Manual de Reparacion Motor s3.8

Workshop Manual
S3.8 Engine
English – Original Instructions 3-2016 A030K288 (Issue 6)

Workshop Manual Publication A030K288
S3.8 Engine Issue 6 - 3 - 2016
“Intentionally Left Blank”
Page 2 Copyright © 2016 Cummins Inc.

Publication A030K288 Workshop Manual
Issue 6 - 3 - 2016 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.
Should you require further assistance contact:
Cummin India Limited

Power Generation Business Unit
35A/1/2, Erandwane
Pune, 411038
India
Tel: +912030248600
Fax: +912066028090
E-mail: cpgiservicesupport@cummins.com
Web Site: www.cumminspower.com
Copyright © 2016 Cummins Inc. Page 3

“Intentionally Left Blank”

Table of Contents
Description Page
To the Owner and Operator......................................................................................................... 06

Routine Service and Parts........................................................................................................... 07
10 Maintenance Steps for Cummins Engines........................................................................... 08
Section 1............................................................................................................................ 09
Operating Instructions-New and rebuilt engine break-in
Section 2............................................................................................................................ 14
Special Operating Conditions
Section 3........................................................................................................................................ 16
Engine Operation in Cold Weather

Section 4............................................................................................................................. 17
Maintenance of Engine Laid up for Long Period.
Section 5.... ................................................................................................................................... 18
Maintenance Operations
Section 6......................................................................................................................................... 23
Lubricants, Fuels & Coolant
Section 7......................................................................................................................................... 27
Disassembly Procedure
Section 8... ..................................................................................................................................... 43
Assembly Procedure
Section 9......................................................... ............................................................................... 54
Valve Clearance Adjustment
Fuel Pump - Spill Cut Off Setting
Section 10....................................................................................................................................... 60
Tolerence &Specifications
Section 11....................................................................................................................................... 71
Checking Valve Timing
Section 12....................................................................................................................................... 74
Water Pump Repair Procedure
Section 13............................................................................................................................ 78
Tightening Torques
Section 14 .................................................................................................................................................... 79
Troubleshooting
Section 15 .................................................................................................................................................... 81
Mechanical Service Tools

To the Owner and Operator
General Information
Preventative maintenance is the easiest and least expensive type of maintenance. Follow the
maintenance schedule outlined in this manual.
Keep records of regularly scheduled maintenance.
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.

Routine Service and Parts
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:
• Engine model and serial number

• Type and make of equipment
• Total hours of operation
• Warranty start date
• Nature of problem
• Summary of the current arranged in order of occurrence
• Name and location of the Cummins Distributor or Dealer

10 MAINTENANCE STEPS FOR CUMMINS ENGINE S3.8
1. KEEP DIRT OUT OF THE ENGINE.
2. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.
3. REGULATE THE ENGINE’S FUEL.
4. CONTROL OPERATING TEMPERATURE.
5. GUARD AGAINST CORROSION.
6. LET THE ENGINE BREATHE.
7. PREVENT OVER-SPEEDING.
8. KNOW YOUR ENGINE’S CONDITION.
9. CORRECT PROBLEMS WHILE THEY ARE SIMPLE.
10. SCHEDULE & CONTROL YOUR ENGINE MAINTENANCE.

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

Check Air Connection

Check air connection to air cleaner and air
crossovers to assure all are secured.
Check Engine Coolant Supply
Remove the radiator cap and check engine coolant

level. Add coolant as needed.
COOLING SYSTEM
Check and top up radiator with Specified coolant

if required. If the coolant starts boiling, there
could be a defect in the cooling system which
may be on account of : Fig. 1-2: Engine Fuel Filter
i. Less coolantor dirt/scale having
Fuel System Bleeding
accumulated inside cooling water
passages, especially in the radiator cores. If the performance of the engine Is affected
due ot presence of air in the fuel system
ii. Choking of the radiator air passages due to
foreign material or damaged radiator fins. (commonly known as air lock) the defect can be
removed by bleeding the fuel system as follows:
iii. Loss of coolant by evaporation and
leakage through defective radiator cap.
iv.Loosew ater pump drive belt. a. Loosen bleeding screw on primary filter.
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.

Oil Pressure before shutting it down to allow lubricating oil and

water to carry heat away from the combustion
Normal engine oil Pressure at temperature 2210F
(1050 C) should be between 2.5 to 5 Kg/cm 2 at chamber, bearings shafts etc. This I s especially
rated speed and 1 to 2 Kg2/cm at low idle speed. important with turbocharged engines.
The turbocharger contains bearings and seals that
Note : Please note that oil pressure will
vary with temperature. are subject to the high heat of combustion exhaust
gases. While the engine is running, this heat is
Note : Individual engines may vary from carried away by oil circulation, but if the engine
above normal pressures. Observe and is stopped suddenly, the turbocharger temperature
record pressure when engine is new to may rise above 360 0 F. The results of extreme
serve as guide for indication of
heat may be seized bearings or loose oil seals.
progressive engine condition. (High oil
pressure during start up is not a cause Do Not Idle Engine For Excessively Long
for alarm.) For record purposes these
Periods
readings are more accurate and reliable
when taken immediately after an oil Long periods of idling are not good for an engine
change. because combustion chamber temperatures drop
Engine Exhaust so low the fuel may not burn completely. This will
The engine exhaust is a good indicator of engine cause carbon to clog the injector spray holes and
operation and performance. A smoky exhaust piston rings and may result in stucked valves.
may be due to a poor grade of fuel, dirty air If engine coolant temperature becomes too low,
cleaner, voerfueling o r poor mechanical
raw fuel will wash lubricating oil off cylinder walls
conditions.
and dilute crankcase oil so all moving parts of the
If engine exhaust is smoky, corrective action
engine will suffer from poor lubrication.
should be taken.
Warning : Inhalation of exhaust gases If the engine is not being used, shut it down.
can result in severe personal injury or Switch off the engine with the shut down coil
death. Use extreme care during
installation to provide a tight exhaust provided on engine.
system. Terminate exhaust pipes away
Or
from enclosed or sheltered aeras,
windows, doors and vents. The engine can be shut down by pulling down
High Altitude Operation mechanical lever fitted on MICO pump.
Some engines, particularly naturally aspirated, lose Radiator
horsepower when operated at high altitude
The radiator used on S-3.8-G engine are state of
because the air is too thin to burn as much fuel
the art aluminium radiators. These radiators are
as at sea level. Operate the engine
using a lower power rquirement a t h igh with aluminium tubes & fins. The top and bottom
altitude to prevent smoke and over-fueling. tank are of moulded plastic material. These
radiators do not have de-aeration cooling system.
Engine Shut-Down
Warning : Do not remove the guarding
Idle Engine A Few Minutes Before Shut-
when the engine is in working condition
.
Down It is important to idle an engine 3 to 5
minutes Warning : Ensure alignment and torque
of related fasteners while connecting
alternator to the engine flywheel housing

