Cummins NTC 400 Big Cam I III Official Workshop Service Repair Manual

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This is the COMPLETE Official Service Repair Manual for the Cummins Engine.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Cummins.

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This Manual contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes, which give you complete step by step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop.

Models And Serials :

ENGINE, DIESEL: 6 CYLINDER
IN-LINE, TURBOCHARGED,
CUMMINS MODEL NTC-400
M915-M920 AND
M915A4*/BIG CAM I
(NSN 2815-01-082-8125)
M915A1 AND M915A4*/BIG CAM III
(NSN 2815-01-142-2745)

CONTENTS :

HOW TO USE THIS MANUAL
CHAPTER 1 INTRODUCTION
Section I. GENERAL INFORMATION
1-1.Overview
1-2. Scope
1-3.Maintenance Forms, Records, and Reports
1-4. Destruction of Army Materiel to Prevent Enemy Use
1-5.Preparation for Storage and Shipment
1-6. Reporting Equipment Improvement Recommendations (EIRs)
1-7. Warranty Information
Section II. EQUIPMENT DESCRIPTION AND DATA
1-8.Equipment Characteristics, Capabilities, and Features
1-9.Location and Description of Major Components
1-10.Equipment Data
CHAPTER 2 SERVICE AND TROUBLESHOOTING INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE,AND SUPPORT EQUIPMENT
2-1.Overview
2-2. Common Tools and Equipment
2-3.Special Tools, TMDE, and Support Equipment
2-4.Repair Parts
Section II. SERVICE UPON RECEIPT OF EQUIPMENT
2-5. Engine Inspection
Section III. TROUBLESHOOTING
2-6.General
2-7. Troubleshooting Symptom Index
2-8. Mechanical Troubleshooting
CHAPTER 3 MAINTENANCE
Section I. GENERAL MAINTENANCE INSTRUCTIONS
3-1.Overview
3-2.General
3-3. Task Summary
3-4. Lifting Engine
3-5.Draining Engine
3-6.Cleaning
3-7.Inspection
3-8.Wear Limits and Tolerances
3-9.Repair
3-10. Assembly
Section II. DISASSEMBLY
3-11.General
3-12. Task Summary
3-13. Mounting Engine on Maintenance Stand
3-14. Vibration Damper and Crankshaft Pulley Removal
3-15. Accessory Drive Pulley Removal
3-16. Fuel Pump Removal
3-17. Air Compressor Removal
3-18.Accessory Drive Housing Assembly Removal
3-19. Oil Pump Removal
3-20. Air Aftercooler Removal
3-21. Engine Retarder Removal
3-22. Rocker Arm Housing Assembly and Pushrods Removal
3-23.Injector Assembly Removal
3-24. Cylinder Head Assembly Removal
3-25.Flexplate or Flywheel, Flywheel Housing, and Rear Cover Removal
3-26. Oil Pan Removal
3-27. Front Gear Cover Removal
3-28. Cam Follower Assemblies and Camshaft Removal
3-29. Piston, Connecting Rod, and Bearings Removal
3-30. Cylinder Liner Removal
3-31. Engine Crankshaft and Main Bearings Removal
Section III. REPAIR
3-32. General
3-33. Task Summary
3-34. Engine Block Repair
3-35. Cylinder Head and Valve Repair
3-36. Vibration Damper and Crankshaft Pulley Repair
3-37. Crankshaft Repair
3-38. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Repair
3-39. Piston, Connecting Rod, and Bearing Repair
3-40. Camshaft, Cam Follower, and Pushrod Repair
3-41. Rocker Levers and Housing Repair
3-42. Oil Cooler Repair
3-43. Oil Pan, Dipstick, Oil Suction Tubes, and Dipstick Tube Repair
3-44. Oil Pump Repair
3-45. Air Aftercooler Repair
3-46. Exhaust Manifold Repair
3-47. Turbocharger Repair
