h,hs, hr, hrsm, nh, nhs, nhrs, nhh, nhhs, nhhrs, nt, nrt ... · connecting rod shells are...
TRANSCRIPT
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THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF
CUMMINS OR IT’S SUCCESSORS. CUMMINS AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
Operator’s Manual
H,HS, HR, HRSM, NH,
NHS, NHRS, NHH, NHHS,
NHHRS, NT, NRT
Diesel Engines
CUM-O-H,NH ENG
OPERATION 1 and
MAINTENANCE
H,HS,HR, H~S- NH,NHS, NHRS
NHH,NHHS,NHHRS -NT, NRT
C PMMINSENGINECOMPAN Y,I NC. ~·CO LU MBU S ,I N 01 AN A,U.S.A.
OPERATION and MAINTENANCE MANUAL 1 11111111111111 U Ill11li II! II P 11111111 1 !Illllllllllllllllllllllllllllllll ~ 1llIIIIIIIIIIIIIIIIIIIIIIIli Ill1l1li 11111 1II!IIIIIlIIIIIII IIIIIIIIIII! 1IIIIIIililil 111111111111 11111111111111111111111 1111111111111111111111111111111111111111111111111111111111111 1I1I1II1Il111111I1I11 1IIIlIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 1111111 llllIlIIllIllIIllIlIllIllllIIlIllllIlIIlIlIIlllIIlIIlIlIIlillllllllllllllllllllllllllllllllll11111111111
TABLE OF CONTENTS SECTION I: Principles of Operation
The Cummins Diesel Cycle The Fuel System The Lubricating System The Cooling System
SECTION II: Operating Instructions
New Engine Break-In Starting The Engine Engine Warm Up Engine Speeds
SECTION III: Maintenance
Fuel Consumption In Relation to the Maintenance Schedule Scheduled Maintenance Operations Engine Overhaul Cleanliness Air. Lubrication Fuel The Cooling System Engine Storage
SECTION IV: Engine Unit Replacements
Generator Cranking Motor Water Pump Cylinder Heads Air Compressor Injectors . Fuel Pump Turbocharger Horizontal Engines Four Cylinder Engines
SECTION V: Trouble Shooting
SECTION VI: Engine Specifications
1-1 to 1-12
1-1 1-3 1-6 1-7
2-1 to 2-14
2-1 2-2 2-5 2-5
3-1 to 3-30
3-1 3-3 3-21 3-21 3-23 3-23 3-25 3-27 3-28
4-1 to 4-14
4-1 4-2 4-2 4-3 4-5 4-7 4-8 4-11 4-12 4-13
5-1 to 5-19
6-1 to 6-3
2 CUMMINS Four and Six Cylinder, 41's and 5Vs Bore, DIESEL ENGINES jlllillillllllllillllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllli1IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIllllllllllllllllllllllllilllllllillilili11I1I11II1111II1II1Ii11l111l1ll1l1ll11l1l11l1ll1l1111l11111ll111111l1111ll11ll1ll11111l1l1II1111II11I1I1Ii!l1II11I1I1II11I1II11I1I1II1I1l1l1l1l11l1l1ll11l1l1l1l1l1i1l1ll1l11ll11l1l1l11ll11ll1l1l1ll1II111111111i111111111111111111111111i11l11ll11llll1ll1l11l1l11l1l1lll1l11illli
INDEX PAGE PAGE
"A" Daily Maintenance ____________________________________ 3-3 Cross Heads ________________________________________________________ 4-4 Adjust Belts ______________________________________________________ 3-10 Cummins Diesel Cycle ______________________________________ l-l Adjust Injectors ________________________________________________ 3-14 Cylinder Heads __________________________________________________ 4-3 Adjust Valves ____________________________________________________ 3-14 Cylinder Head Stud Nuts __________________________________ 3-7 Adjustments For Unstable Speeds _________________ .4-10 Cylinder Liners __________________________________________________ 3-19 Air ________________________________________________________________________ 3-23 Air Compressor ____________________________________________________ 4-5 "D" Maintenance Operations __________________________ 3-10 Air Connections ________________________________________________ 2-2 Daily Report ______________________________________________________ 2-10 Air Cleaners ________________________________________________ 3-6, 3-7 Dilution of Lubricating OiL ___________________________ 3-24 Air Intake __________________________________________________________ 3-20 Down-hill Operation ________________________________________ 2-9 Air Inlet Restriction __________________________________________ 3-17 Draining Cylinder Block.. ________________________________ 2-10 Anti-Freeze ________________________________________________ 3-27, 2-10 Drain Fuel Filter ________________________________________________ 3-6
Application of Protective Compounds __________ 3-29 Drain Lines ________________________________________________________ 1-6 Drain Radiator __________________________________________________ 3-16
