09-2009 a024j818 - mototech.ru · -1-section 1 introduction this is an engine operation &...

A024J81809-2009

No part of this manual may be copied,

photocopied, reproduced, translated or stored in

a retrieval system by any means electronic,

mechanical or otherwise without prior permission

in writing of Cummins India Limited, Kothrud,

Pune 411 038.

BULLETIN NO. A024J818 (Sep. 2009)

Operation Manual

82.5 kVA = 6BT 5.9G1

100 kVA = 6BTA 5.9G1-I

125 kVA = 6BTA 5.9G2-I

140 kVA = 6BTAA 5.9G1-I

160 kVA = 6BTAA 5.9G5

Cummins India LimitedPower Generation Business Unit

35A/1/2, Erandawana,Pune 411 038Maharashtra (India)Phones : + 91 20 66027525, 30248600Fax : + 91 20 66028090

Works : (Daman)Plot No. 19-25A, Silver Industrial Estate,Bhimpore, Daman - 398 210 (India)Phones : (0260) 2262618 / 2261837Fax : (91) (0260) 2262618

Works : (Pirangut)Gat No. 311/1BAt Post - Kasar AmboliTal. Mulshi, Dist. PuneMaharashtra, India

YK

24 Hour Contact

Toll Free Number

1-800-2332000

24 Hour Emergency ServiceIn the very unlikely event of you are not receiving the normal prompt attention from ourfield force, below are the emergency contact numbers for assistance.

While asking for assistance please provide thefollowing information.

1. Your Name & Phone or Fax Number.

2. Genset Serial Number.

3. Name of the Customer.

4. Genset Location.

5. General Description of Assistance required.

INDEX

Sr. Contents Page No.

1. Introduction .............................................................................................1

2. General Safety Instructions ...................................................................2

3. Gen-set Installation - Guidelines ...........................................................5

4. Engine Systems : Overview ..................................................................7

5. Engine Operation .................................................................................. 11

6. Fuel, Oil & Coolant Specifications ...................................................... 21

7. Maintenance Schedule ......................................................................... 25

8. Engine Maintenance ............................................................................. 27

9. Fip Calibration Chart ............................................................................. 37

10. Adjustment, Replacement and Repair B Series ................................. 49

11. Trobule Shooting ................................................................................... 65

- 1 -

Section 1

INTRODUCTION

This is an engine Operation & Maintenance Manual, not a repair manual. The scope of the manual limits to

Cummins 6BT 5.9-G / 6BTA 5.9-G/6BTAA5.94 engines. This manual contains information needed to correctly

operate and maintain your engine as recommended by Cummins. This manual does not cover equipment /

alternator maintenance procedures. Please consult the equipment manufacturer for specific maintenance

recommendations.

This engine is manufactured by Cummins India Limited to suit specific application. Service for this engine

will be rendered by Cummins Sales & Services (CS & S) through its authorised dealer’s network. Please

contact local service dealer or CS & S Area / Regional / Zonal Office for any type of service / technical

support. Please refer Section No. 9 for phone numbers and addresses of CS & S offices and their dealers.

• In order to get the optimum performance of the engine, please,

• adhere to maintenance practices specified in this manual

• use recommended fuel & oils

• use genuine Cummins parts

• get service only from authorised dealers of CS & S

• use all safety & recommended installation practices.

In case you need any type of assistance, please contact Cummins India Limited (LHP BU) or CS & S on

the following addresses :

Registered Office :

Cummins India Limited Service Division

Low Horsepower Business Unit Cummins Sales & ServiceKothrud, Pune 411 038 (India) 35A/1/2, Erandwana, Pune 411 038 (India)

Admin. Office :

35A/1/2, Erandwana, Pune 411 038 (India)

Works :Plot No. 19-20, Silver Industrial Estate,Bhimpore, Daman - 396 210 (India)

- 2 -

Section 2

GENERAL SAFETY INSTRUCTIONS

Improper practices or carelessness can cause burns, cuts, mutilation or other bodily injury or death.

Read & understand all of the safety precautions and warnings before performing any repair. This list contains

the general safety precautions that must be followed to provide personal safety.

• Make sure that the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose

tools, parts, ignition sources and hazardous substances.

• Always wear protective glasses and protective shoes while working on the engine.

• Rotating parts can cause cuts, mutilation or strangulation.

• Do no wear loose fitting or torn clothing.

• Disconnect the battery (negative) cable first and discharge before beginning any repair work.

• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate

the crankshaft by pulling or prying the fan. This practice can cause serious personal injury, property

damage or damage to fan bladed causing premature failure of the engine.

• If the engine has been operating and the coolant is hot, allow the engine to cool before you slowly

loosen the filler cap and relieve the pressure from the cooling system.

• Do not work on anything that is supported only by lifting jacks or a hoist. Always use blocks or proper

stands to support the product before performing any service work.

• Be alert for possible pressure when disconnecting any device from a system that utilises pressure. Do

not check for pressure leaks with your hand. High pressure oil or fuel can cause serious injury.

• Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated

contact with your skin. Do not swallow internally. In case of contact, immediately wash skin with soap

and water.

• To avoid burns, be alert for hot parts and hot fluids in lines, tubes and compartments.

• Always use tools that are in good condition. Use only genuine Cummins replacement parts.

• Always use the same fastener part number when replacing fasteners. Do not use fasteners of lessor

quality of replacements are necessary.

• Avoid inhalation of vapours, ingestion and prolonged contact with used engine oil.

- 4 -

NOTES

- 5 -

Section 3

GEN-SET INSTALLATION - GUIDELINES

BASIC RECOMMENDATIONS

PROPER SELECTION OF GEN-SET ROOM

• Cross ventilation availability in gen-set room

• Enough space around gen-set & above gen-set

• Enough opening in front of ‘radiator’

• Ensuring leak proof joints in ‘exhaust system’

• Ensuring alignment of ‘exhaust bellow’ with exhaust

piping

• Free movement of ‘exhaust pipe’ in side wall

• No circulation of ‘exhaust gases’ in gen-set room

• Ensuring ‘rain protection’ provision over exhaust

outlet

• Proper laying of fuel lines, between fuel tank & engine

• Special care for gen-set housed in acoustic

enclosure

PROPER SELECTION OF GEN-SET ROOM

Considering type of Industry, Gen-Set Room Location

should be away from flowing particles of

• Cotton Fibres / Woolen Fibres

• Foundry Dust / Cement Dust / Stone Dust

• Chemical Fumes / Oil Fumes

CROSS VENTILATION AVAILABILITY IN GEN-SET

ROOM

• Blower Type RADIATORS are used on Gen-set

Engines

• Keep enough OPENINGS in Front of ‘Radiator’,

as well as ‘Main Alternator’ for CROSS

VENTILATION & Free flow of Cool – Clean &

Fresh air

• Take necessary care to Position GEN-SET,

such that, Engine Room Air should flow over

Gen-Set, in direction of ‘Main Alternator’

Towards ‘Radiator’

ENOUGH SPACE AROUND GEN-SET & ABOVE

GEN-SET

• ONE meter FREE SPACE, around Gen-Set is

Recommended

• TWO meter FREE SPACE, above Gen-set is

Recommended

ENOUGH OPENING IN FRONT OF ‘RADIATOR’

• Minimum Opening in Front of Radiator should

be 1.5 Times Radiator Core size

• Minimum Opening at Back ( Gen-set Rear )

should be 2.5 Times Radiator Core size

• If Opening at Back ( Gen-set Rear ) is not

possible, then opening on both sides of Gen-

set, at the rear of ‘Main Alternator’ is

permissible

ENSURING LEAK PROOF JOINTS IN ‘EXHAUST

SYSTEM’

• Ensure proper claiming at Joint of ‘Exhaust

Bellow’ with ‘Exhaust Elbow’

• Ensure proper clamping at Joint of ‘ Exhaust

Pipe’ with ‘Exhaust Silencer’

• Ensure Exhaust Gases are NOT leaking from

any Joints

ALIGNMENT OF ‘EXHAUST BELLOW’ WITH

‘EXHAUST PIPING’

• ‘Exhaust Bellow’ MUST have it’s Free Length,

when installed with Exhaust Pipe

• Ensure proper Alignment of ‘Exhaust Bellow’

with ‘Exhaust Pipe’

• Avoid Tilted / Compressed ‘Exhaust Bellow’

installation

• Proper Supports to be given to ‘Exhaust Pipe’

leading to ‘Exhaust Silencer’

- 6 -

FREE MOVEMENT OF ‘EXHAUST PIPE’ IN SIDE

WALL

• Ensure Free Movement of ‘Exhaust Pipe’ in

Side Wall

• The clearance around ‘Exhaust Pipe’ in wall is

MUST for Free movement & Expansion /

Contraction of ‘Exhaust Pipe’

• DO-NOT fix ‘Exhaust Pipe’ in Side Wall

NO CIRCULATION OF ‘EXHAUST GASES’ IN

GEN-SET ROOM

• Ensure Proper Tightening of following ‘Exhaust

System’ parts

1. Joint of ‘Exhaust Belbow’ with ‘Exhaust

Bellow’

2. Joint of ‘Exhaust Bellow’ with ‘Flange,

Exhaust Pipe’

3. Joint of ‘Exhaust Pipe’ with ‘Exhaust

Silencer’

• Ensure ‘Breather Hose’ to be extended outside

Gen-set Room

ENSURING ‘RAIN PROTECTION’ PROVISION

OVER ‘EXHAUST OUTLET’

For Vertical Outlet of Exhaust Pipe

• ‘Rain Cap’ should be installed over Outlet End

of ‘Exhaust Pipe’

For Horizontal Outlet of Exhaust Pipe

• 45 Degree Cut, slopping downwards, should be

provided at Outlet End of ‘Exhaust Pipe’.

