to 1249 kg [2660 to 2750 lb...........................Low Idle (Minimum Allowable) ..5 in........................ Gal...........................5 liters [0...... H20] • Medium Duty Dry Type Cleaner ....

.................................5 in.............................. 64 mm Hg [2.............................. ....................... ** CCA ratings are based on two 12-volt batteries in series....................................... Maximum Allowable Restriction to Pump: • With Clean Filter ............................................................... 50 kPa [7 psi] Exhaust System Maximum Allowable Back Pressure Created by Piping and Silencer: • Hg .................. 75 mm [3 in... 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.........too1s...........................................................................S..........................www.com General Engine Specifications (Continued) Page 6 Specifications NT855 General Engine Specifications (Continued) Cooling System Metric [U........] Exhaust Pipe Size (Normally Acceptable Inside Diameter) ............................ Hg] Maximum Allowable Return Line Restriction with Check Valves and/or Overhead Tanks . Hg] Maximum Allowable Return Line Restriction without Check Valves .... 82 to 93°C [180 to 200°F] • Optimized Aftercooling ..................................................................................................... 70°C [158°F] Minimum Recommended Pressure Cap ..................................... 127 mm [5 in....... 200 mm Hg [8 in......................... refer to the engine data sheet or the fuel pump code for the particular model involved......................................... 1000 mm [40 in........] Fuel System NOTE: For performance and fuel rate values............................ 100 mm Hg [4 in.........................................5 in.] Standard Modulating Thermostat Range: • Conventional Aftercooling ......................................................................................................... Hg] • With Dirty Filter ............. 350 kPa [50 psi] Maximum Allowable Top Tank Temperature ........ 21 liters [22 U........ qt.........................................................S.............................. Reserve capacity determines the length of time sustained cranking can occur........] • H20 ........................................................................................................ 100°C [212°F] Minimum Recommended Top Tank Temperature ...................... Customary] Coolant Capacity (engine only) .................................... 165 mm Hg [6................................. 79 to 91°C [175 to 195°F] Maximum Coolant Cylinder Block Pressure (Pressure Cap Removed) Closed Thermostat .......................................................

... 35 N•m [25 ft-lb] Without Part No....... Use the correct clearance and correct feeler gauge for the particular engine model........018 in] XXXX XXXX 425 0........................... 45 N•m [35 ft-lb] Without Part No.......... Refer to the table below................41 mm [0.......6 to 0...... 0............. Big Cam IV.................................................05 mm [0.................................. 27 N•m [20 ft-lb] JacobsT Engine Brake Caution: The JacobsT Brake slave piston clearance is not the same for all engine models...................7 N•m [5...........................................................com Specifications NT855 Valve and Injector Adjustments* Page 7 Valve and Injector Adjustments* Valves Initial: Intake ................................... 0.................. 60 N•m [45 ft-lb] Injector Preload (Top Stop) Initial .......53mm[0.............................000 in] Adjusting Screw Lock Nut Torque: With Part No.............. ST-669 ................................ 0...................................... ST-669 ..........................................................too1s.......... 40 N•m [30 ft-lb] Cummins Engine Brake **Adjusting Screw Clearance (Use Dial Indicator) ............................................ or 88 Big Cam IV engines.........00 to 0.......45mm[0........021 in] XXXX XXXX XXXX Brake Model 420 XXXX XXXX XXXX 0......................................00 to 6.................28 mm [0......018 to 0..........www..018 in] XXXX 0................................45mm[0.........030 in] XXXX 0........................10 to 0......... ** The correct adjusting screw must be used.............. NOTE: The JacobsT Model 430 can only be used on 88 Big Cam IV engines..................46 mm [0..................018 in] Adjusting Screw Lock Nut Torque: With Part No....45mm[0............................. * Adjustments must be made when the engine is cold (any stabilized coolant temperature at 60°C [140°F] or below)................................. ST-669 .....018 in] XXXX XXXX XXXX XXXX 401C 0................... ST-669 .................018 in] XXXX XXXX XXXX 430 XXXX XXXX XXXX XXXX 0....................023 in] Recheck Limit: Intake .......................................011 in] Exhaust ............ New Big Cam IV...................34 in] NOTE: The JacobsT Model 425 engine brake is not approved for engines with Mechanical Variable Timing (MVT)............................................................45mm[0. 0...018 in] 0..........00 in-lb] Recheck Limit ......................58 mm [0........... ST-669 ..................................00 mm [0............002 in] Crosshead Adjustment Rocker Lever Clearance .................. 0.....76mm[0............. ST-669 .............. ........004 to 0...76 mm [0.................................... 24 N•m [18 ft-lb] Without Part No.......016 in] Exhaust ................... 0...............................................000 to 0................030 in] Adjusting Screw Lock Nut Torque (Valves and Injectors): With Part No...................................... Step Timing Control (STC).....................45mm[0......................86mm[0.. 0.....................46 to 0.... 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...

................www.......................................... 30 N•m [22 ft-lb] Without Part No.........................................................com Valve and Injector Adjustments* Page 8 Specifications NT855 Adjusting Screw Lock Nut Torque: With Part No....................... ST-669 ......... ST-669 ..........................too1s................ 35 N•m [25 ft-lb] Injector and Valve Adjustment Sequence ...................

20 0.13 17.20 MAX MAX MAX MAX MAX MAX 0.com Specifications NT855 Part or Assembly Engine Assembly .10 0.7 MAX MAX MAX MAX MAX MAX 31. Flywheel Housing Face Alignment T.25 0.05 MAX 0.004 0.63 16.45 MIN MAX 0.I. 00 0 1/2 1 2 3 0.15 MIN MAX 0.010 0.20 0.Specifications Cylinder Liner Protrusion 0.008 0.18 0.R.012 0.4 511.3 447.010 0.006 Cylinder Liner Out of Round 0.I.007 Cylinder Liner to Lower Cylinder Liner Bore Clearance 0.008 0.01 20.13 SAE No.25 0.008 0.05 0.25 0.007 0. Point mm in Engine Assembly . .30 0.012 0.R.010 0.008 0.18 MIN MAX 0.25 0.018 SAE No.20 0.002 Crankshaft End Clearance 0.www.008 Flywheel Housing Bore I.01 25. 00 0 1/2 1 2 3 787. 00 0 1/2 1 2 3 0.30 0.7 648.008 SAE No.002 0. Flywheel Housing Bore Alignment T.Specifications Page 9 Ref.20 MAX MAX MAX MAX MAX MAX 0.0 584.too1s.51 23.20 0.010 0.D.8 409.

68 MAX 0. Point mm in Piston Ring Gap Piston • Top 0.50 MIN MAX 0. for complete instructions.0045 0.001-inch] wear in the cylinder liner wall.64 MAX 0.017 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.13 Note: The rod must move freely from side-to-side.025 Note: Add 0.too1s. Bulletin No.002 0.74 MAX 0. Connecting Rod Side Clearance 0. Backlash Between the Camshaft and the Crankshaft Gear 0.48 MIN 0.020 Injection Timing To verify the correct injection timing for a particular engine refer to the engine dataplate.019 0.08 mm [0. 3810395.51 MIN 0.Specifications Page 10 Part or Assembly Specifications NT855 Ref. Engine Assembly. Refer to Group 00.05 0. Piston Ring End Gap The ring gaps must not be aligned with the piston pin bore. Rotate the rings to position the gaps as shown.33 MIN MAX 0. 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.76 MAX 0.43 MIN 0.029 • Oil 0.03 mm [0.010 0. in the NT855 Shop Manual.114 0. .030 • Third 0.020 0.com Engine Assembly .003-inch] to the maximum limit for each 0. Injection Timing.www. page 0-89.027 • Second 0.25 MIN 0.

