Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
S3.8 Engine
FOREWORD
This manual is designed to be of assistance to all Personnel concerned with the maintenance and
overhaul of the S 3.8 Series Engine.
It presents a complete and detailed Description of the Engine, together with precise instruction on
servicing and overhaul procedure and dimensions which should be closely followed when overhauling
any part of the Engine to the Manufacturers standards.
Effective maintenance can only be carried out if the personnel concerned are fully conversant with the
various components of the Engine.
Before maintenance operations are commenced, this manual should be carefully studied, and it should at
all times be kept where it will be needed in the workshop.
Thoroughly read the Workshop Manual before operating the generator set.
Safe operation and top performance can be obtained only when equipment is operated and maintained
property.
This manual is for guidance and assistance with recommendations for correct and safe procedures.
Cummins Power Generation Limited cannot accept any liability whatsoever for problems arising as a
result of following recommendations in this manual.
The information contained within the manual is based on information available at the time of going to print.
In line with Cummins Power Generation Limited policy of continuous development and improvement,
information may change at any time without notice. The Installers should therefore ensure that before
commencing any work, they have the latest information available.
Consult your Authorised Distributor for further information or assistance if required. It is essential that the
utmost care is taken with the application, installation and operation of any diesel engine due to their
potentially dangerous nature.
Tel: +912030248600
Fax: +912066028090
E-mail: cpgiservicesupport@cummins.com
Web Site: www.cumminspower.com
Table of Contents
Description Page
General Information
Preventative maintenance is the easiest and least expensive type of maintenance. Follow the
maintenance schedule outlined in this manual.
Use the correct fuel, lubricating oil and coolant in your engine.
Cummins Inc. uses the latest technology and highest quality components to produce its engines.
Cummins Inc. recommends using genuine Cummins new parts and ReCon® exchange parts.
Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and
parts support.
General Information
Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and
service of your engine. Cummins has a worldwide service network of Distributors and Dealers who have
been trained to provide sound advice, expert service, and complete parts support.
Problem Solving
General Information
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a
Cummins Authorized Repair Location in your area. If the problem has not been handled satisfactorily,
follow the steps outlined below:
1. If the disagreement is with a Dealer, talk to the Cummins Distributor with whom the has his
service agreement.
2. If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office;
however, most problems are solved below the Division or Regional Office level. Before
contacting, write down the following information:
7. PREVENT OVER-SPEEDING.
Section 1
OPERATING INSTRUCTIONS
The engine operator must assume responsibility of engine care while engine is being operated
.
There are comparatively few rules which operator must observe to get best service from a Cummins
Diesel Engine.
GENERAL-ALL APPLICATION 1. Fill engine with amount of oil listed as low-
New and rebuilt Engine Break-In level oil pan capacity.
S-3.8 engines are tested before being shipped 2. Allow five (5) minutes or more for oil to drain
from the factory and are ready to be put to work. to the oil pan. If engine and/or oil
Note : One receipt of engine by truck, temperature is below 400 F (4 0 C), a longer
ensure unloading of the engine by period may be required for full drain.
skiled personnel. The Personnel have to
use necessary personal protective 3. Insert dipstick into gauge tube fully seated;
equipment to avoid accidents. Engines hold for five (5) ten (10) seconds, then
are to be un loaded using the lifting withdraw slowly.
hooks fitted on the engines. During the
engine nistallation ensure proper 4. Add enough additional oil to fill engine to
fitment of Anti VibrationMounting Pad. listed high-level capacity. The dipstick has
Warning : Ensure that the shipping mark to high & low oil level.
bracket is removed during the engine 5. Start engine and operate at idle for 3
installation.
minutes. Stop engine wait for 10 minutes and
You will get better life from engine by, fill to high mark. Additional oil may be
1. Avoiding operation fo olng periods at required to fill oil filters and lines.
engine dile speeds, or tamaximum
Do not confuse with complete oil system capacity
horsepower levels in excess of five
which also includes drilled passages, lines and
minutes.
filters.
2. Developing the habit of watching engine
Priming the Lubricating System
instruments closely during operation and
letting up on throttle if oil temperature
reaches. 2500F (1210 C) or coolant temperature
exceeds 2030F (950C)
3. Checking engine oil level prior to engine start.
4. For continuous rating, load can be applied
after the engine is commissioned.
New or Rebuilt Engines.
Pre-Starting Instructions-First Time Priming the
Fuel System.
1. Fill fuel filter with clean No. 2 diesel fuel oil
Fig. 1-1 : Pre-lubricating Turbo
meeting the specification outlined.