PROPER LAYING OF ‘FUEL LINES’ BETWEEN

‘FUEL TANK & ENGINE’

• Ensure ‘Leak Free’ joints between Fuel Pipes

& Engine Hoses / Adaptors

• Laying of Pipes should NOT obstruct Free

Movement around Engine

• Location of Diesel Tank should NOT obstruct

Free movement of Ventilation Air

SPECIAL CARE FOR GEN-SET HOUSED IN

‘ACOUSTIC ENCLOSURE’

• Acoustic Enclosure should be placed in such

a way, that all Side Doors can be opened Fully,

without any obstruction.

• Avoid placement of Enclosure, very close to ‘Side

Walls’ OR ‘Pillars

• Utmost care regarding SAFETY should be taken

when ‘Acoustic Enclosure’ is placed on ROOF

TOP of Multistory Building.

• ‘Engine Maintenance’ should be possible easily &

freely, without dismantling ‘Acoustic Enclosure’

• Ensure, Temperature rise inside the Enclosure

should not be more than 5 Degree Centigrade, for

maximum Ambient Temperature above 40 Degree

Centigrade

• Ensuring visibility of Engine Panel, from outside

of Enclosure.

- 7 -

Section 4

ENGINE SYSTEMS : OVERVIEW

This section describes flow through various engine systems. The information given here are of general nature.

This is intended to help the user to understand four principle engine systems viz. Air, Fuel, Lub & Cooling

system. Good understanding in engine systems will help in troubleshooting and preventive maintenance.

4.1 Air System :

Air enters through air cleaner to turbocharger inlet. Turbocharged air passes through intake manifold,

gets distributed to all six power cylinders. After combustion, burnt gases go out through exhaust manifold

& rotates the turbine wheel. Exhaust gases emit out through flexible bellow & muffler.

Intake System

1. Intake Air Inlet to Turbocharger

2. Turbocharger Air to Aftercooler

3. Aftercooler

4. Intake Manifold (Integral part of Cylinder Head)

5. Intake Valve

Exhaust System

1. Exhaust Valve

2. Exhaust Manifold (Pulse-Type)

3. Dual Entry to Turbocharger

4. Turbocharger Exhaust Outlet.

Dual EntryTurbineHousing

PulseExhaustManifold

- 8 -

4.2 Fuel System :

Fuel is sucked from base tank by suction inlet pipe and suction strainer. Lift pump lifts the fuel &

delivers to the filtration system. There is a two stage cleaning of fuel; once by water separator & then

by microfine fuel filter. Cleaned fuel enters to Bosch fuel injection pump which pressurise and delivers

the high pressured fuel to Bosch type injectors fitted on each cylinder. Returned fuel is routed back to

the tank through return pipe.

4.3 Lub system :

Lubricating pump draws oil from the oil pan & forces it to the lubrications system. The pressure regulating

valve controls oil pressure. The filter bypass valve ensures supply of oil when filter gets choked. The

piston pines are lubricated by the splash from piston cooling nozzles. Oil pump idler gear is forced

lubricated. The reminder of the front gear train is lubricated by oil carry over splash.

The schematic given under shows the flow of lubricating oil to all parts of the engine.

1. Lubricating Oil Pump

2. Pressure Regulating Valve

3. Oil Cooler

4. Filter Bypass Valve

5. Oil Filter

6. Turbocharger Oil Supply

7. Oil Return to Pan

8. Piston Cooling Nozzle

9. Oil Pump idler Gear

Main Oil Rifle

Oil Cooler

GerotorLubricationPump

PressureRegulator

Oil Filter

BypassValve

Piston CoolingNozzle Filter

- 9 -

4.4 Cooling System :

B Series cooling system is a 10 PSI closed pressurised system.

Coolant is sucked by the engine driven water pump from the bottom tank of the radiator. Coolant passes

through oil cooler, all cylinder jackets and cylinder head to reach finally at thermostat housing. Coolant

get divided either to the inlet of the water pump or to the radiator depending on coolant temperature.

Complete coolant get diverted to the radiator after coolant temperature reached 90 deg. C.

Flow of coolant through the engine is shown in the following sketch.

Cylinder Block1. Coolant Inlet2. Pump Impeller3. Coolant Flow Past Oil Cooler4. Coolant Flow Past Cylinders5. Coolant to Cylinder Head

Cylinder Head1. Coolant Flow from Cylinder Block2. Coolant to Thermostat Housing

1. Coolant Flow Past Injector 5. By-Pass Closed2. Thermostat 6. Coolant Flow Back to Radiator3. Coolant By-Pass Passage4. Coolant Flow to Pump Inlet

- 10 -

NOTES

- 11 -

Section 5

ENGINE OPERATION

5.1 Starting the engine :

Before starting the engine, perform daily maintenance checks. Please refer Section 7&8 of this manual

for details of maintenance checks.

Caution :

To prevent damage to the starter, do not engage the starting motor more than 10 to 12 seconds. Wait

2 minutes between each attempt to start.

If the engine does not start after three attempts, check the fuel supply system. Absence of blur or

white exhaust smoke during cranking indicates that no fuel is being delivered.

Move the throttle position to idle as soon as the engine starts.

Engine oil pressure must be indicated on the gauge within 15 seconds after starting.

5.2 Stopping the engine :

Remove the load from the engine. Run the engine few minutes before routine shut down, on no load.

It will allow the lubricating oil and coolant to carry heat away from the combusion chamber, bearings,

shafts etc. This is especially emportant for Turbocharged engines.

Minimum oil pressures required

Idle : 10 PSI

Full Speed & Load : 30 PSI

5.3 Operating the engine :

• Do not operate the engine at full throttle below peak torque engine speed for extended periods (More

than 1 minute) of time.

• Allow the engine to idle 3 to 5 minutes before shutting it off after a full load operation.

• Monitor the oil pressure and coolant temperature gauges frequently. Shut off the engine if oil pressure

or coolant temperature does not meet specifications.

• Continuous operation of the engine with low or high coolant temperature can damage the engine.

• Most failures give an early warning. Look and listen for changes in performance, sound or engine

appearance that can indicate service or engine repair is needed. Some changes to look for are as follow:

- 12 -

� Engine misfires

� Vibration

� Unusual engine noise

� Fuel, oil or coolant leakage

� Sudden change in engine operating temperature or oil pressure

� Excessive smoke

� Loss of power

� An increase in oil consumption

� An increase in fuel consumption

- 13 -

Engine preservation procedure

Introduction

On any engine not in service, whether installed in equipment or waiting to be installed, the unpainted surfaces

and various internal passages are subject to rust and corrosion.

Every engine going out of factory is processed and is suitable for storage upto six months from the date of

despatch. However sometimes engines are required to be stored for more than six months, also on many

occasions engines as installed in equipment are not put in service. Hence it is necessary to process such

engines for storage. Based on above the procedure for preservation can be catagorised as below.

i. Engine preservation procedure for engines to be stored upto six months, from the date of engine shipment

from factory.

ii. Engine preservation procedure to be carried out for engine storage beyond six months from date of

shipment from factory.

iii. Engine preservation procedure for engines installed in equipment.

Note

The rate of corrosion varies with climatic condition. Variance in climatic condition makes it very difficult to

state the length of time an engine can be stored without rust and corrosion damage. However the procedures

outlined below are useful for various climatic conditions except for arctic conditions and vary low temperatures.

1. Engine preservation procedure for engines to be stored upto six months, from the date of engine

shipment from factory.

