CUMMINS NTC-400 BIG CAM I II III Engine Workshop Manual

HEADQUARTERS, DEPARTMENT OF THE ARMY JULY 2005 TM 9-2815-225-34&P DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) FOR ENGINE, DIESEL: 6 CYLINDER IN-LINE TURBOCHARGED, CUMMINS MODEL NTC-400 BIG CAM I (NSN 2815-01-082-8125) BIG CAM III (NSN 2815-01-142-2745) BIG CAM III SHOWN. ALL TRUCKS M915-M920 AND M915A4 CAN BE EQUIPPED WITH EITHER BIG CAM I OR BIG CAM III ENGINES. DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Supersedes copy dated August 2001

TM 9-2815-225-34&P a WARNING SUMMARY Operating a deadlined vehicle without preliminary inspection will cause further damage to a malfunctioning component and possible injury to personnel. Use extreme care when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good operating condition and of suitable load capacity. Keep clear of heavy components supported only by lifting device. Failure to comply may result in death or injury to personnel. Compressed air used for cleaning purposes must not exceed 30 psi. Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in death or injury to personnel. When removing hood tilt assist cables, hood must be supported. Failure to comply may result in damage to equipment or injury to personnel. Use pry bars to free engine hangups or snags. Do not use hands. Failure to comply may result in damage to equipment or death or injury to personnel. Use extreme care during engine accessory removal. Engine parts are heavy. Failure to comply may result in death or injury to personnel. Eye protection must be worn when using wire brush for cleaning. Failure to comply may result in injury to personnel. Wear rubber gloves when removing piston pin to prevent burns from hot water or hot piston. Failure to comply may result in injury to personnel Oil pump pressure regulator spring is under tension. Remove oil pump pressure regulator slowly and wear proper eye protection. Failure to comply may result in injury to personnel. Oil pump pressure regulator spring is under tension. Install oil pump pressure regulator screw slowly and wear proper eye protection. Failure to comply may result in injury to personnel. Oil pump pressure regulator spring is under tension. Remove oil pump bypass screw slowly and wear proper eye protection. Failure to comply may result in injury to personnel. Turbine wheel machined edges are very sharp. Wear protective gloves when handling turbine wheel. Failure to comply may result in injury to personnel. Control valve cover is under control valve outer spring pressure. Hold cover securely when removing screws. Failure to comply may cause injury to personnel. Slave piston spring is highly compressed. Be extremely careful during disassembly. Personal injury can occur if spring force is not controlled. Use gloves during piston pin installation if piston has been soaked in hot water. 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 or death to personnel.

TM 9-2815-225-34&P b WARNING SUMMARY (Contd) Allow adequate ventilation for engine exhaust gases. 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 serious injury or death 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. All personnel must stand clear during lifting operations. A snapped chain or swinging or shifting load may result in injury to personnel. When installing hood tilt assist cables, hood must be supported. Failure to comply may result in damage to equipment or injury to personnel. Compressed air source must not exceed 30 psi (207 kPa). Wear eyeshields when cleaning with compressed air. Failure to comply may result in injury to personnel.

TM 9-2815-225-34&P A/B blank LIST OF EFFECTIVE PAGES/WORK PACKAGES The date of issue for original pages/work pages for this TM is: Original 21 July 2005 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 651. TOTAL NUMBER OF WORK PACKAGES IS 62. THE PAGES/WORK PACKAGES CONSIST OF THE FOLLOWING: Page No. . . . . . . . . . . . . . Change No. * Warning a–Warning b . . . . . . . . . . . . . . 0 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B blank . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ii blank . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 iii–vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 viii blank . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0001 00–WP 0062 00 . . . . . . . . . . . 0 Index 1–Index 3 . . . . . . . . . . . . . . . . . . . 0 Index 4 blank . . . . . . . . . . . . . . . . . . . . . 0 0 *Zero in this column indicates original page.

CUMMINS NTC-400 BIG CAM I II III Engine Workshop Manual

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