3-48. Front Gear Cover Repair
3-49. Accessory Drive Repair
3-50. Engine Retarder Repair
3-51. Air Compressor Repair
3-52. Fuel Injector Repair
3-53. Fuel Injector Testing; Test No. 1
3-54. Fuel Injector Testing; Test No. 2
3-55. Fuel Injector Testing; Test No. 3
3-56. Fuel Pump Repair
3-57. Solenoid Valve Repair
3-58. Fuel Damper and Head Repair
3-59. Fuel Gear Pump Repair
3-60. Fuel Pump Governor Spring Repair
3-61. Fuel Pump Front Cover and Governor Repair
3-62. Fuel Pump Main Housing Repair
3-63. Fuel Pump Testing and Calibration
3-20. Air Aftercooler Removal
3-21. Engine Retarder Removal
3-22. Rocker Arm Housing Assembly and Pushrods Removal
3-23.Injector Assembly Removal
3-24. Cylinder Head Assembly Removal
3-25.Flexplate or Flywheel, Flywheel Housing, and Rear Cover Removal
3-26. Oil Pan Removal
3-27. Front Gear Cover Removal
3-28. Cam Follower Assemblies and Camshaft Removal
3-29. Piston, Connecting Rod, and Bearings Removal
3-30. Cylinder Liner Removal
3-31. Engine Crankshaft and Main Bearings Removal
Section III. REPAIR
3-32. General
3-33. Task Summary
3-34. Engine Block Repair
3-35. Cylinder Head and Valve Repair
3-36. Vibration Damper and Crankshaft Pulley Repair
3-37. Crankshaft Repair
3-38. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Repair
3-39. Piston, Connecting Rod, and Bearing Repair
3-40. Camshaft, Cam Follower, and Pushrod Repair
3-41. Rocker Levers and Housing Repair
3-42. Oil Cooler Repair
3-43. Oil Pan, Dipstick, Oil Suction Tubes, and Dipstick Tube Repair
3-44. Oil Pump Repair
3-45. Air Aftercooler Repair
3-46. Exhaust Manifold Repair
3-47. Turbocharger Repair
3-48. Front Gear Cover Repair
3-49. Accessory Drive Repair
3-50. Engine Retarder Repair
3-51. Air Compressor Repair
3-52. Fuel Injector Repair
3-53. Fuel Injector Testing; Test No. 1
3-54. Fuel Injector Testing; Test No. 2
3-55. Fuel Injector Testing; Test No. 3
3-56. Fuel Pump Repair
3-57. Solenoid Valve Repair
3-58. Fuel Damper and Head Repair
3-59. Fuel Gear Pump Repair
3-60. Fuel Pump Governor Spring Repair
3-61. Fuel Pump Front Cover and Governor Repair
3-62. Fuel Pump Main Housing Repair
3-63. Fuel Pump Testing and Calibration
3-64. Water Pump Repair
Section IV. ASSEMBLY
3-65. General
3-66. Task Summary
3-67. Cylinder Liner Installation
3-68. Engine Crankshaft and Main Bearings Installation
3-69. Pistons, Connecting Rod, and Bearings Installation
3-70. Cam Follower Assemblies and Camshaft Installation
3-71. Cylinder Head Assembly and Pushrods Installation
3-72. Injection Timing
3-73. Accessory Drive Housing Assembly Installation
3-74. Oil Pump Installation
3-75. Front Gear Cover Installation
3-76. Accessory Drive Pulley Installation
3-77. Air Compressor Installation
3-78. Fuel Pump Installation
3-79. Vibration Damper and Crankshaft Pulley Installation
3-80. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Installation
3-81.Oil Pan Installation
3-82.Injector Assembly Installation
3-83. Valve Crossheads Installation and Adjustment
3-84. Rocker Arm Housing Assembly Installation
3-85. Injector and Valve Adjustment
3-86. Engine Retarder Installation
3-87. Air Aftercooler Installation
3-88. Removing Engine from Maintenance Stand
Section V. TESTING
3-89.General
3-90. Task Summary