Note

Every engine going out of factory is processed for storage upto six months. Hence no additional processing

is required except proper storage, as given on next page.

i) If engine has to be stored in the engine box, as received from factory

Sr. No. Description

a Store engine box along with kit boxes, in enclosed place protected from water / rain water,

dust etc.

b Tag all these boxes indicating following,

ENGINE SHIPMENT DATE :

THE ENGINE HAS BEEN TREATED FOR

PRESERVATION FOR A PERIOD OF SIX

MONTHS FROM THE ENGINE

SHIPMENT DATE MENTIONED ABOVE.

c Do not stack any material on engine box to avoid damage to engine / engine box.

- 14 -

ii) If engine has to be stored with out engine box, and / or skid.

Sr No. Description

a Store engine along with kit boxes, in enclosed place protected from water / rain water, dust etc.

b Tag all these boxes indicating following,

ENGINE SHIPMENT DATE :

THE ENGINE HAS BEEN TREATED FOR

PRESERVATION FOR A PERIOD OF SIX

MONTHS FROM ENGINE SHIPMENT DATE

MENTIONED ABOVE.

c Ensure that all engine openings and opening on kit items such as radiators, air cleaners,

silencers etc. are covered by water proof protective caps / plastic tapes.

d Do not rotate the engine, as engine is in dry condition.

2) Engine preservation procedure to be carried out for engine storage beyond six months from date

of shipment from factory.

The engine system wise details of the process are described below.

Cooling System Passage :

SR.

NO.

a

b

c

DESCRIPTION

Prepare engine for Ensis, treatment Long

storage Process.

Fill the cooling system with Ensis oil Rustilo

DW 901, (Castrol India make) up to

thermostat outlet connection, using external

priming pump trolley.

Keep the Ensis oil in the engine for 5 minutes

and then drain it completely, from engine.

REMARKS

Fabricate and install a plate to close the

water pump inlet connection.

Leave the drain cocks open until all air is

completely vented out. Progressively close

the cocks until the ensis oil flows from the

thermostat housing.

Remove the fabricated plate at water pump inlet

and close the opening by plastic cap. (Collect the

drained oil in clean container for reuse.)

ii) Fuel Passage :

For preserving the fuel system 5 to 10% of engine anticorrosion oil has to be added to the fuel in the fuel

tank as well as to the oil in the housing of the injection pump. The operate the engine for a few minutes.

The above fuel mixture provided sufficient protection against corrosion even if the injection pump is not operated

for a long period of time. The remove pump cover and spray pump elements and springs with engine oil

containing 5 to 10% of anticorrosion oil. Screw on pump cover and spray outside of the pump with the mixture.

- 15 -

Note :

a) The above procedure for engine preservation is to be carried out / repeated at the end of every

six months during the storage period. The procedure may have to be done at OEM works or at

customer’s place depending upon location of engine.

b) Loosen the belt tension on fan belt, alternator belt, water pump belt and other accessories driven

by belt.

c) Tag the engine indicating preservation process date and due date for next preservation (6 months period).

ENGINE PRESERVATION PROCESS DATE :

THE ENGINE HAS BEEN TREATED FOR PRESERVATION

FOR A PERIOD OF SIX MONTHS.

DUE DATE FOR NEXT PRESERVATION PROCESS

(IF NOT INSTALLED IN THE EQUIPMENT).

DATE :

3) Engine preservation procedure for engines installed in equipments.

Many times, the engines shipped from factory are installed on the equipment or Genset within six months

from date of shipment from factory. However these engines as installed in the equipment are not put in

the service for a long period. For such engines the engine coolant and engine lub oil is generally filled

in the engine. Hence no special ensis process is required, but periodic running of engine as given below

is mandatory requirement.

Run the engine once in eery week for 5 to 10 min. at Low idle RPM. “B” check to be carried out

at every six months as mentioned in Section 6.

4) Preparing a preserved (treated) engine for putting in service.

When an engine is removed from storage and put into service the operation listed below should be performed.

i) Clean off all accumulated dirt from exterior of engine

ii) Remove all protective caps, tape and wrappings from connections such as Breathers, Fuel in and

out, connection Water in and out connections etc.

iii) Use suitable solvent, cleaner or decreaser to remove rust preventive compound from unpainted

external surfaces of the engine.

iv) Refill oil pan with fresh lubricating oil. Replace the fuel, lub oil filters and lub oil bypass filters,

only in case wherein engine is stored beyond six months from the date of shipment.

v) Check and correct the engine belt tensioning.

vi) Refer Section 1 for engine starting instructions.

SR. NO. DESCRIPTION REMARKS

a Prepare engine for Lub oil priming. Use lub oil priming pump for priming.

b Prime the engine with engine lub oil Use engine Lub oil trolley pump for priming.15W40. (CF-4 category) Circulate the lub oil till the lub pressure gauge

shows 1 kg/cm sq. pressure. It will take maxfive min. to reach this lub oil pressure.Bar the engine during the process.

c Drain the Lub oil from the oil pan.

iii) Lubricating Oil Passage :

- 16 -

NOTES

- 20 -

A3 page Blank

- 21 -

Section 6

FUEL, OIL & COOLANT SPECIFICATIONS

For proper operation of any engine, it is essential that good quality of lubricating oil, fuel and engine coolant

are used, so that your engine will perform at its optimum level.

6.1 Fuel Specifications :

• Use only good quality ASTM No. 2-D climatized diesel fuel.

• In extreme cold conditions, a winter blend of fuel should be used to avoid waxing in the fuel

filters.

• Do not use diesel contaminated by dirt or water. Contaminate fuel can cause severe damage to

engine fuel system.

• Maintain fuel storage tanks properly.

Table 6.1 Fuel Oil Properties : Recommended specifications

Property Recommended Specifications

Viscosity 1.3 to 5.8 centistrokes(ASTM D445) (1.3 to 5.8 mm per second) at 1.4F (40C)

Cetane Number 40 Minimum above 32 F(ASTM D-613 45 minimum below 32 F

Sulfur Content Not to exceed 1.0 mass percent(ASTM D-129 or 1552)

Active Sulfur Copper Strip Corrosion not to exceed No. 2 rating after(ASTM D1796) three hours at 122F (50C)

Water and Sediment Not to exceed 0.1 volume percent(ASTM D1796)

Carbon Residue Not to exceed 0.35 mass percent on 10 volume percent residuum(Rams bottom, ASTM D524 orConradson, ASTM D189)

Density (ASTN D 287) 42 to 30 API gravity at 60F (0.816 to 0.876 g/cc at 15 C)

Cloud Point 10 F (6 C) below lowest ambient temperature which the fuel is(ASTM D97) expected to operate

Ash Not to exceed 0.02 mass percent (0.05 mass percent with(ASTM D 482) lubricating oil blending)

Distillation The distillation curve must be smooth and continuous.(ASTM D 86)

Acid Number Not to exceed 0.1 Mg KOA per 100 ML.

(ASTM D 664)

- 22 -

6.2 Lubricating oil Specifications :

The lubricating oil used in a diesel engine performs the following functions :

1. It provides a film between the moving parts to reduce wear & friction.

2. It acts as a heat transfer media to carry heat away from the critical areas, thus provides cooling.

3. It dampens & cushions the components that operate under high stress, such as gears & tubes.

4. It protects the critical components from oxidation & corrosion.

In order to get all these functions done, it is essential that recommended lubricating oil MUST be used in the

engine.

Recommendations :

Quality of Lubricating oil is one of the key drive factors to decide the performance, durability and total cost

of operation of diesel engine. Hence we have always been recommending the best available/suitable engine

oil to be used in our engine.

Cummins India Limited strongly recommends the use of SAE 15W40 lub oil with API, CF4 classification

for all Cummins engines to get the various advantages and optimum performance from the engine.

This oil should have a minimum TBN of 10.5 to counteract the higher sulphur content of high speed diesel

available in India.

Note :

Above limits are for reference only and exact applicable values can be obtained from the respective

oil manufacturer against specific 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 engine

performances. Hence, oil should always be procured from the original manufacturer or the authorized

distributors.

Lubricating oil to be used on the engine must meet all the qualities as per manufacturer’s specifications.

Cummins recommends audit checks of fresh engine oil to ensure the quality of oil. Facility to check

suitability of oil for using it in the engine is available with Cummins Service Network.

Do not intermix different brands of oil since two different brands may not be compatible with each

other. It is therefore recommended that the brand which is used for initial fill, should only be used

for top-up.

However, in case of non-availability of specific brand, different brand of oil may be used at the time

of oil change. In that case, drain all the existing oil and flush the lub oil system with new brand oil

and then charge the system with new brand oil.

- 23 -

COOLANT RECOMMENDATIONS -

(Use FLEETGUAD Coolant only)

Cummins recommends, use of Premix Coolant, for

engine cooling. This is ‘Ready to Use’ type Coolant

& is available under Cummins Part No. 4962836

in 5 Litre Can. Coolant is ‘Ethylene Glycol’

(Type JIS K 2234-94, Class 2)

Coolant is recommended to prevent Corrosion

of Engine & Radiator. It also broadens the Operating Temperature range by Lowering the coolant freezing point & by raising it’s boiling point.

