Cummins Big Cam I Big Cam Iii Shop Manual

Full download: http://manualplace.com/download/cummins-big-cam-i-big-cam-iii-shop-manual/

TM 9-2815-225-34&P

Supersedes TM 9-2815-225-34&P-1, TM 9-2815-225-34&P-2,

TM 9-2815-222-34&P and all changes.

DIRECT SUPPORT AND GENERAL SUPPORT (DS/GS)

MAINTENANCE MANUAL INCLUDING
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) HOW TO USE THIS MANUAL viii
FOR
GENERAL INFORMATION 1-1
ENGINE, DIESEL: 6 CYLINDER
IN-LINE, TURBOCHARGED,
CUMMINS MODEL NTC-400 EQUIPMENT DESCRIPTION AND DATA 1-2
M915-M920 AND
M915A4*/BIG CAM I
(NSN 2815-01-082-8125) SERVICE UPON RECEIPT 2-1
M915A1 AND M915A4*/BIG CAM III
(NSN 2815-01-142-2745)
TROUBLESHOOTING 2-2

GENERAL MAINTENANCE
3-1
INSTRUCTIONS

TESTING 3-672

REPAIR PARTS AND SPECIAL TOOLS LIST B-1

EXPENDABLE SUPPLIES AND

C-1
MATERIALS LIST

TORQUE LIMITS E-1

BIG CAM II SHOWN

* M915A4 TRUCKS WILL BE EQUIPPED WITH WEAR LIMITS AND TOLERANCES F-1
EITHER BIG CAM I OR BIG CAM III ENGINES

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

AUGUST 2001

This is the cut pages sample. Download all 940 page(s) at: ManualPlace.com
 TM 9-2815-225-34&P

WARNING

CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU

Carbon monoxide is without color or smell, but can kill you. Breathing air with carbon monoxide produces symptoms of
headache, dizziness, loss of muscular control, a sleepy feeling, and coma. Brain damage or death can result from heavy
exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning heaters and internal combustion engines. Carbon
monoxide can become dangerously concentrated under conditions of no air movement. Precautions must be followed to
ensure crew safety when the personnel heater or engine of any vehicle is operated for any purpose.

1. DO NOT operate personnel heater or engine of vehicle in a closed place unless the place has a lot of moving air.

2. DO NOT idle engine for long periods without ventilator blower operating.

3. DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors removed unless
necessary for maintenance purposes.

4. BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms. If either is present,
IMMEDIATELY VENTILATE personnel compartments. If symptoms persist, remove affected crew to fresh air; keep
warm; DO NOT PERMIT PHYSICAL EXERCISE. If necessary, give artificial respiration. FOR ARTIFICIAL
RESPIRATION, REFER TO FM 21-11.

5. BE AWARE: the field protective mask for Chemical-Biological-Radiological (CBR) protection will not protect you
from carbon monoxide poisoning.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION.

WARNING SUMMARY

• Compressed air used for cleaning purposes will not exceed 30 psi. Use only with effective chip guarding and
protective equipment such as goggles or shield, gloves, etc. Failure to comply may result in injury to personnel.

• Wear heat-resistant gloves when handling heated crankshaft gear. Failure to comply may result in injury to
personnel.

• Perform operation out of doors or in a well-ventilated room. Failure to comply may result in injury to personnel.

• Remove pressure regulator assembly slowly to prevent spring tension from shooting assembly from oil pump body.
Wear eye protection. Failure to comply may result in damage to equipment or injury to personnel.

• Eye protection must be worn when using wire brush for cleaning. Failure to comply may result in injury to personnel.

• The machined edges on turbine wheel are very sharp. Wear protective gloves. Failure to comply may result in injury
to personnel.

• Wear rubber gloves when removing piston pin to prevent burns from boiling water or hot piston. Failure to comply
may result in injury to personnel.

• Control valve cover is under pressure from control valve outer spring. Wear suitable eye protection and hold cover
down when removing screw and cover. Failure to comply may result in injury to personnel.

Warning a
 TM 9-2815-225-34&P

WARNING SUMMARY (Contd)

• Improper cleaning methods and use of unauthorized cleaning solvents will not be used. Refer to
TM 9-247 for proper cleaning methods and solvents. Failure to comply may result in damage to equipment or injury
to personnel.

• The stamped steel oil pan on M915A1/Big Cam III or on M915/Big Cam I engines must not be used to support weight
of engine; the pan will permanently deform and may collapse, allowing engine to fall over. Failure to comply may
result in damage to equipment and injury to personnel.

• All personnel must stand clear during lifting operations. A snapped chain or swinging or shifting load may result in
injury to personnel.

• Use extreme caution during disassembly or assembly; engine components are heavy. Failure to comply may result
in damage to equipment or injury to personnel.

• Operation of a deadlined vehicle without preliminary inspection will cause further damage to a malfunctioning
component and possible injury to personnel.