05 MIN 0.I.016 Flywheel Bore Runout T.406 MAX MAX MAX MAX MAX 0.002 0.too1s.0050 0.Specifications Page 11 Ref.008 0. Flywheel Face Runout T. 0.I.I.R. Radius mm 203 254 305 356 406 (A) in 8 10 12 14 16 .I.004 Vibration Damper Face Alignment (‘‘Wobble’’) T.R.203 0.www. the gear must be replaced. the lubricating oil pump drive gear must be replaced.002 Oil Pump Drive Gear and the 0.50 MAX Note: If the backlash is not within specifications.010 0. Align the timing mark on the accessory drive gear with the timing mark on the camshaft gear.05 MIN Drive and the Camshaft Gear 0.007 0.R.305 0.254 0.014 0.10 MAX 0. Backlash Between the Accessory 0. 0.127 MAX 0. Point mm in Accessory Drive Assembly Timing Position the accessory drive shaft dowel pin at the 12:00 o’clock position.com Specifications NT855 Part or Assembly Engine Assembly . 0.18 MAX 0.020 Camshaft Gear Note: If the backlash is not within specifications.R. Vibration Damper Eccentricity T.50 MAX 0.356 0.012 0.020 Backlash Between the Lubricating 0.

Bulletin No. .www.58 MIN MIN 0. Group 00. page 0-133. Point mm in PTD Top-Stop Injector Adjustment Refer to Engine Assembly.Specifications Page 12 Part or Assembly Specifications NT855 Ref.011 0.com Engine Assembly .too1s. Bulletin No. 3810395. page 0-129.023 Air Compressor to Accessory Drive Timing Position the air compressor crankshaft timing mark at the 10:00 o’clock position. PTD Top-Stop Injector Adjustment. PTD STC Injector Adjustment Refer to Engine Assembly.28 0. in the NT855 Shop Manual. Align the ‘‘A’’ valve set mark on the accessory drive pulley with the pointer on the gear cover. Group 00. PTD STC Injector Adjustment. 3810395. in the NT855 Shop Manual. Intake Valve Lash Specifications Exhaust Valve Lash Specifications 0.

Point Belt Tension Water Pump Belt (Big Cam IV and New Big Cam IV) • 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 .too1s. Point Belt Tension Water Pump Belt (88 Big Cam IV) • New Belt Tension • Used Belt Tension Ref. Point Belt Tension Fan Belts • New Belt Tension • Used Belt Tension Ref.com Specifications NT855 Engine Assembly . Point Belt Tension Alternator Belts • New Belt Tension • Used Belt Tension Ref.Specifications Page 13 Part or Assembly Ref.

Capscrew Torque Values Adapter Plate to Rebuild Stand 100 Mounting Plate Adapter to Rear Water Header. 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.Capscrew Torque Values Page 14 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Engine Assembly . 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 . Main Bearing Capscrews (3/4-inch Diameter Capscrews) Note: Tighten in the sequence shown.www.too1s. Liner Force Plate Screw Main Bearing Capscrews (1 inch diameter capscrews) Note: Tighten in the sequence shown.com Engine Assembly .

com Specifications NT855 Part or Assembly Flywheel Housing Note: Tighten in the sequence shown. Repeat steps 1. Accessory Drive Mounting Capscrews Lubricating Oil Pump Gear Cover 60 45 55 40 70 50 . 2. the three housings of the MVT cam followers must be installed to the engine as an assembly. and 3 to install each cylinder head. 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.www. Engine Assembly .too1s. Note: With mechanical variable timing.Capscrew Torque Values Page 15 Step Connecting Rod Capscrews Note: Tighten the connecting rod capscrews in alternating sequence. Tighten the center cam follower housing first. Cylinder Head Note: Tighten in the sequence shown.

to a final torque of 18 N•m [156 in-lb]. SAE grade No. tighten the capscrews alternately and evenly. 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. . Water Manifold Assembly Injectors (PTD-Top Stop) • Big Cam IV engines 18 156 in-lb Note: For Big Cam IV engines (5/16-inch .18 capscrews).too1s.www. 6 N•m [48 in-lb] torque one at a time.com Engine Assembly .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.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 . 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..Lock Nut • Less JacobsW Brake: . 11 N•m [8 ft-lb] torque one at a time to a final torque of 34 N•m [25 ft-lb].56-0. Less adapter • With JacobsW Brake Model 401 adjusting screw (exhaust crosshead only) . Part No. 80 95 60 70 STC External Oil Manifold 11 95 in-lb 0.www.68 5-6 in-lb Injector Adjusting Screw .com Specifications NT855 Part or Assembly Injectors (PTD-Top Stop) Engine Assembly . ST-669 . With adapter. With adapter.. Injectors (PTD-STC) Fuel Crossovers 54 4 40 35 in-lb Crossheads ..16 capscrews). Part No.too1s. ST-669 .

JacobsW Lock Nut • With torque wrench adapter.com Engine Assembly . Part No.www. 90 65 30 35 22 25 Note: Tighten the C Brake 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.too1s. 669 • Without adapter .68 ft-lb 35 45 6 in-lb Valve Lock Nut • With torque wrench adapter. Part No. 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. ST-669 • Without adapter Valve Lash Clearance (Torque Wrench Method Using Specified Feeler Gauge) Torque Values N•m 45 60 0.

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.www. 45 35 45 35 DFC Signal Line Tube Nuts 15 Oil Pan • Four 5/16-inch capscrews in rear of the oil pan.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. • Thirty-two 7/16-inch capscrews Note: Tighten in the sequence shown. Engine Assembly . Lubricating Oil Transfer Tube 120 in-lb Aftercooler • Big Cam IV Unitized Aftercooler 70 Note: Tighten the nine capscrews in the sequence shown. 50 Air Compressor 65 50 Fuel Pump 45 35 . tighten the capscrews (2) at the lubricating oil pump. • Second. Use only grade 8 capscrews.

www.com Engine Assembly . 4 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.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. 6 No.

com Specifications NT855 Engine Assembly . tighten to the maximum value. 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.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.www. If used belt tension is below the minimum. .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.

Fan Hub 110 80 • Hexagon Head • Slotted Head 15 10 140 in-lb 95 in-lb Hand Hole Cover 45 35 Piston Cooling Nozzles .com Engine Assembly . If the belt tension is below the minimum.www. tighten to the maximum value.too1s.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.

and NTC-444 Only 12 110 in-lb Thermostat (Reserve Flow Cooling) 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 .com Specifications NT855 Part or Assembly Coolant Filter Head (88 Big Cam IV) Engine Assembly . New Big Cam IV. New 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.too1s.www.

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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

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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)

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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.

too1s.www.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 .com Engine Assembly .

612 120.7505 63.842 .102 0.6.166. (Installed) Note: If one of the bushings exceeds the maximum specifications.4983 2.3330 .60 MIN MAX 6.6.741 .197 None 6.662 .com Specifications NT855 Part or Assembly Cylinder Block .725 .010 120.004 0.124 6.159.126 0.167.6.6.3350 Upper Press Fit Design Upper Liner Bore Diameter Cylinder Liner Lower Bore I.663 MIN MAX 4.6100 • Standard • Oversize Lower Press Fit Design Upper Liner Bore Diameter 160.45 MIN MAX 16.5615 .632 Upper Press Fit Design Counterbore Diameter • Standard • Oversize Lower Press Fit Design Counterbore Diameter 166.5635 6.2950 6. .713 167. 155.3070 None • Standard • Oversize 159.Rebuild Specifications Cylinder Block Height 421.6.2930 . Main Bearing Bore I. all of the bushings must be replaced.5023 Cylinder Block to Main Bearing Cap Press Fit/Side Clearance • Press Fit • Clearance *Measured between the block and either side of the cap.7485 4.457 63.893 160. Camshaft Bushing I.D.160.909 6.558 MIN MAX 2.220 6.166.too1s.3030 .5700 6.5815 .Rebuild Specifications Page 29 Ref.254* MIN MAX 0.6.6.894 6.87 422.54 155.878 167. Point mm in Cylinder Block .6040 .160.170 .167.096 .5835 • Standard • Oversize 166.D.5640 .www.D.609 16.858 .

