$3.00 first class shipping in the U.S. Public domain U.S. government manual; not copied from another CD-ROM product. Numerous illustrations and matrices.

TITLE: DIRECT SUPPORT AND GENERAL SUPPORT (DS/GS) MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) FOR ENGINE, DIESEL: 6 CYLINDER IN-LINE, TURBOCHARGED, CUMMINS MODEL NTC-400. Published by the Department of the Army on 28 August 2001. Copied to CD-ROM; 940 pages.

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 INFOR1-1 1-1. Overview 1-1 1-2. Scope .1-1 1-3. Maintenance Forms, Records, and Reports .1-1 1-4. Destruction of Army Materiel to Prevent Enemy Use 1-1 1-5. Preparation for Storage and Shipment .1-2 1-6. Reporting Equipment Improvement Recommendations (EIRs) .1-2 1-7. Warranty Information 1-2 Section II. EQUIPMENT DESCRIPTION AND DATA 1-2 1-8. Equipment Characteristics, Capabilities, and Features .1-2 1-9. Location and Description of Major Components .1-3 1-10. Equipment Data 1-5 CHAPTER 2 SERVICE AND TROUBLESHOOTING INSTRUCTIONS2-1 Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT 2-1 2-1. Overview 2-1 2-2. Common Tools and Equipment .2-1 2-3. Special Tools, TMDE, and Support Equipment .2-1 2-4. Repair Parts .2-1 Section II. SERVICE UPON RECEIPT OF EQUIPMENT.2-1 2-5. Engine Inspection .2-1 Section III. TROUBLESHOOTING 2-2 2-6. General 2-2 2-7. Troubleshooting Symptom Index .2-3 2-8. Mechanical Troubleshooting .2-3 CHAPTER 3 MAINTENANCE3-1 Section I. GENERAL MAINTENANCE INSTRUCTIONS .3-1 3-1. Overview 3-1 3-2. General 3-1 3-3. Task Summary .3-2 3-4. Lifting Engine .3-3 3-5. Draining Engine.3-3 3-6. Cleaning .3-3 3-7. Inspection 3-4 3-8. Wear Limits and Tol3-5 3-9. Repair 3-5 3-10. Assembly .3-7 Section II. DISASSEMBLY.3-8 3-11. General 3-8 3-12. Task Summary .3-8 3-13. Mounting Engine on Maintenance Stand 3-10 3-14. Vibration Damper and Crankshaft Pulley Removal .3-26 3-15. Accessory Drive Pulley Removal .3-28 3-16. Fuel Pump Removal3-30 3-17. Air Compressor Remo3-36 3-18. Accessory Drive Housing Assembly Removal 3-40 3-19. Oil Pump Removal 3-42 3-20. Air Aftercooler Remova3-46 3-21. Engine Retarder Rem3-48 3-22. Rocker Arm Housing Assembly and Pushrods Removal 3-50 3-23. Injector Assembly Removal .3-52 3-24. Cylinder Head Assembly Removal 3-54 3-25. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Removal .3-56 3-26. Oil Pan Removal .3-62 3-27. Front Gear Cover Removal .3-64 3-28. Cam Follower Assemblies and Camshaft Removal 3-66 3-29. Piston, Connecting Rod, and Bearings Removal 3-68 3-30. Cylinder Liner Removal .3-72 3-31. Engine Crankshaft and Main Bearings Removal 3-74 Section III. REPAIR .3-78 3-32. General 3-78 3-33. Task Summary .3-78 3-34. Engine Block Repair .3-85 3-35. Cylinder Head and Valve Repair .3-112 3-36. Vibration Damper and Crankshaft Pulley Repair 3-148 3-37. Crankshaft Repair 3-150 3-38. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Repair .3-170 3-39. Piston, Connecting Rod, and Bearing Repair .3-174 3-40. Camshaft, Cam Follower, and Pushrod Repair 3-188 3-41. Rocker Levers and Housing Repair .3-208 3-42. Oil Cooler Repair 3-218 3-43. Oil Pan, Dipstick, Oil Suction Tubes, and Dipstick Tube Repair 3-236 3-44. Oil Pump Repair .3-246 3-45. Air Aftercooler Repair .3-264 3-46. Exhaust Manifold Repair .3-272 3-47. Turbocharger Repair .3-276 3-48. Front Gear Cover Repair 3-292 3-49. Accessory Drive Repair 3-296 3-50. Engine Retarder Repair 3-304 3-51. Air Compressor Repair .3-312 3-52. Fuel Injector Repair 3-340 3-53. Fuel Injector Testing; Test No. 1 3-352 3-54. Fuel Injector Testing; Test No. 2 .3-258 3-55. Fuel Injector Testing; Test No. 3 .3-362 3-56. Fuel Pump Repair 3-384 3-57. Solenoid Valve Repair 3-388 3-58. Fuel Damper and Head Repair 3-394 3-59. Fuel Gear Pump Repair 3-398 3-60. Fuel Pump Governor Spring Repair .3-404 3-61. Fuel Pump Front Cover and Governor Repair 3-408 3-62. Fuel Pump Main Housing Repair .3-426 3-63. Fuel Pump Testing and Calibration .3-448 3-64. Water Pump Repair 3-518 Section IV. ASSEMBLY 3-539 3-65. General 3-539 3-66. Task Summary .3-539 3-67. Cylinder Liner Installation 3-542 3-68. Engine Crankshaft and Main Bearings Installation .3-544 3-69. Pistons, Connecting Rod, and Bearings Installation .3-552 3-70. Cam Follower Assemblies and Camshaft Installation .3-558 3-71. Cylinder Head Assembly and Pushrods Installation .3-562 3-72. Injection Timing 3-566 3-73. Accessory Drive Housing Assembly Installation .3-576 3-74. Oil Pump Installation .3-580 3-75. Front Gear Cover Installation 3-584 3-76. Accessory Drive Pulley Installation 3-590 3-77. Air Compressor Installation .3-592 3-78. Fuel Pump Installation 3-596 3-79. Vibration Damper and Crankshaft Pulley Installation 3-606 3-80. Flexplate or Flywheel, Flywheel Housing, and Rear Cover Installation 3-608 3-81. Oil Pan Installation 3-620 3-82. Injector Assembly Installation 3-632 3-83. Valve Crossheads Installation and Adjustment 3-636 3-84. Rocker Arm Housing Assembly Installation 3-640 3-85. Injector and Valve Adjustment .3-644 3-86. Engine Retarder Installation 3-650 3-87. Air Aftercooler Installation .3-656 3-88. Removing Engine from Maintenance Stand .3-660 Section V. TESTING .3-672 3-89. General 3-672 3-90. Task Summary .3-672 3-91. Starting Repaired Engine 3-674 3-92. Engine Dynamometer Testing .3-680 3-93. On-Engine Fuel Pump Adjustment 3-690 Section VI. STORAGE .3-704 3-94. General.3-704 3-95. Task Summary .3-704 3-96. Temporary Storage .3-704 3-97. Long-Term Storage 3-705 3-98. Preparing an Engine from Storage to Service 3-706 APPENDIX A REFERENCE .A-1 A-1. Publication Indexes .A-1 A-2. Forms A-1 A-3. Other Publications A-1 APPENDIX B REPAIR PARTS AND SPECIAL TOOLS LIST .B-1 Section I. INTRODUCTION B-1 B-1. Scope .B-1 B-2. General.B-1 B-3. Explanation of Columns (Sections II and III) B-1 B-4. Explanation of Columns (Section IV) .B-4 B-5. Special Information .B-5 B-6. How to Locate Repair Parts B-5 Section II. REPAIR PARTS LIST .1-1 1 GROUP 01 ENGINE 0100 Dressed Engine and Container .1-1 1 0101 Engine Block 2-1 2 0101 Cylinder Head Assembly .3-1 3 0102 Crankshaft Assembly 4-1 4 0103 Flexdisk, Ring Gear, and Housing .5-1 5 0104 Piston and Connecting Rod Assembly .6-1 6 0105 Camshaft Assembly and Followers .7-1 7 0105 Rocker Arm Assembly 8-1 8 0105 Rocker Cover .9-1 9 0106 Oil Cooler and Filter, M915A1 Only . 