Section 2
SPECIAL OPERATING CONDITIONS
Precautions to be observed when operating at clockwise or anti-clockwise direction as the case

high altitudes and low ambient temperatures. may be, results in a reduction of quantity of fuel
Because of low atmospheric pressure which injection, 1/4 turn correspond to approx. 7% of the
reduces the oxygen content at high altitudes it is total quantity injected.
necessary to make certain adjustments in the fuel For smoke-free operation of the diesel altitude, the
injection pump output to prevent black smoke quantity above 2000 meters altitude, the quantity
caused by unburnt fuel emitting from the engine. injected should be reduced by about 20%
(corresponding to 3/4 turn of the stop screw)
Similarly the ulbrication, fuel and the cooling
system have to be properly attend to when Mark injection pump by the letter "z' behind the
S-3.8-G engine is operated at very low ambient pump designation after the work was carried out.
temperatures. The adjustment to the fuel injection pump should
We are giving below special instructions to be be carried out at authorised MICO dealers
followed whileo perating Cummins Diesel workshops.
Engines at high altitudes and low ambient 2) LOW TEMPERATURE OPERATION
temperature.
Lubrication System
1) HIGH ALTITUDE OPERATION
The lubrication oils for engine, are required to be
Fuel System
of lower viscosity.
The engine output decreases due to reduction in Recommendations for the same are as un:der
the atmospheric pressure and density. To ensure
an optimum operation of the engine at these The recommended types of engine oils and the
conditions, it is necessary to reduce fuel supply range of ambient temperatures at which these can
for the range of altitudes are given below. This be used are given in the following table.
is necessary since devices which will correct fuel Ambient temperature Engine oil
supply during operation at varying altitudes are not in deg. C grade
available. SAE 15W40
-10 and above
For Alternating in low and high altitudes up to -20 to 0 SAE 10W30
approx. 2000 meters, no changes of the setting SAE 5W20
-10 and Below
are necessary in general.
These oils should confirm to SAE API CH4-15W40
For operation above 2000 meters, injection pumps
specification.
which inject a reduced quantity of fuel as
compared to the standard pump are required. Cooling System
In injection pumps installed as standard Certain precautions have to be taken to enable
equipment, the quantity of fuel i njected can be the cooling system to function properly at very low
reduced by loosening the lock nut & turning the ambient temperatures. To attain the recommended
full-load stop screw for the control rod clockwise working temperature of the engine faster, it i s
for RSV pumps.The adjustment should be made necessary to use a radiator blind.
on an injection pump test stand. Turning the Use the antifreeze and water to 50:50 proportion.
stop screw

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
Satisfactory performance of a diesel engine a change to warmer climate normally required

operating in low ambient temperature conditions only a minimum of revision. Most of the
requires modification of the engines, surrounding accessories should be designed in such a way
equipment, operating practices and maintenance that they can be disconnected so there is little
procedures. the colder the temperature effect on the engine when they are not in use.
encountered the greater the amount of
The two commonly used terms associated with
modification required and yet with the
preparation of equipment for low temperature
modifications applied, the engines must still be
operation are “winterization” and “Artic
capable of operation in warmer climates without
Specifications.”
extensive changes. The following formation is
provided to engine o wners, operators and Winterization of the engine and/or components so
maintenance personnel on how the modifications starting and operation possible in the lowest
can be applied to get satisfactory performance temperature to be encountered requires :
from their diesel engines. 1. Use of correct materials.
There are three basic objectives to be
2. Proper lubrication, low temperature lubricating
accomplished :
oil.
1. Reasonable starting characteristics followed
by practical and dependable warm-up of 3. Protection from the low temperature air. The
engine and equipment. metal temperature does not change, but the
rate of heat dissipation is affected.
2. A unit of installation which is as independent
as possible from external influences. 4. Fuel of proper grade for lowest temperature.
3. Modifications which maintain satisfactory 5. Heating to be provided to increase engine

operating temperatures with a minimum block and component temperature to a
increase in maintenance of the equipment minimum of -25 ° F (-32° C) for starting in
and accessories. lower temperatures.
4. Winterize Winterize Arc tic 6. Proper external heating source available.

Specifications 7. Electrical equipment capable of operating in
3°°F(-1°C)to -1° °F(-23°C)to -25° F (-32° C)to lowest expected temperature.
-1°°F(-23°C) 2-5 °F(-32°C) -65° F (-54° C) Arctic Specification refer to the design material and
Use antifreeze to Use ethylene glycol Use ethylene glycol specifications ofcomponents necessary for
satisfactory engine operation i n extreme low
protect to antifreeze 5°% antifreeze 5°% temperatures to -65°F (-54 ° C). Contact Cummins
-2°°F (-29°C) water5°% water 5°% mixture. India Limited or the equipment manufacturer to
obtain the special items required.
If satisfactory engine temperature is not
maintained higher maintenance cost will result Caution : ''Anti-leak'' antifreeze are not
due to increased engine wear, poor performance recommended to use in Cummins
and formation of excessive carbon, varnish and Engines. The ''anti-leak'' agents may
other deposits. Special provisions to overcome clog the coolant filters and render them
ineffective.
low temperatures are definitely necessary, whereas

Section 4
MAINTENANCE OF ENGINE LAID UP FOR LONG PERIOD
For engines which are not likely to be operated doing so.

for a long period the following maintenance After the cylinder head cover has been
operations are recommended to prevent removed and the inlet ports closed, the rocker
deterioration : arms, valves etc. should be sprayed with engine
1. Add 1% of water soluble anticorrosion oil to anticorrosion oil and the cover refitted.
the cooling water in the radiator. Then run the 6. Batteries, which are not used, should be
engine until it is warm-water temperature serviced at regular intervals, in order to keep
should reach at least 60 0 C, so that the them in good condition. Batteries should be
anticorrosion oil is distributed throughout the stored in a cool and dry room. Check battery
cooling system. Then drain cooling water condition every fortnight and if necessary
completely. recharge.
2. For preserving the fuel system 5 to 10% of 8. Cover up opening for air cleaner, exhaust pipe
engine anticorrosion oil has to be added to and engine breather pipe. The parking area
the fuel in the fuel tank as well as to the should be airy and dry.
oil in the housing of the injection pump. Then PREPARATION OF ENGINE AFTER EXTENDED
operate the engine for a few minutes. The STORAGE PERIOD
above fuel mixture provides sufficient
protection against corrosion even if the i. a . Check engine oil level, top up, if
injection pump is not operated for a long necessary.
period of time. Then remove pump cover and b. Remove injectors and check for spray
spray pump elements and springs with engine and nozzle opening pressure.
oil containing 5 to 10% of anticorrosion oil.
ii .Hold injection pump control lever in "stop'
Screw on pump cover and spray outside of
position.
the pump with the mixture.
iii. a. Crank the engine with the help of starter
3. To preserve the engine, drain engine oil while
until oil pressure is nidicated on hte
it is hot and replace by recommended
gauge. Do not depress accelerator pedal.
anticorrosion oil. Then crank the engine for
Cranking interval should be long enough
5 seconds with the starter motor.
to allow for battery recoveries.
4. For the protection of the cylinder walls
b. Refit injectors.
remove the nozzles and inject 20 cc of
anticorrosion engine oil into each cylinder. iv. Finally start engine in the usual manner.
When doing so, the piston should be at the v. The initial operation oil (running-in-oil) may
bottom dead centre. Refit nozzle and crank remain in the engine for a short period of
the engine with the starter motor for about 5 time (not more than 25 hrs.) after termination
seconds. Before doing so, disconnect injection of the storage period. However, the oil should
lines from the injection pump, so that be drained as soon as possible and replaced
5. Spray the unpaintedparts of the engine with by HD oil grade in accordance with the
anticorrosion oil Rustban 339 compound. ambient temperature conditions.
Cover the fan belt and rubber hoses before

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.