586 166.007 0. Cylinder Liner Protrusion Specifications NT855 Ref.28 MIN MAX MIN MAX 6.694 139.46 0.6865 2.009 0.Rebuild Specifications Page 30 Part or Assembly Cylinder Block Camshaft Bore I. 0.too1s.79 MIN MAX MIN MAX 6.040 Oversize .74 167.18 0.53 0.D.008 0.031 0.48 0.827 MIN MAX 5. (Upper Press Fit Area) Lower Press Fit Design • Standard • .4998 5.018 0.77 167.D.72 166.72 166.77 167.237 68.20 0.004 0.6875 0.021 0.020 0.57 0. Point mm in 68.020 0.022 139.007 Counterbore Sealing Ring Thickness • Standard Lower Press Fit or Upper Press Fit Liners • Oversize Lower Press Fit Liners Cylinder Liner I.79 1.23 167.020 Oversize Liner O.564 6.566 6.51 0.D.10 0.56 0.18 MIN MAX 0.019 0.www.564 6.23 0.606 Liner O.062 0.604 6.51 0.262 MIN MAX 2.5050 166.584 6.D.com Cylinder Block .566 6. (Upper Press Fit Area) Upper Press Fit Design • Standard • .

152 mm [0. Point mm in Liner O.493 .too1s.485 5.006 inch] feeler gauge.D.366 9. The piston must be replaced if the widest part of the gauge touches the piston.020 Oversize Cylinder Liner Flange Thickness Lower Press Fit Design • Standard • .27 9.com Specifications NT855 Part or Assembly Cylinder Block . Piston Oil Ring Groove Width Use a new oil ring and a 0.486 5.31 139.98 MIN MAX MIN MAX 6. ST-560-6.375 0.491 5.336 6.299 159. Part No.52 MIN MAX MIN MAX 5.47 139.86 159.376 Liner O.29 MIN MAX MIN MAX 0.D.01 9.355 0.52 9.296 6.93 160.04 9. If the feeler gauge enters the oil ring groove without resistance.365 0.040 Oversize Cylinder Liner Flange Thickness Upper Press Fit Design • Standard • .294 6.99 MIN MAX MIN MAX 6.55 MIN MAX MIN MAX 0.04 9.91 159.99 159.86 159.356 0.020 Oversize 159.299 6.www.298 6. the piston must be replaced.96 160.34 139.040 Oversize Piston Compression Ring Grooves Width Use piston ring groove wear gauge.294 6.356 0. Piston Skirt Outside Diameter (A) (B) 139.338 9.Rebuild Specifications Page 31 Ref.01 9. (Lower Press Fit Area) Lower Press Fit Design • Standard • .355 0. (Lower Press Fit Area) Upper Press Fit Design • Standard • .

D.800 in MIN MAX 1.522 MIN MAX 3.7607 Crankshaft Front Oil Seal Area O. Crankshaft Connecting Rod Journal O.38 MIN MAX 3.www.7600 3. 92.D.001-inch] out of round.07 92.10 MIN MAX 3.626 Crankshaft Rear Oil Seal Area O. . Point mm 50.9985 1.125 Crankshaft Gear Fit Area O.D.too1s.D.762 MIN 50.Rebuild Specifications Page 32 Part or Assembly Piston Pin Bore Specifications NT855 Ref.504 95.000 79. Crankshaft Oil Seal Wear Groove 0.com Cylinder Block .010 95.9990 Piston Pin O.0000 50.D.30 79.35 152. 152. 1.762 50.9985 2.625 3.998 6.122 3.40 MIN MAX 5.03 mm [0.775 MAX Note: Discard the piston pin if it is more than 0.25 MAX 0.

394 95.3785 1.522 MIN MAX 3. page 1-87.7557 3.23 76.626 3. 95. Point mm in 114.003 Crankshaft Gear Bore I.052 MIN MAX 1.3800 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 .7600 3.too1s. in the NT855 Shop Manual.D. 3810395.4975 4.237 114.415 MIN MAX 3.7565 Crankshaft Gear Fit Area O.504 95.www.28 MIN MAX 3. 95.17 MIN MAX 3.629 35.5000 76.001 3. .10 92.D. Refer to Crankshaft Magnetic Crack Inspection (01-10).D.300 MIN MAX 4.com Specifications NT855 Part or Assembly Crankshaft Main Bearing Journal O. Bulletin No.Rebuild Specifications Page 33 Ref. Cylinder Block .013 35.Group 01.7607 92.

Alignment: • (Without Bushing) • (With Bushing) .3167 Piston Pin Bushing I.Length 304.0022 Connecting Rod . 50.3157 3.405 MIN MAX 0.1238 Thrust Bearing Thickness 6.086 3.2445 0.2475 Connecting Rod Bearing Thickness (Standard) 2.286 MIN MAX 0.825 50.D.com Cylinder Block .219 84.Rebuild Specifications Page 34 Part or Assembly Specifications NT855 Ref.25 0.010 0.81 14.0947 Connecting Rod Capscrew O.145 MIN MAX 0.590 Connecting Rod Crankshaft Bore I.998 12.www. 84.244 MIN MAX 3.000 0.75 304.0010 2.99 MIN MAX 0.362 2.004 Connecting Rod .583 0.D.0930 0.1215 0.210 6.80 MIN MAX 11.856 MIN MAX 2. 14. Point mm in Main Bearing Shell Thickness (Standard) 3.10 MAX MAX 0.D.too1s.

D.29 2.7985 44. 3810395.www.50 0.Twist: • (Without Bushing) • (With Bushing) 0.37 63.455 44.526 44.too1s.733 45. Refer to Camshaft .497 2. Camshaft Bushing Journal O. Point mm in Connecting Rod . .682 MIN MAX MIN MAX 1.49 MIN MAX 0.539 45.7502 1.com Specifications NT855 Part or Assembly Cylinder Block . • Flanged Camshaft • Flangeless Camshaft The instructions for performing a magnetic crack inspection of the camshaft and camshaft gear is provided in Group 01.495 2.8005 1. Bulletin No.Rebuild Specifications Page 35 Ref. • Flanged Camshaft • Flangeless Camshaft Camshaft Gear Press Fit O.Magnetic Inspection (01-18). Camshaft Thrust Washer Thickness 63.020 0.090 0.Magnetic Inspection (01-15).D. Refer to Connecting Rods .8010 Camshaft Gear Bore I.098 44. page 1-123.25 MAX MAX 0. Bulletin No.7510 1.745 MIN MAX MIN MAX 1. 3810395. in the NT855 Shop Manual. in the NT855 Shop Manual.D. page 1-109.42 MIN MAX 2.7535 1.010 The instructions for performing a magnetic crack inspection of the connecting rod is provided in Group 01.662 45.7530 1.Magnetic Inspection (01-19).7977 1.475 45. page 1-118 and Camshaft Gear .

