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Page Title: TM-9-2815-226-34-1

• ENGINE, DIESEL, 6 CYLINDER INLINE, TURBOCHARGED, CUMMINS MODEL NTC-400 BC2
• Direct Support and General Support Maintenance Manual
• WARNING
• WARNING (cont)
• WARNING (cont)
• Table of Contents
• Table of Contents (cont)
• Chapter 1. INTRODUCTION
• Section II. EQUIPMENT DESCRIPTION AND DATA
• LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
• DIFFERENCES BETWEEN MODELS
• EQUIPMENT DATA
• EQUIPMENT DATA (cont)
• Chapter 2. MAINTENANCE INSTRUCTIONS
• Table 2-1. TROUBLESHOOTING PROCEDURES
• Table 2-1. TROUBLESHOOTING PROCEDURES (Cont)
• ENGINE STOPS, BUT IS NOT SEIZED.
• ENGINE SUDDENLY STOPS AND IS SEIZED.
• ENGINE MISSES.
• EXCESSIVE BLACK SMOKE AT IDLE.
• EXCESSIVE WHITE SMOKE AT IDLE.
• EXCESSIVE SMOKE WHILE ACCELERATING.
• EXCESSIVE SMOKE WHILE ACCELERATING. (Cont)
• LOW POWER OR LOSS OF POWER.
• LOW POWER OR LOSS OF POWER. (cont)
• CANNOT REACH GOVERNED RPM.
• ENGINE ACCELERATES SLOWLY.
• EXCESSIVE FUEL CONSUMPTION.
• POOR ENGINE DECELERATION.
• ERRATIC IDLE SPEED.
• ENGINE SURGES AT GOVERNED RPM.
• EXCESSIVE OIL CONSUMPTION.
• LUBRICATING OIL DILUTION.
• COOLANT TEMPERATURE TOO HIGH (ENGINE OVERHEATING).
• LOW IDLE OIL PRESSURE (LESS THAN 10 PSI, [69 KPA]).
• LOW OIL PRESSURE AT TORQUE PEAK (LESS THAN 30 PSI, [207 KPA]).
• HIGH OIL PRESSURE AT RATED ENGINE RPM (HIGHER THAN 45 PSI, [311 KPA]).
• Chapter 3. REPAIR OF ENGINE ASSEMBLY
• Oil Passages
• INSPECTION
• Table 3-1. REPAIR AND REPLACEMENT STANDARDS
• Table 3-1. REPAIR AND REPLACEMENT STANDARDS (Cont)
• Table 3-1. REPAIR AND REPLACEMENT STANDARDS (Cont)
• Table 3-1. REPAIR AND REPLACEMENT STANDARDS (Cont)
• Table 3-1. REPAIR AND REPLACEMENT STANDARDS (Cont)
• CYLINDER HEAD
• CYLINDER HEAD (cont)
• ROCKER LEVER
• ROCKER LEVER (cont)
• WATER PUMP
• LUBRICATING OIL PUMP
• FINAL ASSEMBLY
• Table 3-2. VALVE SEAT INSERTS
• REPAIR
• Ball Bearings.
• Gears.
• ASSEMBLY INSTRUCTIONS.
• Table 3-3. TORQUE CHART
• TABLE 3-3. TORQUE CHART (Cont)
• TABLE 3-3. TORQUE CHART (Cont)
• TABLE 3-3. TORQUE CHART (Cont)
• TABLE 3-3. TORQUE CHART (Cont)
• TABLE 3-3. TORQUE CHART (Cont)
• TABLE 3-3. TORQUE CHART (Cont)
• Section II. ENGINE DISASSEMBLY
• Remove Remaining Engine Components.
• Mount Engine in Engine Rebuild Stand.
• Remove Vibration Damper.
• Remove Exhaust Manifold.
• Remove Lube Oil Pump.
• Remove Water Manifolds and Thermostat Housing.
• Remove Front Engine Support.
• Remove Engine Retarder Housing Assemblies.
• Remove Rocker Lever Housing.
• Remove Cylinder Heads.
• Remove Cylinder Heads. (cont)
• Remove Cylinder Heads. (cont)
• Remove Cam Follower Housing Assemblies.
• Remove Flex Disk and Ring Gear Assembly.
• Remove Flywheel Housing.
• Remove Oil Pan.
• Remove Rear Cover.
• Remove Front Gear Cover.
• Remove Camshaft and Gear.
• Connecting Rod and Piston Assemblies.