ENGINE MAIN\ENANE SHE\ULE & MAN\A\ORY HEKS FOR ‘S’ SERIES

With Spin-on type Fuel & Lube Oil Filter
SYS\EM A – heck B – heck - heck \ - heck
GROUP Daily Every 475 – 500 Hrs Every 1450–1500 Hrs Every 2900- 3000 Hrs
OR 6 months, which is OR 12 months, which OR 24 months, which is
earlier is earlier earlier
Check \be o\l level & Repeat A Check Repeat B Check. Repeat C Check
top-p \be o\l pto ‘H’ hange Lube Oil * Check visually for Measre Blow Bye .
LUBRIATION mark on D\pst\ck * Use only CH4-15W40 metal particles in ( Max. 8 inches of H2O
SYSTEM * Use only H4-15W40 lube Oil used lube Oil Water colmn with
Lube oil change Spin-on Lube Clean Breather 0.221 inches Dia
Oil Filter. arrangement Orifice )
* 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.
2) ONE TIME SERVICE 6. Check and tighten if necessary :

Delivery valve holders, injection pressure lines,
Commissioning Service
leak-off lines, oil sump screws, heat exchanger
This service is to be performed only once bolts, oil pressure connectionon ehat
at the time of commissioning the engine. exchanger, coolant temperature transducer on
upper cooling line, exhaust manifold, push rod
3) REGULAR SERVICING ACCORDING TO cover, timing gear cover, cylinder head cover,
THE MAINTENANCE SCHEDULE air filter mounting, air hose connection, engine
and radiator mountings, radiator h ose
In the chart indicating maintenance
connection, fuel filter mounting bolts, alternator
Intervals the type of service to be and starter motor.
performed are specified according to the
hours of operation and the fuel consumed. 7. Check connections of starter motor and
The Service intervals prescribed inthe alternator and tighten if necessary.
chart are valid for normal operating 8. Check for leakage of fuel at :
conditions. Abnormal or extreme operating
Fuel lines, pre-filter on feed pump, fuel
conditions would necessitate servicing at
shorter intervals. filter. 9. Check for leakage of engine oil at :
Oil sump, cylinder head cover, push rod cover,
RECORDING OF SERVICES timing gear cover, oil filter, heat exchanger and
The maintenance jobs which have been carried oil pressure connections.
out at specified intervals are to be recorded
in the OPERATOR’S SERVICE BOOK. As per 10.Check for leakage of coolant at :
the chosen basis for servicing, the actual hours Radiator (check cap), water pump, thermostat,
of operation or the amount of fuel consumed hose connections and coolant temperature
are to be entered in the appropriate transducer.
columns.
11.Remove and clean engine breather cap strain
COMMISSIONING SERVICE
in kerosene oil and by blowing air in reverse
At the time of commissioning the Equipment and direction and refit.
before the engine is put to operation, please 12.Tighten cylinder head nuts (with engine warm)
and in correct sequence. Check valve
clearance and adjust if necessary. (This is to

be done after 5 to 10 hours of every

remounting of cylinder head).
13.Check condition of alternator and fan belt and
adjust tension, if necessary.
14.Start engine and check :
(a) Engine idling and running (watch for any
unusual noise)
(b) Alternator and regulator operation (watch
battery charging indicator lamp)
(c) Oil pressure

(d) Water temperature.

Page 22
PRODUCT DAILY WEEKLY MONTHLY QUARTERLY
S3.8 Engine
MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

Workshop Manual
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 the tightening torque

of the fasteners.
A115 Alternator Check belt tension Check battery terminal Check the tightening torque
(Lucas TVS make) voltage while charging. of the fasteners.
No. 322000 Check the smoothness of

ball bearings.
Check tightness of output Clean and apply petroleum
& WL terminal connections jelly for battery terminals.
**DE -Drive end

**CE -Commutator end
GENERAL INSTRUCTIONS :
Ensure the panel switch is not stickily.
Do not crank the starter more than 20 seconds
If the clutch slip noise is heard, do not try to start the engine
.
MAINTENANCE SCHEDULE FOR STARTER AND ALTERNATOR
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
Copyright © 2016 Cummins Inc.

Issue 6 - 3 - 2016
Publication A030K288
Section 6
LUBRICANTS, FUELS & COOLANT
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.
FUELS a small and cheap private filling station. Before

HS-Diesel oils recommended for use on S 3.8 G refilling, drain off the sediments through the drain
series diesel engines o
c nfirm ot ofllowing cock provident at the bottom of the tank.
specification. If the diesel fuel has been split, the affected spots
IS 1460 can be cleaned by using a mixture of 25-50%
DIN 51601 or equivalent vinegar and 75-50% water (depending on the
Do not mix kerosene with diesel as a cost degree of contamination). This will help go get rid
reducing measure. This mixture has poor of the offensive adour.
lubricating properties. It causes faster wear and At very low temperatures fluidity of diesel may
tear of fuel injection equipment components under become nisufficient to paraffin separation. it is
normal operating conditions. therefore, necessary to mix supplementary fuel
Cleanliness of the fuel influences the efficiency and with summer or winter grade diesel. The
life of the fuel filters and fuel injection equipment. supplementary fuel to be used i s kerosene of
It is, therefore, more economical to fill clean fuel aviation turbine fuel.
into the tank. All precautions should be taken to Ratios for mixing of supplementary fuel and diesel
ensure that no dirt enters the tank while filling the are shown in table :
fuel.
Ambient percentage
Special precautions if fuel is stored in drums. temperature Summer supple
1. Do not roll the drum to the engine to pump 0C grade mentary
the fuel into the tank. The drum must be diesel fuel
kept standing for at elast 24 hours to allow
upto 0 100
impurities to settle down.
0 to -10 7030
2. When placing the suction pump into the drum
see that approximately 15 cm distance is left Ambient ercentPage
between the bottom of the drum and the end temperature winter Supple -
of the suction pipe, so that sediments (dirt, 0C grade mentary
mud, water) are not sucked in. diesel fuel
3. The suction bore at the end of the suction upto -15 100 0
pipe must be protected by a fine mesh
-15 to -20 70 30
sieve.
4. Put a piece of clean flannel cloth into filter -20 and below 50 50
opening. Care should be taken that diesel and
5. Keep suction pump free from dust. Do not supplementary fuel are thoroughly mixed before
place it on the floor. filling.
To ensure that clean fuel is always available for COOLANTS
refuelling it is advisable to set up a large tank Presence of dirt I n coolant chokes up radiator,
(containing about 500 to 1000 liters, according to water passages in cylinder head and crankcase,
requirement) at a suitable place, thus establishing thereby causing overheating of engine.

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

CLEANING OF COOLING SYSTEM Cummins strongly recommends the use of

SAE 15W40 lub oil with API, CH4 classification
Wait until the temperature falls below 50°C before
for all Cummins engines to get the various
draining. advantages and optimum performance from
Draining procedure the engine.
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
Head Group Disassembly
Description :- Drain The Engine oil before starthing the

disassembly
Remove the rocker cover bolts
Tools :- 22 mm ring spaner
13 mm socket with ratchet
Torque :- not required
Description :- Remove The Exhust Manifold &

Hose Connection
Tools :- 13 mm Socket & 8mm Socket or

screwdriver

Description :- Take Out The Rocker Cover & remove

The Gasket
Tools :- By Hand
Description :- Disconnect the thermostat hose

connection
Remove upper Cooling Line
Tools :- 8 mm Scoket or screwdriver
10 mm spanner

Description :- Remove The Rocker Arm Assembly

&push rods
Tools :- 18 mm socket
Accessories Group Disassembly
Description :- Fan Removal By Unlocking the lock

plate
Tools :- 13 mm Socket

Description :- Charging Alternator removal
Tools :- 17 mm Ring Spaner
Description :- Fan Belt Removal
Tools :- Remove By Hand