D.382 Vibration Damper Thickness Measure the thickness in four places 90 degrees apart approximately 3. The difference between any two of the four measurements must not exceed 0.688 MIN MAX 4.07 43.D.D.25 mm [0. Point mm 35.697 Crankshaft Seal Bore I. 39.696 1.com Cylinder Block .www.too1s.571 Accessory Drive Bushing Bore I.7515 Accessory Drive Bushing I.90 MIN MAX 1.565 1.380 1.010 inch]. Specifications NT855 Ref. 43.038 MIN MAX 3.1905 120.7485 4.D.611 120.18 mm [0.125 inch] from the outside diameter.10 in MIN MAX 1.1875 3. 80. .75 39.962 81.D.05 35.10 MIN MAX 1. Accessory Drive Seal Bore I.Rebuild Specifications Page 36 Part or Assembly Crankshaft Pulley I.

Connecting Rod Capscrews NOTE: Tighten the capscrews in alternate sequence. 110 210 305 90 170 255 .Torque Values Page 37 Step Torque Values N•m ft-lb Cylinder Block .too1s.www.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. Main Bearing Capscrews (3/4-inch diameter) Note: Tighten the main bearing capscrews in the sequence shown.com Specifications NT855 Part or Assembly Cylinder Block .

90 MIN 0.D.www.Rebuild Specifications Page 38 Part or Assembly Specifications NT855 Ref.too1s.D. Valve Guide I.114 11.00 in.08 MAX MAX 0.85 111.5 lbf 73.40 11.557 MIN MAX 0.635 43.4530 0.com Cylinder Head .380 68.25 MIN MAX 4.671 • Valve Spring Part No. 3035996 381 N 412 N 11.4550 Cylinder Head Thickness Valve Spring Free Height: A • Valve Spring Part No. 211999 • Valve Spring Part No.449 0.7 lbf 92. 211999 295 N 326 N MIN MAX 66.506 11.5 lbf • Valve Spring Part No. 3035996 Valve Spring Working Height: • Valve Spring Part No.4 mm [1. Valve Head Thickness at O.0008 0.724 1.7 lbf 0.D.020 0. Point mm in Cylinder Head .685 2.93 Nominal Nominal 2.325 4.79 42.44 Nominal Nominal 1.003 109.46 MIN MAX MIN MAX 85.] of Length Cylinder Head Flatness (Total Overall Length) 0. 211999 • Valve Spring Part No. 3035996 Load for Working Height: B C Valve Stem O.451 2. (Installed) 1 .20 66.Rebuild Specifications Cylinder Head Flatness Per 25.

975 11.055 0.085 Crosshead Guide O.4321 0.4335 47.060 0.Rebuild Specifications Page 39 Ref.063 0.52 1. Crosshead Guide Height (Installed) Valve Seat Area Width 1 Valve Protrusion • Pre-88 NT • 88 NT .www.880 1.860 1.165 0.125 Injector Tip Protrusion 1.09 MAX 0.too1s.011 MIN MAX 0.40 2.280 10.D.26 32.67 4.25 47.78 MIN MAX 0.19 1.com Specifications NT855 Part or Assembly Cylinder Head .0035 2.18 MIN MAX 0.070 Valve Seat to Valve Guide Concentricity (Per 360 Degrees) 0.75 MIN MAX 1. Point Valve Guide Height (Installed) mm in 32.60 3.16 MIN MAX MIN MAX 0.51 MIN MAX 1.105 0.270 1.

060 Valve Guide O.24 7.05 19.101 MIN MAX 0.290 50.750 0.18 MIN MAX 0. (Standard Insert) Crosshead Guide Bore I.www.07 MIN MAX 0.D.60 3.7520 7.91 1.125 Valve Guide Bore I.D.9995 2.813 MIN MAX 1.751 19.972 MIN MAX 0.285 0.D.com Cylinder Head .7515 0.52 Approx.063 0.787 50. 19. MIN 0. Point mm in Valve Seat Width Limit 1.too1s. Valve Seat Insert Bore Depth (Standard Insert) Valve Seat Insert Bore I.4310 0.4320 11.947 10.Rebuild Specifications Page 40 Part or Assembly Specifications NT855 Ref.0005 10.D.088 19. Injector to Injector Sleeve Seat Pattern: • Distance from Cylinder Head Surface • Pattern Width 1 2 .37 MIN MAX 0.469 0.

Bulletin No. Valve Crosshead Stem Bore I.16 MIN MAX 0.17 MIN MAX 0.03 11.434 0.www. in the NT855 Shop Manual.com Specifications NT855 Part or Assembly Cylinder Head . 1 2 3 11.65 10.Rebuild Specifications Page 41 Ref.too1s.Vacuum Testing Valve Seating For Reuse (02-10). 3810395.440 Valve Crosshead Stem Pocket to Pad Face 1 9. page 2-38.400 .D.380 0. Point mm in Valve Seat Leakage (Hg) 508 MIN 20 635 MAX 25 Note: Refer to Cylinder Head .

com Cylinder Head .www. in the NT855 Shop Manual.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.Torque Values Page 42 Specifications NT855 Part or Assembly Step Torque Values N•m ft-lb Cylinder Head .too1s. and Cylinder Head . Bulletin No. 3810395. 1 2 3 . page 2-35. page 2-17. 3810395. in the NT855 Shop Manual.Rebuild (02-02). in the NT855 Shop Manual. page 2-30. Bulletin No. Bulletin No. Refer to Cylinder Head Replacing the Injector Sleeves (02-07).Replacing the Injector Sleeves (02-07). 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 . Refer to Cylinder Head-Pressure Testing (02-08). page 2-33. 3810395. Injector Sleeve Expander Mandrel Injector Sleeve Holding Tool Capscrews Note: This torque value is for pressure testing the cylinder head.

562 28.17 36.D.1286 1.1235 1.15 30.Rebuild Specifications Page 43 Ref.437 Rocker Lever Shaft O.3775 28.988 MIN MAX MIN MAX 1.D.Rebuild Specifications Rocker Lever Bushing Bore I.1245 1.436 1.052 MIN MAX 0.D.50 MIN MAX MIN MAX 1.187 1.666 34.188 1. Point mm in Rocker Lever Housing Assembly .too1s.3725 16.3735 1.002 16.3705 1. (Internal Cup Plug Design Only) Rocker Lever Bore I. • Pre-88NT • 88NT Rocker Lever Shaft I.47 36.860 MIN MAX MIN MAX 1.630 0.1215 1. • Pre-88NT • 88NT .D.632 30.810 34.www.490 28.com Specifications NT855 Part or Assembly Rocker Lever Housing Assembly .540 34. (Installed) • Pre-88NT • 88NT 28.886 34.

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.com Rocker Lever Housing Assembly . Part No. ST-1182.Torque Values Page 44 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Rocker Lever Housing Assembly .www. Spray nozzles must be aligned with valve spring spray nozzle locator.too1s. Rocker Lever Shaft Threaded Plugs 95 70 .

003 0.com Specifications NT855 Part or Assembly Cam Follower Assembly .D.www.100 MIN MAX 0.61 MIN MAX 0.008 19.009 0.Rebuild Specifications Page 45 Ref.too1s.7520 Cam Follower Shaft O.61 MIN MAX 0.749 0.08 0.009 0.7501 0.23 0.05 MIN MAX 0.20 MIN MAX 0.00 19.748 0.D.008 Cam Follower Lever Bushing I.749 Cam Follower Shaft Bore I.20 MIN MAX 0. 19.Rebuild Specifications Fixed Injection Timing Cam Follower Roller Side Clearance 0.052 19.750 Cam Follower Roller Side Clearance 0. MVT Injection Timing .D.02 MIN MAX 0.02 19.024 Cam Follower Roller to Pin Clearance 0.003 0. Point mm in Cam Follower Assembly . 19.08 0.23 0.024 Cam Follower Roller to Pin Clearance 0.