2. Check the oil level of the MICO fuel pump Note : On turbocharged engines,
with the dipstick provided. remove oil inlet ilne rfom the
turbocharger and pre-lubricate bearing
3. Check & fill fuel tanks. by adding 2 to 3 oz. (50 to 60cc) of clean
Oil Pan Capacities lubricating oil. Reconnect oil supply
High Low line.
(liters) (liters)
8 6
v. Coolanlte akage from the cooling system. b. Unscrew lift pump lever knob and prime till
diesel coming out of the bleeding screw of
Always use genuine radiator cap. A proper radiator the primary filter is free from any air bubble.
cap firmly fitted maintains pressure in the cooling
c. Tigtten bleeding screw and plunger knob.
system and makes the engine more efficient by
permitting a slightly higher operating temperature. d. Repeat this process on bleeding screw on
The vacuum in the radiator is relieved by a valve the secondary fuel filter and then on the fuel
provided in the cap. The radiator pressure cap injection pump gallery. If the air bubbles
value is 7 PSI. Degrease and clean cooling continue coming out of the bleeding screws,
system regularly. either there is less diesel in the tank or there
is an air leak in the suction pipe. Check and
Caution : Do not add cold water too
quickly to hot engine. rectify.
In case the engine running is found to be irregular
Overflow Valve
FUEL SYSTEM
The photograph shows different points for fuel or shows a tendency to fall or there is loss of
system. The description of these points are, power, this may be due to faulty operation of the
1. Bleeding screw primary filter overflow valve in the fuel filter system.
2. Bleeding screw secondary filter If necessary, replace it.
3. Drain plug secondary filter. Nozzle Operation
4. Drain plug primary filter.
If the engine is running irregularly or there is a
5. Bleeding screw on fuel injection pump. diesel knock or the fuel consumption is abnormal,
faulty injection nozzle operation may be the cause. the oil can immediately flow to the bearings
Generally, this is due to dirt in the fuel system. and the time required by the oil to attain the
If excessive black smoke is emitted on correct pressure is minimised.
acceleration, its could be due to drubbing of If this instruction is ignored the bearing may get
nozzles. Get the nozzles checked at MICO dealer damaged. The oil filter must be kept clean as far
point. as possible to protect the engine components
CHANGING ENGINE OIL from rapid and excessive wear and tear due to
abrasion. Tighten the centre bolt to 4 Kg-m. torque.
The engine oil should be drained while it is still hot.
a. Unscrew sump drain plug and allow the oil Note : In case the old filter cartridge was found
to drain out for 20 mins. damaged/punctured, the filter top cover
assembly should also be removed and
b. Unscrew filler plug of oil filter, drain out oil
refitted after thorough cleaning.
and refit filler plug.
Proceed as below :
c. Unscrew centre bolt and remove oil filter
bowl. Discard oil filter cartridge.T he filter i. Remove the two screws holding the filter top
cartridge should not be cleaned or cover to the crankcase and remove it with
reused. its gasket.
d. Check "O' ring and seal for any damage. ii. Remove the bypass valve assembly and
Replace if found damaged. clean the valve and its seat.
e. Clean the bowl thorougha lyn d insert a iii. Clean all oil passage in cover thoroughly.
new genuine fuel flow oil filter cartridge Replace "O' ring and seals if found
into the bowl. damaged.
f. During re-assembly of the oil filter, fill the iv. Reassemble bypass valve with new sealing
filter bowl with one litre of engine oil through washer if necessary.
the drain plug and fit the filter bowl to the
top cover and tighten the centre bolt to the v. Fit new gasket on the cover.
specified torque. Before starting, crank the vi. Refit oil filter cover assembly to the
engine with the help of ignition key, so that crankcase taking care that the gasket does
not get damaged during fitment.
vii. Tighten evenly and equally the two mounting
bolts of cover to 6 Kg-m. torque.
viii.Clean the drain plug of the engine oil sump Starting the Engine
and refit with a new sealing washer if Starting requires theclean air & fuel t ob e
necessary. Tighten to 4 to 6 Kg-m. torque. supplied to the combustion chambers in proper
ix. Fil in 8 liters of engine oil into the sump. quantities at the correct time.
x. Start engine and allow it to run for a few Engine Warm-up
minutes and stop.