NOTE :

This Premix Coolant Do-Not require, any addition OR

mixing of Raw Water. Coolant is to be used, directly

from Coolant Can (Ready To Use)

Coolant recovery Bottle is to be filled externally, with

Coolant. Radiator is to be filled slowly, upto bottom

of Fill Neck.

Check Coolant Level Daily, before starting Gen-set.

CAUTION – Do-not add cold coolant to hot engine.

Engine castings can be damaged . Allow engine to

cool below 50 0 C, before adding Coolant.

Do-Not remove Cap, Radiator, from hot engine. Allow

engine to cool below 50 0 C, before adding Coolant.

Failure to do so, can result in personal injury from

steamy coolant.

Do-Not use sealing additives, to stop leaks in the

cooling system. This can result in coolant system

plugging & inadequate coolant flow, causing, engine

to Over heat.

Premix nt

- 24 -

NOTES

Section 7

MAINTENANCE SCHEDULE

ENGINE MAINTENANCE SCHEDULE & MANDATORY CHECKS FOR ‘B’ SERIES – G DRIVE

SYSTEM A – Check B – Check C - Check D - Check

GROUP

Daily

Every 225 – 250 Hrs OR 6 months, which is earlier



LUBRICATION SYSTEM

■ Check Oil level

■ Repeat all A Checks

■ Repeat all A & B

■ Clean Breather ■ Change Lubrication Oil ■ Change Lube Oil Filter

■ Repeat all A - B & C

Checks ■ Check Blow Bye

COOLING SYSTEM

■ Check Coolant level in Radiator & Recovery Bottle

■ If required, fill Premix Coolant, at the Rate of 9 Lit / min.

■ Check Belt condition

■ Repeat all A Checks ■ Check coolant level &

top up, if required ■ Check Fan Hub & Fan

Drive arrangement ■ Check Seal of cap,

Radiator

■ Repeat all A & B Checks

■ Check Coolant condition

■ Check Recovery Bottle & Seal

■ Check connections & sealing’s of Radiator

■ Clean Radiator, externally

■ Repeat all A - B & C Checks

■ Check Belt Tension & replace Belt, if required

■ Replace Coolant & use Premix Coolant only

■ Replace Cap. Radiator

FUEL SYSTEM

■ Check fuel Strainer ■ Clean Breather on

Fuel Tank ■ Drain Sediments from

Fuel Water Separator

■ Repeat all A Checks ■ Change Fuel Filter &

Fuel Water Separator ■ Drain sediments from

Fuel Tank


■ Check all joints in Fuel Lines & tighten.

■ Check Feed Pump & clean Baby Filter


Checks ■ Clean Fuel Tank ■ Replace Fuel Hoses if

required

AIR SYSTEM

■ Check Vacuum

Indicator for Air Restriction (Red Band)

■ Check sealing’s & condition of Air Filter

■ Repeat all A Checks ■ Clean Air Filter in

reverse direction, using dry air with max 0.5 kg/sq cm pressure



Checks ■ Check Turbocharger

End clearances

OTHER CHECKS

& ENGINE TESTING

■ Check for leaks & rectify if required

■ Run Engine & Record, all Parameters

■ Repeat all A Checks ■ Check Battery

condition ■ Clean Battery Leads ■ Secure all connectors

in Engine Electrical system.


■ Check AVMs and replace if required


Checks ■ Tighten all clamps ■ Check Valve lashes &

adjust, if required

- 25 -

- 26 -

NOTES

- 27 -

Section 8

ENGINE MAINTENANCE

8.1 Daily :

Preventive Maintenance begins with a day-to-day

awareness of condition of the engine & its

systems.

Before Start up, check oil & coolant level and

look for leaks, loose parts, frayed belts etc.

Check Oil Level :

Never operate the engine with the oil level

below “L” (Lower) mark or above “H”

(Higher) mark.

Lubricating oil Capacity between Low & High

marks is 2.10 Litres.

Check Coolant Level :

Check the coolant level by removing radiator

cap.

Caution :

Never remove the cap when the coolant is Hot.

Always use caution when removing the cap to avoid

personal injury.

Check fuel water trap :

Drain the water from fuel/water separator.

- 28 -

8.2 Every 3 months or 250 Hours :

Change / Replace Lub oil :

Warm up the engine.

Remove the plug and allow the oil to drain.

A drain pan with capacity of 20 litres will be

adequate.

Check condition of fused oil :

Thin/black oil indicates fuel dilution. Milky discoloration

indicates coolant dilution.

Contact the nearest Cummins Dealer for corrective

action, if necessary.

Change/Replace lub oil filter :

Clean around the filter head. Remove the filter & clean

the gasket surface.

- 29 -

Fill the filter with clean lubricating oil.

Apply a light film of lubricating oil to the gasket sealing

surface before installing the filter.

Caution :

Mechanical Overtightening of the filter may distort the

threads or damage the filter element seal.

Install the oil pan drain plug and tighten to 75 N. M.

(55 ft-lbs).

- 30 -

Ensure that proper brand & grade of lubricating oil is

used.

Fill the engine with the required amount of oil.

Lubricating oil capacity : 14.3 Litres.

Operate the engine at idle speed & inspect for any

leaks at drain plug or at the filter.

Shut the engine off. Allow 5 minutes for oil to drain

down. Check the oil level with the dipstick.

Check Air Cleaner :

Check the vacuum indicator.

If it is showing red mark, clean/ replace the air cleaner

element.

Check air intake system :

Inspect the intake piping for damage, cracked hoses,

loose clamps etc.

Never operate the engine without air cleaner.

Check coolant concentration :

Please refer Section 6 for details.


Change Fuel Filter :

Remove the two filters from the dual filter adapter.

- 31 -

Fill the new filters with clean fuel.

Lubricate the seal with clean lubricating oil.

Install the filters.

Caution :

Mechanical overtightening may distort the

threads or damage the filter element seal.

- 32 -

Bleeding the fuel System :

Controlled venting is provided at the injection

pump. Small amount of air introduced by

changing the filters will be vented automatically.

However, manual bleeding will be required if :

• Fuel filter is not filled properly

• Injection pump is replaced

• high pressure fuel lines are replaced.

Venting the low pressure lines :

Open the bleed screw.

Operate the hand lever (lift pump) until the fuel

flowing from the fitting is free of air.

Tighten the bleed screw.

Venting the low pressure lines :

Loosen the fittings at the injectors, and crank

the engine to allow entrapped air to bleed from

the lines. Tighten the fittings.

Caution :

High Pressure could cause penetration of skin.

Do not bleed a hot engine as this could cause

fuel to spill onto a hot exhaust manifold creating

a danger of fire.

!

- 33 -


Adjust Valve Clearance :

Remove the valve covers.

Valve Clearances :

Intake Clearance : 0.254 mm (0.010 Inch)

Exhaust Clearance : 0.508 mm (0.020 Inch)

Check / Set valves with engine cold - below 60 deg.

C as described in Step 1 & Step 2 below.

Note :

The clearance is correct when some resistance is

‘FELT’ when the feeler gauge is slipped between the

valve stem & rocker lever.

Step 1 :

Locate the TDC for cylinder no. 1.

Check /Adjust the valves indicated in the sketch.

Make the pulley & rotate the crankshaft 360 degrees.

Caution :

Ensure that the engine timing pin is disengaged.

- 34 -

Step 2 :

Set the valves as indicated in the sketch.

Tighten the lock nut to 24 N.m. (18 ft lbs.) and

recheck the valve lash.

Checking of belt, belt tension, belt tensioner & fan

hub :

Measure the belt deflection at the longest span

of the belt.

Maximum deflection : 9.5 - 12.7 mm

Check belt tension.

Note :

Cummins belt tension gauge ST-1293 should be

used. The required gauge value is 80-110 lbs.

Check the drive belt, tensioner bearing & fan

hub.

Remove the drive belt.

- 35 -

Inspect the belt for damage

Check the tensioner bearing.

Note :

The tensioner pulley should spin freely with no

rough spots detected under hand pressure.

Check the fan hub bearing.

Note :

The fan hub should spin freely without

excessive end play.

Install the drive belt.

- 36 -

NOTES

- 37 -

82.5 KVA TO 160 KVA

FIP CALIBRATION CHART

FOR

CPCB ENGINES

Section 9

- 38 -

REFERENCE NO : SSE-TS-TCL 5.88 a4

Edition : 05.2004

Replaces (edition) : -

Test oil : 9 916 034 004

Combination No. : F 002 AOZ 267-E A40 126000

Injection pump : PES 6A 95 D 320 RS 2000

Governor : RSV 500...750 A7C1376 R

C.

