Cummins – Big Cam I & Big Cam III Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Cummins – Big Cam I & Big Cam III Shop Manual – PDF DOWNLOAD
HOW TO USE THIS MANUAL
ABOUT YOUR MANUAL:
Maintenance tasks in this manual are written in sequence for the complete disassembly of the engine. They can also be used in conjunction with troubleshooting to repair a specific engine component or part without performing a complete engine overhaul. In either event, always refer to the maintenance record (or attached instructions if the engine arrives for repair in a container). This will prevent any unnecessary work on your part. Follow the steps listed below under “Using Your Manual” to become familiar with how to use this book
TROUBLESHOOTING STEPS:
1. Look at the cover of this manual. You’ll see chapter/section titles listed from top to bottom on the right-hand side.
2. Look at the right edge of the manual. On some of the pages you’ll see black bars (edge indicators) that are aligned with the chapter/section bars on the cover. These are the locations of the chapters/section in the text.
3. Look for “TROUBLESHOOTING” in the chapter/section list on the cover.
4. Turn to those pages with the edge indicator matching the black bar for TROUBLESHOOTING. Page numbers are also listed next to chapter/section titles.
5. One of the first pages having the mechanical systems troubleshooting edge indicators is the ‘”TROUBLESHOOTING SYMPTOM INDEX.”
6. Look down the list until you find “ENGINE KNOCKS.”
TABLE OF CONTENTS:
Cummins – Big Cam I & Big Cam III Shop Manual – PDF DOWNLOAD
HOW TO USE THIS MANUAL viii
GENERAL INFORMATION 1-1
EQUIPMENT DESCRIPTION AND DATA 1-2
SERVICE UPON RECEIPT 2-1
TROUBLESHOOTING 2-2
GENERAL MAINTENANCE
INSTRUCTIONS3-1
TESTING 3-672
REPAIR PARTS AND SPECIAL TOOLS LIST B-1
EXPENDABLE SUPPLIES AND
MATERIALS LIST C-1
TORQUE LIMITS E-1
WEAR LIMITS AND TOLERANCES
DISTRIBUTION STATEMENT A – Approved for public release; distribution is unlimited
TABLE OF CONTENTS
PAGE
HOW TO USE THIS MANUAL viii
CHAPTER 1 INTRODUCTION 1-1
Section I GENERAL INFORMATION 1-1
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
* This manual supersedes TM 9-2815-225-34&P-1, TM 9-2815-225-34&P-2, dated Dec 1983 and TM 9-2815-222-34&P dated Dec
1980 and all changes
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TM 9-2815-225-34&P
TABLE OF CONTENTS (Contd)
PAGE
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 INSTRUCTIONS 2-1
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 MAINTENANCE 3-1
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 Tolerances 3-5
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 Removal 3-30
3-17 Air Compressor Removal 3-36
3-18 Accessory Drive Housing Assembly Removal 3-40
3-19 Oil Pump Removal 3-42
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TABLE OF CONTENTS (Contd)
PAGE
3-20 Air Aftercooler Removal 3-46
3-21 Engine Retarder Removal 3-48
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
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TABLE OF CONTENTS (Contd)
PAGE
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
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TABLE OF CONTENTS (Contd)
ILLUS
PAGE FIG
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
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TABLE OF CONTENTS (Contd)
ILLUS
PAGE FIG
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 INTRODUCTION 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
VIDEO PREVIEW OF THE MANUAL:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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