When the engine is started, it takes a while to
xi. After 2° minutes check level of oil indicated
get the lubricating oil film re-established between
on the dipstick. It should be at the upper
shafts and bearings and between pistons and
mark and if not, top up.
liners. The most favourable clearances between
xii. Check oil level in fuel injection pump and moving parts are obtaining only after all engine
governor. Top up, if necessary. parts reach normal operating temperature. Avoid
Caution : Make sure that only genuine seizing pistons in liners and running dry shafts in
oil filter cartridge is used. Inspection of dry bearings by brining the engine up to operating
non genuine filter cartridges available speed gradually as it warms up.
in the market at low prices have
revealed: Oil Temperature
i. Use of inferior filtering material which cannot The oil temperature gauge normally should read
properly filter the engine oil. between 167°F (75° C)and 221°F(1°5°C).Under
full load conditions, an oil temperature of 24°° F
ii.Improper dimensions which cannot prevent (116° C) for a short period is not a cause for alarm.
filtered oil getting mixed with unfiltered oil.
Caution : Any sudden increase in oil
Since it is extremely difficult todistinguish temperature which is not caused by
between genuine and non-genuine filter elements, load increase is a warning of possible
obtain these only from Cummins Dealers. mechanical failure and should be
investigated at once.
PREPARING THE ENGINE FOR A OPERATION During warm-up period, apply load gradually
PREPARING THE ENGINE FOR A DAY'S WORK until oil temperature reaches 14° F (6°C).
Check the following : While oil is cold ti does not do a good job of
1. Fuel level in fuel tank, Top up, if necessary lubricating. Continuous operating or long periods
and secure cap. of dile with oil temperatures below14°F(6 ° C)may
2. Engine oil level -First thing in the morning or cause crankcase dilution and acids in the
at least 2° minutes after stopping the engine. lubricating oil which quickly accelerate engine
Top up, if oil level is less than midway between wear.
minimum and maximum marks. Water Temperature
The oil Should not exceed the maximum A water temperature of 167 to 2°3 F (75 C to
favourable of clearances. Maximum engine coolant
level mark. Use only approved brand of oil.
95 C) is the best assurance that working parts of
3. Radiator coolant level. Top up, if necessary the engine have expanded evenly t othe most
and secure radiator cap.
temperatures should not exceed 2°3 ° F (95)°
4. Condition and tension of fan belt. Adjust Keep thermostats always in the engine, avoid long
tension, if necessary. period of idling and take necessary steps to keep
5. All gauges, for proper functioning. water temperature up to a minimum of 167 ° F
(75 ° C). If necessary in cold weather, use radiator
6. Leakage of coolant, fuel or oil at all joints
shutters or cover a part of the radiator to prevent
of hoses and pipes and rectify, if necessary.
overcooling.
Section 2
SPECIAL OPERATING CONDITIONS
Recommended Antifreeze Agents Before adding the antifreeze agent into the
The specification for low silicate antifreeze which cooling system.
meets ASTM 4985 test (GM6038M spec) criteria.
i.Inspect the cooling system for leakages and
clean it thoroughly.
Note :
ii.Inspect the thermostat and replace if found
1. Engine is supplied with Premix Coolant as defective.
First Fill. It is advisable to attach a warning sign to
2. Mixing of other brands with Antifreeze the radiator neck reading.
Coolant is not recommended.
"Antifreeze Solution is effective upto -
Before adding the antifreeze agent into the 400C. Do not drain off cooling system'
cooling system.
It is recommended that the entire cooling
i.Inspect the cooling system for leakages and system should be drained and filled with fresh
clean it thoroughly. mixture of antifreeze agent and water in the
ratio of 50:50 for ambient temperature of upto
Certain precautions have to be taken to enable
-400C Coolant should be drained nd a
the cooling system to function properly at very low
ambient temperatures. To attain the recommended replenished in the recommended ratio every
working temperature of the engine faster, it i s two years Or 2400 hrs. which ever is
necessary to use a radiator blind. earlier.
Electrical System
In view of the grave risk of damage due to frost,
the cooling system of the engine should be filled At low ambient etmperatures prticular care
with recommended quantity of antifreezing agent. should be taken for electrical system. Useful
instructions on this subject are given below.
Percentage of antifreeze agent in cooling system
which depends upon ambient temperature is shown A full state of charge In battery should be
in following table : maintained by carefully servicing and reduced
current consumption. Below ambient temperatures,
the starting capacity of a battery si seriously
affected.
The specific gravity of the electrolyte should
be raised from 1.21 to 1.28 when operating at
0
temperatures below -15 C. The battery should
be removed and stored in a warm place when not
in operation. While reconnecting the battery,
observe polarity and care should be taken to
check that the terminals are kept clean and free
from oxide. A run down battery should be
charged. Do not add distilled water to discharged
or cold battery.
Section 3
ENGINE OPERATION IN COLD WEATHER
Section 4
Section 5
MAINTENANCE OPERATIONS
Maintenance is the key to lower operating costs. A diesel engine requires regularly schedule
maintenance to keep it running efficiently.