Description :-Turbocharger hose removal
Tools :- 8 mm Socket Or Screwdriver
Description :- Starter Motor Removal
Tools :- 16 mm Spanner

Description :- Turbocharger removal
Tools :- 10-11 mm Socket
Description :- Remove Intake Manifold
Tools :- 16 C Spanner

Description :- Fuel Filter Removal

Fuel Intel &outlet Hose Connection
Tools :- 17 mm spanner
17 mm & 19 mm ring spanner
Description :- Disconnect the fuel overflow

Connection
Tools :- 13 mm & 19 mm open

Spanner

Description :- Fuel Pump Removal Disconnect

the Hp pipe from fuel pump end
unscrew 5 mounting Bolts
Tools :- 13 mm Ring spanner
Description :- Cylinder Head & Cylinder Head

Gasket Removal

Description :- water pump &its gasket

Removal
Description :- Crankshaft pulley and gear case cover

removal -lock the engine from flywheel
end

Description :- Time Gear Removal
Tools :- Allen Key
Description :- oil Clear removal

Description :- Oil Filter Assembly
Tools :- Oil Filter Cap Wrench
Description :- removal The Tappet Cover &Tappets
Tools :- 13 mm Ring Spanner & monkey plyer

Pan Group Disassembly
Description :- Oil Pan Removal Along With Its Gasket

(if Feasible invert the Engine upside _down
Tools :- 10 mm Extend The Socket
Description :- Lube oil Pump along With Suction

Tube removal

Description :- Gear Case Removal
Description :- Flywheel &Flywheel Housing

Removel

Description :- Gear Case Removal
Description :- Flywheel &Flywheel Housing

Removel

Description :- Camshaft Removal -Remove the Clamp First

& Then The Camshaft
Tools :- Screwdriver
Description :- Connecting Rod Cap

Removal

Description :- Pull Out Piston Assembly From The Block
Tools :- By Hand

Section 8
ASSEMBLY PROCEDURE
Block Group Assembly- Piston Assembly on Connecting Rod
Description :- Insert The Piston With Arrows Pointing towards

Gear Case Cover
Mount The Crankshaft on The Block
Tools :- Ring Compressor
lifting Hook And Crane
Block Group Assembly
Description :- Insert The Piston With Arrows Pointing towards

Gear Case Cover
Mount The Crankshaft on The Block
Tools :- Ring Compressor
lifting Hook And Crane

Description :- Fit The Main Journal Along With Bearing&

Thrust Washer
Apply torque in the Squnce:4-3-5-2-1
Mentioned On the Cap
Tools :- 19 mm scoket
Torque Wrench
Torque :- Tighten Bolt
Description :- Fit The Large End Bearing along with con

rod cap.
Torque :- 10 kg Fm

Description :- Insert The Camshaft Gently Without damaging

The Bush
Block The Oil Hole By The Clamp
Tools :- By Hand
Screwdriver
Torque :- Not Required
3 kgfm
Description :- Fit The Lube Oil Pump Along With Suction

Tube
Tools :- 10 mm ring Spanner
Torque :- 3 kgFm

PAN GROUP ASSEMBLY

Description :- Fit The Oil Sump Along With Gasket
Torque :- 0.5 kgfm
END GROUP ASSEMBLY

Description :- Fit The Flywheel Housing
Torque :- 9 kgfm
Description :- Insert The Flywheel
Torque :- 10 kgFm

Description :- Align The Camshaft Gear With Key Way

Camshaft
Match The 0-0 On The Crankshafts Gear &the
camshafts gear
Tighten With Allen Key
Torque :- 8 kgfm
Description :- Timing mark on the flywheel &fip Gear

Matching With Camshaft Gear To be
Confirmed & tighten fip mountings bolts
Tools :- 10-11 mm ring Spanher
Torque :- 2.5 kgfm

Description :- Fit The Cylinder Head Along With Gasket

&apply Torque in the sequence given
Torque :- 1ststage - 6
2nd stage - 9
3rd stage - 11
Description :- Insert Push rods &

Rocker assembly on the cylinder head
Torque :- 0.4-0.6Kgfm
11Kgmf

ACCESSORIES GROUP ASSEMBLY

Description :- Fit The Cylinder Head Along With Gasket
&apply Torque in the sequence given
Torque :- 3.5 kgfm
Ends Group Assembly
Description :- Fit the Front gear case cover
Torque :- 0.8 kgfm
HEAD Group Assembly
Description :- Fit the upper cooling line with thermostat

hose
Tools :- 10 mm spanner & 8mm or Screwdriver
Torque :- 3 Kgfm

Ends Group Assembly
Description :- Mount the Crankshaft pulley
Torque :- 50-55 kgfm
ACCESSORIES GROUP ASSEMBLY

Description :- Fit the Charging alternator.
Torque :- 5 kgfm
Description :- Fan belt fitment- Achieve the required belt

tension by adjusting adjuster nut on the
Charging alternator
Tools :- By Hand
Torque :- Not Required

Description :- Fit the Starter Motor
Tools :- 12-13 C spanner
Torque :- 5KgfM
Description :- Fit the turbocharger and its hose connection
Tools :- 10-11mm socket
Torque :- 3.5 KgfM

Description :- Fit the Fuel filter & Injector Overflow

connection
Tools :- 16-17mm Ring spanner
Torque :- 2 Kgfm
Description :- Fit the Fan & lock its locking plate properly
Torque :- 3.5KgfM

Description :- Fit the turbocharger and its hose connection
Torque :- 3.5 KgfM
Description :- Do the Tappet setting

Fit the Rocker cover
Tools :- 13mm socket
Torque :- Not Requird

Section 9
DISASSEMBLY PROCEDURE
§Valve Clearance Adjustment

§Step 1:Bring First Piston at TDC by matching “0”mark on flywheel
ØValve nos.1 2 3 4 5 6 7 8
Fan side E I I E E I I E Flywheel side
Fuel Pump Side
§Step 2: Adjust tappets in sequence 1-2-3-5
§Step 3”: Rotate the engine by 360 and adjust in sequence 8-7-6-4
§Step4:For inlet valve gap is 0.2mm & for exhaust 0.3mm

Fuel Pump - Spill Cut Off Setting
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.
Step 2: Install fuel injection pump with new gasket into

timing gear housing in such a manner that the tooth
of the injection pump gear marked with a notch is in
alignment with pointer in timing housing small cover.
Fit mounting bolts with spring washer and tighten
Pointer to align with

rear end of the
helical tooth.

Step 3: Rotate the crankshaft till 10 deg (BTDC) mark on

Flywheel coincide with pointer
§Remove #1 delivery valve holder and remove delivery

valve spring and peg.

Step 4: Refit delivery valve holder without delivery valve,

spring & peg and tighten the holder to specified torque.
Delivery Valve,
Step 5: Install swan neck tube tight on #1 holder spring & peg
and tight all other tubes
Swan neck tube

Step 6: Supply diesel with gravity to the fuel injection pump.
Supply fuel with

gravity
Step 7: Set control lever to full throttle position.
Step 8: Loosen mounting bolts of the fuel injection

pump to intermediate plate to swivel the pump.

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).
NOTE: If this condition does not exist, either timer is faulty or

crankshaft gear mismatched or the fuel injection pump is
not properly timed to the engine camshaft.
Fig(a)
§If the pump is correctly mounted, proceed as follows:

Swivel fuel injection pump towards engine, when the flow of
fuel will resume. Now swivel pump away from the engine slowly
when the flow of fuel decreases. Fig. (a) and ultimately the flow
nearly stops, giving a drop in 15 to 20 seconds. Fig. (b)
Check flywheel position once again to make sure that the 10 ͦ
mark (BTDC) on the flywheel aligns with the pointer.
Step 9: Tighten fuel injection pump bolts (4 numbers) Fig(b)

carefully so as not to disturb the position of the
fuel injection pump.
Step 10: Turn crankshaft in the reverse direction by approx.30 degrees.