3-91. Starting Repaired Engine
3-92. Engine Dynamometer Testing
3-93. On-Engine Fuel Pump Adjustment
Section VI. STORAGE
3-94. General
3-95. Task Summary
3-96. Temporary Storage
3-97. Long-Term Storage
3-98. Preparing an Engine from Storage to Service
APPENDIX A REFERENCE
A-1.Publication Indexes
A-2. Forms
A-3.Other Publications
APPENDIX B REPAIR PARTS AND SPECIAL TOOLS LIST
Section I. INTRODUCTION
B-1. Scope
B-2. General
B-3. Explanation of Columns (Sections II and III)
B-4. Explanation of Columns (Section IV)
B-5. Special Information
B-6. How to Locate Repair Parts
Section II. REPAIR PARTS LIST
GROUP 01 ENGINE
0100 Dressed Engine and Container
0101 Engine Block
0101 Cylinder Head Assembly
0102 Crankshaft Assembly
0103Flexdisk, Ring Gear, and Housing
0104 Piston and Connecting Rod Assembly
0105 Camshaft Assembly and Followers
0105 Rocker Arm Assembly
0105 Rocker Cover
0106 Oil Cooler and Filter, M915A1 Only
0106 Oil Cooler and Filter, M915 Only
0106 Oil Pan, Dipstick, and Breather Tube
0106 Oil Lubricating Pump
0108 Air Aftercooler
0108 Exhaust Manifold
0109 Gear Cover
0109 Accessory Drive Pulley and Fan Clutch
0112 Engine Retarder
0121 Air Compressor Lines and Fittings
0121 Air Compressor and Governor Assembly
GROUP 03 FUEL SYSTEM
0301 Fuel Injector
0302 Fuel Lines and Fittings
0302 Fuel Pump
0302 Fuel Pump Main Housing
0302 Fuel Gear Pump
0305 Turbocharger and Component Parts
0305 Turbocharger Assembly
0306 Solenoid Valve
0308 Fuel Pump Front Cover, Governor, and Tach Drive
0309 Fuel Pump Damper, Head, and Fuel Filter
0311 Ether Quick-Start Kit
0312 Fuel Control Lever
PAGE
GROUP 05 COOLING SYSTEM
0503 Thermostat Housing, Water Manifold, and Component Parts
0503 Water Filter and Component Parts
0504 Water Pump and Idler
GROUP 94 REPAIR KITS
9401 Repair Kits
GROUP 95 BULK MATERIAL
9501 Bulk Material
Section III. SPECIAL TOOLS
GROUP 26 SPECIAL TOOLS
2604 Direct Support Special Tools-1
2604 Direct Support Special Tools-2
2604 Direct Support Special Tools-3
2604 Direct Support Special Tools (Supplemental)
2604 General Support Special Tools-1
2604 General Support Special Tools-2
2604 General Support Special Tools-3
2604 General Support Special Tools (Supplemental)-1
2604 General Support Special Tools (Supplemental)-2
2604 General Support Special Tools (Supplemental)-3
2604 Direct and General Support Special Tools-1
2604 Direct Support Special Tools-2
2604 Direct Support Special Tools-3
2604 General Support Special Tools-1
2604 General Support Special Tools-2
2604 General Support Special Tools-3
2604 General Support Special Tools-4
Section IV. CROSS-REFERENCE INDEXES
National Stock Number Index
Part Number Index
APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section I. INTRODUCTION
C-1. Scope
C-2. Explanation of Columns
APPENDIX D ILLUSTRATED LIST OF MANUFACTURED ITEMS
Section I. INTRODUCTION
D-1. General
D-2. Manufactured Item Part Number Index
Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS
APPENDIX E TORQUE LIMITS
Section I. STANDARD TORQUE SPECIFICATIONS
Section II. ENGINE ASSEMBLY TIGHTENING SPECIFICATIONS
APPENDIX F WEAR LIMITS AND TOLERANCES
F-1.General
F-2.Repair Standards
GLOSSARY
Section I. LIST OF ABBREVIATIONS
Section II. DEFINITION OF UNUSUAL TERMS
INDEX