D.062 19.7520 Injector Lever Bushing I.00 19. 19.15 MIN MAX 0.7502 19.746 0.00 MIN MAX 0.052 19.963 35.100 MIN MAX 0.750 0.7505 0.D.7525 Actuator Shaft Bore I.113 MIN MAX 0.D.3740 1.3748 2 19.www.3784 1 34.05 19.754 Actuator Shaft O. Point mm in Valve Lever Bushing or Bore I.029 19.D.7501 0.95 19.D. Cam Follower Shaft O.011 MIN MAX 1. .com Cam Follower Assembly .055 MIN MAX 0.02 MIN MAX 0.3765 1.D.D. 18. 19.Rebuild Specifications Page 46 Part or Assembly Specifications NT855 Ref.7492 0. Cam Follower Shaft Bore I.748 0.900 34.920 MIN MAX 1.748 Injector Cam Follower Lever Eccentrics O.749 19.too1s. 34.

www.81 4.495in] MIN MAX 0.60 49. 3021515 3024029 3024030 MIN 35.28 19.002 .996 2.72mm [1.11mm [1.too1s.920 Spring Tester Working Height C D 67.D. 19. 49.97mm [1.43mm [1.06 Actuator Spring Free Length MAX 35.485in] Timing Spacer Flange Thickness 3.762 Actuator Plunger O.69 50.76 Nominal Nominal Load for Working Height C 391N 480N 578N 711N MIN MAX MIN MAX 50.68mm [1.38 Nominal 4.215in] 37.395in] 30.953 1.225in] 37.D. Point mm in Actuator Shaft Guide I.640 1.35 MIN MAX 0.149 2.05 48.78 MIN MAX 1.com Specifications NT855 Part or Assembly Cam Follower Assembly .960 Timing Spacer Length Part No.405in] 31.86mm [1. 88 108 130 160 lbf lbf lbf lbf 1.150 0.Rebuild Specifications Page 47 Ref.D.160 105.759 0.85 MIN MAX D Actuator Housing Cylinder Sleeve I.

97 57. 17.02 MIN MAX 2.2505 The Shaft End Opposite the Actuator Must Have a Depth in the Housing as Follows: Dimensions . 56. 57.6992 0. 17.711 31.05 57.856 17.6997 Valve Lever Roller Bore I.4990 0.2505 Crowned Injector Roller O.2485 1.D.5040 Injector Lever Roller Bore I.Rebuild Specifications Page 48 Part or Assembly Cam Follower Shaft From Housing Extension Dimension Specifications NT855 Ref.www.D.7040 Crowned Valve Roller O.D.246 2.687 MIN MAX 0.762 MIN MAX 1.935 25.250 Valve Lever Roller Pin Bore I. 12.776 12.D.D.5030 0.D. 31.30 25.759 17.75 MIN MAX 0.D.996 1.881 MIN MAX 0.25 23.15 MIN MAX 2. 31.674 12.243 2.4995 Injector Lever Roller Pin Bore I.com Cam Follower Assembly .7030 0.too1s.40 MIN MAX 0. 12.762 MIN MAX 1.2485 1.772 MIN MAX 0. Point mm in 23.915 0.801 MIN MAX 0.000 Actuator Housing Cylinder Bore I.D.711 31.245 Actuator Housing Cylinder Sleeve O.

23 0.7490 0.too1s.4997 0.7505 0. Point mm in Valve Roller Pin O.024 (1) Cam Follower Socket O.6997 0.com Specifications NT855 Part or Assembly Cam Follower Assembly .0025 Cam Follower Roller Side Clearance Press Fit Between Lever and Socket .064 MIN MAX 0.61 MIN MAX 0.D.700 MIN MAX 0.772 17. 17.7000 0.692 12.5000 Injector Roller Pin O.7515 (2) Cam Follower Lever Bore I.0005 0.Rebuild Specifications Page 49 Ref.780 MIN MAX 0.D.050 MIN MAX 0.D.www.7500 0.088 MIN MAX 0. 12.025 19. 19.D.013 0.063 19. 19.009 0.

www.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. 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 .com Cam Follower Assembly .too1s.Torque Values Page 50 Part or Assembly Specifications NT855 Step Torque Values N•m ft-lb Cam Follower Assembly .

3810344.www.com Specifications NT855 Part or Assembly Spring Retainer Lock Nut Fuel Pump .Rebuild Specifications The disassembly. assembly and calibration procedures for the fuel pump are covered in PT Fuel Pump Rebuilding and Calibration Instructions.too1s. Bulletin No. 3810313. . Bulletin No. repair.Rebuild Specifications The disassembly. 3379084.Rebuild Specifications Page 51 Step Actuator Cap Torque Values N•m 45 40 ft-lb 35 30 Fuel Pump . inspection. Injectors . inspection. For Top-Stop Injectors: • Shop Manual PT (type D) Top Stop Injectors. 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. Bulletin No.

Capacities Oil Pan Capacity: • Automotive 30 35 Low High 8.Capacities Page 52 Part or Assembly Specifications NT855 Ref.877 22. 22.0 9. .874 0. Point mm in Lubricating Oil Pump .28 MIN 0.8725 22.877 22.73 MAX 1.D.33 MAX 0.33 MAX 0.05 0. 6. 22. Lubricating Oil Pump Drive Shaft O. 22.0 • Industrial Part or Assembly Ref.002 0.840 Note: If the valve seat depth is greater than the maximum specifications given.5 High Refer to Lubrication System Specifications.D. page 5.28 MIN 0. Point U.22 MIN MAX 0.13 MIN MAX 0.5 22.187 MAX 0.875 22.20 22. Lubricating Oil Pump Driven Gear Bushing I.too1s. the bushings must be replaced.879 Note: If the bushings are worn larger than the maximum given.D. Valve Seat Depth 46.com Lubricating Oil System . Main Drive Gear Bore I.879 Note: If the bushings are worn larger than the maximum given. Gallons Liters Lubricating Oil System .7 Low 26.the bushings must be replaced. for additional specifications.8735 Note: If the main drive gear bore is worn beyond the maximum limit.S. the drive gear must be replaced.161 MIN 0.www.Inspection Specifications Lubricating Oil Pump Drive Shaft End Clearance 0. the oil pump body must be replaced.005 Lubricating Oil Pump Body and Cover Bushing I.0 7.D.

the pump body must be replaced.200 MAX 0.Inspection Specifications Page 53 Ref.30 MIN MAX 0.com Specifications NT855 Part or Assembly Lubricating Oil Pump Body and Cover Bushing Bore I.28 22.D.8785 . Bushing I.www.D.D.20 MIN 0. Drive Shaft O.8775 Note: If the shaft bore diameter is not within specifications.8765 22. Point mm 25.0005 Note: If the bushing bore inside diameter is not within specifications.8740 Note: If the bore inside diameter is not within specifications.387 25. Driven Shaft Bore I.289 MAX 0. 25.877 0.9995 25.413 in MIN MAX 0. the gear must be replaced.187 MIN 0.D. 22.878 Drive Gear Bore I.874 22.8735 22. 22.too1s.413 MAX 1.387 MIN 0.0005 Driven Gear Bushing Bore I.D. Driven Shaft Press Fit Area O.301 22. the gear must be replaced.8780 0. (New) 22.263 MIN 0.314 MIN MAX 0.D.D. 22.9995 1. 22.875 Note: Shafts that are damaged or worn smaller than the minimum given must be replaced.22 MAX 0. Lubricating Oil Pump .