• Connecting Rod and Piston Assemblies. (cont)
• Connecting Rod and Piston Assemblies. (cont)
• Crankshaft and Main Bearings.
• Crankshaft and Main Bearings. (cont)
• Crankshaft and Main Bearings. (cont)
• Remove Cylinder Liners.
• Remove and Discard Camshaft Bearings.
• Remove and Discard Camshaft Bearings. (cont)
• Section III. CYLINDER BLOCK REPAIR
• CLEAN CYLINDER BLOCK
• CLEAN CYLINDER BLOCK (Cont)
• INSPECT CYLINDER BLOCK
• Check camshaft bearings
• Check cylinder liner upper counterbore.
• Check cylinder liner protrusion.
• Check cylinder liner lower counterbore.
• Check cylinder liner lower counterbore. (cont)
• Check main bearing caps.
• Check main bearing bore diameter.
• Check main bearing bore alinement.
• Check main bearing bore alinement. (cont)
• Check main bearing bore alinement. (cont)
• REPAIR CYLINDER BLOCK
• Top surface refinishing.
• Cylinder liner upper counterbore resurfacing.
• Install tool and cut counterbore
• Install tool and cut counterbore (cont)
• Install tool and cut counterbore (cont)
• Cylinder liner upper counterbore enlarging.
• Assemble and install ST-1168 liner counterbore salvage tool.
• Assemble and install ST-1168 liner counterbore salvage tool. (Cont)
• Preset and install cutter assembly.
• Preset and install cutter assembly. (cont)
• Preset and install cutter assembly. (cont)
• Cut counterbore to accept replacement sleeve
• Cylinder liner upper counterbore replacement sleeve installation.
• Cylinder liner lower counterbore enlarging.
• Preset and install tool bit assembly.
• Adjust tool boring depth.
• Adjust tool boring depth. (Cont)
• Install counterbore salvage boring tool.
• Cut counterbore to accept replacement sleeve.
• Cylinder liner lower counterbore replacement sleeve installation.
• Main bearing line boring.
• Assemble micrometer tool bit setting gage.
• Assemble micrometer tool bit setting gage. (cont)
• Feed assembly and cutter holder assembly installation.
• Feed assembly and cutter holder assembly installation. (cont)
• Feed assembly and cutter holder assembly installation. (cont)
• Cut bore and bearing cap.
• Main bearing saddle salvage sleeve installation.
• Main bearing saddle salvage sleeve installation. (cont)
• Main bearing saddle salvage sleeve installation. (cont)
• Main bearing (no. 7) thrust surface repair.
• Main bearing (no. 7) thrust surface repair. (cont)
• Main bearing (no. 7) thrust surface repair. (cont)
• Boring bar bridges installation.
• Boring bar bridges installation. (cont)
• Cylinder Block Cylinder Head Bolt Thread Repair.
• Cylinder Block Cylinder Head Bolt Thread Repair. (cont)
• Cylinder Block Cylinder Head Bolt Thread Repair. (cont)
• Cylinder Block Cylinder Head Bolt Thread Repair. (cont)
• Eroded water hole repair.
• Adjust ST-1010-11 counterbore cutter depth.
• Eroded water hole repair. (cont)
• No. 7 Main Bearing Cap Machining.
• No. 7 Main Bearing Cap Machining. (cont)
• Section IV. CYLINDER LINERS INSPECTION
• INSPECT LINERS
• Section V. CRANKSHAFT ASSEMBLY REPAIR
• INSPECT CRANKSHAFT
• INSPECT CRANKSHAFT (cont)
• INSPECT CRANKSHAFT (cont)
• INSPECT CRANKSHAFT (cont)
• INSPECT CRANKSHAFT (cont)
• INSPECT CRANKSHAFT (cont)
• Perform magnetic crack inspection of crankshaft.
• REPAIR CRANKSHAFT
• Section VI. BEARING HALVES INSPECTION
• Section VII. CONNECTING ROD REPAIR
• INSPECT CONNECTING RODS
• INSPECT CONNECTING RODS (cont)
• Adjust checking fixture for rod size.
• Check rod bend, twist, and length.
• Check bolts, bolt holes, and bolt pads.
• Measure rod bearings (shells).
• REPAIR CONNECTING RODS
• Resize crankpin bore.
• Chamfer piston pin bore.
• Chamfer piston pin bore. (cont)
• Install piston pin bushing.
• Bore rod piston pin bushing.
