WEAR LIMITS
TM 9-2815-225-34&P · Work Package 0054 00
SCOPE
This Work Package (WP) contains a table of wear limit information for the M915, M915A1, M916, M915A4, M920 vehicle. Parts exceeding these wear limits must be replaced.
TM page 0054 00-2
Table 1. Wear Limits.
PART DESCRIPTION/LOCATION WEAR LIMIT
Cylinder sleeve Maximum pit depth .0625 in. (1.6 mm) maximum
Cylinder sleeve Inside bore diameter 5.505 in. (13.983 cm) maximum
Main bearing halves Thickness 0.1215 in. (3.0861 mm) acutal limit
Connecting rod Length 0.002 in. (0.050 mm) maximum
Between piston pin
Connecting rod for twist holding mandrel and dial 0.20 in. (0.5078 mm) maximum
indicator holding plate
1.2495 in. (31.737 mm) minimum
Camshaft follower roller Outside diameter
1.2505 in. (31.763 mm) maximum
Expansion plug Flush with edge of hole 0.010 in. (0.254 mm) maximum
1.1238 in. (2.855 cm) minimum –
Rocker lever housing shaft bore Inside diameter
1.1246 in. (2.857 cm) maximum
1.1230 in. (2.552 cm) minimum –
Rocker lever shaft Outside diameter
1.1240 in. (2.855 cm) maximum
Turbocharger wheel and shaft Runout 0.00005 in. (0.0127 mm) maximum
Turbocharger wheel and shaft and 0.005 in. (0.127 mm) minimum –
Clearance
turbine housing 0.043 in. (0.092 mm) maximum
0.006 in. (0.152 mm) minimum –
Turbocharger wheel and shaft End play
0.0018 in. (0.457 mm) maximum
Camshaft support Inside diameter 1.757 in. (4.46 cm) maximum
Accessory drive shaft bushing Surface outer dimension 1.310 in. (3.327 cm) minimum
Accessory drive gear to accessory 0.002 in. (0.051 mm) minimum –
Allowable clearance
drive housing 0.012 in. (0.305 mm) maximum
0.002 in. (0.508 mm) maximum
Connecting rod Bend or twist bend and 0.004 in. (0.102 mm)
maximum twist
Connecting rod and crankshaft End inside diameter 1.935 in. (49.149 mm) maximum
Cylinder housing inside bore Diameter 3.6285 in. (9.2164 cm) maximum
Cylinder housing bore Out-of-round 0.0015 in. (0.0381 mm) maximum
Piston pin bore Diameter 0.6885 in. (17.4879 mm) maximum
Piston pin Outside diameter 0.6876 in. (17.4625 mm) maximum
0.010 in. (0.254 mm) minimum –
Piston ring End gap
0.020 in. (0.508 mm) maximum
1.872 in. (4.755 cm) minimum –
Crankshaft front support journal Diameter
1.873 in. (4.757 cm) maximum
1.003 in. (2.548 cm) minimum –
Crankshaft half coupling journal Diameter
1.0035 in. (2.549 cm) maximum
TM page 0054 00-3
Table 1. Wear Limits (Contd).