MAINTENANCE SCHEDULE
Preventive maintenance Is the easiest and elast A maintenance schedule should be established
expensive type of maintenance. I permits the using the check-sheet as a guide; the result
Maintenance Department to do the work at a will be a maintenance program to fit a specific
convenient time. operation.
A good Maintenance Schedule Depends on The check-sheet shown can be reproduced by any
Engine Application printer. The person making each check can then
Actual operating environment o f the engine indicate directly on the sheet that the operation
ihas been completed. When a complete column
governs the maintenance schedule. The suggested
check-sheet on the following page indicates some (Under A, B, C etc.) of checks is indicated, the
checks have to be performed more often heavy engine will be ready for additional service until the
dust or other special conditions. next check is due.
Using the Suggested Schedule Check Sheet Storage for Engines Out of Service
If an engine remains out of service and its use
The maintenance schedule check-sheet is
is not immediately forthcoming, special precautions
designed as guide until adequate experience is
obtained to establish a schedule to meet a should be taken to prevent rust as per procedure
given in Section 4.
specific operation.
A detailed list of component checks is provided Note : Please refer the table for the
through several check periods; also a suggested engine maintenance schedule and
mandatory checks for S series.
schedule basis is given for hours of operation, or
calendar of time.
* Check for leaks. Rect\fy Repeat A Check Repeat B Check. Repeat C Check
leak if found any. Check Fan Drive Check condition of Change Belt, Fan Drive
* Check Coolant level in arrangement. Hoses & clamps. change coolant &
Radiator (Caution : Do * Check Belt for Replace if necessary. fill Radiator with
not remove Cap when looseness. Tighten* Check sealings around Premix coolant only
hot ) if required. Radiator
OOLING * Check Coolant level in If reqired,clean dust
SYSTEM Tank, coolant.. If on Core of Radiator by
required, fill Premix very very low pressure
Coolant only in the Tank, of Air. ( 0.2 Kg/ ) 2
coolant up to H mark. * Check Cap,radiator for
seal. Change the Cap
if required.
* Check for fel leaks. Repeat A Check Repeat B Check. Repeat C Check
* Rectify leak if any. In hange Spin-on Fuel Check all joints in Fuel change Fuel Hoses if
FUEL case of leak at Banjo, Filter lines & tighten. Required
SYSTEM change the Copper * Clean Fuel tank inlet Clean Pre-Filter of * Calibrate Nozzles &
Washer strainer Feed Pump, Fuel. FIP at BOSCH service
Drain Sediments from Clean Breather on Fuel centre.
Fuel Water Separator Tank
Check Indicator Service Repeat A Check Repeat B Check Repeat C Check
for Air Restriction Clean Element, Air * change the Element, * Check axial & radial
( Red Band indication ). Cleaner, if required Air Filter clearances of
* Clean Element, Air * Check Hose & Clamps. Turbocharger.
AIR Cleaner in reverse * Check indicator * Measure exhaust Back
SYSTEM direction of Air flow, Service, for its proper pressure. Should not
using dry air with max function. exceed 3” of Hg. Take
0.5 kg /cm2 pressure corrective action as
Check sealing & required.
condition of Air Cleaner
* Check lugs of Battery Repeat A Check Repeat B Check Repeat C Check
ENGINE cable, for tightness. Check condition of Check Valve lashes & Tighten all clamps &
INSPECTION* Ensure Battery charging Battery adjst, if reqired monting nut bolts.
& Rn Engine, till coolant Clean Battery leads Check AVMs condition. * Check Copling bolts.
ENGINE attain minimum operating Secre all connectors Change if reqired
TESTING temp. 800 C). in Engine Electrical
* Record all Parameters system.
in Log Book.
A Note : The daily checks can be performed by the operator whereas weekly
(and above) are to be done by Specialist only.
* Belt to be checked by skilled service engineer only
SERVICE DETAILS: ensure that the following service has been carried
out. This service should be carried out by the
1) ROUTINE SERVICE -DAILY (A-check)
authorised dealer.
1. Check engine oil level, top up is 1. Check coolant level in radiator, top-up if
necessary. necessary and secure radiator cap.
2. Check fuel level in fuel tank and 2. Lubricate with the oil can. Controls to the
secure the tank cap. fuel injection pump.
3. Check coolant level in radiator & top
3. Check oil level in FIP and governor and top-
up if necessary and secure the cap.
up if necessary.
4. Check for leakage of coolant, fuel and
lube oil and rectify. 4. Check the oil level in the sum and top-up if
5. Check if all instruments are necessary.
functioning. 5. Clean air cleaner.