• Approved solvents may be flammable and will not be used near open flame. Use only in well-ventilated area. Failure
to comply may result in injury to personnel.

• Do not perform fuel system procedures while smoking or within 50 ft (15.2 m) of sparks or open flame. Diesel fuel is
flammable and may explode. Failure to comply may result in injury to personnel.

• Allow adequate ventilation for engine exhaust gases. Failure to comply may result in brain damage or death to
personnel.

Warning b
 TM 9-2815-225-34&P

LIST OF EFFECTIVE PAGES

REVISION SUPERSEDES COPIES DATED DECEMBER 1983, INCLUDING ALL CHANGES.

NOTE: The portion of the test affected by the revision is listed below.

Date of issue for original:

Original ........... 0............ 28 August 2001

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 864, CONSISTING OF THE FOLLOWING:

Page No .................................. *Change No. Page No............................ *Change No.

Warning a - Warning b................................0 52-2 Blank...........................................0
A ...............................................................0 I-1 - I-44 ..............................................0
B Blank......................................................0 C-1 - C-4.............................................0
i - xi ...........................................................0 D-1 - D-4.............................................0
xii Blank .....................................................0 E-1 - E-4 .............................................0
1-1 - 1-6.....................................................0 F-1 - F-5..............................................0
2-1 - 2-10...................................................0 F-6 Blank ............................................0
3-1 - 3-537 .................................................0 Glossary 1...........................................0
3-538 Blank ...............................................0 Glossary 2 Blank .................................0
3-539 - 3-706 .............................................0 Index 1 - Index 6..................................0
A-1 - A-2 ....................................................0
B-1 - B-5 ....................................................0
Figure 1 - Page 52-1 ..................................0

*Zero in this column indicates original page.

A/(B blank)
 *TM 9-2815-225-34&P

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
NO. 9-2815-225-34&P Washington, D.C., 28 August 2001

DIRECT SUPPORT AND GENERAL SUPPORT (DS/GS)

MAINTENANCE MANUAL INCLUDING
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)
FOR
ENGINE, DIESEL: 6 CYLINDER IN-LINE,
TURBOCHARGED, CUMMINS MODEL NTC-400
M915-M920/BIG CAM I (NSN 2815-01-082-8125)
M915A1/BIG CAM III (NSN 2815-01-142-2745)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve
the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to
Publications and Blank Forms), through the Internet, on the Army Electronic Product Support
(AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need a password, scroll
down and click on "ACCESS REQUEST FORM". The DA Form 2028 is located in the ONLINE
FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this
form on the AEPS will enable us to respond quicker to your comments and better manage the DA
Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to:
AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The
email address is [email protected]. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

TABLE OF CONTENTS
PAGE
HOW TO USE THIS MANUAL ....................................................................................................................viii

CHAPTER 1 INTRODUCTION ........................................................................................................................................1-1

Section I. GENERAL INFORMATION..........................................................................................................................1-1

1-1. Overview ....................................................................................................................................................1-1

1-2. Scope .........................................................................................................................................................1-1
1-3. Maintenance Forms, Records, and Reports .................................................................................................1-1
1-4. Destruction of Army Materiel to Prevent Enemy Use ....................................................................................1-1
1-5. Preparation for Storage and Shipment .........................................................................................................1-2
1-6. Reporting Equipment Improvement Recommendations (EIRs) .....................................................................1-2
1-7. Warranty Information ..................................................................................................................................1-2

* This manual supersedes TM 9-2815-225-34&P-1, TM 9-2815-225-34&P-2, dated Dec 1983 and TM 9-2815-222-34&P dated Dec
1980 and all changes.

i
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TABLE OF CONTENTS (Contd)

PAGE

Section II. EQUIPMENT DESCRIPTION AND DATA ....................................................................................................1-2

1-8. Equipment Characteristics, Capabilities, and Features .................................................................................1-2

1-9. Location and Description of Major Components ...........................................................................................1-3
1-10. Equipment Data ..........................................................................................................................................1-5

CHAPTER 2 SERVICE AND TROUBLESHOOTING INSTRUCTIONS..............................................................................2-1

Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE,

AND SUPPORT EQUIPMENT ....................................................................................................................2-1

2-1. Overview ....................................................................................................................................................2-1

2-2. Common Tools and Equipment ...................................................................................................................2-1
2-3. Special Tools, TMDE, and Support Equipment .............................................................................................2-1
2-4. Repair Parts ...............................................................................................................................................2-1

Section II. SERVICE UPON RECEIPT OF EQUIPMENT...............................................................................................2-1

2-5. Engine Inspection .......................................................................................................................................2-1

Section III. TROUBLESHOOTING ................................................................................................................................2-2

2-6. General ......................................................................................................................................................2-2

2-7. Troubleshooting Symptom Index .................................................................................................................2-3
2-8. Mechanical Troubleshooting .......................................................................................................................2-3

