- 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
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