CUMMINS NTC-400 BC2 Diesel Engine Service Manual

TM 9-2815-226-34-1 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE SERVICE MANUAL FOR ENGINE, DIESEL, 6 CYLINDER INLINE, TURBOCHARGED, CUMMINS MODEL NTC-400 BC2 NSN 2815-01-156-6210 SEPTEMBER 1985

TM 9-2815-226-34-1 C1 Direct Support and General Support Maintenance Service Manual ENGINE, DIESEL, 6 CYLINDER INLINE, TURBOCHARGED CUMMINS MODEL NTC-400 BC 2 (2815-01-156-6210) TM 9-2815-226-34, September 1985 is changed as follows: 1. Remove old pages and insert new pages as indicated below. 2. New or changed material is indicated by a vertical bar in the margin of the page. 3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration identification number. 4. The purpose of Change 1 to this manual is to identify configuration diffe rences between the 1980, 1982, and 1984 models. Model designators can be determined by viewing the data plate on your truck chassis. Remove Pages Insert Pages Remove Pages Insert Pages i i 3-139 and 3-140 3-139 and 3-140 ii ii 3-151 and 3-152 3-151 and 3-152 1-1 thru 1-4 1-1 thru 1-4 3-155 and 3-156 3-155 and 3-156 1-5/(1-6 blank) 1-5 and 1-6 3-177 thru 3-180 3-177 thru 3-180 3-29 thru 3-34 3-29 and 3-34 INDEX-1 and INDEX-2 INDEX-1 and INDEX-2 3-37 and 3-38 3-37 and 3-38 3-53 thru 3-56 3-53 thru 3-56 3-65 thru 3-68 3-65 thru 3-68.1/ (3-68.2 blank) 3-133 and 3-134 3-133 and 3-134 File this change sheet in front of the publication for reference purposes.

WARNING EXHAUST FUMES The following precautions must be observed to ensure the safety of personnel when the engine of any vehicle is operated: 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 operation. If tactical situation permits, open hatches. 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 are present, IMMEDIATELY VENTILATE personnel compartment. If symptoms persist, remove affected crew to fresh air; keep warm; DO NOT PERMIT PHYSICAL EXERCISE; if necessary, give artificial respiration and get immediate medical attention. 5. BE AWARE; neither the gas particulate filter un it nor the field protection mask for nuclear-biological-chemical protection will protect you from carbon monoxide poisoning. WARNING COMPRESSED AIR Compressed air used for cleaning purposes will not exceed 30 PSI (207 KPA). Use only with effective chip guarding and personal protective equipment (goggles, shield, gloves, etc.). a

WARNING FIRE AND EXPLOSION Do not use gasoline for cleaning or as fuel. Do not get battery electrolyte on your skin, clothing, or in your eyes. It is an acid which can cause injury. Keep all sparks and flames away from batteries. The battery gas is explosive. When disconnecting battery terminals, always disconnect the ground terminal first. When reconnecting battery terminals, always connect the ground terminal last. Methyl alcohol is highly flammable and poisonous, and can be absorbed through the skin. Do not drink or breathe it. If you spill any on your skin, wash it off immediately with water. Keep it away from sparks or flames. Ether quick-start is explosive and poisonous. Do not permit canisters to be subjected to excessive heat. Do not attempt to start vehicle if ether line to engine is broken or disconnected. When filling fuel tank with diesel fuel, be sure hose nozzle on container contacts filler tube on fuel tank to carry off static electricity. Do not smoke, permit open flame or uncovered battery compartments while you are servicing the diesel fuel system. Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles and gloves and use only in well ventilated area. Avoid contact with skin, eyes, and clothes, and do not breathe vapors. Do not use near open flame or excessive heat. WARNING EXHAUST PIPE AND MUFFLER During normal operation, the exhaust pipe and muffler can become very hot. Do not touch these components with your bare hands. b

WARNING ENGINE COOLANT Take extreme care when removing engine coolant tank fill cap if temperature gage reads above 195°F (91ºC), to prevent burns or serious injury. WARNING JACKING UP TRUCK Hydraulic jack is intended for lifting the truck, not for supporting the vehicle when performing maintenance. To prevent serious injury, do not get under truck unless it is properly supported with blocks or jack stands. WARNING COOLING FAN When working in engine compartment with the engine running, stay clear of the cooling fan. The fan may engage automatically at any time and can cause serious injury. WARNING HOISTING TRUCK Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel. C

TM 9-2815-226-34-1 TECHNICAL MANUAL No. 9-2815-226-34-1 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL ENGINE, DIESEL, 6 CYLINDER INLINE, TURBOCHARGED, CUMMINS MODEL NTC-400 BC2 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS 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. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Tank-Automotive command, ATTN: AMSTA-MBS, Warren, MI 48397-5000. A reply will be furnished to you. VOLUME 1 OF 2 Page 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 Change 1 i

TM 9-2815-226-34-1 Page 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 ii

TM 9-2815-226-34-1 CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMATION 1-1. SCOPE. a. Type of Manual:Direct Support and General Support Maintenance. b. Model Number and Equipment Name: Cummins Model NTC-400 BC2, Six-Cylinder Inline, Turbocharged Diesel Engine. c. Purpose of Equipment: Engine for Truck Chassis, Direct Support Section, Topographic Support System (TSS). 1-2. 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). 1-3. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE. Procedures outlined in TM 750-244-6 (Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use) are applicable to this equipment. 1-4. PREPARATION FOR STORAGE OR SHIPMENT. Instructions concerning storage or shipment of engine are found in Chapter 3, Section XXXIII of this manual. 1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). EIR can and must be submitted by anyone who is aware of an unsatisfactory condition with the equipment design or use. It is not necessary to show a new design or list a better way to perform a procedure. Just simply tell why the design is unfavorable or why a procedure is difficult. EIR may be submitted on SF 368 (Quality Deficiency Report). Mail directly to: Commander, U.S. Army Tank - Automotive Command, ATTN: AMSTA-QR, Warren, Michigan 48397-5000. A reply will be furnished to you. Change 1 1-1

TM 9-2815-226-34-1 Section II. EQUIPMENT DESCRIPTION AND DATA 1-6. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES. The following information describes engine characteristics and features: Camshaft: 2-1/2 inch diameter gear driven camshaft which controls 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 strength steel forging. Bearing journals and fillets induction hardened. Fully counterweighted. Cylinder Block: Alloy cast iron with removable, wet liners. Cylinder Head: Each head serves two cylinders. Drilled fuel supply and return lines. High temperature inserts on exhaust valve seats. Fuel System: Integral flyweight type governor. Injectors: Camshaft actuated top stop type. Intake Manifold: Single pass water aftercooler. Lubricating Oil Cooler: Demand flow. 1-2

TM 9-2815-226-34-1 1-7. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS. The illustrations below show the location of the major engine components. 1-3

CUMMINS NTC-400 BC2 Diesel Engine Service Manual

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