PART DESCRIPTION/LOCATION WEAR LIMIT
1.872 in. (4.755 cm) minimum –
Crankshaft rear coupling journal Diameter
1.873 in. (4.757 cm) maximum
Air compressor seat Height 0.485 in. (12.319 mm) minimum
Air compressor seating area on seat Height 0.270 in. (6.858 mm) minimum
1.307 in. (3.320 cm) minimum –
Air compressor support thrust flange Depth
1.310 in. (3.327 cm) maximum
Fuel injector barrel ball Seat depth 0.050 in. (1.27 mm) maximum
Solenoid valve seat Width 0.015 in. (0.381 mm) minimum
Fuel pump weight-assist plunger Protrusion 0.800 in. (20.32 mm) exact limit
Concentricity of inside
Camshaft follower intake, injector, 0.0020 in. (0.051 mm) must be
diameter with outside
and exhaust within this measurement
diameter
Camshaft follower intake, injector, Squareness of sides with 0.0040 in. (0.102 mm) must be
and exhaust roller pin bore within this measurement
Fuel pump front cover gear and
Clearance 0.002-0.005 in. (0.050-0.127 mm)
bushing
Between feeler gauge and
Cylinder block flatness 0.02 in. (0.51 mm) max measured
cylinder block
Cylinder liner counterbore Depth 0.412 in. (10.465 mm) maximum
Cylinder sleeve Protrusion 0.006 in. (0.152 mm) maximum
Vibration damper Thickness 0.125 in. (3.157 mm) maximum
Rear oil seal Contact area 5.998 in. (15.234 cm) minimum
Front oil seal Contact area 3.625 in. (9.207 cm ) minimum
Rod bearing journal Diameter 3.124 in. (7.933 cm) minimum
Main bearing journal Diameter 4.489 in. (11.426 cm) minimum
Thrust ring Thickness 0.245 in. (6.223 mm)
Crankshaft keyway Width 0.375 in. (9.525 mm) maximum
0.002 in. (0.05 mm) minimum –
End play
Oil pump driveshaft 0.008 in. (0.20 mm) maximum
Diameter 0.874 in. (22.20 mm) minimum
Idler shaft Outside diameter 0.874 in. (22.20 mm) minimum
Air Aftercooler to intake manifold Clearance 0.013 in. (0.330 mm) maximum
Turbocharger bearing housing Length 2.986 in. (7.584 cm) minimum
V-band clamp to turbin housing Clearance 0.035 in. (0.889 mm) minimum
Impeller to impeller housing Clearance 0.006 in. (0.152 mm) minimum
TM page 0054 00-4
Table 1. Wear Limits (Contd).
PART DESCRIPTION/LOCATION WEAR LIMIT
Injector cam follower roller Inside diameter 0.704 in. (17.882 mm) maximum
Intake/exhaust roller Pin diameter 0.4997 in. (12.692 mm) minimum
Injector roller Pin diameter 0.6997 in. (17.772 mm) minimum
Intake/exhaust cam follower roller Pin bore 0.4995 in. (12.687 mm) maximum
Injector cam follower roller Pin bore 0.6997 in. (17.772 mm) maximum
Oil pump driveshaft Diameter 0.874 in. (22.20 mm) minimum
0.060 (1.52 mm) minimum –
Oil pump gear Clearance
0.070 in. (1.78 mm) maximum
Piston pin dowel Diameter 0.220 in. (5.59 mm) minimum
Pilot area diameter 0.541 in. (13.74 mm) minimum
Connecting rod bolt
Threaded area diameter 0.6245 (15.862 mm) minimum
Connecting rod Inside diameter 3.3167 in. (8.4244 cm) maximum
Camshaft bearing Journal diameter 2.495 in. (6.337 cm) minimum
Cam follower bushing Inside diameter 0.7511 in. (19.078 mm) maximum
Intake/exhaust cam follower roller Inside diameter 0.5015 in. (12.738 mm) maximum
Crankshaft gear Step diameter 3.761 in. (9.552 cm) minimum
Crankshaft Thrust flange 0.003 in. (0.076 mm) maximum
Piston ring to piston ring groove Clearance 0.006 in. (0.15 mm) maximum
Piston Outside diameter 5.480 in. (13.919 cm) minimum
Piston skirt Outside diameter 5.493 in. (13.952 cm) minimum
Piston pin bore Diameter 2.000 in. (5.080 cm) maximum
Piston pin Outside diameter 1.9988 (5.0769 cm) minimum
Fuel gear pump idler shaft Outside diameter 0.499 in. (12.70 mm) minimum
0.7483 in. (19.007 mm) minimum –
Fuel gear pump idler gear Length
0.7486 in. (19.014 mm) maximum
0.7478 in. (18.994 mm) minimum –
Fuel gear pump Gear body depth
0.7481 (19.002 mm) maximum
Fuel gear pump gear body shaft bore Inside diameter 0.5016 in. (12.741 mm) maximum
Driveshaft backlash 0.004 in. (0.1016 mm) maximum
Fuel gear pump 0.0009 in. (0.228 mm) minimum –
Driveshaft endplay
0.0015 in. (0.038 mm) maximum
Tachometer drive bushing Inside diameter 0.752 in. (19.10 mm) maximum
0.002 in. (0.051 mm) smaller than
Governor barrel Diameter
governor barrel outside diameter
TM page 0054 00-5
Table 1. Wear Limits (Contd).