The fuel will start flowing freely. Then slowly turn crankshaft in the forward direction
till the fuel flow nearly stops and a drop forms on the swan neck in 15 to 20 seconds.
ØThe position should coincide with Yellow mark (BTDC) on flywheel aligning with
the pointer. This check confirms that the fuel injection timing has been correctly set.
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
ENGINE REPAIR DATA
Fig. 1 Cylinder block Fig. 2 Cylinder liner
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 À' and `B'. Fig. 1 359.0 / 359.1 mm
Permissible maximum machining allowance on cylinder block. 0.2 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
Parent bore in cyl. block for liner À'. Fig. 2 100.035/100.000 mm
Liner outer dia 100.095/100.065 mm
Interference between cyl. liner & parent bore in block 0.030 - 0.095 mm
Liner inner dia (unfinished) 96.150/95.850 mm
Cylinder bore to be finished to size `B' Fig. 2 97.000 ± 0.01 mm
Maximum permissible taper and ovality of finished bore 0.01 mm
Maximum Permissible shift in perpendicularity of cyl. bore from crankshaft axis when 0.04 mm
Checked at 200 mm from crankshaft axis.
Surface finish of cylinder bore 0.002 / 0.0035 mm

PISTON & RINGS
2
B
A. PISTON DIA
B. PISTON PIN BORE DIA
C. PISTON RING GROOVE WIDTH
` Fig. 3. Piston and rings
PISTON & RINGS
Piston selection data
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
Piston pin bore in piston 36.007 / 36.002 mm
Piston pin outside dia 36.000 / 35.995 mm
Clearance between piston pin and piston pin bore 0.012 / 0.002 mm

PISTON RING DATA
Ring Application Description Width of Piston Lateral Butt

Groove of Ring Piston Ring Groove Clearance Clearances in
Width in groove cylinder bore
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
Height of cylinder head (Standard) 92 ± 0.1 mm

Minimum permissible height of cylinder head 91.0 mm
(after machining)
Permissible unevenness of mating surface to cyl. block. Length wise : measure over entire length : 0.05 mm
over 150 mm : 0.015 mm
Permissible parallelism of lower and upper
machined surfaces 0.1 mm
Surface finish on lower machined surface of cylinder head R < 15 microns

Rz <
max 25 microns
Wf = 10 microns (cut-off 2.5 mm)
Surface finish on Upper surface = 6.3 microns
o o
Pressure test cyl. head for leakages at water temperature 70 to 80 C
and at pressure 5 - 0. 5 bar

VALVE GUIDES S S
Fig. 4 Valve guides
VALVE GUIDES
Bore in Valve Guide Valve guides Length of valve

cyl. head OD ID Dim 'P' guide Dim 'R'
Inlet/ Inlet/ Inlet Exhaust Inlet Exhaust

exhaust exhaust
Dim- `S' Dim- `S'
Standard 15.018 15.046

15.000 15.028
Standard - I 15.118 15.146

15.100 15.128
9.022 10.022 73.5 68.5
9.000 10.000
Repair 15.218 15.246
size — I 15.200 15.228
Repair 15.518 15.546

size — II 15.500 15.528
Interference of valve guide in cylinder head 0.010 / 0.046 mm
Clearance of valve stem and valve guide Inlet 0.05 / 0.087 mm

seat on cylinder head
Exhaust 0.06 / 0.097 mm
Maximum run-out of valve seat in cylinder head in 0.04 mm

relation to valve guide centre axis
Height of valve guide end from spring seat in 20.0 - 19.5 mm

cylinder head
Maximum permissible out of perpendicularity of 0.1 mm

valve guide bore with respect to cylinder head bottom face

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 Ì' 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'
Width of valve seat in mm 1.6 – 2.0 2.0 – 2.5

cyl. head 'H'
Maximum diameter of the mm 43.4 – 43.38 35.4 – 35.38
valve seat in cylinder head 'F'

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
Description Inlet Exhaust
o o
Valve seat angle on valve 45 ± 10' 45 ± 10'
Valve head diameter — À' 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 — È' 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
Hardness of valve on stem end HRC 57 ± 3 (2.5±0.5 deep) 57 ± 3 (2.5±0.5 deep)

Distance between narrow dia of valve face BS - III 0.5 0.5 mm
to contact line

CRANK SHAFT
Fig. 9 Crank shaft
Standard and Repair sizes of crankshaft BS-I, II & III

Dimensions in mm
Size Main bearing Crankpin Width of 2nd
journal dia dia main journal
'A' 'C' 'B'
Normal 88.00 ± 0.01 +0.015 +0.062
60.00 -0.010 32.00 - 0.000
Normal - I 87.90 ± 0.01 +0.015 +0.062
59.90 -0.010 32.00 - 0.000
Repair size — I 87.75 ± 0.01 59.75 +0.015 32.00 +0.062
-0.010 -0.000
Repair size — II 87.50 ± 0.01 +0.015 +0.062
59.50 - 0.010 32.00 - 0.000
Repair size — III 87.25 ± 0.01 +0.015
59.25 - 0.010
Repair size — IV 87.00 ± 0.01 59.00 +0.015 -0.010
Crankshaft End Play measurement is from 0.140 mm to 0.330 mm
Standard and repair sizes of main bearing Dimensions in mm
Size Bearing bore in Wall thickness of bearing

installed condition shells ready for installation
BS- III
Standard 88.07 ± 0.01 2.477 - 2.465
Standard — I 87.97 ± 0.01 2.515 - 2.527
Repair size — I 87.82 ± 0.01 2.602 - 2.590
Repair size — II 87.57± 0. 01 2.715 - 2.727
Repair size — III 87.32 ± 0.01 2.852 - 2.977
Repair size — IV 87.07 ± 0.01 2.965 - 2.977

CONNECTING ROD
Standard and repair sizes of connecting rod big end bearing
Bearing bore in Wall thickness of bearing

installed condition shells ready for installation
mm mm
Standard 60.085/60.065 2.462/2.472

Standard — I 59.985/59.965 2.512/2.522
Repair size — I 59.835/59.815 2.587/2.597
Repair size — II 59.585/59.565 2.712/2.722
Repair size — III 59.335/59.315 2.837/2.847
Repair size — IV 59.085/59.065 2.962/2.972
Connecting rod big end bearing parent bore 65.019/65.00 mm
Maximum permissible taper and ovality in big end bearing parent bore 0.005 mm
Pretension of connecting rod bearing shells 0.08 – 0.14 mm
End play of connecting rod 0.100 – 0.400 mm
Maximum permissible out of parallelism (bend) between small end and 0.025 mm
big end bores (at 50 mm from centre axis)
Maximum permissible twist of connecting rod (at 50 mm from centre 0.10 mm

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
Parent bore Bush outside diameter

mm mm
Standard 39.025/39.000 39.075/39.045
Standard — I 39.225/39.200 39.275/39.245
Repair size — I 39.525/39.500 39.575/39.545
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
Standard and repair sizes of journals and bushes
Camshaft Camshaft bearing Finished bore Crank pin for

bearing No. journal dia diameter of pressed Air compressor
mm in bearing mm mm
Normal 1 55.960/55.941 56.030/56.000 32.000