Engine model : 6 BT 5.9 G1

Engine code : 75006

Application : Generator 75/82.5 KVA CPCB

TEST BENCH REQUIREMENTS

Test oil inlet temperature : 38° - 42° C

Overflow valve : F 002 A10 627

Inlet pressure in bar : 2.0

Test injector : 0681 343 009

Opening pressure in bar : 172 - 176

High pressure pipe : 6 x 2 x 600

(OD x ID x length) in mm

(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION

Direction of rotation : Clockwise

Prestroke in mm : 2.60-2.70 (2.55 - 2.75)

Control rack position in mm : 9-12

Cam sequence : 1-5-3-6-2-4

Cam displacement : 60° ± 0.5°

Tappet clearance in mm : Min 0.2

Injection Timing Clocking : 9.0°-0.5°

BASIC SETTING

Speed - min-1 (rpm) : 730

Control rack travel in mm : 10.3

Delivery quantity (⎯x ) : 110.55-10.85

in cm3 / 100 strokes

Maximum spread in cm3 ( Δ ) : 0.4 (0.8)

Speed - min (rpm) : 500

Control rack travel in mm : 5.1-5.3

Delivery quantity (⎯x ) : 0.7-1.1(0.4-1.4)



(B) ADJUSTMENT OF PUMP AND GOVERNOR

GUIDE SLEEVE TRAVEL

Control lever position : Free

Speed - min~ (rpm) : 800

Control rack travel in mm : 0.3 - 0.7

1. MAXIMUM SPEED CONTROL (RATED SPEED)

(without supplementary idling spring)

Control lever position : 43° ± 4°



Speed - min-1 (rpm) : 751 - 757


Speed - min-1 (rpm) : 777-787




2. FULL LOAD DELIVERY


Boost pressure in bar : -


Delivery quantity (⎯x ) : 53.0 - 54.0 (52.0-55.0)

in cm3/500 strokes


Speed - min-1 (rpm) : -


Control rack travel in mm : -

Delivery quantity (⎯x ) : -

in cm3 /500 strokes

Maximum spread in cm3 ( Δ ) : -

3. TORQUE CONTROL







82.5 KVA CPCB

Test Specifications(Subject to alterations)

For Field Service only

- 39 -

SSE-TS-TCL 5.88 A4

4. COURSE OF DELIVERY









in cm3/500 strokes


5. IDLING SPEED CONTROL (RATED SPEED)



Control rack travel in mm : 5.1 - 5.3 #


Control rack travel in mm : Minimum 19.0

Speed - min-1 (rpm) :

Control rack travel in mm :

Speed - min-1 (rpm) : 520-580



(with supplementary idling spring)





OTHER INFORMATION:

Element : F 002 B10 570

Delivery valve : 9 411 038 576

Flyweight assembly : 1428 194 043

Governor spring : 1 424 650 007

Note:

1. SI. No. of the operations indicate the sequence of

operstions.

2. Values given in brackets are overchecking values.

# Adjust idlling stop screw to obtain 1.4 - 1.6mm control

rack travel. Then adjust supplementary idlling spring to

otain 5.1-5.3 mm control rack travel

7. GOVERNOR CUTTING IN SPEED

Speed - min-1(rpm) : 751 - 757

Control rack travel in mm : Less by 1 mm from full load

control rack travel

While over checking, if the cutting-in speed is above the

rated speed and if,

- the delivery values are within the overchecking tolerance

- control rack remains at full load position even at 50 min-1

(rpm) less than the rated speed

the cutting-in speed should be declared OK.

8. DEGREE OF IRREGULARITY

Speed - min-1 (rpm) : 790-810


Noofnotches : 14

9. STARTING TRAVEL

Speed -min-1 (rpm) : -


10. STARTING FUEL DELIVERY



Delivery quantity (⎯x ) : 9.9.-11.9 (9.4-12.4)


Adaption capsule : Nil

Nozzle : 0 433 175 147


3. ⎯x : Average of the cylinders

Applicable only for BOCSH and MICO test benches

These Test specification should not be copied to trasmitter to a third party without our written permission. All rights reserved.

030304

- 40 -

REFERENCE NO : SSE-TS-TCL 5.9 d1

Edition : 03.2004


Test oil : 9 916 034 004

Combination No. : F 002 AOZ 379-E 040 166 300

Injection pump : PES 6A 95D 320RS 2000

Governor : RSV 500...750 A7C 1376 R

Customer : Tata Cummins Pvt. Ltd.

Engine model : 6 BTA 5-9 G1-I

Engine code : 75006

Application : Generator (100 KVA)











Prestroke in mm : 2.60-2.70 (2.55 - 2.75)





Injection Timing Clocking : 7.5°± 0.5°

BASIC SETTING








Delivery quantity (⎯x ) : 1.3-1.7 (1.0-2.0)




GUIDE SLEEVE TRAVEL









Speed - min-1 (rpm) : 752 - 758


Speed - min-1 (rpm) : 775-785









in cm3/500 strokes






in cm3 /500 strokes


3. TORQUE CONTROL







100 KVA CPCB



- 41 -

SSE-TS-TCL 5.88 A4










in cm3/500 strokes










Speed - min-1 (rpm) : 540-600








OTHER INFORMATION:

Element : F 002 B10 570




Note:


operstions.


# Adjust idlling stop screw to obtain 3.1 - 3.3mm control




Speed - min-1(rpm) : 752 - 758


control rack travel


rated speed and if,






Speed - min-1 (rpm) : 790-810


Noofnotches : 16

9. STARTING TRAVEL

Speed -min-1 (rpm) : 100








Nozzle : 0 433 175 147





030304

- 42 -

REFERENCE NO : SSE-TS-TCL 5.9 G

Edition : 03.2004


Test oil : 9 916 034 004



Governor : RSV 500...750 A7C 1374 R


Engine model : 6 BTA 5-9 G2-I

Engine code : 75006

Application : Generator (125 KVA)











Prestroke in mm : 2.60 - 2.70 (2.55 - 2.75)





Injection Timing Clocking : 7.5° ± 0.5°

BASIC SETTING












GUIDE SLEEVE TRAVEL









Speed - min-1 (rpm) : 747 - 753


Speed - min-1 (rpm) : 778-788









in cm3/500 strokes






in cm3 /500 strokes


3. TORQUE CONTROL







125 KVA CPCB



- 43 -

SSE-TS-TCL 5.88 A4










in cm3/500 strokes










Speed - min-1 (rpm) : 565-625








OTHER INFORMATION:

Element : F 002 B10 570




Note:


operstions.



Speed - min-1(rpm) : 747 - 753


control rack travel


rated speed and if,






Speed - min-1 (rpm) : 810 - 830


Noofnotches : 16

9. STARTING TRAVEL

Speed -min-1 (rpm) : 100








Nozzle : 0 433 175 147





050304

- 44 -



REFERENCE NO : SSE-TS-TCL F_487

Edition : 05.2005


Test oil : 9 916 034 004



Governor : RSV 550...750 A 1C 1375 R

C.

Engine model : 6 BTAA 5.9 G1-I

Engine code : 75006

Application : Genset






Opening pressure in bar : 207.0 - 210.0





Prestroke in mm : 2.85-2.95 (2.8 - 3.0)

Control rack position in mm : 9.5-11.5


Cam displacement : 0-60-120-180-240-300° ± 0.5°


Injection Timing Clocking : 6.75

BASIC SETTING



Delivery quantity (⎯x ) : 14.35 - 14.65









GUIDE SLEEVE TRAVEL









Speed - min-1 (rpm) : 772 - 778


Speed - min-1 (rpm) : 825 - 835








Delivery quantity (⎯x ) : 72.0 - 73.0 (71.0 - 74.0)

in cm3/500 strokes






in cm3 /500 strokes


3. TORQUE CONTROL







140 KVA CPCB

- 45 -

SSE-TS-TCL 5.9 d1










in cm3/500 strokes



Control lever position : 30.0° ± 4.0°







Speed - min-1 (rpm) : 610-670


# Adjust idlling stop screw to obtain 3.1 - 3.3 mm control









OTHER INFORMATION:

Element :

Delivery valve :

Flyweight assembly :

Governor spring :

Note:


operstions.



