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

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Cummins NTC 400 Big Cam I III Official Workshop Service Repair Manual The Best  PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization ! 

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. This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 
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.

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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 ======================================== File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader & WinZip 

 

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