6M-14 starter Check tightness of Check battery specific Top up *DE Shield Remove **CE cover and smear
(Lucas make) Battery and circuit gravity. reservoir with Molybdenum Sulphide grease
connections Multi grade 15W40 overCE bearing pin.
(API-CD) oil.
Check visually Clean the brush dust inside
battery electrolyte the starter and secure CE
level. cover property. Apply Elcoprine
sealing compound around cover.
Check whether Warning Lamp ‘goes off’ when the engine is star.ted
Before starting the engine, check warning Lamp glows when the engine is started
.
Ensure the correct wattage of Warning Lamp. The wattage of the bulb to be 2.2 W
.att
Section 6
Providing and maintaining an adequate supply of clean, high quality fuel, lubricating oil, grease
and coolant in an engine is one way of insuring long life and satisfactory performance.
To prevent rush formation and freezing of water oil filter cartridge change period specified by us. The
inside water jackets of crankcase and cylinder engine oil should be replace by at every 500 hrs
head mix antifreezing agent as recommended. along with the engine oil filter cartridge and "O' ring.
Percentage of antifreeze agent in cooling system The oils of two different specification should not
which depends upon ambient temperature is be mixed.
shown in following table : Do not use recycled oils even for topping up.
They have already lost their vital properties. The
Recommended Antifreeze Agents adverse effect using reclaimed oil will not be seen
leetguard
F Compleat Eg Coolont It Is immediately, but the life of the components will
recommended that engine system be greatly reduced.
should be drained &filled With Premix It is difficult to recognise a poor quality oil.
Fleetgurd Complete Eg Coolant. Therefore, buy the recommended brands in sealed
use only premix coolant for top up & tins only from authorised dealers.
&during d Check
The oil change periods recommended in
. maintenance schedule should be adhered to.
LUBRICANTS Recommended grades of engine oils confirming to
Please use only recommended brands of oil for SAE API CH4 and MB 228.1 specifications and
getting optimum engine performance and life. grade selected according to range of ambient
There are several brands of lubricating oils in temperatures are to be as given below :
the market. Only some of these oils have been Coolant
approved by us for use in S-3.8-G engine. The Coolant reservoir is to be filled externally, upto ‘L’ level
lubricating oils approved by us is Fleetguard with same coolant concentration.
which conform to following specification : Coolant is recommended to prevent corrosion of
SAE API CH4 Engine Oils engine & radiator and to increase boiling point of
The recommended oils have certain vital properties water. An ethylene glycol (type JIS K 2234-94,
that help to reduce the wear and tear of the class 2)
components. We have tested these oils for
thousands of hours in similar conditions your
equipments is likely to encounter. The optimum
period of use for each oil filling has been carefully
determined. Therefore, always use only the
approved oil. Strictly adhere to the engine oil and
Drain the cooling system. Use a drain pan with a This oil should have a minimum TBN of 10.5.
capacity of 20 litres. NOTE
Above limits are for reference only and exact
Prolonged and repeated contact with used
applicable values can be obtained from the
antifreeze can cause skin disorders or other
respective oil manufacturer against specific
body injury.
brand of oil.
The responsibility of meeting oil quality lies
with the oil manufacturer and Cummins will
not be responsible for problems occurring on
engines due to poor quality of oil.
If in doubt about the lub oil quality, contact
lub oil manufacturing company and get the oil
analysed in laboratories.
CAUTIONS
Beware of spurious oils in the market. Bad
quality of lubricating oil is detrimental to
System flushing & filling
engine performances. Hence, oil should
Mix 0.5 kg of sodium carbonate with water for always be procured from the original
preparing flushing mixture. manufacturer or the authorized distributors.
Fill the system slowly. Lubricating oil to be used on the engine must
meet all the qualities as per manufacturer’s
Wait 2 or 3 minutes to allow air to be vented and specifications. cummins recommends audit
add mixture to bring the level to the top. checks of fresh engine oil to ensure the
quality of oil. Facility to check suitability of oil
Do not install the radiator c.ap
for using it in the engine is available with
Operating procedure Cummins Service Network.
Do not intermix different brands of oil since
Operate the engine for 5 mins. with the flushing
two different brands may not be compatible
mixture temperature above 80°C.
with each other. It is therefore recommended
Shut the engine off and drain the cooling system. that the brand which is used for initial fill,
should only be used for top-up.