67 Step in MIN MAX Torque Values N•m 0.90 18.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) .705 0. Point Driven Shaft Protrusion Part or Assembly mm 17.Torque Values Page 54 Part or Assembly Specifications NT855 Ref.too1s.www.735 ft-lb Lubricating Oil System .com Lubricating Oil System .

www.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) .too1s.com Specifications NT855 Part or Assembly Oil Cooler Connection (Housing) to Support Capscrews (88 Big Cam IV) Lubricating Oil System .

D.918 MIN MAX 0.001 25.022 MIN MAX 0.6262 0.6262 0.6267 1 15.011 MIN MAX 0.D.www.9847 0.625 16.Rebuild Specifications Water Pump Body Bearing Bore I.D.020 0.624 0.436 15.918 MIN MAX 0.88 MIN MAX 0.85 15.9851 3 15.47 MIN MAX 1.9843 0. (88 Big Cam IV) Water Pump Impeller Vane To Body Clearance .4406 2.D.905 15.D.000 17.D.6262 0.6267 • Phenolic 0.011 25.918 MIN MAX 0.624 0.51 MIN MAX 0.435 1.017 MIN MAX 2.02 MIN MAX 0.008 MIN MAX 0.010 0.85 15. • Pre-88 NT • 88 NT Water Pump Shaft Journals O.924 16.4416 36. (Big Cam IV and New Big Cam IV) Water Pump Shaft Journals O.6673 15.905 15.6663 0. 61.9847 3 15.040 Water Pump Body Seal and Seat Assembly Bore I.625 1 17.905 15.949 MIN MAX 0.25 0.991 62.6267 2 25.020 • Cast Iron 0. Water Pump Impeller Bore I.6693 0.51 1.Rebuild Specifications Page 56 Part or Assembly Specifications NT855 Ref.too1s. Water Pump Drive Pulley Bore I.com Water Pump Assembly .6696 2 25.45 36.88 MIN MAX 0. Point mm in Water Pump Assembly .

D.D.9817 0. 65.4414 Idler Shaft O.www.998 .999 2.0457 2.Inspection Specifications Inner Bearing Spacer Length (1) 50.961 51.67 50.9838 0.989 25.75 MIN MAX 1.5605 2.3750 Fan Hub Bore I. (88 Big Cam IV) 24.3745 1.5620 Fan Hub .912 34.Inspection Specifications Page 57 Ref.0467 Bearing Spacer O.012 MIN MAX 2.038 65. 34.82 MIN MAX 1.995 1.9847 Idler Pulley Bearing Bore I. (Big Cam IV and New Big Cam IV) 24. Point mm in Water Pump Idler Pulley Bearing Bore I.001 Outer Bearing Spacer Length (2) 50. (Big Cam IV and New Big Cam IV) 61.986 MIN MAX 2.D.com Specifications NT855 Part or Assembly Fan Hub .996 62.075 MIN MAX 2.4408 2.78 50.D.too1s.D. (88 Big Cam IV) 51.D.011 MIN MAX 0.925 MIN MAX 1.986 MIN MAX 0.9837 Fan Hub Shaft O.935 24.

507 • 49 State Engine (EPA Certified) 3.D.003 0.197 Radiator Thermostat Seat Bore I.125 0.185 0.17 MIN MAX 0.7505 1. Point mm 0.Rebuild Specifications Page 58 Part or Assembly Fan Hub End Clearance Specifications NT855 Ref.70 5.386 44. (Big Cam IV and New Big Cam IV) 44.www.462 44.00 MIN MAX 0.28 MIN MAX 1.437 MIN MAX 1.18 38.386 44.125 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) .7475 1.92 3.18 3.503 1.too1s.Rebuild Specifications Radiator Thermostat Seat Height (Big Cam IV and New Big Cam IV) 38.D.7495 Radiator Thermostat Seat O.7475 1.7495 2.010 Thermostat Housing Assembly . (Big Cam IV and New Big Cam IV) 44.D.513 MIN MAX 1.140 • 50 State Engine (EPA and CARB Certified) 4.437 MIN MAX 1.com Thermostat Housing Assembly .08 0.56 MIN MAX 0.25 in MIN MAX 0. (Big Cam IV and New Big Cam IV) 44.115 0.7525 Bypass Thermostat Seat Bore I.

35 6.630 • Radiator Thermostat 5.185 0. Point Bypass Thermostat Seat O.03 5.312 • 49 State Engine (EPA Certified) 3.513 MIN MAX 1.55 66.Operating Temperature Page 59 Ref.D.70 5.630 • Bypass Thermostat 66. mm in Thermostat Rectangular Seal Bore I.18 3.55 66.80 MIN MAX 2.92 MIN MAX 0.87 7.255 • 50 State Engine (EPA and CARB Certified) 7.80 MIN MAX 2.13 MIN MAX 0.202 Thermostat Rectangular Seal Bore Depth .com Specifications NT855 Part or Assembly Thermostat (Reserve Flow Cooling) .too1s. (Big Cam IV and New Big Cam IV) mm in 44.00 MIN MAX 0.7505 1.08 mm MAX MAX 200°F 0.03 5.125 0.620 2. Point Degree °C Degree °F Thermostat (Reserve Flow Cooling) .Operating Temperature Optimized Aftercooling Thermostat: • Initial Opening Temperature • Fully Open Temperature • Maximum Open Distance Part or Assembly Ref.7525 • 49 State Engine (EPA Certified) 6.462 44.620 2.140 • 50 State Engine (EPA and CARB Certified) 4.D.202 • Bypass Thermostat 5.197 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.198 0.200 in.www.56 MIN MAX 0.13 MIN MAX 0. • Radiator Thermostat 66.250 0.198 0.48 MIN MAX 0.310 0. Point 87°C 89°C MIN MAX 188°F 192°F 93°C 5.

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.too1s. Water Transfer Tube Clamp Capscrews (Big Cam IV and New Big Cam IV) 45 35 Thermostat Cover Capscrews (88 Big Cam IV) 45 35 .www.

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 .www.too1s.

0030 1.3765 1. .Rebuild Specifications Page 62 Part or Assembly Specifications NT855 Ref.963 34.425 25.321 2.0010 1. Hub Coupling I.0015 34.002 0.D.com Fuel Pump and Compressor Drive . Drive Pulley Bore I.476 25.274 33.0000 1.325 MIN MAX 1.489 25.662 39.D.3100 1.751 MIN MAX 1.976 MIN MAX 1.D. Thrust Bearing Thickness Drive Shaft Journal O.3752 1.3770 2 39.012 33.5650 Drive Housing Bushing Bore I. Point mm in Fuel Pump and Compressor Drive .too1s.400 25.5620 3 33.950 MIN MAX 1.43 33. Drive Gear Bore I.5642 1.www.930 34.D.3120 4 25.41 MIN MAX 0.674 MIN MAX 1.090 0.0010 1.3760 39.095 1 34.55 MIN MAX 1.730 39.Rebuild Specifications Drive Shaft End Clearance 0. Splined Coupling I.29 2.30 MIN MAX 0.425 25.05 0.0035 1.438 MIN MAX MIN MAX MIN MAX 1.D.D.316 1.5615 1.

D. Point mm in Drive Shaft Gear Fit Journal O.5665 1.814 MIN MAX 1.001 Accessory Drive Pulley Wear Sleeve Fit Area O. Part or Assembly Step Torque Values N•m ft-lb Fuel Pump and Compressor Drive .5675 Drive Housing Bushing Bore I.Torque Values Page 63 Ref.www.447 50.D.789 39.D. 36.73 36.999 2. 39.77 50.82 MIN MAX 1.Torque Values Accessory Drive Housing Capscrew 45 35 Accessory Drive Housing Pipe Plug 8 75 in-lb .446 1.75 MIN MAX 1.com Specifications NT855 Part or Assembly Fuel Pump and Compressor Drive .too1s.