CHAPTER 3 MAINTENANCE..........................................................................................................................................3-1

Section I. GENERAL MAINTENANCE INSTRUCTIONS .............................................................................................3-1

3-1. Overview ....................................................................................................................................................3-1

3-2. General ......................................................................................................................................................3-1
3-3. Task Summary ...........................................................................................................................................3-2
3-4. Lifting Engine .............................................................................................................................................3-3
3-5. Draining Engine...........................................................................................................................................3-3
3-6. Cleaning .....................................................................................................................................................3-3
3-7. Inspection ..................................................................................................................................................3-4
3-8. Wear Limits and Tolerances.........................................................................................................................3-5
3-9. Repair ........................................................................................................................................................3-5
3-10. Assembly ...................................................................................................................................................3-7

Section II. DISASSEMBLY...........................................................................................................................................3-8

3-11. General ......................................................................................................................................................3-8

3-12. Task Summary ...........................................................................................................................................3-8
3-13. Mounting Engine on Maintenance Stand ......................................................................................................3-10
3-14. Vibration Damper and Crankshaft Pulley Removal .......................................................................................3-26
3-15. Accessory Drive Pulley Removal .................................................................................................................3-28
3-16. Fuel Pump Removal ....................................................................................................................................3-30
3-17. Air Compressor Removal.............................................................................................................................3-36
3-18. Accessory Drive Housing Assembly Removal ..............................................................................................3-40
3-19. Oil Pump Removal ......................................................................................................................................3-42

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TABLE OF CONTENTS (Contd)

PAGE

3-20. Air Aftercooler Removal...............................................................................................................................3-46

3-21. Engine Retarder Removal............................................................................................................................3-48
3-22. Rocker Arm Housing Assembly and Pushrods Removal ..............................................................................3-50
3-23. Injector Assembly Removal .........................................................................................................................3-52
3-24. Cylinder Head Assembly Removal ..............................................................................................................3-54
3-25. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Removal .............................................................3-56
3-26. Oil Pan Removal .........................................................................................................................................3-62
3-27. Front Gear Cover Removal .........................................................................................................................3-64
3-28. Cam Follower Assemblies and Camshaft Removal ......................................................................................3-66
3-29. Piston, Connecting Rod, and Bearings Removal ..........................................................................................3-68
3-30. Cylinder Liner Removal ...............................................................................................................................3-72
3-31. Engine Crankshaft and Main Bearings Removal ..........................................................................................3-74

Section III. REPAIR .....................................................................................................................................................3-78

3-32. General ......................................................................................................................................................3-78

3-33. Task Summary ...........................................................................................................................................3-78
3-34. Engine Block Repair ...................................................................................................................................3-85
3-35. Cylinder Head and Valve Repair .................................................................................................................3-112
3-36. Vibration Damper and Crankshaft Pulley Repair ..........................................................................................3-148
3-37. Crankshaft Repair ......................................................................................................................................3-150
3-38. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Repair .................................................................3-170
3-39. Piston, Connecting Rod, and Bearing Repair ...............................................................................................3-174
3-40. Camshaft, Cam Follower, and Pushrod Repair ............................................................................................3-188
3-41. Rocker Levers and Housing Repair .............................................................................................................3-208
3-42. Oil Cooler Repair ........................................................................................................................................3-218
3-43. Oil Pan, Dipstick, Oil Suction Tubes, and Dipstick Tube Repair ....................................................................3-236
3-44. Oil Pump Repair .........................................................................................................................................3-246
3-45. Air Aftercooler Repair .................................................................................................................................3-264
3-46. Exhaust Manifold Repair .............................................................................................................................3-272
3-47. Turbocharger Repair ...................................................................................................................................3-276
3-48. Front Gear Cover Repair ............................................................................................................................3-292
3-49. Accessory Drive Repair ..............................................................................................................................3-296
3-50. Engine Retarder Repair ..............................................................................................................................3-304
3-51. Air Compressor Repair ...............................................................................................................................3-312
3-52. Fuel Injector Repair ....................................................................................................................................3-340
3-53. Fuel Injector Testing; Test No. 1 ..................................................................................................................3-352
3-54. Fuel Injector Testing; Test No. 2 .................................................................................................................3-258
3-55. Fuel Injector Testing; Test No. 3 .................................................................................................................3-362
3-56. Fuel Pump Repair ......................................................................................................................................3-384
3-57. Solenoid Valve Repair ................................................................................................................................3-388
3-58. Fuel Damper and Head Repair ....................................................................................................................3-394
3-59. Fuel Gear Pump Repair ..............................................................................................................................3-398
3-60. Fuel Pump Governor Spring Repair .............................................................................................................3-404
3-61. Fuel Pump Front Cover and Governor Repair ..............................................................................................3-408
3-62. Fuel Pump Main Housing Repair .................................................................................................................3-426
3-63. Fuel Pump Testing and Calibration .............................................................................................................3-448