However, in case of non-availability of specific
System filling brand, different brand of oil may be used at
RECOMMENDATIONS the time of oil change. In that case, drain all
Quality of Lubricating oil is one of the key drive the existing oil and flush the lub oil system
factors to decide the performance, durability and with new brand oil and then charge the
total cost of operation of diesel engine. Hence we system with new brand oil.
have always been recommending the best available/COOLANT RECOMMENDATIONS
suitable engine oil to be used in our engine. Cummins recommends, use of Premix Coolant, for
engine cooling. This is ‘Ready to Use’ type Coolant &
is available
Section 7
DISASSEMBLY PROCEDURE
Tools :- By Hand
Tools :- 18 mm socket
Tools :- 13 mm Socket
Tools :- 16 mm Spanner
Tools :- 16 C Spanner
Tools :- 17 mm spanner
17 mm & 19 mm ring spanner
Torque :- not required
Tools :- 19 mm Socket
Tools :- 16 mm Socket
Tools :- 13 mm Socket
Tools :- 13 mm Socket
Tools :- 10 mm Socket
Tools :- 19 mm Socket
Tools :- 10 mm Socket
Tools :- 19 mm Socket
Tools :- Screwdriver
Tools :- 19 mm Socket
Tools :- By Hand
Section 8
ASSEMBLY PROCEDURE
Tools :- 19 mm Socket
Torque :- 10 kg Fm
Tools :- By Hand
Screwdriver
Torque :- Not Required
3 kgfm
Torque :- 3 kgFm
Tools :- 10 mm Socket
Tools :- 16 mm Socket
Torque :- 9 kgfm
Tools :- 19 mm Socket
Torque :- 10 kgFm
Tools :- 22 mm Socket
Torque :- 8 kgfm
Tools :- 19 mm Socket
Torque :- 1ststage - 6
2nd stage - 9
3rd stage - 11
Tools :- 18 mm Socket
Torque :- 0.4-0.6Kgfm
11Kgmf
Tools :- 19 mm Socket
Tools :- 10 mm Socket
Torque :- 3 Kgfm
Tools :- 46 mm Socket
Tools :- 17 mm Socket
Torque :- 5 kgfm
Tools :- By Hand
Torque :- 5KgfM
Torque :- 2 Kgfm
Description :- Fit the Fan & lock its locking plate properly
Torque :- 3.5KgfM
Section 9
DISASSEMBLY PROCEDURE
§Step 3”: Rotate the engine by 360 and adjust in sequence 8-7-6-4
Step 1: Remove inspection cover on the flywheel housing and rotate crankshaft till 0 mͦ ark (BTDC) on
flywheel coincides with pointer. Ensure that piston No. 1 is in compression stroke by the feel
of the push rods Of no.1 cylinder which should be free.
Delivery Valve,
Step 5: Install swan neck tube tight on #1 holder spring & peg
and tight all other tubes
Step 8:
Swivel pump towards engine when fuel should start
flowing freely through swan neck. Fig. (a). Swivel
pump away from the engine. Fuel flow should
completely cut off Fig(b).
Step 14: Connect fuel hoses to the feed pump and fuel injection pump main gallery.
Step 15: Connect high pressure lines to injection pumps. Tighten cap nuts to 2.5 mkg.
Ensure that the high pressure lines are free from tension and are aligned properly.
Step16: Bleed the fuel system as follows: Loosen the bleeding screw on the fuel filter
and allow air to escape to bleed the system
Section 10
TOLERENCES &SPECIFICATIONS
CYLINDER BLOCK
o o
Pressure test cylinder block for leakages of water at a temperature of and at 70 to 80 C
a pressure of 5 bar
Heights of cylinder block dimension `A' and `B'. Fig. 1 359.0 / 359.1 mm
Permissible unevenness —
In longitudinal direction `C' 0.03 or 0.015/150 mm
In crosswise direction `D'. Fig. 1. 0.00 mm
Maximum permissible out of parallelism between 0.2 mm
cyl. block upper & lower machined faces
Interference between cyl. liner & parent bore in block 0.030 - 0.095 mm
Maximum Permissible shift in perpendicularity of cyl. bore from crankshaft axis when 0.04 mm
Checked at 200 mm from crankshaft axis.