Speed - min-1(rpm) : 757 - 763


control rack travel


rated speed and if,






Speed - min-1 (rpm) : 795-815


Noofnotches : 16

9. STARTING TRAVEL

Speed -min-1 (rpm) : -







Adaption capsule :

Nozzle :

Opening pressure in bar :


- 46 -



REFERENCE NO : TSS-TS-TCL 0..495

Edition : 08.2009


Test oil : 9 916 034 004

Injection pump : 0460.426.495-VE 12F750R1115

: B 460 816 584


Engine model : 6 BTAA 5-9 G5

Application : Genset - CPCB



Inlet pressure in bar : 1 688 901 022

Opening pressure in bar : 130 -133

High pressure pipe : H-S/EFEP 109

(OD x ID x length) in mm : 6 x 2 x 450

1. SETTING

1.1 Timer travel


Boost Pressure in bar : -

Timer travel in mm : 2.0 ± 0.2

1.2 Vane Pump Pressure


Boost Pressure in bar : -

Timer travel in mm : 8.0 ± 0.3

1.3 Full load delivery



Delivery quantity (⎯x ) : 63.0 ± 0.25

in cm3/300 strokes

Maximum spread in cm3 ( Δ ) : 1.8




in cm3 /500 strokes




in cm3 /500 strokes

160 KVA CPCB

1.4 Ldling delivery




in cm3/300 strokes

Maximum spread in cm3 ( Δ ) : 3.0

1.5 Maximum speed regulation




in cm3/300 strokes

1.6 Starting fuel delivery



in cm3/300 strokes

1.7 Load dependent port closing (LFB)


See procedure given below

2. TESTING

2.1 Timer travel



Timer travel in mm : -



Timer travel in mm : (1.4 - 2.6)



Timer travel in mm : 1.8 - 3.2 #

(# With power (12 V) connected to KSB)

2.2 Vane pump pressure



Timer travel in mm : (7.2 - 8.8)



Timer travel in mm : 8.2 - 10.2 #

(# With power (12 V) connected to KSB)

2.3 Overflow quantity



Overflow quantity : 47 - 131

in cm3/10 seconds : -


Overflow quantity : -

in cm3/10 seconds : -

- 47 -




in cm³ /500 strokes

Idle stop

Control lever position : Ldling position


Delivery quantity (⎯x ) : (23 - 31)


Delivery quantity (⎯x ) : Maximum 1.5


Electrical shutoff (solenoid)

(By disconnecting solenoid switch)

Control lever position : LIdling position





Maximum spread in cm³ ( Δ ) : -

Mechanical shutoff

(By operating stop lever)





2.5 Solenoid

Rated voltage : 12 V

3. ASSEMBLY AND SETTING DIMENSIONS

Description

K : 3.64 - 3.76 mm

KF : 8.2 - 8.6 mm

TSS-TS-TCL 0..495

2.4 Fuel deliveries

End stop

Control lever position : Maximum



Delivery quantity (⎯x ) : (61.8 - 64.2)






























OTHER INFORMATION :Caution: KSB solenoid should be disconnected while calibrating the pump at all points except where indicated.PL. NOTE THE CHANGE IN NUMBER OF STROKES (300 INSTEAD OF 500) AT CERTAIN CHECKING POINTPROCEDURE FOR SETTING OF LOAD DEPENDENT PORT CLOSING (LFB)- Adjusting governor shaft: (See 9.1 and 9.7 of VE pump Repair & Testing booklet )

Before start of calibration, screw-in governor shaft until there is a gap of approximately 3 mm from the housing flange to the endface of governor shaft. Then calibrate pump as per calibration chart .(from 1.1 to 1.6)

- Setting load dependent port closing operation 1.7.

Loosen the lock nut of the governor shaft. Run the test bench at the specified speed (as per 1.7). Keep the control lever inmaximum position. Screw-out governor shaft slowly till the vane pump pressureb egins to fall. Then screw-in governor shaft againby 1/8 of a turn. Lock the governor shaft by tightening the lock nut to the specified torque.

Note: 3 (⎯x ) : Average of the cylinders

1 .Sl. No. of the operations indicate the sequence of operation.

2 .Values given in brackets are overchecking values

Applicable only for BOSCH and MICO test benches 190809

These Test specifications should not be copied or transmitted to a third party without our written permission. All rights reserved.

- 48 -

NOTES

- 49 -

Section A - Adjustment, Replacement and Repair B series

Injection Pump Replacement (Inline)Preparatory Steps :

• Clean debris. • Remove all fuel lines.

• Remove control linkage. • Remove fuel shutoff solenoid.

Removing

Engine Barring Gear

Locate TDC for cylinder number 1. Push the TDC pin

into the hole in the camshaft gear while slowly rotating

the crankshaft.

Caution : Be sure to disengage the pin after locating

TDC to prevent damage to the pin.

Injection Pump

22 mm (PES.A Pump), 27 mm (PES. MW Pump),

30 mm (PES.P Pump)

Remove the gear cover access cap.

Remove the nut and washer from the fuel pump

shaft.

75 mm T-Bar Puller

Pull the fuel pump drive gear loose from the shaft.

Section 10

ADJUSTMENT, REPLACEMENT AND REPAIR B SERIES

- 50 -

Section A - Adjustment, Replacement and

Repair B Series

10mm, 15 mm

Remove the four mounting nuts and the

capscrews that fasten the pump support to the

cylinder block.

Remove the fuel pump.

Installing

Engine Barring Gear

Make sure the engine has cylinder number 1 at

TDC.

Injection Pump - Timing

The injection pump also has a timing pin (1),

located in the governor housing, to position the

pump shaft to correspond with TDC for cylinder

number 1. After the pump is installed the pin is

to be reversed and stored in the housing (2).

Note : The industrial governor is shown in the

illustration. The procedure is the same for

automotive governors.

24 mm

Remove the access plug.

- 51 -

Section A - Adjustment, Replacement and

Repair B Series

Remove the timing pin.

If the timing tooth is not aligned with the

timing pin hole. Rotate the pump shaft

until the timing tooth aligns.

Reverse the position of the pin so the slot of

the pin will fit over the timing tooth in the

pump.

Install and secure the pin with the access

plug.

Make sure the o-ring seals for the fill orifice

and pilot are correctly installed and are not

damaged.

Lubricate the mounting flange with clean

engine oil.

- 52 -

Slide the pump shaft through the drive gear and

position the pump flange onto the mounting

studs. If the pump is equipped with a support

bracket, use your fingers to tighten the

mounting nuts.

Use your fingers to tighten the capscrews for

the support bracket, if so equipped.

15 mm

Tighten the mounting nuts.

Torque Value : 43 Nm (32 ft-lb)

10 mm

Tighten the capscrews for the rear support

bracket.

Torque Value : 24 Nm (18 ft-lb)

- 53 -

Injection Pump - Removal (Rotary TypePumps)

13 mm

Caution: A diesel engine cannot tolerate dirtor water in the fuel system. A tiny piece ofdirt or a few a drops of water in theinjection system can cause damage to thesystem.

Clean all external surfaces of the injectionpump, including all line connections and fittingsthat are to be disconnected. Clean the areaaround the injection pump gear cover to preventdirt from entering the crankcase.

Remove the injection pump support bracket andcapscrews.

Gear Lash - Check

Position an indicator on the tooth of theinjection pump drive gear.

Note the total indicator travel as injection pumpdrive gear backlash. Mark the pump drive gearand camshaft gear for further analysis if thebacklash exceeds the limits.

Injection Pump Drive GearBacklash Limit (A)

mm in

0.076 MIN 0.0030.330 MAX 0.01 3

NOTE: Prevent movement of adjoining gearwhen checking backlash or the reading will bethe total of both gears.

- 54 -

Locking the Pump

Locate TDC for Cylinder Number 1 by slowly barring

the engine while pushing in on TDC pin.

BE SURE TO DISENGAGE THE PIN AFTER

LOCATING TDC.

14 mm

Loosen the CAV injection pump lockscrew, position

the special washer with the small opening showing,

then tighten the lockscrew against the pump drive

shaft.

Torque Value: 7 N*m [5 ft-lb]

318 inch

Loosen the lockscrew for the Stanadyne DB4 fuel

injection pump. Position the special washer behind

the lock screen head. Tighten the lockscrew.

10 mm

The special washer on the Bosch injection pump

must be removed so the lockscrew can be tightened

against the drive shaft.

NOTE: Before removing the Bosch pump, the pump

must be locked with the No. 1 Cylinder in TDC

position.

Torque Value: 30 N*m [22 ft-lb].

Wire the special washer to the Bosch pump.

- 55 -

Drive Gear - Removal

22 mm

Caution: Hold the crankshaft to prevent the

rotation of A the locked injection pump.

Remove the mounting nut and lock washer from

the pump drive shaft.

75 mm T-Bar Puller or Fuel Pump Drive Gear

Puller Part No. 3824469

Pull the pump drive gear loose from the drive

shaft. The puller hole threads are MB X 1.25.

13 mm

Remove the three mounting nuts. Remove the

injection

NOTE : Refer to the applicable Manufacturer's

Service Instructions for injection pump testing/

repair. Minor repairs are described in Component

Section 5.

