CUMMINS NTC-400 BC2 Engine Manual CD 560 pg.

CUMMINS NTC-400 BC2 Engine Manual CD 560 pg.
Public domain U.S. government manual; product. Numerous illustrations and matrices.
TITLE: DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR ENGINE, DIESEL, 6 CYLINDER INLINE, TURBOCHARGED, CUMMINS MODEL NTC-400 BC2 (volumes 1 and 2).
Published by the Department of the Army on 10 April 1987. Copied to CD-ROM; 560 pages total.
OVERVIEW: 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). 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 inductionhardened 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.
TABLE OF CONTENTS: CHAPTER 1 INTRODUCTION 1-1 Section I General Information 1-1 Section II Equipment Description and Data. 1-3 CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS 2-1 Section I Repair Parts, Special Tools, TMDE, and Support Equipment . Section II Troubleshooting. 2-1 Section III General Maintenance 2-1 CHAPTER 3 REPAIR OF ENGINE ASSEMBLY . 3-1 Section I General . 3-1 Section II Engine Disassembly. 3-28 Section III Cylinder Block Repair. 3-57 Section IV Cylinder Liners Inspection. 3-115 Section V Crankshaft Assembly Repair. 3-117 Section VI Bearing Halves Inspection 3-126 Section VII Connecting Rod Repair 3-127 Section VIII Piston Assembly Repair . 3-140 Section IX Camshaft Repair 3-146 Section X Gear Case Cover Repair 3-150 Section XI Cylinder Head Assembly Repair 3-156 Section XII Rocker Lever Housing Assembly Repair 3-198 Section XIII Push Tubes Repair . 3-210 Section XIV Cam Follower Housing Assembly Repair . 3-212 Section XV Vibration Damper Repair . 3-224 Section XVI Flex Disk and Ring Gear Assembly Repair 3-226 VOLUME 2 OF 2 Section XVII Flywheel Housing Repair 3-229 Section XVIII Rear Cover Repair 3-230 Section XIX Rocker Lever Covers Repair. 3-231 Section XX Oil Pump Assembly Repair . 3-234 Section XXI Oil Pan Repair 3-240 Section XXII Oil Cooler Assembly Repair 3-244 Section XXIII Aftercooler Repair 3-250 Section XXIV Exhaust Manifold Repair. 3-253 Section XXV Accessory Drive Assembly . 3-254 Section XXVI Engine Brake Assembly Repair. 3-257 Section XXVII Fuel Injector Repair 3-262 Section XXVIII Fuel Pump Repair . 3-287 Section XXIX Turbocharger Repair . 3-374 Section XXX Water Pump and Idler Pulley Assembly Repair 3-390 Section XXXI Engine Reassembly . 3-398 Section XXXII Engine Testing 3-462 Section XXXIII Preparation for Storage or Shipment . 3-472 APPENDIX A REFERENCES. A-1 APPENDIX B EXPENDABLE SUPPLIES AND MATERIALS LIST. B-1 APPENDIX C TORQUE LIMITS C-1 INDEX .INDEX-1 Also includes the easy to use Adobe Acrobat Reader 5.0 for viewing and printing publications.