2 55.710/55.691 55.770/55.740 31.984
3 55.460/55.441 55.520/55.490
Normal — I 1 55.860/55.841 55.930/55.900 31.900

(0.1 undersize) 2 55.610/55.591 55.670/55.640 31.884
3 55.360/55.341 55.420/55.390
Repair size — I 1 55.710/55.691 55.780/55.750 31.750

(0.25 undersize) 2 55.460/55.441 55.520/55.490 31.734
3 55.210/55.191 55.270/55.240
Repair size — II 1 55.460/55.441 55.530/55.500 31.500

(0.50 undersize) 2 55.210/55.191 55.270/55.240 31.484
3 54.960/54.941 55.020/54.990
Parent bore of camshaft bearing in cylinder block (BSI, II , III) 59.970/60.00 mm
Outside diameter of cam bush 60.18/60.15 mm
Radial play of camshaft bearings 0.030 – 0.079 mm

Axial play of camshaft 0.39 – 0.11 mm
Maximum permissible radial run-out of camshaft when supported at 1 & 3

journals measure at: Cam base circle 0.025 mm
Helical gear 0.06 mm
Bearing journal No. 2 0.025 mm
Camshaft gear seat 0.02 mm
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
Camshaft spigot diameter for camshaft gear 34.995/34.980 mm
Camshaft gear I.D. 35.025/35.000 mm
Fuel injection pump drive gear I.D. 35.025 - 35.00 (BS III) mm

B
C
Fig. 10 Flywheel
FLYWHEEL Fig. 10
Diameter for holding starter ring gear on flywheel `C' 335.53/335.39 mm
Ring gear inside diameter 'C' (BS- I, II, III) 334.69/334.83 mm
Diameter for holding crankshaft flange `B' 130.040 / 130.000 mm
Maximum permissible material removal on friction face 1.0 mm
Surface finish on friction surface 3.2 Micron in Ra
Permissible run-out on friction face when measured on a diameter of 0.10 mm

360 mm w.r.t. dia 130 H7
Permissible diametrical run-out of flywheel on diameter for starter ring gear 0.1 (BS-II & III) 0.05 (BS-I) mm
Width of flywheel `D' 40.1 / 39.9 mm
Permissible imbalance of flywheel at 1000 rpm 20 cm-gm

+0.046
Bore dia for drive shaft spigot Bearing 'A' 78 0.000 mm

FUEL INJECTOR INSTALLATION
1. Apply a ilght coat of grease/oil to new

sealing ring and place it in cylinder head.
Fig. 18.
2. Screw in protective sleeve into cylinder head
with adapter and tighten to
specified torque. Fig. 19.
3. Insert new copper washer for the injectors
into protective sleeves.
4. Insert injectors into cylinder head after
aligning the locating lug of the nozzle holder
into slot provided into cylinder head.
5. Screw-in pressure screw for nozzle holder
Fig. 18
with socket and tighten to
specified torque. Fig. 20.
6. Install leak off line with new sealing washers
and tighten banjo bolts to specified torque.
7. Connect high pressure line to injectors and
delivery valve holder ensuring the pipes are
free from tension. If necessary align pipes
free of tension with special tool,
Tighten high pressure ilnes cap
nuts to specified torque. Fig. 21.
8. Screw-in and tighten inner screw plugs into
cylinder head.
9. Tighten outer screw plug into the inner screw
plug over sealing rings.
10. Fit high pressure line clamps.
11. Install cylinder head covers with gasket.
Fig. 19
INSPECTION OF INJECTION NOZZLES
(Injectors removed)
1. CHECKING NOZZLE OPENING PRESSURE
Carefully remove carbon deposits from nozzle.

Connect injector assembly to nozzle tester.
Depress nozzle tester lever down slowly with
pressure gauge connected one stroke per
second and read opening pressure when
nozzle tsarts poening. f Ihte poening
pressure is too high or too low, disassemble
and clean injection nozzle and adjust as
required by selecting the adjusting shims. (If
the pressure
is too high, use thinner shims, if too low, use Fig. 20

Section 11
CHECKING VALVE TIMING
REMOVAL AND INSTALLATION OF INJECTOR

AND PROTECTIVE SLEEVE
REMOVAL
1 Drain coolant from radiator and cylinder block.
2 Remove cylinder head cover.
3 Remove clamps holding high pressure lines.
4 Loosen The outer screw plugs sealing high
pressure lines and remove inner screw plugs
holding high pressure line in cylinder head.
5. Disconnect high pressure lines from injectors
and delivery valve holders and slide high
pressure lines away from injectors.
NOTE : Do not bend high pressure lines. Fig. 15
6. Unscrew leak off line banjo bolts along with
sealing washer and remove leak off line
assembly Fig. 14. U nscrew and remove
pressure screw holding nozzle holder to the
cylinder head with the help of socket, g hp r e s s u r el
Fig. 15.
7. Remove nozzle holder with puller,
Fig. 16.
8. Loosen protective sleeve in cylinder head
with adaptor. Fig. 17.
9. Remove protective sleeve and its sealing ring
from cylinder head.
Fig. 16
Fig. 14 Fig. 17
thicker shims). When testing nozzle, never

put your hand under the jet of a spraying
nozzle. The jet will penetrate into the skin
which is dangerous.
2. CHECK NOZZLE FOR LEAKAGE
Push nozzle tester elver down slowly until
needle on pressure gauge shows 20 kg/cm’
below opening pressure. The nozzle is elak
proof if no drop comes out of nozzle tip
within 10 seconds.
In the event of elak, disassemble nijection Fig. 21
nozzle and clean as per procedure. If the
leak could not be repaired by careful cleaning
of seats or nozzle body and nozzle needle,
replace nozzle.
(When testing injectors with the pressure
gauge in circuit, operate nozzle tester lever
slowly as otherwisegauge mayget
damaged.)
3. CHECKING NOZZLE SPRAY (Fig. 22)
Cut off the pressure gauge from the circuit
by closing shut off valve. Move pump lever
up and down approx. 4 to 5 times per Fig.
22
second. The nozzle will then buzz very softly.
Atomization is satisfactory when the 4 jet
cones have uniform closed contours and are
finely atomized. There should be no lateral
streams. The presence of small non-buzzing
ranges with non-atomized cones is of no
significance. The te st oil will emerge in the
shape of a non-atomized cone until the
buzzing range is attained.
DISASSEMBLY,REPAIR AND ASSEMBLY OF
NOZZLE HOLDER AND INJECTION NOZZLE
Fig. 23
(Nozzle holder removed)
1 Insert nozzle holder in to holder
and unscrew pressure nut with special
wrench from nozzle body. Fig. 23.
2 Clean nozzle externally and niternally ni

diesel fuel, particularly the middle seat and
the ring groove by means of a small piece
of wood. Clean injection holes of nozzle body
with a cleaning needle from special tool
Fig. 24.
Fig. 24

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.
6. Tighten pressure nut with special wrench

to specified torque. Fig. 26.
Fig. 26

Section 12
Water Pump Repair Procedure
Removal of water Pump
1.Drain cooling water mixed with anti-

corrosive /antifreeze agent into clean
container so that it can reused. Fig. 27
2.Remove bypass hose with thermostat.
3.Unlock and unscrew mounting bolts for fan

and remove fan. Fig. 28
4.Slacken and remove 'V' Belt.Then remove

water pump pulley. Fig. 27
5.Unscrew water pump mounting bolts from

cylinder block and remove water pump. Fig. 29
Disassembly of Water Pump
1.Clamp puller on the hub.Mount the holder

on the puller to avoid rotation of hub.
2.Pull out hub slowly from the water pump

shaft by rotating centre bolt of the puller.
Fig. 30
3.Unscrew and remove water pump front
cover with oil seal and gasket.Pick out
shims.Remove oil seal from the cover using Fig. 28
drift.
4.Unscrew and remove water pump rear
Fig. 29
Fig. 30

Disassembly of Water Pump
5.Support water pump housing and press out

water pump shaft along with bearings from
the impeller using drift. Fig. 31
6. Press out the water seal from the water

pump housing.
7.Press out inner oil seal using drift. Fig. 32
8.Remove outer race of inner bearing using

puller from the water pump housing.
Fig. 31
9.Remove inner bearing race from the water
pump shaft,if required.
10.Remove outer bearing inner race from the

shaft if required.
11. Remove insert from the impeller along

with its rubber sleeve.
12.Clean all the parts thoroughly.Inspect

water pump housing,shaft and impeller.
Assembly of Water Pump
1. Press new oil seal in the housing with drift.