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TABLE OF CONTENTS (Contd)

PAGE

3-64. Water Pump Repair ....................................................................................................................................3-518

Section IV. ASSEMBLY ................................................................................................................................................3-539

3-65. General ......................................................................................................................................................3-539

3-66. Task Summary ...........................................................................................................................................3-539
3-67. Cylinder Liner Installation ............................................................................................................................3-542
3-68. Engine Crankshaft and Main Bearings Installation .......................................................................................3-544
3-69. Pistons, Connecting Rod, and Bearings Installation .....................................................................................3-552
3-70. Cam Follower Assemblies and Camshaft Installation ...................................................................................3-558
3-71. Cylinder Head Assembly and Pushrods Installation .....................................................................................3-562
3-72. Injection Timing ..........................................................................................................................................3-566
3-73. Accessory Drive Housing Assembly Installation ...........................................................................................3-576
3-74. Oil Pump Installation ...................................................................................................................................3-580
3-75. Front Gear Cover Installation ......................................................................................................................3-584
3-76. Accessory Drive Pulley Installation ..............................................................................................................3-590
3-77. Air Compressor Installation .........................................................................................................................3-592
3-78. Fuel Pump Installation ................................................................................................................................3-596
3-79. Vibration Damper and Crankshaft Pulley Installation ....................................................................................3-606
3-80. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Installation ..........................................................3-608
3-81. Oil Pan Installation ......................................................................................................................................3-620
3-82. Injector Assembly Installation ......................................................................................................................3-632
3-83. Valve Crossheads Installation and Adjustment ............................................................................................3-636
3-84. Rocker Arm Housing Assembly Installation ..................................................................................................3-640
3-85. Injector and Valve Adjustment .....................................................................................................................3-644
3-86. Engine Retarder Installation ........................................................................................................................3-650
3-87. Air Aftercooler Installation ...........................................................................................................................3-656
3-88. Removing Engine from Maintenance Stand .................................................................................................3-660

Section V. TESTING ...................................................................................................................................................3-672

3-89. General ......................................................................................................................................................3-672

3-90. Task Summary ...........................................................................................................................................3-672
3-91. Starting Repaired Engine ............................................................................................................................3-674
3-92. Engine Dynamometer Testing .....................................................................................................................3-680
3-93. On-Engine Fuel Pump Adjustment ..............................................................................................................3-690

Section VI. STORAGE .................................................................................................................................................3-704

3-94. General.......................................................................................................................................................3-704
3-95. Task Summary ...........................................................................................................................................3-704
3-96. Temporary Storage .....................................................................................................................................3-704
3-97. Long-Term Storage ....................................................................................................................................3-705
3-98. Preparing an Engine from Storage to Service ..............................................................................................3-706

APPENDIX A REFERENCE .............................................................................................................................................A-1

A-1. Publication Indexes .....................................................................................................................................A-1

A-2. Forms ........................................................................................................................................................A-1
A-3. Other Publications ......................................................................................................................................A-1

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TABLE OF CONTENTS (Contd)

ILLUS
PAGE FIG

APPENDIX B REPAIR PARTS AND SPECIAL TOOLS LIST .................................................................................B-1

Section I. INTRODUCTION ............................................................................................................................B-1

B-1. Scope .............................................................................................................................................B-1

B-2. General...........................................................................................................................................B-1
B-3. Explanation of Columns (Sections II and III) ....................................................................................B-1
B-4. Explanation of Columns (Section IV) ...............................................................................................B-4
B-5. Special Information .........................................................................................................................B-5
B-6. How to Locate Repair Parts ............................................................................................................B-5

Section II. REPAIR PARTS LIST ..................................................................................................................... 1-1 1

GROUP 01 ENGINE

0100 Dressed Engine and Container ....................................................................................................... 1-1 1

0101 Engine Block .................................................................................................................................. 2-1 2
0101 Cylinder Head Assembly ................................................................................................................. 3-1 3
0102 Crankshaft Assembly ...................................................................................................................... 4-1 4
0103 Flexdisk, Ring Gear, and Housing ................................................................................................... 5-1 5
0104 Piston and Connecting Rod Assembly ............................................................................................. 6-1 6
0105 Camshaft Assembly and Followers ................................................................................................. 7-1 7
0105 Rocker Arm Assembly .................................................................................................................... 8-1 8
0105 Rocker Cover ................................................................................................................................. 9-1 9
0106 Oil Cooler and Filter, M915A1 Only ............................................................................................... 10-1 10
0106 Oil Cooler and Filter, M915 Only ................................................................................................... 11-1 11
0106 Oil Pan, Dipstick, and Breather Tube ............................................................................................. 12-1 12
0106 Oil Lubricating Pump .................................................................................................................... 13-1 13
0108 Air Aftercooler ............................................................................................................................... 14-1 14
0108 Exhaust Manifold .......................................................................................................................... 15-1 15
0109 Gear Cover .................................................................................................................................. 16-1 16
0109 Accessory Drive Pulley and Fan Clutch ......................................................................................... 17-1 17
0112 Engine Retarder ........................................................................................................................... 18-1 18
0121 Air Compressor Lines and Fittings ................................................................................................. 19-1 19
0121 Air Compressor and Governor Assembly ....................................................................................... 20-1 20