BHT3B/HT3B 0.Inspection Specifications Turbocharger Shaft End Clearance Model No.15 MAX 0.53 MAX 0. Bulletin Nos. Air Compressor .002 0.www. 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. 3810230 or 3810241.53 MAX 0. BHT3B/HT3B BHT4C/HT4B Turbocharger Compressor Impeller Radial Clearance Model No.03 0.008 0. Use two mounting nuts locked together to tighten the studs.008 Note: Specifications and instructions for rebuilding the two cylinder air compressor are provided in the Air Equipment Rebuild Manual. .004 0.021 BHT4C/HT4B 0.018 0.018 Turbocharger Turbine Wheel Radial Clearance Model No. 3810242. BHT3B/HT3B BHT4C/HT4B 0. Bulletin No.20 MIN 0.com Turbocharger .46 MIN MAX MIN MAX 0.002 0. Two Cylinder Air Compressor Crankshaft End Clearance 0.021 Note: Specifications and instructions for rebuilding the turbocharger are provided in the Turbocharger Component Shop Manuals.05 MIN 0.002 0.005 0.05 0.46 0.05 MIN 0.too1s.Inspection Specifications Single Cylinder Air Compressor Crankshaft End Clearance 0.10 0.19 MAX 0.13 MIN MAX MIN MAX 0. 3810257.006 Note: Specifications and instructions for rebuilding the single cylinder air compressor are provided in the Air Equipment Rebuild Manual. Bulletin No.Inspection Specifications Page 64 Part or Assembly Specifications NT855 Ref.001 0. for Holset turbochargers.20 MIN 0.15 0.006 0. Point mm in Turbocharger .15 0.006 0.008 0.

Rebuild Specifications Note: The specifications and instructions for rebuilding the JacobsT Brake are provided in the JacobsT Brake Installation Manual.too1s. in the NT855 Shop Manual. in the NT855 Shop Manual.Group 14. Vehicle Braking .Test Specifications Page 65 Engine Testing .Test Specifications Note: The specifications and instructions for testing the engine are provided in Engine Testing .www. Bulletin No. Bulletin No.Group 20. 3810395. . page 14-1. 3810395. Refer to Vehicle Braking . page 20-1.com Specifications NT855 Engine Testing .

163 to -0.68 -0.75 to -1.41 -0.13 to -2. 3021601 3021596 3021596 3021597 3021601 3022353 3022352 3021594 3021601 3021601 3021594 3021592 3022352 3021601 3022352 3021601 3021601 Amount of Offset 0.161 mm [0.26 to -2.064 to -0.007 inch] of gasket thickness affects injection timing by approximately 0.35 to -3.00 0.00 0.084 to -0.14 to -4.094 to -0.104 -2.80 -0.90 -0.53 -0.64 -0.071 -1.58 mm [0.00 0.096 -2.073 to -0.85 to -1.0185 0.59 to -2.165 -3.2032 inch] BTDC piston travel.069 to -0.066 -1.0310 0.128 Camshaft Key Part No.094 to -0.75 to -1.089 to -0.0390 0.213 -3.096 -4.’’ This travel represents the injection timing value.211 to -0. for a complete up-to-date timing code list.37 to -1.075 -1. Bulletin No.00 0.0185 0.054 to -0.59 -0. .091 -2. 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 -1.36 to -5.069 to -0.100 to -0.63 to -1.www. Each 0.137 to -0.40 -0. Note: The injection timing can be changed by removing the cam follower housing and by increasing or decreasing the gasket thickness.105 -2.056 -1.071 -2.127 to -0.0185 0.0255 0. In the example shown. the value is 0.132 to -0.0185 0.19 -0.102 -5.18 mm [0.00 0. 3379133.too1s.139 -3.05 mm [0.25 -0.18 -0.0115 0.102 to -0.44 -0.00 0.48 to -3.42 -0.23 to -3.39 to -2.54 to -2.134 -2.103 to -0.67 -0.0255 0.002 inch] indicator travel.44 -0.0185 0.com Injection Timing Codes Page 66 Specifications NT855 Injection Timing Codes Note: Injection timing is measured at 5.31 -0.086 -2.023 in].62 to -2. Read the push rod travel gauge counterclockwise from ‘‘0.80 -0.00 * Refer to the Control Parts List Manual.39 to -2.

tighten the belt to the maximum value. Belt Tension Gauge Part No.380 3822524 N/A 620 140 270 490 MIN MAX 60 110 .www. Click-Type Burroughs Belt Tension .com Specifications NT855 Drive Belt Tension Specifications Page 67 Drive Belt Tension Specifications SAE Belt Width in.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. If the belt tension is less than the minimum value.New Belt Tension .Used* N lbf N lbf . .too1s.

) lb kilograms kg 0. liter l 3.S. CUSTOMARY METRIC FROM U.7853 0.219976 cubic inch in3 liter l 0.01639 61.204623 Torque Volume: liquid displacement Weight (mass) * British measurement .S.3769 0.) gal. CUSTOMARY MULTIPLY BY Abbr. Area sq.019299 inches of mercury in-Hg millimeters of mercury mm-Hg 25.546 0.com Weights and Measures . inch in2 sq.2488 4.039370 pound force per foot lb-ft Newton-Meter N•m 1.40 0. CUSTOMARY TO METRIC MULTIPLY BY Unit Name Unit Name Abbr.40 0. millimeters m2 645.039370 inches of water in-H20 millimeters of water mm-H20 25.4536 2.29613 inches of mercury in-Hg kilopascal kPa 3. liter l 4.16 0.4482 0.264179 gallon (Imp*) gal.S.224809 Length inch in millimeters mm 25.02545 pound (avoir.40 0.35582 0.www.Conversion Factors Page 68 Specifications NT855 Weights and Measures .29613 inches of water in-H20 kilopascal kPa 0.113 8.737562 pound force per inch lb-in Newton-Meter N•m 0.S. inch psi kilopascal kPa 3.too1s.3769 0.Conversion Factors QUANTITY U. FROM METRIC TO U.001550 Force pounds force lbf Newton N 4.039370 Pressure pounds force per sq.850756 gallon (U.

55625 0.484375 31/64 25.46875 15/32 24.71562 0.265625 17/64 19.68437 0.76250 0.82812 0.84375 27/32 9.65312 0.00 1/64 Metric mm Decimal in Fractions 13.www.70000 0.21875 7/32 18.71875 23/32 5.625 3.34375 11/32 21.828125 53/64 8.93750 0.too1s.078125 5/64 14.28125 9/32 19.1875 3/16 17.90625 29/32 10.98437 0.8125 13/16 8.Conversion Factors Page 69 Decimal and Metric .0625 1/16 14.63750 0.25625 0.296875 19/64 20.578125 37/64 2.44687 0.87500 0.671875 43/64 4.12812 0.250 1/4 19.328125 21/64 21.38125 0.33437 0.53125 17/32 1.19062 0.015625 0.14375 0.453125 29/64 24.203125 13/64 17.125 1/8 15.140625 9/64 16.81250 0.15937 0.234375 15/64 18.90625 0.27187 0.Conversion Factors Metric mm Decimal in Fractions 0.08125 0.890625 57/64 10.03437 0.171875 11/64 17.22500 0.875 9.390625 25/64 22.546875 35/64 1.03125 1/32 13.73125 0.89062 0.703125 45/64 5.59375 19/32 2.921875 59/64 11.24062 0.15625 5/32 16.765625 49/64 7.74687 0.95312 0.77812 0.00312 0.36562 0.375 3/8 22.96875 0.05000 0.984375 63/64 12.57187 0.09375 3/32 15.66875 0.859375 55/64 9.9375 15/16 11.953125 61/64 11.20937 0.3125 5/16 20.1750 0.85937 0.609375 39/64 3.84375 0.6875 11/16 5.49375 0.796875 51/64 7.5625 1.50937 0.40000 1.40625 13/32 23.com Specifications NT855 Decimal and Metric .359375 23/64 21.79375 0.734375 47/64 6.640625 41/64 3.09687 0.30312 0.109375 7/64 15.52500 0.96875 31/32 12.92187 0.046875 3/64 13.58750 0.39688 0.4375 7/16 23.54062 0.421875 27/64 23.500 1/2 25.31875 0.750 6.41562 0.11250 0.43125 0.35000 0.46250 0.515625 33/64 9/16 5/8 3/4 7/8 1 .28750 0.47812 0.60625 0.65625 21/32 4.01875 0.78125 25/32 7.06562 0.62187 0.