Fig. 32
2. Fit outer race of inner bearing in the
housing using drift. Fig. 33
3.Fit new water seal in the housing using

sleeve of the puller
4. Fit inner bearing inner race on the shaft

with the help of drift.
5.Fit inner race of the outer bearing on the

shaft with the help of drift.
6. Pack bearing cages with grease.Fill the

space between bearings on the shaft with
approximately 70gms of grease(Specification
of grease lit MP 301). Locate shaft in the
housing.
Fig. 33
7.Fit out bearing outer race and press it

gently using drift and handle.
Assembly of Water Pump
8. Fit new oil seal in front cover with the

help of drift and handle.Apply shellac over
the cover sealing surface and place new
gasket.
9. Place the shims of required thickness

between front cover and water pump
housing.
Tighten the cover mounting bolts fully.The
shims ahould be selected such as to
provide a play of 0.03 to 0.08 mm for taper
roller bearings after tightening the
cover.There should be no preloaded on the Fig.34
bearing.
10. Smear outer oill seal lip with grease.

Support water pump shaft rear end.Press
hub over shaft front end with the help of
drift.Check water pump shaft for free
rotation.
11. Fit new insert and rubber sleeve in the

impeller. Fig.34
Installation of Water Pump
1. Install water pump on the cylinder

block,tighten the mounting bolts to
specified torque. Fig. 35
2.Connect by pass hose with thermostat. Fig. 35
3.Connect cooling water inlet to water

pump.
4.Mount water pump pulley on water pump

pulley hub.
5. Mount fan on water pump pulley with

spacer. Tighten bolts to specified torque
and lock it.
6. Fit fan belt and adjust belt tension such

that centre of the vertical postion of the belt
should yeild about 15mm under thumb
pressure. Fig. 36
7. Fill cooling system with water and anti

freeze as per recommendation.
Fig. 36
8. Run the engine and ensure that there is
no leakage.

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.
Description Torque (KgfM)
Engine
1 Main. bearing cap bolts 5+1*
*Further tightening by (90 + 20 )

2 Coun.terweight bolts on crankshaft 3 +1 o o
3. Connecting rod bearing

Cap bolts M 12 x 1.25 x 56.5 (Serrated Type) 4 +1* (40 Nm +1* / 29 Lbf-ft +1*)
Cap bolts M 14 x 1.25 x 60 (Dowel Type) 5 +1* (49 Nm +1* / 36 Lbf-ft +1*)
(implementation from Oct'09)

Cap bolts M 12 x 1.25 x 56.5 (Fractured Type) 4 +1* (40 Nm +1* / 29 Lbf-ft +1*)
(implementation from June'12)

Cap Bolts M 12 Cap nuts -M14
4. Cylinder head nuts
Tighten cylinder head 1st stage 6
in 3 stages as per sequence 2nd stage 9
shown on page 22 3rd stage 11
5. Screw plug in cylinder head 10 to 20
6. Protective sleeve in cylinder head M14 x 1 6
7 . Nuzzle in nozzle holder 8
8. Nuzzle holder in cylinder head 7
9. Cap nuts on high pressure lines 2.5
10. Rocker arm support bolts M12 11
11. Cylinder head cover bolts M8 2.5
12. Screw plug in crankcase M18 8
13. Push rod chamber cover bolts M8 0.4 -0.6
14. Oil cooler bolts on Cyl. Cr. case M8 3.5
15. Timing gear housing on crankcase M10 4.5
16. Timing gear nut (Injection pump) M14 x 1.5 8
17. Timing gear housing cover M6 0.8
18. Camshaft center pin (timer on camshaft) 30
19. Vibration damber lock bolt M24 x 1.5 50 to 55
20. Flywheel mounting bolts M12 10
21. Flywheel housing on crankcase 9
22. Oil pump to crankcase 4
23. Oil pump pressure relief valve 4.5
24. Oil sump screw -M 6 0.5
25. Oil sump screw -M8 0.5
26. Oil sump drain plug 5 +1
27. Screw on water pump pulley hub 3.5
28. Exhaust manifold bolts M10 3.5
29. Starter motoron clutch housing M1 0 5
30. Clamping bolt for alternator M10 5
31. Nut on alternator pulley M14 x 1.5 3.5
32. Fuel filter bowl mounting bolts M12 x 1.5 2
33. Nuts to banjo union on leak oil line 5
34. Banjo bolt of leak oil line 2.5
35. Centre bolt of oil filter housing 6
36. Oil filter on crankcase M10 6
37. Oil pump cover on oil pump M8 3
38. Suction pipe on oil pump cover M8 3
39. Screw plug oil pressure relief valve M24 1.5+1
40. Castle Nut tightening torque -water pump 5.5

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.
The tsarter motor etrminal or Eliminate body contact.

brushes have body contact.
Carbon brushes of starter motor are Check, clean or replace carbon

not in contact with The commutator, brushes.
stuck in their guide broken, oily or
dirty.
Excessive voltage drop in the lines, Check starter motor lines and their
damaged lines or loose line connections.
connections.
Pinion or ring gear damaged, smoothern burns.

B) The armature is turning, but burns visible on the teeth.
the pinion does not mesh.
1. Battery insufficiently charged. Charge battery.
When switching on, hte starter 2. Insufficient pressure of carbon Check, clan or replace carbon
armature turns until the pinion brushes. brushes.
is positively connected, and 3. Excessive voltage drop in the Check lines and their connections.
then stops. lines.
Starting switch does not disengage. Immediately disconnect starting cable

at Battery or starter motor. Have
Starter motor continues to
switch repaired or replaced or have
operate after The switch has
starter motor repaired.
been released.
Pinion or flywheel eteth are very Thoroughly clean or smoothen burr

Pinion does not disengage dirty or damaged : release spring at the lfywheel toothing and pinion,
after the engine has started. is weak or broken. have starter motor repaired.
No fuel in the tank. Refill tank. After filling a tank which

C) Engine does not start has been completely emptied, at first
although the starter motor is vent the fuel system.
operating.
Engine is too cold. Follow hetnsitruction or f iwnter
Inadequate venting of fuel system. operation. Vent system once more.
When doing so, Check the fuel pipes
for leaks and the filler for dirt.

II. During Operation Trouble Cause Remedy

A) Engine fails. 1. No fuel in tank Refill tank. After filling a tank which
has been completely emptied. at
first vent the fuel system.
2. Fuel filter is dirty Clean.