GROUP 03 FUEL SYSTEM

0301 Fuel Injector ................................................................................................................................. 21-1 21

0302 Fuel Lines and Fittings .................................................................................................................. 22-1 22
0302 Fuel Pump ................................................................................................................................... 23-1 23
0302 Fuel Pump Main Housing .............................................................................................................. 24-1 24
0302 Fuel Gear Pump ........................................................................................................................... 25-1 25
0305 Turbocharger and Component Parts ............................................................................................. 26-1 26
0305 Turbocharger Assembly ................................................................................................................ 27-1 27
0306 Solenoid Valve ............................................................................................................................. 28-1 28
0308 Fuel Pump Front Cover, Governor, and Tach Drive ....................................................................... 29-1 29
0309 Fuel Pump Damper, Head, and Fuel Filter ..................................................................................... 30-1 30
0311 Ether Quick-Start Kit ..................................................................................................................... 31-1 31
0312 Fuel Control Lever ........................................................................................................................ 32-1 32

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TABLE OF CONTENTS (Contd)

ILLUS
PAGE FIG

GROUP 05 COOLING SYSTEM

0503 Thermostat Housing, Water Manifold, and Component Parts ......................................................... 33-1 33
0503 Water Filter and Component Parts ................................................................................................ 34-1 34
0504 Water Pump and Idler ................................................................................................................... 35-1 35

GROUP 94 REPAIR KITS

9401 Repair Kits ....................................................................................................................................Kit-1

GROUP 95 BULK MATERIAL

9501 Bulk Material ............................................................................................................................. Bulk-1

Section III. SPECIAL TOOLS

GROUP 26 SPECIAL TOOLS

2604 Direct Support Special Tools-1....................................................................................................... 36-1 36

2604 Direct Support Special Tools-2....................................................................................................... 37-1 37
2604 Direct Support Special Tools-3....................................................................................................... 38-1 38
2604 Direct Support Special Tools (Supplemental) ................................................................................. 39-1 39
2604 General Support Special Tools-1 ................................................................................................... 40-1 40
2604 General Support Special Tools-2 ................................................................................................... 41-1 41
2604 General Support Special Tools-3 ................................................................................................... 42-1 42
2604 General Support Special Tools (Supplemental)-1 ........................................................................... 43-1 43
2604 General Support Special Tools (Supplemental)-2 .......................................................................... 44-1 44
2604 General Support Special Tools (Supplemental)-3 .......................................................................... 45-1 45
2604 Direct and General Support Special Tools-1 .................................................................................. 46-1 46
2604 Direct Support Special Tools-2 ...................................................................................................... 47-1 47
2604 Direct Support Special Tools-3 ...................................................................................................... 48-1 48
2604 General Support Special Tools-1 ................................................................................................... 49-1 49
2604 General Support Special Tools-2 ................................................................................................... 50-1 50
2604 General Support Special Tools-3 ................................................................................................... 51-1 51
2604 General Support Special Tools-4 ................................................................................................... 52-1 52

Section IV. CROSS-REFERENCE INDEXES

National Stock Number Index ...........................................................................................................I-1

Part Number Index ........................................................................................................................ I-15

APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST ....................................................... C-1

Section I. INTRODUCTION............................................................................................................................ C-1

C-1. Scope ........................................................................................................................................... C-1

C-2. Explanation of Columns ................................................................................................................. C-1

APPENDIX D ILLUSTRATED LIST OF MANUFACTURED ITEMS ....................................................................... D-1

Section I. INTRODUCTION ........................................................................................................................... D-1

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TABLE OF CONTENTS (Contd)

ILLUS
PAGE FIG

D-1. General.......................................................................................................................................... D-1

D-2. Manufactured Item Part Number Index ........................................................................................... D-1

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS .................................................................... D-2

APPENDIX E TORQUE LIMITS ...........................................................................................................................E-1

Section I. STANDARD TORQUE SPECIFICATIONS ......................................................................................E-2

Section II. ENGINE ASSEMBLY TIGHTENING SPECIFICATIONS ..................................................................E-3

APPENDIX F WEAR LIMITS AND TOLERANCES ................................................................................................F-1

F-1. General ..........................................................................................................................................F-1

F-2. Repair Standards ...........................................................................................................................F-1

GLOSSARY ......................................................................................................................................................... Glossary-1

Section I. LIST OF ABBREVIATIONS ............................................................................................................... Glossary-1

Section II. DEFINITION OF UNUSUAL TERMS ................................................................................................. Glossary-1

INDEX .............................................................................................................................................................. Index-1

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 TM 9-2815-225-34&P

HOW TO USE THIS MANUAL

ABOUT YOUR MANUAL

Maintenance tasks in this manual are written in sequence for the complete disassembly of the engine. They can also be used in
conjunction with troubleshooting to repair a specific engine component or part without performing a complete engine overhaul. In either
event, always refer to the maintenance record (or attached instructions if the engine arrives for repair in a container). This will prevent
any unnecessary work on your part. Follow the steps listed below under "Using Your Manual" to become familiar with how to use this
book.