• Section VIII. PISTON ASSEMBLY REPAIR
• Measure ring gap with feeler gage
• INSPECT PISTONS
• The ring groove width be checked
• Discard piston if diameter exceeds 5.483 in. (139.268 mm).
• REPAIR PISTONS
• Section IX. CAMSHAFT REPAIR
• INSPECT CAMSHAFT
• REPAIR CAMSHAFT
• Install timing gear.
• Section X. GEAR CASE COVER ASSEMBLY REPAIR
• INSPECT CAMSHAFT SUPPORT
• REPAIR GEAR CASE COVER.
• Remove crankshaft oil seal.
• Remove crankshaft oil seal. (cont)
• Replace accessory drive oil seal.
• Section XI. CYLINDER HEAD ASSEMBLY REPAIR
• DISASSEMBLE CYLINDER HEAD ASSEMBLY
• DISASSEMBLE CYLINDER HEAD ASSEMBLY (cont)
• REPAIR CYLINDER HEAD
• Cylinder head air pressure test
• Fuel line passages test
• Magnetic particle inspection.
• Valve seat insert security and seat width check
• Injector sleeve seating area pattern and tip protrusion inspections.
• Valve guides inspection.
• Valve crosshead guides and crossheads inspection.
• Valve crosshead guides and crossheads inspection. (cont)
• Valve inspection.
• Cylinder head mounting surface and water holes inspection.
• Valve springs inspection.
• Repair eroded water holes.
• Repair eroded water holes. (cont)
• Repair eroded water holes. (cont)
• Repair eroded water holes. (cont)
• Cylinder head resurfacing.
• Valve seat insert counterboring.
• Valve seat insert counterboring. (cont)
• Valve seat insert counterboring. (cont)
• Valve seat grinding.
• Valve seat grinding. (cont)
• Grind valves.
• Grind valves. (cont)
• Valve guide replacement.
• Install oversize guides
• Crosshead guides replacement.
• Crosshead guides replacement. (cont)
• Injector sleeve replacement.
• Install injector sleeve.
• Install injector sleeve. (cont)
• Expand injector sleeve.
• Injector seat cutting.
• Injector seat cutting. (cont)
• ASSEMBLE CYLINDER HEAD
• Install valves.
• Install valves. (cont)
• Valve seating test.
• Valve seating test. (cont)
• Section XII. ROCKER LEVER HOUSING ASSEMBLY REPAIR
• Disassemble housing.
• Disassemble housing. (cont)
• Disassemble housing. (Cont)
• INSPECT ROCKER LEVER HOUSING ASSEMBLY
• Inspect rocker levers.
• Inspect rocker levers. (cont)
• Inspect rocker lever adjusting screws.
• REPAIR ROCKER LEVER HOUSING ASSEMBLY
• Replace rocker lever bushings.
• ASSEMBLE ROCKER LEVER HOUSING ASSEMBLY
• Assemble rocker lever housing assembly.
• Section XIII. PUSH TUBES REPAIR
• INSPECT PUSH TUBES
• Section XIV. CAM FOLLOWER HOUSING ASSEMBLY REPAIR
• INSPECT CAM FOLLOWER HOUSING ASSEMBLY
• Inspect housing.
• Inspect cam follower levers.
• Inspect cam follower lever rollers and pins.
• Inspect cam follower lever rollers and pins. (cont)
• Inspect cam follower lever rollers and pins. (cont)
• REPAIR CAM FOLLOWER HOUSING ASSEMBLY
• Replace follower lever insert.
• Repair cam follower housing.
• ASSEMBLE CAM FOLLOWER HOUSING ASSEMBLY
• Assemble cam follower housing assembly.
• Section XV. VIBRATION DAMPER REPAIR
• Inspect pulley.
• Section XVI. FLEX DISK AND RING GEAR ASSEMBLY REPAIR
• Inspect ring gear.
• ALPHABETICAL INDEX
• ALPHABETICAL INDEX (Continued)
• ALPHABETICAL INDEX (Continued)
• ALPHABETICAL INDEX (Continued)
• ALPHABETICAL INDEX (Continued)
• ALPHABETICAL INDEX (Continued)
• ALPHABETICAL INDEX (Continued)
• THE METRIC SYSTEM AND EQUIVALENTS
• TM-9-2815-226-34-1
• Recommended Changes to Equipment Technical Publications
• Recommended Changes to Equipment Technical Publications
• Recommended Changes to Equipment Technical Publications
• Recommended Changes to Equipment Technical Publications
• Blank Page
• Distribution
• Distribution