PART DESCRIPTION/LOCATION WEAR LIMIT
Distortion on mating
0.002 in. (0.051 mm) maximum
Cylinder head surface
Height 4.30 in. (11.024 cm) minimum
Turbocharger bearing housing bore Inside diameter 0.876 in. (22.268 mm) maximum
Turbocharger wheel and shaft Seal ring clearance 0.0005 in. (0.13 mm) maximum
Turbocharger wheel and shaft
Outside diameter 0.5611 in. (14.252 mm) minimum
bearing area
Turbocharger thrust collar Thickness 0.0980 in. (2.489 mm) minimum
Turbocharger oil slinger Seal ring clearance 0.0005 in. (0.13 mm) maximum
Turbocharger turbine blade Turbine housing clearance 0.008 in. (0.20 mm) minimum
Impeller housing
Turbocharger impeller 0.006 in. (0.15 mm) minimum
clearance
0.001 in. (0.254 mm) minimum –
Turbocharger wheel and shaft End play
0.004 in (0.1 mm) maximum
Water pump housing Bearing bore 2.45 in. (62.22 mm) maximum
Impeller must be smaller than water Maintain a press fit
0.001 in. (0.025 mm)
pump shaft impeller end to between components
0.6262 in. (15.905 mm) minimum –
Water pump shaft impeller End outside diameter
0.6267 in. (15.918 mm) maximum
Pulley end outside 0.6693 in. (17.000 mm) minimum –
Water pump shaft
diameter 0.6696 in. (17.008 mm) maximum
Water pump pulley must be smaller Maintain a press fit
0.001 in. (0.025 mm)
than water pump shaft pulley end to between components
0.6663 in. (16.924 mm) minimum –
Water pump pulley bore Inside diameter
0.6673 in. (16.949 mm) maximum
0.624 in. (15.85 mm) minimum –
Water pump impeller bore Inside diameter
0.6625 in. (15.88 mm) maximum
0.020 in. (0.508 mm) minimum –
Impeller and water pump housing Clearance
0.040 in. (1.016 mm) maximum
0.007 in. (0.178 mm) minimum –
Crankshaft and thrust bearing Total end clearance
0.018 in. (0.457 mm) maximum.
washers
Clearance for worn parts 0.022 in. (0.559 mm) maximum
0.002 in. (0.051 mm) minimum –
Camshaft gear to crankshaft gear Backlash
0.020 in. (0.508 mm) maximum
Crankshaft and main bearings 0.014 in. (0.356 mm) minimum –
Thickness
gasket 0.080 in. (2.032 mm) maximum
0.004 in. (0.102 mm) minimum –
Connecting rod cap and crankshaft Side clearance
0.013 in. (0.330 mm) maximum
TM page 0054 00-6
Table 1. Wear Limits (Contd). PART DESCRIPTION/LOCATION WEAR LIMIT Accessory drive gear to camshaft 0.002 in. (0.051 mm) minimum – Backlash gear 0.016 in. (0.406 mm) maximum 0.002 in. (0.051 mm) minimum – Oil pump drive gear Backlash between gears 0.016 in. (0.406 mm) maximum Oil pan mounting flange on gear Gear cover must be even with front cover with oil pan mounting flange Alignment cylinder block flange within 0.004 on cylinder block in. (0.102 mm) Mounting flange of camshaft support 0.008 in (0.203 mm) minimum – Thickness of shim pack and gear cover 0.13 in. (3.302 mm) maximum Flywheel, flexplate, and flywheel Outside diameter 0.5005 in. (12.713 mm) minimum housing dowel pins Alignment must not Crankshaft 0.008 in. (0.203 mm) exceed
END OF WORK PACKAGE
PDF page 509
SUPPORTING INFORMATION FOR ENGINE, DIESEL CUMMINS MODEL NTC-400
M915, M915A1, M915A4,
M916, M920 VEHICLES
PDF page 510
PDF page 511
Work Package Title Work Package/Page No.
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0055 00-1 Repair Parts Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0056 00-1 Repair Parts Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0057 00-1 Repair Parts and Special Tools List (RPSTL) . . . . . . . . . . . . . WP 0058 00-1 National Stock Number (NSN) Index . . . . . . . . . . . . . . . . . . . . WP 0059 00-1 Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . WP 0060 00-1 Tools and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0061 00-1 Mandatory Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . WP 0062 00-1
PDF page 512
TM page 0055 00-1