USING YOUR MANUAL

Task: The operator of an M915 series vehicle has complained

the engine knocks under a load, and the vehicle has been
assigned to you for repair.

TROUBLESHOOTING STEPS:

1. Look at the cover of this manual. You'll see

chapter/section titles listed from top to bottom on the
right-hand side.

2. Look at the right edge of the manual. On some of the

pages you'll see black bars (edge indicators) that are
aligned with the chapter/section bars on the cover.
These are the locations of the chapters/section in the
text.

3. Look for "TROUBLESHOOTING" in the

chapter/section list on the cover.

4. Turn to those pages with the edge indicator matching

the black bar for TROUBLESHOOTING. Page
numbers are also listed next to chapter/section titles.

5. One of the first pages having the mechanical systems

troubleshooting edge indicators is the
'"TROUBLESHOOTING SYMPTOM INDEX."

6. Look down the list until you find "ENGINE KNOCKS."

7. Turn to the page indicated: 2-5.

viii
 TM 9-2815-225-34&P

8. On page 2-5, steps/tests relating to resolving the

problem of "Engine Knocks" are listed:

Step 1. You check for a possible damaged

piston.

Step 2. During your inspection you discover that

a piston is damaged. The part must be
replaced. Chapter 3, paras. 29 and 69,
are referenced.

9. Before turning to paras. 3-29 and 3-69, turn to chapter

3, section I, "GENERAL MAINTENANCE
INSTRUCTIONS," and review the guidelines to be
followed during maintenance of engine (paras. 3-2
through 3-10).

10. Because replacement of a piston is extensive, refer to

chapter 3, section II, "DISASSEMBLY." Find "Piston,
Connecting Rod, and Bearings Removal" in the task
summary (para. 3-12.)

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 TM 9-2815-225-34&P

11. Turn to para. 3-29 on page 3-89. Here you find the detailed procedure for removing the piston, connecting rod, and bearings.

DETAILED MAINTENANCE PROCEDURES:

12. Detailed procedures: Include everything you must do to accomplish a basic maintenance task.

a. Before beginning the maintenance task, look through the procedure. You must familiarize yourself with the entire maintenance
procedure before beginning the maintenance task. The entire procedure of para. 3-29, "Piston, Connecting Rod, and Bearings
Removal," include the task REMOVAL under the heading "THIS TASK COVERS."

b. The ten basic headings listed under "INITIAL SETUP" outline the task conditions, materials, manpower requirements, and
special conditions or tools. They are:

• Applicable Models: Any models that require that particular maintenance task.

• Special Tools: Those special tools required to finish a maintenance task. The use of common tools is not
explained.

• Test Equipment: Test equipment required to complete a task.

• Materials/Parts: All materials or parts required to complete a task.

• Personnel Required: The number and type of personnel needed to accomplish a task.
NOTE: If you think an assistant will be necessary to correctly or safely complete a task (perhaps as the
result of unusual conditions, etc.), alert your supervisor and ask for help.

• References (TM): Those manuals required to complete the task.

• Troubleshooting References: Specific troubleshooting symptom or those manuals required to complete the task.

• Equipment Condition: Notes the conditions that must exist prior to starting the task.

• Special Environmental Conditions: Outlines specific environmental conditions necessary to perform a task. For
example: Work area clean and away from blowing dirt and dust.

• General Safety Instructions: Summarizes all safety warnings for the maintenance task.

x
 TM 9-2815-225-34&P

c. A step-by-step maintenance procedure follows the INITIAL SETUP. Three columns "Location/Item," "Action," and "Remarks"
give detailed instructions for the procedure. They are:

• Location/Item: Indicates the general location and specific part(s) you are working on in a step. For example, the
location/item of step 2 is the "crankshaft (10)." The number(s) in parentheses correspond to that part(s) callout
number(s) in the accompanying illustration.

• Action: Specifies the action to be taken with the part(s) listed in the Location/Item column. In our example, you
are directed to "Rotate [the crankshaft (10) ] until rod cap (7) is accessible."