- 56 -

Unlocked Bosch VE Injection Pump -

Installation

VE Installation

The following procedure was written for those

without immediate access to a fuel pump timing

tool, Pan No. 3377259. The procedure for timing

an unlocked Bosch VE fuel pump with the pump

off of the engine is given in Section 5. If the

pump is installed using the following

procedure, it should be adjusted to the exact

timing using tool No. 3377259 before being put

into service. This procedure is available in Bulletin

Nos. 3810348-01and 3810486.

Locate top dead center (TDC) for Cylinder Number

1 by rotating the crankshaft while pushing in on

the timing pin until it engages.

The Robert Bosch VE pump uses a spring loaded

cam mechanism that makes positioning the

keyway more difficult.

To align the Robert Bosch VE keyway, secure the

pump in a vise and install the lock washer and

nut on the drive shaft.

8 mm Allen or 10 mm Hex

Remove the special washer by loosening the

lockscrew.

Preparatory Steps :

• Clean debris. • Remove all fuel lines.

• Remove control linkage. • Remove fuel shutoff solenoid.

- 57 -

22 mm; 8 mm Allen or 10 mm Hex

Turn the shaft so the key is aligned with the hash

mark on the seal housing.

Lock the pump shaft by tightening the lockscrew.


Remove the drive nut and washer from the drive

shaft by striking the wrench with a sharp blow in a

counterclockwise direction.

Be sure the timing pin is disengaged.

Caution: Make sure the key does not fall into the

gear housing.

Install the pump.

- 58 -

Secure the pump by finger tightening the three

mounting nuts. The pump must be free to move in

the slots.

22 mm

Install the drive gear mounting nut and lock washer

on the pump drive shaft.


NOTE: This is not the final torque value. The drive

shaft nut will be torqued to the final specification

after the pump is unlocked.

8 mm Allen or 10 mm Hex

Loosen the Bosch pump lockscrew and position the

special washer behind the lockscrew head.

Tighten the lockscrew in the unlocked position.

Torque Value: 13 N*m [10 ft-Ib]

22 mm

Tighten the drive gear mounting nut.


- 59 -

13 mm

Rotate the pump to align the scribe marks on the

pump and housing.

Tighten the three mounting nuts.

Torque Value: 24 Nom [18 ft-Ib]

Disengage the TDC pin.

Be sure the backlash is correct for replaced

gears.

Use a dial indicator to measure backlash.

Pump Gear Backlash Limit

A = .076 to .330 mm [0.003 to 0.013 in]

- 60 -

10 mm

Attach the injection pump support bracket. Finger

tighten all capscrews before final tightening.

NOTE: Tighten the capscrews which attach the

bracket to the block (1) before tightening the

capscrew which secures the bracket to the pump (2).


- 61 -

Static Injection Timing setting on Bosch Rotary VE Pump

Please refer the below detailed procedure circulated by Bosch

Subject : Static timing setting on VE pump.

Procedure:

1. Fix the pump in vise. Ref a.

2. Ensure that driveshaft locking screw is unlocked [FBB plate inserted]. Ref b.

3. Bring the keyway inline with 'D' port of the pump. [5 o'clock position when observed from driveshaftside]. Ref c, d

4. Remove the bleeder screw. Ref e.

5. Insert dial gauge with adaptor & feeler. Pre-load it to 213 mm. Ref f.

6. Rotate the driveshaft check the zero position 8 set dial gauge to Zero.

7. Rotate driveshaft in anticlockwise direction till the required lift is achieved.

8. Remove the FBB plate and tighten the locking screw to 12.5 ± 2 Nm.

9. Tie the FBB plate to the control lever.

10. Remove the diai gauge and adaptor.

11. Insert the bleeder screw and tighten it to 29 + 3 Nrn [Ensure that copper washer is present]

Note: Ensure that FBB plate is inserted between the drive shaft locking screw & pump house after mountingthe pump on the engine before starting it.

- 62 -

b)

c)d) Key way -5 o’clock position

‘D’

port

a)

- 63 -

e) f)

Use Cummins Timing Tool Part # 3377259

Thread the timing tool extension into the access

plug hole.

Finger tight only

g) h)

- 64 -

NOTES

- 65 -

Section 11

TROUBLE SHOOTING

- 66 -

- 67 -

- 68 -

- 69 -

- 70 -

- 71 -

- 72 -

- 73 -

- 74 -

- 75 -

- 76 -

- 77 -

- 78 -

- 79 -

- 80 -

- 81 -

ENDPLAY AND BACK LASH VALUES

1. Crankshaft Endplay 0.102 mm - 0.432 mm (0.004” - 0.017”)

2. Cam Shaft Endplay 0.12 mm - 0.34 mm (0.005” - 0.013”)

3. Turbocharger Endplay - Axial 0.03 mm - 0.08 mm (0.001” - 0.003”)

4. Turbocharger Endplay - Radial 0.30 mm - 0.46 mm (0.012” - 0.018”)

5. F.P. Drive Gear Backlash 0.076 mm - 0.330 mm (0.003” - 0.013”)

6. Camshaft Gear Backlash 0.076 mm - 0.330 mm (0.003” - 0.013”)

ENGINE COMPONENT TORQUE VALUES

Socket or Torque Nom (Ft-lb)Wrench SizeMM (Inch)

10 Aftercooler Mounting ......................................................................... 24 (18)

(5/16) Aftercooler Water Hose Clamp ......................................................... 5 (41)

(15/16) Alternator Pulley ............................................................................... 80 (59)

13 or (3/4) Alternator Link (Delco 15-20-27 SI) ................................................. 43 (32)

16 Alternator Mounting Bolt 15 SI ........................................................ 43 (32)

18 Alternator Mounting Bolt and Nut 20-27 SI .................................... 77 (57)

13 Alternator Support (Upper) ............................................................... 24 (18)

Allen 5 mm Belt Tensioner Flat Bracket .............................................................. 24 (18)

15 Belt Tensioner Mounting ................................................................... 43 (32)

Camshaft Bolt ........................................................................ Step 1 27 (20)

.............................................................Step 2 Rotate 180 Degrees

13 Cam Thrust Plate ............................................................................. 24 (18)

(3/8) Coolant Heater .................................................................................. 12 (91)

12 Connecting Rod Bolt .............................................................. Step 1 35 (261)

(Alternately Tighten ................................................................ Step 2 70 (51)

in Three Steps) ...................................................................... Step 3 100 (73)

15 Crankshaft Damper & Pulley ........................................................... 125 (92)

18 Cylinder Head Mounting ................................................ Step 1 (All) 90 (66)

.................................................................... Step 2 (All Recheck to 90 (66)

................................................................ Step 3 (Long Capscrews) 120 (90)

........................................Step 4 Recheck (Long Capscrews Only) 120 (90)

.................................................................... Step 5 (All) Rotate 90°

(5/16) Crossover Clamp .............................................................................. 5 (4)

13 Exhaust Manifold .............................................................................. 43 (32)

- 82 -

13 Exhaust Outlet Pipe Brkt. Mounting ................................................ 43 (32)

13 Exhaust Outlet Pipe, Flanged.......................................................... 24 (18)

(7/16) Exhaust Outlet Pipe, V Band Clamp .............................................. 8 (6)

10 Fan Bracket Mounting ...................................................................... 24 (18)

13 Fan Pulley ......................................................................................... 24 (18)

19 Flywheel ............................................................................................ 137 (101)

15 Flywheel Housing .............................................................................. 77 (57)

13 Flywheel Housing Access Cover ..................................................... 24 (18)

(1/2) Flywheel Housing Plug ..................................................................... 36 (25)

- Front Cover Cap ..........................................................Hand Tighten

18 Front Engine Support Mounting ....................................................... 77 (57)

(1 1/8) Front Engine Support (Barrel) .......................................................... 350 (257)

17 Fuel Banjo Screw (In Fuel Pump) ................................................... 32 (24)

17 Fuel Banjo Screw (In Head) ............................................................ 24 (181)

10 Fuel Banjo Screw (In Injector) ......................................................... 9 71

10 Fuel Vent Screw (In Banjo) .............................................................. 9 (7)

80-95 Fuel Filter .......................................................................................... 3/4 Turn After Contact

14 Fuel Low Pressure Supply (Lift Pump Outlet) ................................ 24 (18)

24 Fuel Filter Adapter ............................................................................ Nut 32 (24)

17 Fuel Line Fitting (High Press) .......................................................... 24 (18)

22 Fuel Pump Drive Gear (With Pump Unlocked)

Bosch (Rotary), Lucas CAV, Stanadyne DB4 ................................. 65 (48)

Nippondenso ...................................................................................... 123 (92)