"B" Maintenance Operation ____________________________ 3-4 Dry-Type Air Cleaner ________________________________________ 3-7 Bearing Shells ____________________________________________________ 3-19 Dual Governor Used with Blow-by ______________________________________________________________ 3-13 Torque Converters _____________ . _________________________ A-9 Break-In ______________________________________________________________ 2-1 By-pass Filter ____________________________________________________ 3-8 "E" Maintenance Operation ____________________________ 3-16
Electric Wiring __________________________________________________ 3-11 "C" Maintenance Operations.. ________________________ 3-8 Engine Break-In ________________________________________________ 2-1
Change Hydraulic Governor OiL ____________________ 3-16 Engine Coolant _____________________________________________ : ____ 3-8 Change Lubricating OiL _________________________________ 3-4 Engine Cross-section ________________________________ 1-10, 1-11 Change Oil Strainers ________________________________________ 3-4 Engine Idling ____________________________________________________ 2-9 Change Oil, Air Cleaner __________________________________ 3-7 Engine Models __________________________________________________ 1-9 Check Hydraulic GovernoL ____________________________ 2-2 Engine Overhaul ______________________________________________ 3-21 Check Lubricating OiL _________________________________ 2-1 Engine Shut Down ______________________________________________ 2-9 Check Oil LeveL _______________________________________________ 3-3 Engine Specifications ______________________________________ 6-1 Chromate Compounds ______________________________________ 3-27 Engine Storage __________________________________________________ 3-28 Cleanliness __________________________________________________________ 3-21 Engine Unit Replacments ______________________________ ..4-1 Clean Air Cleaners ____________________________________________ 3-3 Engine Warm Up ______________________________________________ 2-5 Clean Engine ______________________________________________________ 3-10 Ether Compound EquipmenL ________________________ 2-4 Clean Injectors __________________________________________________ 3-17 Ether Starting ____________________________________________________ 2-5 Clean Turbocharger __________________________________________ 3-13 Exhaust Back Pressure ______________________________________ 3-21 Cold Weather Protection __________________________________ 2-10 Exhaust Stroke __________________________________________________ 1-3 Cold Weather Starting ______________________________________ 2-3 Exhaust Systems ________________________________________________ 3-20 Compression Release ________________________________________ 2-9 Compression Stroke __________________________________________ 1-2 .oF" Maintenance Operations ____________________________ 3-18 Connecting Rods ______________________________________________ 3-19 Failure To StarL ________________________________________________ 2-4 Continuous-Duty Speeds __________________________________ 2-5 Fan Bracket and Water Pump _______________________ A-2 Cooling System ---- ______________________________________ 1-7, 3-27 Fan Hub ______________________________________________________________ 3-17 Corrosion Resistor ____________________________________________ 3-27 Fill Cooling System ____________________________________________ 3-4 Crankshaft End Clearance ________________________________ 3-17 Fill Fuel Tanks __________________________________________________ 3-4 Crankcase Luhrication ____________________________________ 3-23 Flush Crankcase ________________________________________________ 3-10 Cranking Motor __________________________________________ 4-2, 3-11 Flush Radiator __________________________________________________ 3-16
OPERATION and MAINTENANCE MANUAL 3-11
used) and fill the crankcase with the proper grade luhricating oil. Three and one-half extra gallons oil are required for the Diesel-Pack filter and housing.
CHANGE FUEL FILTER ELEMENT: 1. Loosen the hex nut at the top of the fuel filter.