• Remarks: Provide additional information. Our example notes: "Use lint-free paper to remove loose debris from
cylinder liner (9)."

d. At the end of a procedure, "FOLLOW-ON TASK(S)" will list additional task(s) that must be performed to complete the
procedure. The Follow-On Tasks for our example procedure is: "For repair or installation of piston, connecting rod, and
bearings, refer to para. 3-69 or 3-39."

13. Refer to the example pages for para. 3-29, "Piston, Connecting Rod, and Bearings Removal," as we review the following points:

a. Modular Text: Both pages of text and illustrations are to be used together. This manual was designed so the two pages
Would be visible at once, making part identification and procedure sequence easy to follow.

b. Legend: Use the legend found at bottom of each illustration page to find part name and callout number in relation to text and
illustration.

c. Illustrations: A locator illustration of the cylinder block is provided. An exploded view of the component, removed from the
cylinder block, shows specific part locations, attachments, and spatial relationships.

14. You can also use the Table of Contents (page ii) to find more information about the engine. For example: Appendix E, Torque
Values.

15. Refer to Appendix B, Direct Support and General Support Maintenance Repair Parts and Special Tools List (RPSTL) when
requisitioning parts, special tools, and equipment for organizational maintenance.

16. Your manual is easier to use once you understand its design and we hope this will encourage you to use it more often.

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 TM 9-2815-225-34&P

CHAPTER 1
INTRODUCTION

Section I. GENERAL INFORMATION

Section I. General Information (page 1-1)

Section II. Equipment Description and Data (page 1-2)

PARA. TITLE PAGE

NO. NO.

1-1. Overview 1-1

1-2. Scope 1-1
1-3. Maintenance Forms, Records, and Reports 1-1
1-4. Destruction of Army Materiel to Prevent Enemy Use 1-1
1-5. Preparation for Storage and Shipment 1-2
1-6. Reporting Equipment Improvement Recommendations (EIRs) 1-2
1-7. Warranty Information 1-2
1-8. Equipment Characteristics, Capabilities, and Features 1-2
1-9. Location and Description of Major Components 1-3
1-10. Equipment Data 1-5

1-1. OVERVIEW

NOTE
All information contained in this manual applies to both M915 and M915A4/Big Cam I and
M915A1 and M915A4/Big Cam III engines except where differences are specifically noted.

This chapter familiarizes the technician with standard forms, record data, and the equipment to be maintained at the direct support and
general support maintenance levels. This information is covered in the following sections:

Section I. General Information

Section II. Equipment Description and Data

1-2. SCOPE

a. Type of Manual: Direct Support and General Support Army Maintenance.

b. Model Number and Name: NTC-400, Cummins, six-cylinder, in-line, turbocharged diesel engine.
c. Purpose of Equipment: • Engine for M915 through M920 and M915A4 Truck, Big Cam I.
• Engine for M915A1 and M915A4 Truck, Big Cam III.

1-3. MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738-750, The
Army Maintenance Management System (TAMMS).

1-4. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of Army equipment to prevent enemy use can be found in TM 750-244-6.

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 TM 9-2815-225-34&P

1-5. PREPARATION FOR STORAGE AND SHIPMENT

Information concerning storage or shipment of equipment can be found in TM 740-90-1. Additional information concerning storage of
Cummins NTC-400 engine can be found in Chapter 3, Maintenance.

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know.
You may mail, fax or email your letter, DA Form 2028, or DA Form 2028-2 direct to: Commander, U.S. Army Tank-automotive and
Armaments Command, ATTN: AMSTA-LC-CIP-WT, Rock Island, IL 61299-7630. The email address is TACOM-TECH-
[email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

1-7. WARRANTY INFORMATION

The Cummins diesel engine (model NTC-400) is warranted in accordance with TB 9-2300-295-15/21. The warranty starts on the date
found in block 23, DA Form 2408-9, in logbook. Report all defects in material or workmanship to your supervisor, who will take
appropriate action.

Section II. EQUIPMENT DESCRIPTION AND DATA

1-8. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

NOTE
'"M9151Big Cam I" is intended and will be written hereafter to mean M915 through M920
series and M915A4 trucks with Big Cam I engines.

a. The Cummins NTC-400 diesel engine is used on all M915 through M920, M915A1, and M915A4 trucks. It is a turbocharged,
liquid-cooled, overhead valve, four-cycle engine of in-line six-cylinder design. The NTC-400 engine has a compression ratio of 13.5: 1
(M915) and 14.0: 1 (M915A1), and develops 400 horsepower at 2100 rpm. Peak torque is 1150 lb-ft at 1500 rpm (M915) and
1300 lb-ft at 1300 rpm (M915A1).

b. The following engine characteristics and features apply to both M915/Big Cam I and M915A1/Big Cam III engines, except
where differences are noted.

Camshaft: 2-1/2-inch diameter camshaft with gear drive controlling all valve and injector movement. Made of induction-
hardened alloy steel. Camshaft followers are roller type.

Connecting Rods: Drop-forged, rifle-drilled for pressure lubrication.