Bosch (P3000, P7100) ..................................................................... 165 (122)

10 Fuel Pump Lock (Bosch) ................................................................. 30 (22)

Fuel Pump Unlock (Bosch) .............................................................. 13 (10)

- Fuel Pump Mtg. Nut (Bosch In-Line) .............................................. 43 (32)

- Fuel Pump Solenoid

24 (Bosch VE) ........................................................................................ 43 (32)

22 (CAV) ................................................................................................. 15 (11)

10 Fuel Pump Support Bracket ............................................................ 24 (18)

10 Gear Cover ........................................................................................ 24 (18)

10 Gear Housing - to- Block ................................................................. 24 (18)

24 Injector Retaining Nut ....................................................................... 60 (44)

10 Intake Manifold Cover ...................................................................... 24 (18)

(5/8) Intake Heater Plug............................................................................ 125 (90)

10 Lift Pump Mounting / Cover Plate .................................................. 24 (18)


- 83 -

23 Main Bearing Cap .................................................................. Step 1 60 (44)

............................................................................................... Step 2 119 (88)

............................................................................................... Step 3 176 (129)

15 Oil Fill Tube Mounting ....................................................................... 43 (32)

75-85 Oil Filter ............................................................................................ 3/4 Turn After Contact

10 Oil Cooler Assembly ......................................................................... 24 (18)

17 Oil Pan Drain Plug............................................................................ 80 (60)

17 Oil Pan Heating Plug ........................................................................ 80 (60)

10 Oil Pan Mounting .............................................................................. 24 (18)

19 Oil Pressure Regulator Plug ............................................................ 80 (60)

13 Oil Pump Mounting ........................................................................... 24 (18)

13 Oil Suction Tube (Flange) ................................................................. 24 (18)

10 Oil Suction Tube Brace .................................................................... 24 (18)

8 Rear Seal Mounting .......................................................................... 9 (7)

13 Rocker Support ................................................................................. 24 (18)

(14) Rocker Lever Nut ............................................................................. 34 (25)

10 Starter Mounting ............................................................................... 43 (32)

10 Tach Drive Retainer .......................................................................... 3 (2)

10 Tappet Cover / Fuel Drain Line Supports ....................................... 24 (18)

10 Thermostat Housing .......................................................................... 24 (18)

T-25 Torx Timing Pin Flange Mounting ............................................................ 5 (4)

10 Turbocharger Compressor Housing V-Band ...................................... 8.5 (6)

15 Turbocharger Mounting Nut .............................................................. 43 (32)

13 Turbocharger Oil Drain Tube ............................................................. 24 (18)

(5/81) Turbocharger Oil Supply (Both Ends) .............................................. 35 (26)

13 Turbocharger Turbine Housing ........................................................... 20 (15)

Water Hose Clamps .......................................................................... 4-5 (4)

13 Water Inlet Connection ..................................................................... 43 (32)

(3/8) Water Inlet Plugs .............................................................................. 24 (18)

13 Water Pump Mounting ...................................................................... 24 (18)

15 Valve Cover ...................................................................................... 24 (18)

- Valve Cover Oil Fill .......................................................................... Hand Tighten


- 84 -

NOTES

- 85 -

CUMMINS ZONAL OFFICES

EAST ZONE

KOLKATA

94, Tivoli Court, 1C Ballygunge Circular Road,

Kolkata 700 019, West Bengal, India

Tel.: (033) 22472481 / 22878065

Fax: (033) 22903839

KOLKATA

101 Tivoli Court, 1/C Ballygunge,

Circular Road, Calcutta 700 019 (WB).

Tel.: 033 22814387 / 22870777

Fax: 033 22833622

SIVASAGAR

B P Chaliha Road, Near Pollution Control Board

Office, Melachakkar, Sivasagar 785 640, Assam.

Tel.: (03772) 285135 / 285101

Fax: (03772) 285135 / 285101

RANCHI

D-77, Park Road, Road No.1, Ashoknagar,

Ranchi 834 002, Jharkhand.

Tel.: (0651) 2241948 / 2241521

Fax: (0651) 2242815

ASANSOL

Joy Villa Hill View Park (East),

S. B. Goari Road, Asansol 713 304 (WB).

Tel.: (0341) 2283841

Fax: (0341) 2283858

GUWAHATI

Flat No.D/1G, “Pragiyotika” Apartments,

Anandanagar, Bye Lane No-3,

Behind The Sentinel Building, G.S. Road,

Christian Basti, Guwahati 781 005, India.

Tel.: (0361) 2461862 / 2461861

Fax: (0361) 2461862

CENTRAL ZONE

RAIPUR

Vanijya Bhavan Ist Floor, Sai Nagar, Near Fafadih

Devendra Nagar Road, Raipur 492 009 (Chhattisgarh).

Tel.: (0771) 2521301/2521311/ 2881101 / 2881102

Fax: (0771) 2521103

BILASPUR

1st Floor, Chitale Colony,

Near Home guard Office, Tilaknagar,

Bilaspur 495 001, Chhattisgarh.

Tel.: (07752) 224218, 224219

Fax: (07752) 224218

NAGPUR

301, Shreemohinee Building, 3rd Floor,

Kings Way, Nagpur 440 001.

Tel.: (0712)2523203 / 2521247

Fax: (0712) 2541217

SAMBALPUR

Unit No.15, Plot No.228/5255, Pradhanpara,

(Jamkani) PO Budharaja,

Sambalpur 768 004 (Orissa)

Tel.: (0663) 2541150 / 2541316

Fax: (0663) 2541150

NORTH ZONE

DELHI

911-912, Hemkunt Tower, 98 Nehru

Place New Delhi 110 019.

Tel.: (011) 26416947 / 26445756

Fax: (011)26212817

NOIDA

Flat No. 104, First Floor, Ocean Plaza,

P - 5, Sector 18, Noida 201 301.

Tel.: (0120) 2514284 / 2514285

Fax: (0120) 2514590

- 86 -

CHANDIGARH

SCF - 58, Second Floor, Sector 65, Phase – 11,

Mohali, Punjab 160 062.

Tel.: (0172) 2240371/372/373

Fax: (0172) 2240372

JAIPUR

405 & 406, Geeta Enclave, G8, Vinoba Marg,

C Scheme, Jaipur 302 001.

Tel.: (0141) 2370201/2370356/2371427

Fax: (0141) 2363746

LUCKNOW

B-191 Nirala Nagar,Opposite Ramkrishna Math,

Lucknow 226 020 (UP).

Tel.: (0522) 2786718 / 2788959 / 2787514

Fax: (0522) 2787880

SINGRAULI

P.B.No.06, PO Singrauli Colliery, 486889,

Dist. Sidhi (MP).

Tel.: (07805) 266643 / 267247

Fax: (07805) 266587

WEST ZONE

MUMBAI

‘Unit Nos. 603 & 60 6th floor, Raheja

Arcade Co-operative Premises Society Ltd.,

Plot No. 61, Sector No.11, CBD Belapur,

Navi Mumbai 400 614.

Tel.: (022) 27566351 / 27566352 / 27566353 / 27566354

Fax: (022) 27566355

VADODARA

315 to 321, 3rd Floor, ‘Marble Arch’,

Race Course Circle, Alkapuri, Vadodara 390 007.

Tel.: (020) 30278000 / 25431234

Fax: (022) 27566355

PUNE

35 A /1 /2 Erandwana, Pune 411 038.

Tel.: (020) 30278000 / 25431234

Fax: (020) 25439490

SOUTH ZONE

BANGALORE

24, 9th Main Rajmahal Vilas Extension,

Bangalore 560 080.

Tel.: (080) 23613831 / 23611958

Fax: (080)23614552

HYDERABAD

3-6-482, Street No.6, Hardikar Bagh,

Himayat Nagar, Hyderabad 500 029 (AP).

Tel.: (040) 66612932 /27678891/ 27663017/ 66827267

Fax: (040) 27678892

CHENNAI

Ground Floor, New No 6, 1st Street,

Tiger Varadachari Road, Kalashetra Colony,

Besant Nagar, Chennai 600 090.

Tel.: (044) 2446 8114 / 24468112 / 2446 8111

Fax: (044) 2491 1120

KOTHAGUDEM

5-3-32,Babu Camp, Kothagudem 507 101 (AP).

Tel.: (08744)246110 / 242005

Fax: (08744)246608

HUBLI

C/O Shobha B Kalbandi,

No. 31 Sharada Housing Colony,

36th Cross Lingaraja Nagar (South),

Hubli 580 031.

Tel.: (0836) 2373840

COIMBATORE

NO.22, SRIRAM LAYOUT, SAIBABA

COLONY, COIMBATORE 641 011.

Tel.: (0422) 2430197

Fax: (0422) 2445904

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