10-1 10 0106 Oil Cooler and Filter, M915 Only . 11-1 11 0106 Oil Pan, Dipstick, and Breather Tube . 12-1 12 0106 Oil Lubricating Pump 13-1 13 0108 Air Aftercooler . 14-1 14 0108 Exhaust Manifold 15-1 15 0109 Gear Cover 16-1 16 0109 Accessory Drive Pulley and Fan Clutch . 17-1 17 0112 Engine Retarder . 18-1 18 0121 Air Compressor Lines and Fittings . 19-1 19 0121 Air Compressor and Governor Assembly . 20-1 20 GROUP 03 FUEL SYSTEM 0301 Fuel Injector . 21-1 21 0302 Fuel Lines and Fittings 22-1 22 0302 Fuel Pump . 23-1 23 0302 Fuel Pump Main Housing 24-1 24 0302 Fuel Gear Pump . 25-1 25 0305 Turbocharger and Component Parts . 26-1 26 0305 Turbocharger Assembly 27-1 27 0306 Solenoid Valve . 28-1 28 0308 Fuel Pump Front Cover, Governor, and Tach Drive . 29-1 29 0309 Fuel Pump Damper, Head, and Fuel Filter . 30-1 30 0311 Ether Quick-Start Kit . 31-1 31 0312 Fuel Control Lever 32-1 32 GROUP 05 COOLING SYSTEM 0503 Thermostat Housing, Water Manifold, and Component Parts . 33-1 33 0503 Water Filter and Component Parts 34-1 34 0504 Water Pump and Idler . 35-1 35 GROUP 94 REPAIR KITS 9401 Repair Kits Kit-1 GROUP 95 BULK MATERIAL 9501 Bulk Material . Bulk-1 Section III. SPECIAL TOOLS GROUP 26 SPECIAL TOOLS 2604 Direct Support Special Tools-1. 36-1 36 2604 Direct Support Special Tools-2. 37-1 37 2604 Direct Support Special Tools-3. 38-1 38 2604 Direct Support Special Tools (Supplemental) . 39-1 39 2604 General Support Special Tools-1 . 40-1 40 2604 General Support Special Tools-2 . 41-1 41 2604 General Support Special Tools-3 . 42-1 42 2604 General Support Special Tools (Supplemental)-1 . 43-1 43 2604 General Support Special Tools (Supplemental)-2 44-1 44 2604 General Support Special Tools (Supplemental)-3 45-1 45 2604 Direct and General Support Special Tools-1 46-1 46 2604 Direct Support Special Tools-2 47-1 47 2604 Direct Support Special Tools-3 48-1 48 2604 General Support Special Tools-1 . 49-1 49 2604 General Support Special Tools-2 . 50-1 50 2604 General Support Special Tools-3 . 51-1 51 2604 General Support Special Tools-4 . 52-1 52 Section IV. CROSS-REFERENCE INDEXES National Stock Number Index .I-1 Part Number Index I-15 APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST . C-1 Section I. INTRODUC C-1 C-1. Scope . C-1 C-2. Explanation of Columns . C-1 APPENDIX D ILLUSTRATED LIST OF MANUFACTURED ITEMS . D-1 Section I. INTRODUCTION . D-1 D-1. General D-1 D-2. Manufactured Item Part Number Index . D-1 Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS D-2 APPENDIX E TORQUE LIMITS .E-1 Section I. STANDARD TORQUE SPECIFICATIONS E-2 Section II. ENGINE ASSEMBLY TIGHTENING SPECIFICATIONS E-3 APPENDIX F WEAR LIMITS AND TOLERANCES F-1 F-1. General F-1 F-2. Repair Standards .F-1 GLOSSARY . Glossary-1 Section I. LIST OF ABBREVIATIONS . Glossary-1 Section II. DEFINITION OF UNUSUAL TERMS . Glossary-1 INDEX Index-1.