Crankshaft: High-tensile steel forging. Bearing journals and fillets-induction hardened. Fully counterweighted.

Cylinder Block: Alloy cast iron with removable wet liners.

Cylinder Heads: Each head serves two cylinders. Drilled fuel supply and return lines. High temperature inserts on exhaust
valve seats.

Turbocharger: Model T-50 (M915/Big Cam I); Model T-46-B, which has a redesigned compressor wheel, compressor
housing, turbine wheel and shaft, bearing housing assembly, location of oil inlet line, and vee bands (M915A1/Big Cam III).

Exhaust Manifold: Conventional log-type (M915/Big Cam I). Pulse-type for less restriction (M915A1/Big Cam III).

Fuel System: Integral flywheel-type governor.

Injectors: Camshaft actuated top-stop type.

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 TM 9-2815-225-34&P

1-8. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

Intake Manifold: Conventional aftercooler (M915/Big Cam I). Triple-pass water aftercooler (M915A1/Big Cam III).

Lubrication Oil Cooler: Conventional oil cooler and filter with separately mounted bypass oil filter on engine firewall
(M915/Big Cam I). Demand flow automatically regulates oil pressure, routes engine coolant through engine oil cooler twice.
Engine and cooler core are made of cast aluminum and incorporates mounting adapters for spin-on type full-flow and bypass
oil filters, and incorporates a bypass valve and pressure sending unit (M915A1/Big Cam III).

Oil Pan: Made of cast aluminum (M915(Big Cam I). Made of stamped steel (M915A1/Big Cam III).

Water Transfer Tube: Made of cast iron (M915/Big Cam I). Made of stamped, welded steel (M915A1/Big Cam III).

1-9. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Right and left views of the NTC-400 engine and its components are shown below and on the following page. Identification can be made
from the engine identification plate located on the gear case mounting flange of the engine block. Because of changes made during
production, some engines may have minor differences not shown in the following views.

NOTE
Below is a 3/4-view of right side of engine as viewed from front.

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 TM 9-2815-225-34&P

1-9. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Contd)

NOTE
Below is a 3/4-view of left side of engine as viewed from front.

1-4
Cummins Big Cam I Big Cam Iii Shop Manual
Full download: http://manualplace.com/download/cummins-big-cam-i-big-cam-iii-shop-manual/
TM 9-2815-225-34&P

1-10. EQUIPMENT DATA

Manufacturer ................................................................................................................... Cummins Engine Company, Inc.

Model .............................................................................................................................. NTC-400
Type ............................................................................................................................... 4-cycle, turbocharged diesel,
compression ignition

DIMENSIONS
Length ............................................................................................................................ 58.88 in. (149.6 cm)
Width .............................................................................................................................. 33.63 in. (85.4 cm)
Height ............................................................................................................................. 50.91 in. (129.3 cm)
Net Weight, Dry ............................................................................................................... 2,600 lbs (1,180.4 kg)

CYLINDERS
Number ........................................................................................................................... 6
Arrangement ................................................................................................................... In-line
Firing Order ..................................................................................................................... 1-5-3-6-2-4
Bore ................................................................................................................................ 5.5 in. (14 cm)
Stroke ............................................................................................................................. 6 in. (15.2 cm)
Displacement .................................................................................................................. 855 cu-in. (14 L)
Compression Ratio .......................................................................................................... 13.5:1 (M915/Big Cam I)
14.0:1 (M915A1/Big Cam III)

GOVERNED SPEED
Full Load ......................................................................................................................... 2100 rpm
No Load .......................................................................................................................... 2460 rpm
Idle Speed ....................................................................................................................... 600 rpm

LUBRICATION SYSTEM
Type ............................................................................................................................... Force-fed
Operating Pressure (Normal) ........................................................................................... 35-45 psi (M915A1/Big Cam III)
50-70 psi (345-483 kPa)
(M915/Big Cam I)
Operating Pressure (Minimum) ........................................................................................ 15 psi (100 kPa) @ idle
System Capacity Including Bypass Filter .......................................................................... 44 qt (41.6 L) (M915A1)
46 qt (43.5 L) (M915)
Operating Temperature (Normal) ..................................................................................... 200-250°F (93-121°C)
Oil Pump ......................................................................................................................... Gear-type

COOLING SYSTEM
Type ............................................................................................................................... Liquid with fan and radiator
Operating Temperature (Normal) ..................................................................................... 175-195°F (79-91°C)
Thermostat ...................................................................................................................... 1

PERFORMANCE HEAD
Maximum Torque ............................................................................................................ 1150 lb-ft @ 1500 rpm (M915/Big
Cam I)
1300 lb-ft @ 1300 rpm
(M915A1/Big Cam III)
Maximum Output ............................................................................................................. 400 BHP
Piston Speed @ 2100 rpm................................................................................................ 2100 ft/min

1-5

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