2. Take out the dirty filter' element, clean the filter case, and install a new filter element.
Fig. 3-12. Changing fuel filter element
3. Install a new gasket in filter head and assemble case and element to the filter head.
BLOW DUST FROM GENERATOR AND CRAN KI NG MOTOR: Dust and dirt, if allowed to accumulate in the generator and cranking motor, will cause excessive wear of bearings, brushes and commutator.
Remove the covel' band and blowout the dust and dirt with a compressed air jet.
CHECK GENERATOR BRUSHES AND COMMUTATOR: The failure of a generator may cause unit down-time and nearly always results in expensive replacement.
1. Dirty commutators should be cleaned with No. 00 sandpaper; NEVER WITH EMERY CLOTH.
2. Replace worn· brushes. If brushes wear rapidly, check for incorrect brush spring tension or high mica on the commutator. Check generator output and action of ammeter indicator after brush replacement.
3. Shorts and incorrect polarization can be detected at the ammeter. Incorrect polarization is indicated by minus reading when generator is turned. Take unit to electric i'erviee station for quick correction.
CHECK ELECTRIC WIRING: 1. Poor starting conditions are often traceable to loose or corroded hattery connections. A loose connection will overwork the generator and regulator and shorten their life.
2. Add water to hattery cells to keep tops of plate covel·ed.
3. Remove corrosion from and around terminals, then coat with vaseline.
4. Keep connections clean and tight. Prevent wire and lugs from touching each other or any metal except screw terminals to which they are attached.
5. Replace broken or worn out wires and their terminals.
6. Have battery tested periodically for any faults hy competent agency. Follow hattery manufacturer's instructions for maintenance.
TIGHTEN MANIFOLD NUTS: Exhaust, intake and water mainfolds should be checked for tightness. Fig. 3-13.
Fig. 3-13. Tighten manifold stud nuts
6-2 CUMMINS Four and Six Cylinder, 4'l"s and 5% Bore, DIESEL ENGINES lIilliilllliiillllillilillllllill!ll!iIllllHlllllill!III11I1II1I1I1HIlIlIliIIIlUllllllllllillIlIlllIllI1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111I1I11II11I11I1I1I1I1111111111II111I1II1I1II11111II11I11II111!lllIIillIllllIlIlIlIll1IIIIIIIIIIIIlIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIHllllllllllllillii1IIIIIIIIIIIIIlIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIlIIIIIIIIllIIIIIIII
PART OR LOCATION
Con. Rod Bearings-Copper Lead Shell Thickness Journal Clearance Tightening .010, .020, .030, and .040 undersize connecting rod shells are available.
CONNECTING ROD
Center to Center Crankpin Bore Piston Pin Bushing Bore Misalignment-Bend Bore Misalignment-Twist
PISTON
Ring Groove Clearance Piston Pin Bore (at 70° F.)
Aluminum Pistons Cast Iron Pistons
Piston Pin Ring Gap Clearances (with new liners)
104200 41878,100232 42330 9236-2,42331,65325,65326 60471,61263,65354 .010, .020, .030 and .040 oversize pistons and rings are available for Hand NH engines.
CAMSHAFT
Journal Diameter
CYLINDER HEAD
Intake and Exhaust Valve Seat Angle Valve Guide Bore-2-valve heads Valve Guide Borec----4-valve heads Valve Crosshead Guidec----4-valve heads Injector Tip Protrusion Through Head Tighten Head Stud Nuts
Steel Asbestos Gasket Valve Clearance
H,HR,HRBB HS, HRS NH(S), NHRS, NHHRS
NEW DIMENSIONS WORN REPLACEMENT Minimum Maximum LIMIT
.07225
.0015 .073 .0045
Template Method
11.998 12.000 3.2722 3.2732 2.001 2.0015
.000 .004 in 12"
.000 .010 in 12"
.070
.007
Same
2.0025 .004 on ST-227 .010 on ST-227
Wedge Type Keystone Rings
1.9987 1.9989 2.000 1.9994 1.9996 2.0005 1.9988 1.9990 1.9978
.017 .027
.013 .023
.013 .023
.010 .018
.010 .020
1.997 1.998 1.996
30° 30° 30° .4995 .5005 .5015 .4045 .4062 .407 .3750 .376 .378 .040 .055 .065
430 450 Intake Exhallst .014 .022 .016 .028 .014 .027