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Swapping a Cummins NH220 engine with a more powerful NTA855 engine in heavy machinery is a significant undertaking that can breathe new life into aging equipment. This guide delves into the technical considerations, challenges, and real-world experiences associated with such an engine swap.
Understanding the Engines: NH220 vs. NTA855
NH220 Engine:
Key Considerations for the Engine Swap
1. Structural Modifications
The NH220 and NTA855 have different physical dimensions and mounting configurations. Modifications to the engine mounts, flywheel housing, and possibly the engine compartment may be necessary to accommodate the NTA855. For instance, when swapping a Big Cam 350 into a Komatsu track hoe, adjustments were made to the flywheel housing and rear cam seal, and the aluminum oil pan was replaced to fit the new engine configuration.
2. Transmission Compatibility
The NTA855 may require a different transmission or adapter plate to ensure proper coupling. It's crucial to verify the compatibility of the transmission with the new engine's power output and mounting configuration.
3. Cooling System Adjustments
The NTA855 generates more heat due to its increased power output. Upgrading the radiator and cooling lines is essential to prevent overheating. Additionally, replacing cooling nozzles and ensuring the oil pump suction line is compatible with the new engine's oil pan design are recommended steps.
4. Electrical and Fuel Systems
The NTA855 may have different electrical and fuel system requirements. Modifications to the wiring harness, fuel lines, and possibly the fuel tank may be necessary to accommodate the new engine's specifications.
5. Exhaust System Modifications
The exhaust manifold and routing may differ between the NH220 and NTA855. Custom fabrication of the exhaust system might be required to ensure proper fitment and compliance with emissions standards.
Real-World Experiences and Challenges
Several operators have undertaken similar engine swaps with varying degrees of success. For example, a swap of a Big Cam 400 into a B-75 truck involved using the 220 flywheel for the CL-50 clutch, drilling the clutch housing bolt holes to accommodate larger bolts, and fabricating trunnion crossmembers for the front mount.
Another instance involved swapping a Big Cam 350 into a Manitowoc crane. The original flywheel housing was retained, but adjustments were made to accommodate the push-type clutch, including shimming between the pressure plate and flywheel.
These examples highlight the importance of thorough planning and customization when undertaking an engine swap.
Potential Pitfalls and Solutions
1. Parts Availability
As equipment ages, sourcing parts for the NH220 becomes increasingly challenging. In contrast, the NTA855 has a broader parts availability, facilitating easier maintenance and repairs.
2. Cost Implications
While the NTA855 offers enhanced performance, the cost of the engine, modifications, and labor can be substantial. It's essential to weigh the benefits against the costs to determine if the upgrade is financially viable.
3. Downtime
The engine swap process can lead to significant downtime for the equipment. Planning for this downtime and having contingency measures in place can mitigate operational disruptions.
Conclusion
Swapping a Cummins NH220 engine with an NTA855 can significantly enhance the performance and longevity of heavy equipment. However, the process requires careful planning, technical expertise, and a willingness to invest in necessary modifications. By addressing the structural, mechanical, and logistical challenges upfront, operators can achieve a successful engine swap that yields long-term benefits.
Understanding the Engines: NH220 vs. NTA855
NH220 Engine:
- Configuration: 6-cylinder in-line
- Displacement: Approximately 14.9 liters
- Power Output: Around 220 horsepower
- Torque: Approximately 600 lb-ft
- Common Applications: Agricultural machinery, marine engines, and older construction equipment
- Configuration: 6-cylinder in-line
- Displacement: Approximately 14.0 liters
- Power Output: Ranges from 250 to 400 horsepower, depending on the variant
- Torque: Varies with power output
- Common Applications: Construction equipment, trucks, and industrial applications
Key Considerations for the Engine Swap
1. Structural Modifications
The NH220 and NTA855 have different physical dimensions and mounting configurations. Modifications to the engine mounts, flywheel housing, and possibly the engine compartment may be necessary to accommodate the NTA855. For instance, when swapping a Big Cam 350 into a Komatsu track hoe, adjustments were made to the flywheel housing and rear cam seal, and the aluminum oil pan was replaced to fit the new engine configuration.
2. Transmission Compatibility
The NTA855 may require a different transmission or adapter plate to ensure proper coupling. It's crucial to verify the compatibility of the transmission with the new engine's power output and mounting configuration.
3. Cooling System Adjustments
The NTA855 generates more heat due to its increased power output. Upgrading the radiator and cooling lines is essential to prevent overheating. Additionally, replacing cooling nozzles and ensuring the oil pump suction line is compatible with the new engine's oil pan design are recommended steps.
4. Electrical and Fuel Systems
The NTA855 may have different electrical and fuel system requirements. Modifications to the wiring harness, fuel lines, and possibly the fuel tank may be necessary to accommodate the new engine's specifications.
5. Exhaust System Modifications
The exhaust manifold and routing may differ between the NH220 and NTA855. Custom fabrication of the exhaust system might be required to ensure proper fitment and compliance with emissions standards.
Real-World Experiences and Challenges
Several operators have undertaken similar engine swaps with varying degrees of success. For example, a swap of a Big Cam 400 into a B-75 truck involved using the 220 flywheel for the CL-50 clutch, drilling the clutch housing bolt holes to accommodate larger bolts, and fabricating trunnion crossmembers for the front mount.
Another instance involved swapping a Big Cam 350 into a Manitowoc crane. The original flywheel housing was retained, but adjustments were made to accommodate the push-type clutch, including shimming between the pressure plate and flywheel.
These examples highlight the importance of thorough planning and customization when undertaking an engine swap.
Potential Pitfalls and Solutions
1. Parts Availability
As equipment ages, sourcing parts for the NH220 becomes increasingly challenging. In contrast, the NTA855 has a broader parts availability, facilitating easier maintenance and repairs.
2. Cost Implications
While the NTA855 offers enhanced performance, the cost of the engine, modifications, and labor can be substantial. It's essential to weigh the benefits against the costs to determine if the upgrade is financially viable.
3. Downtime
The engine swap process can lead to significant downtime for the equipment. Planning for this downtime and having contingency measures in place can mitigate operational disruptions.
Conclusion
Swapping a Cummins NH220 engine with an NTA855 can significantly enhance the performance and longevity of heavy equipment. However, the process requires careful planning, technical expertise, and a willingness to invest in necessary modifications. By addressing the structural, mechanical, and logistical challenges upfront, operators can achieve a successful engine swap that yields long-term benefits.