803. divide Newton-Meters by 9.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.too1s. .www.

Capscrew Markings and Torque Values .(Thread) 1/4 .18 5/8 .10 .20 1/2 .20 .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 .11 .com Specifications NT855 Capscrew Markings and Torque Values Page 71 Capscrew Markings and Torque Values Caution: When replacing capscrews.16 . Customary SAE Grade Number Capscrew Head Markings These are all SAE Grade 5 (3) line Capscrew Body Size (Inches) . 3. always use a capscrew of the same measurement and strength as the capscrew being replaced. 5 Capscrew Torque . Do not use the torque values in place of those specified in other sections of this manual. The table below lists the capscrew markings and the correct value for the capscrew.14 1.14 . Always use the torque values listed in the following table when specific torque values are not available.U. It is important to use the correct torque values for SAE grade 5 and 8 capscrews. SAE capscrews are graded according to the strength of the capscrew.20 9/16 .16 7/8 .13 .24 7/16 .14 Refer to the notes above.12 . SAE capscrews are identified by: U.S.8 .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 .too1s.24 3/8 . They are marked on the head so the correct strength and torque value are known.9 . 2.18 3/4 .S.28 5/16 . Using incorrect capscrews can result in engine damage. The torque values in the table are based on the use of lubricated threads.18 . 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.www.

41 13.32 42.7 1.66 48.54 17.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.2 1.too1s.6 0.32 10.3 1.4 0.3 0.90 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 .D.68 21.5 1.85 26.7 0.www. mm in 8.05 33.1 0.

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 .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. New Big Cam IV. T-46. 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. Canada. and 88 Big Cam IV NT855 Engines 3810387 3810395 3822017 Analysis and Prevention of Bearing Failures Shop Manual Big Cam IV. and 88 Big Cam IV.. New Zealand.Big Cam IV.S.A. T-50. Australia. T-35. New Big Cam IV.www. 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 .Step Timing Control Shop Manual 3810316 PACE Master Repair Manual 3810366 Troubleshooting and Repair Manual .too1s. VT-50. 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.

IN 47201 . Inc. Columbus.. Inc. Inc. Mid-East. Inc.B. Literature Center 100-G Pasir Panjang Road Singapore 0511 Australia and New Zealand Cummins Diesel Australia Maroondah Highway. Australia All Regions (for Service Products Catalog only) Service Products Company. KY 40232-4470 U. and Eastern European Countries Cummins Daventry Royal Oak Way South Northants. refer to the addresses listed below: Region Ordering Location United States and Canada Gannett Direct Marketing Services. Africa.too1s.www.O. Mail Code 40700 1460 National Road Columbus. Europe. 139 Ringwood 3134 Victoria.com Service Literature Ordering Location Page 74 Specifications NT855 Service Literature Ordering Location Order service literature from your nearest regional location. Mail Code 40931 Cummins Engine Company. Box 34470 Louisville. O. England NN11 5NU South and Central America (excluding Brazil and Mexico) Cummins Americas. 3400 Robards Court P.K. P. FL 33104 Brazil and Mexico International Parts Order Dept. 16085 Northwest 52nd Avenue Hialeah. IN 47202-3005 Far East (excluding Australia and New Zealand) Cummins Diesel Sales Corp.

.........Rebuild Specifications ...Rebuild Specifications....... 0-5 Injection Timing Codes ..................... 0-7 Cummins Engine Brake .....Rebuild Specifications .......................................................... 0-45 Fixed Injection Timing ........... 0-6 Exhaust System.......................... 0-51 Fuel Pump and Compressor Drive ........Rebuild Specifications ............. 0-74 Specifications . 0-4 Thermostat Housing Assembly ........................ 0-64 Valve and Injector Adjustments* .......................................... 0-5 Lubrication System ..............................com Specifications NT855 Additional Service Literature ...................................................................Test Specifications ................................................. 0-71 Cooling System -Torque Values............... 0-7 Vehicle Braking ......Inspection Specifications .................................................. 0-69 Drive Belt Tension Specifications ...................................... 0-37 Cylinder Head .............. 0-64 Cam Follower Assembly ........... 0-67 Engine Assembly ...................................Capscrew Torque Values .............................. 0-62 Fuel Pump and Compressor Drive .......Rebuild Specifications ..... 0-7 Valves ............ 0-66 Injectors .................... 0-57 Fuel Pump .................................. 0-45 MVT Injection Timing ............................................. 0-59 Turbocharger ..Torque Values .......Torque Values .................... 0-56 Weights and Measures ...................................................................................................................Torque Values ...............................Capacities...............too1s.......................... 0-9 Engine Diagrams ....Specifications .................................................................. 0-5 Intake System.................... 0-2 Engine Identification ......................................... 0-52 Lubricating Oil System .........................................................................Rebuild Specifications........ 0-73 Air Compressor ......... 0-72 Rocker Lever Housing Assembly .... 0-43 Rocker Lever Housing Assembly ...................U.......................................... 0-45 Cam Follower Assembly .................... 0-7 Crosshead Adjustment... 0-51 Lubricating Oil Pump ........................... 0-29 Cylinder Block ............................. Customary ........ 0-71 Capscrew Markings and Torque Values ......... 0-1 Engine Testing ..............www............................................................ 0-63 General Engine Specifications ................................................................... 0-44 Service Literature Ordering Location .............................................. 0-50 Capscrew Markings and Torque Values ................................................................................ 0-65 Water Pump Assembly .......................................... 0-65 Fan Hub ..................................Rebuild Specifications ..S................. 0-6 General Engine Data ..........Torque Values ...... 0-6 Fuel System ....General Information ......................................................................... 0-52 Lubricating Oil System ...................... 0-14 Engine Assembly ............Conversion Factors .....................................................................Inspection Specifications......................................................... 0-38 Cylinder Head ............ 0-42 Decimal and Metric ............................ 0-70 Pipe Plug Torque Values................Rebuild Specifications ............................................................................... 0-58 Thermostat (Reserve Flow Cooling) ...................... 0-6 Electrical System .................................Inspection Specifications ...................Torque Values................................ 0-7 JacobsT Engine Brake ... 0-5 Cooling System ........................ 0-54 Newton-Meter to Foot-Pound Conversion Chart ............................ 0-60 Cylinder Block .......................Torque Values ................................................Conversion Factors...Rebuild Specifications ............................................................Rebuild Specifications ....................................................Inspection Specifications ......................... 0-7 Injector Preload (Top Stop) ...Operating Temperature...... 0-68 Index Page 75 ..........................

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