2
B
A. PISTON DIA
B. PISTON PIN BORE DIA
C. PISTON RING GROOVE WIDTH
Cyl. bore dia (mm) Piston stamped sizes available for selection
± 0.005
Standard 97.00 + 0.01 (96.90 / 96.89 /96.88) mm
Permissible difference in weight in a set of four pistons with pin and rings (maximum) 5 gm
Clearance between piston pin and piston pin bore 0.012 / 0.002 mm
Gr-I Plasma filled Internally 2.570 - 2.595 2.695 - 2.725 0.100 - 0.155 0.20 - 0.35
stepped Keystone
Ring Top
(BS III) Gr-II Taper Faced 2.465 - 2.495 2.575 - 2.595 0.080 - 0.130 0.30 - 0.60
Internally stepped
(M/s
compression ring
GIL)
Gr-III Nitride Steel 2.970 - 2.990 3.010 - 3.030 0.020 - 0.060 0.25 - 0.45
Oil Ring
CYLINDER HEAD
VALVE GUIDES S S
VALVE GUIDES
Fig 5
VALVE SEAT INSERTS
INLET EXHAUST
Standard Repair Repair Standard Repair Repair
size-I size-II size-I size-II
BS III O.D. of valve seat mm 45.080 45.380 45.580 38.080 38.380 38.580
insert `I' 45.070 45.370 45.570 38.070 38.370 38.570
Basic bore in cyl. head mm 45.025 45.325 45.525 38.025 38.325 38.525
for valve seat insert 'I' 45.000 45.300 45.500 38.000 38.000 38.500
Interference of valve seat mm 0.045 - 0.080 0.045 - 0.080
insert in cylinder head.
Depth of parent bore in mm 11.2 – 11.0 11.2 – 11.0
cylinder head `J'
Height of valve seat mm BS III 8.20 - 8.30 8.40 - 8.50
insert `K'
Distance of parting surface mm BS III 2.80 - 3.00 2.60 - 2.80
of cyl. head from face
– 10' – 10'
o O
Valve seat angle in cyl. head 45 45
– 20' – 20'
INJECTION BEGINS
O
11 BEFORE T.D.C. (BS III)
O
18
INLET OPENS T.D.C. EXHAUST CLOSES
O O
29 BEFORE T. D. C. 20 51' BEFORE T.D.C.
INLET CLOSES
O
Fig. 6 Valve 55 53' AFTER B.D.C . B.D.C. EXHAUST OPENS
O
Fig.7 Valve timing diagram 53 58' BEFORE B.D.C .
VALVE
o o
Valve seat angle on valve 45 ± 10' 45 ± 10'
Valve head diameter — `A' 44.10/43.90 36.10/35.90 mm
Valve seat dia on valve — `C' BS III 42 (gauge dia) 34 (gauge dia) mm
@ 2.65±0.15 depth @ 2.65±0.15 depth
Valve stem diameter — `E' 8.950/8.935 9.940/9.925 mm
Valve seat width — `D' 3.5/2.8 4.2/3.5 mm
Length of valve 140.7/140.3 140.7/140.3 mm
Tappet clearance BS III 0.15 - 0.25 0.25 - 0.35 mm
(Cold or moderately warm engine cooling
o
system temp. 50 max.)
Permissible run-out between valve seat and stem 0.03 0.03 mm
Permissible run-out between valve head and stem 0.2 0.2 mm
Permissible ovality of valve seat 0.01 (max) 0.01 (max) mm
Minimum thickness of valve `B' head BS III 2.65±0.15 2.65±0.15 mm
@ gauge dia @ gauge dia
CRANK SHAFT
CONNECTING ROD
Maximum permissible taper and ovality in big end bearing parent bore 0.005 mm
Maximum permissible out of parallelism (bend) between small end and 0.025 mm
big end bores (at 50 mm from centre axis)
Measure the twist and bend of connecting rod with a feeler gauge with respect to vertical face of the
connecting rod alignment gauge in vertical and horizont al planes and at a distance of 50 mm from the line
joining centers of small and big end bosses. If necessary straighten the connecting in cold condition.
Standard and Repair sizes of connecting rod small end parent bore and bush
Maximum permissible taper and ovality in small end parent bore 0.005 mm
Maximum permissible taper and ovality in small end bush bore 0.005 mm
Connecting rod bush inside dia (small end) 36.03/36.02 mm
(finished size after installation)
Piston pin outside dia 36.000/35.995 mm
Connecting rod big end centre to small end centre distance 230.05/230.00 mm
Permissible difference in weight of connecting rods in the engine 20 gm
CAMSHAFT
Permissible concentricity of spigot dia for FIP drive gear w.r.t bore on 0.02 mm
camshaft gear
Permissible run-out of flyweight butting face w.r.t bore on camshaft gear 0.05(BS I) mm
Hardness of bearing journals base circle and cam lobes 55-61(BSII &III) 57 - 63(BS I) mm
Permissible run-out of flyweight butting face w.r.t bore on FIP drive gear 0.03 (BS I) mm
Backlash between camshaft gear and crankshaft gear 0.12 - 0.17(BSII &III) 0.07 – 0.18(BS I) mm
Backlash between injection pump drive gear and driven gear( Camshaft gear) 0.12 - 0.17(BSII &III) 0.07 -0.18(BS I) mm
Backlash between oil pump driving gear and driven gear 0.18 – 0.34 mm
Fuel injection pump drive gear I.D. 35.025 - 35.00 (BS III) mm
B
C
Fig. 10 Flywheel
FLYWHEEL Fig. 10
Permissible diametrical run-out of flywheel on diameter for starter ring gear 0.1 (BS-II & III) 0.05 (BS-I) mm
Section 11
CHECKING VALVE TIMING
Fig. 16
Fig. 14 Fig. 17
Copyright © 2016 Cummins Inc. Page 71
Workshop Manual Publication A030K288
S3.8 Engine Issue 6 - 3 - 2016
3 Immerse nozzle needle and nozzle body in Mark injection pump by the letter “Z” behind the
clean diesel oil and check slide ability by pump designation after the work has been carried
means of drop test. out.