3. Leaking fuel pipe. Firmly tighten connections.
4. Fuel feed pump does not Replace. Have the old pump
supply fuel. checked at MICO dealer.
5. Dirty or damaged injection Replace nozzles : have old nozzles
nozzles checked or lceaned by MICO
dealer.
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.

Trouble Cause Remedy

G) Oil pressure suddenly drops. Lack of oil in crankcase. Refill
Caution : In case of a Line between engine housing and Tighten connecting screws.
sudden decrease stop the oil filter is leaking.
engine immediately ! The drive of engine oil pump or Dismount pump and have it
the pump itself is damaged. repaired a t CDSS Dealer
If the above-mentioned conditions workshop.
do not apply, the oil pressure Loosen connection line fro pressure
gauge is not working properly or gauge at filter. If oil flows out of
the engine is damaged. the connecting joint while the
engine is running,t hen the oil
pressure gauge or the pressure
gauge line is damaged and should
be replaced. Otherwise, the engine
is damaged, witch should only be
repaired at authorised dealer’s
workshop.
H) oiI pressure ncreaises, There is water in the oil due to Find out and eliminate leakage.
vapours and moist air leakage in cylinder head or
escapes through the breather. crankcasee
I) Engine output drops and it is

breathing irregularly.
Stop engine immediately
The piston is seized Lack of oil or inadequate cooling.
Replace piston, if necessary, re-
bore/hone cylinder at CDSS Dealer
Crankshaft or connecting rod Lack of oil. workshop, Replace bearing, check
bearing are seized. crankshaft.
Vaporous and moist breathing There is water in the oil due to Get complaint attended by CDSS
of engine. leakage. Dealer’s workshop.
J) Trouble with alternator and
regulator.
Defective regulator or alternato.r Have it repaired at an authorised
dealer’s workshop.
Battery is not charged.
Brushes are not in contact with the Check, clean or replace brushes.
commutator, they get stuck in their
guides, are worn out, broken, oily
or dirty.
Commutator dirty or oiled up. Clean commutator.
Commutator worn out. Smoothen and recut commutato.r
Loose or damaged lines. Repair or replace lines, tighten
connections.

Section 15
Mechanical Service Tools
Item Part No. Description Qty

1 A044Z991 PLIERS, NIPPLE ROCKER ARM SHAFT 1
2 A044Z995 PULLER FOR REMOVING INJECTORS 1
3 A044Z996 ADAPTOR CHECKING COMPRESSION 1
4 A044Z997 SPANNER FOR TURNING CRANKSHAFT 1
5 A044Z987 SOCKET FOR PROTECTIVE SLEEVE 1
6 A044Z998 DRIFT(INSTALL CRANKSHAFT GEAR) 1
7 A045A000 PULLER FOR ALTERNATOR PULLEY 1
8 A044Z999 PULLER FOR CRANKSHAFT GEAR 1
9 A044Z994 SPANNER FOR FITMENT/REMOVAL OF PRESSURE SCREWS 1
10 A044Z992 CROW FOOT SPANNER FOR CYLINDER HEAD NUT 1
11 A044Z989 VALVE SPRING COMPRESSOR 1
12 A044Z985 TOOL FOR INSTALLING 7TH MAIN BEARING OIL SEAL 1
13 A052S295 PTFE SEAL SERVICE TOOL 1

Cummins Power Generation 1400 Cummins Power Generation Cummins Power Generation 10
Columbus Avenue Manston Toh Guan Road #07-01 TT
73rd Avenue NE Minneapolis Park International Tradepark
MN 55432 Manston Singapore 608838
USA Ramsgate
Kent CT12 5BF
United Kingdom
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
Cummins Power Generation Cummins Power Generation

35A/1/2, Erandawana Pune Rua Jati, 310 - Cumbica
411 038 Guarulhos –SP
India Brazil
CEP: 07180-900
Tel.: (91 020) 3024 8600 Tel.: (55 11) 2186 4195
Fax: (91 020) 6602 8090 Fax: (55 11) 2186 4729
e-mail: cpgiservicesupport@cummins.com e-mail: falecom@cumminspower.com.br
Web: www.cumminspower.com Web:www.cumminspower.com
Copyright © 2016 Cummins Inc. All rights reserved.

Cummins Power Generation, the "C" logo, and Cummins are trademarks of Cummins Inc.
PowerCommand, AmpSentry, InPower and “Our energy working for you.” are trademarks of
Cummins Power Generation Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

Manual de Reparacion Motor s3.8

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Manual de Reparacion Motor s3.8

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Workshop Manual

English – Original Instructions 3-2016 A030K288 (Issue 6)

“Intentionally Left Blank”

Page 2 Copyright © 2016 Cummins Inc.

Should you require further assistance contact:

Cummin India Limited

Copyright © 2016 Cummins Inc. Page 3

“Intentionally Left Blank”

Page 4 Copyright © 2016 Cummins Inc.

To the Owner and Operator......................................................................................................... 06

Engine Operation in Cold Weather

Copyright © 2016 Cummins Inc. Page 5

To the Owner and Operator

Keep records of regularly scheduled maintenance.

Page 6 Copyright © 2016 Cummins Inc.

Routine Service and Parts

• Engine model and serial number

Copyright © 2016 Cummins Inc. Page 7

10 MAINTENANCE STEPS FOR CUMMINS ENGINE S3.8

1. KEEP DIRT OUT OF THE ENGINE.

2. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.

3. REGULATE THE ENGINE’S FUEL.

4. CONTROL OPERATING TEMPERATURE.

5. GUARD AGAINST CORROSION.

6. LET THE ENGINE BREATHE.

8. KNOW YOUR ENGINE’S CONDITION.

9. CORRECT PROBLEMS WHILE THEY ARE SIMPLE.

10. SCHEDULE & CONTROL YOUR ENGINE MAINTENANCE.

Page 8 Copyright © 2016 Cummins Inc.

Copyright © 2016 Cummins Inc. Page 9

Check Air Connection

Check Engine Coolant Supply

Remove the radiator cap and check engine coolant

Check and top up radiator with Specified coolant

Page 10 Copyright © 2016 Cummins Inc.

Copyright © 2016 Cummins Inc. Page 11

Page 12 Copyright © 2016 Cummins Inc.

Oil Pressure before shutting it down to allow lubricating oil and

Copyright © 2016 Cummins Inc. Page 13

Precautions to be observed when operating at clockwise or anti-clockwise direction as the case

Page 14 Copyright © 2016 Cummins Inc.

Copyright © 2016 Cummins Inc. Page 15

Satisfactory performance of a diesel engine a change to warmer climate normally required

3. Modifications which maintain satisfactory 5. Heating to be provided to increase engine

4. Winterize Winterize Arc tic 6. Proper external heating source available.

Page 16 Copyright © 2016 Cummins Inc.

MAINTENANCE OF ENGINE LAID UP FOR LONG PERIOD

For engines which are not likely to be operated doing so.

Copyright © 2016 Cummins Inc. Page 17

Page 18 Copyright © 2016 Cummins Inc.

ENGINE MAIN\ENANE SHE\ULE & MAN\A\ORY HEKS FOR ‘S’ SERIES

Copyright © 2016 Cummins Inc. Page 19

2) ONE TIME SERVICE 6. Check and tighten if necessary :

Page 20 Copyright © 2016 Cummins Inc.

be done after 5 to 10 hours of every

(c) Oil pressure

Copyright © 2016 Cummins Inc. Page 21

MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

Check the tightening torque

No. 322000 Check the smoothness of

**DE -Drive end

Copyright © 2016 Cummins Inc.

LUBRICANTS, FUELS & COOLANT

FUELS a small and cheap private filling station. Before