DROP TEST
Keep nozzle body vertical, pull out the needle
to one-third of its length. It must drop back
on its seat by its own weight slowly. If the
needle does not slide in body, smear a little
mutton allow on it and lap the needle in
nozzle body. Do lapping in back and forth
and rotary movement of needle in nozzle
body. While doing so, the nozzle needle seat
should not touch the seat in nozzle body.
Wash in diesel and recheck by drop test.
4. Assemble nozzle in the sequence as shown
into the nozzle holder taking care to match
the locating pins on intermediate disc and
screw on pressure screw. Fig. 25 Fig. 25
5. Place nozzle holder into holder.
Fig. 26
Section 12
Water Pump Repair Procedure
Fig. 29
Fig. 30
SECTION 13
TIGHTENING TORQUES
When selecting torque wrench, remember that it should not be subject to torque exceeding three-fourth of its
maximum capacity. Before tightening, clean threads and apply a little oil to them.
Engine
1 Main. bearing cap bolts 5+1*
Cap bolts M 14 x 1.25 x 60 (Dowel Type) 5 +1* (49 Nm +1* / 36 Lbf-ft +1*)
Section 14
TROUBLE SHOOTING
I. When Starting Trouble Cause Remedy
A) Starter Motor does not operate Key not inserted properly into main Insert Key correctly.
line switch.
Battery not in order :
1. Inadequate charging condition. Have battery recharged via an
2. Bad contact. outside source of current.
Thoroughly clean battery and cable
terminals so that they are bright.
Replace starting switch.
Starting switch damaged (the parts
are loose, The switch does not
engage, it is burnt out).
Solenoid switch in starter motor Have it repaired at authorised
stuck. dealers workshop.
Excessive voltage drop in the lines, Check starter motor lines and their
damaged lines or loose line connections.
connections.
B) Engine udsdenly starts Injection nozzle has got stuck. Remove load from the engine .
knocking heavily Repeatedly shift from diling to full
load for a short time. If the knocking
does not stop, have the entire fuel
system cleaned soon
as possible.
C) Some Cylinders fail to One or more nozzles are not Dismount and check nozzles at
operate. working. MICO dealer’s workshop.
Injection pump does not function Get it checked a MICO Dealer’s
properly. workshop.
Broken valve spring at intake or Replace it.
exhaust valve.
Nozzles are damaged or the nozzle Check. if necessary, change and
D) Engine emits dense black needle got stuck. clean them.
smoke. 1. Fuel injection pump is not Have this repaired at MICO
working properly. authorised service station only.
2. Incorrect fuel injection timing. Check and reset the fuel timing
.
3. Air filter is dirty. Clean.
Fuel filter choked. Replace fuel filter elements & clean
fuel filter bowls.
E) Engine output decreases. 1. Lack of water in radiator. Slowly add cooling water only while
the engine is running.
F) Engine overheating. 2. Leaking pipes. Retighten pipe connection, if
Caution : Immediately put necessary Replace gaskets.
engine Back to idling 3. Cooling system is dirty. Clean
position and stop it after
4. Thermostat is damaged. Remove. Replace by new over as
some minutes !
soon as possible.
5. Water pump is damaged. Have it repaired at CDSS Dealer’s
workshop.
6. V-belt tension is not in order. Check
7. Cylinder head gasket elaks Check gasket.When fastening
(can be noticed by gas cylinder head again pay attention
bubbles in the cooling water) to the tightening sequence.
Section 15
Tel:+1 (763) 574-5000 Tel:+44 (0) 1843 255000 Fax:+44 Tel: (65) 6417 2388
Fax:+1 (763) 574-5298 (0) 1843 255902 Fax:(65) 6417 2399
e-mail: pgamail@cummins.com e-mail: cpgk.uk@cummins.com e-mail: cpg.apmktg@cummins.com
Web: www.cumminspower.com Web:www.cumminspower.com Web:www.cumminspower.com