Workshop Manual: S3.8 Engine

Workshop Manual
S3.8 Engine
English – Original Instructions 01-2010 A030K288 (Issue 2)

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. Careful reference should also be made to other Cummins Power
Generation Limited literature, in particular the Health and Safety Manual 0908-0110.
Should you require further assistance contact:
Cummin India Limited

Power Generation Business Unit
35A/1/2, Erandwane
Pune, 411038
India
Tel: +91 2030248600

Fax: +91 2066028090
E-mail: [email protected]
Web Site: www.cumminspower.com
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Workshop Manual A030K288 (Issue 2)
S3.8 Engine 01-2010
TABLE OF CONTENTS
DESCRIPTION PAGE NO.
To the Owner and Operator ........................................................................... 6

Routine Service and Parts ............................................................................. 7
10 Maintenance Steps for Cummins Engines ................................................ 8
Section 1........................................................................................................ 9
Operating Instructions
New and rebuilt engine break-in .................................................................... +
Section 2...................................................................................................... 15
Special Operating Instructions
Section 3...................................................................................................... 17
Engine Operation in Cold Weather
Section 4...................................................................................................... 18
Maintenance of Engine Laid up for Long Period
Section 5...................................................................................................... 19
Maintenance Operations
Section 6...................................................................................................... 25
Lubricants, Fuels & Coolant
Section 7 ..................................................................................................... 29
Checking Valve Timing
Section 8...................................................................................................... 37
Tightening Torques
Section 9...................................................................................................... 39
Troubleshooting
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S3.8 Engine 01-2010
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.
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S3.8 Engine 01-2010
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
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S3.8 Engine 01-2010
10 MAINTENANCE STEPS FOR CUMMINS ENGINES
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.
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S3.8 Engine 01-2010
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 (40 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 installation ensure proper 4. Add enough additional oil to fill engine to
fitment of Anti Vibration Mounting 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 for long periods at required to fill oil filters and lines.
engine idle speeds, or at maximum
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 (1210C) 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 line from 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
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S3.8 Engine 01-2010
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 coolant or 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 to 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. Loose water pump drive belt. a. Loosen bleeding screw on primary filter.
v. Coolant leakage 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. Tighten 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.
Overflow Valve
FUEL SYSTEM
In case the engine running is found to be irregular
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,
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S3.8 Engine 01-2010
the oil can immediately flow to the bearings

and the time required by the oil to attain the
correct pressure is minimised.
If this instruction is ignored the bearing may get
damaged. The oil filter must be kept clean as far
as possible to protect the engine components
from rapid and excessive wear and tear due to
abrasion. Tighten the centre bolt to 4 Kg-m. torque.
Fig. 1-3 Cross-section of Lub-oil Filter
faulty injection nozzle operation may be the cause.

Generally, this is due to dirt in the fuel system.
If excessive black smoke is emitted on
acceleration, its could be due to drubbing of
nozzles. Get the nozzles checked at MICO dealer Fig. 1-4 : Oil Filling Point on Engine
point.
Note : In case the old filter cartridge was found
CHANGING ENGINE OIL damaged/punctured, the filter top cover
assembly should also be removed and
The engine oil should be drained while it is still hot.
refitted after thorough cleaning.
a. Unscrew sump drain plug and allow the oil
to drain out for 20 mins. Proceed as below :
i. Remove the two screws holding the filter top
b. Unscrew filler plug of oil filter, drain out oil
cover to the crankcase and remove it with
and refit filler plug.
its gasket.
c. Unscrew centre bolt and remove oil filter
bowl. Discard oil filter cartridge. The filter ii. Remove the bypass valve assembly and
cartridge should not be cleaned or clean the valve and its seat.
reused. iii. Clean all oil passage in cover thoroughly.
d. Check "O' ring and seal for any damage. Replace "O' ring and seals if f ound
Replace if found damaged. damaged.
e. Clean the bowl thoroughly and insert a iv. Reassemble bypass valve with new sealing
new genuine fuel flow oil filter cartridge washer if necessary.
into the bowl.
v. Fit new gasket on the cover.
f. During re-assembly of the oil filter, fill the
vi. Refit oil filter cover assembly to the
filter bowl with one litre of engine oil through
crankcase taking care that the gasket does
the drain plug and fit the filter bowl to the
not get damaged during fitment.
top cover and tighten the centre bolt to the
specified torque. Before starting, crank the vii. Tighten evenly and equally the two mounting
engine with the help of ignition key, so that bolts of cover to 6 Kg-m. torque.
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S3.8 Engine 01-2010
viii. Clean the drain plug of the engine oil sump Starting the Engine
and refit with a new sealing washer if Starting requires the clean air & fuel to be
necessary. Tighten to 4 to 6 Kg-m. torque. supplied to the combustion chambers in proper
ix. Fill 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 to distinguish 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 it 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 idle with oil temperatures below 14°° 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
level mark. Use only approved brand of oil. 95° C) is the best assurance that working parts of
the engine have expanded evenly to the most
3. Radiator coolant level. Top up, if necessary
favourable of clearances. Maximum engine coolant
and secure radiator cap.
temperatures should not exceed 2°3° F (95°
4. Condition and tension of fan belt. Adjust C).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.
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S3.8 Engine 01-2010
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 2210 F
(1050 C) should be between 2.5 to 5 Kg/cm2 at chamber, bearings shafts etc. This is especially
rated speed and 1 to 2 Kg/cm2 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 3600 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, overfueling or 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 areas,
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. This loss is about 5 percent for
with aluminium tubes & fins. The top and bottom
each 1800 ft. of altitude above sea level for a
tank are of moulded plastic material. These
naturally aspirated engine. Operate the engine
using a lower power requirement at high radiators do not have de-aeration cooling system.
altitude to prevent smoke and over-fueling.
Warning : Do not remove the guarding
Engine Shut-Down when the engine is in working condition.
Idle Engine A Few Minutes Before Shut-
Down It is important to idle an engine 3 to 5
minutes
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S3.8 Engine 01-2010
NOTES
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S3.8 Engine 01-2010
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 lubrication, 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 while operating 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 under :
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 CF4+
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 injected 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 is
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
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S3.8 Engine 01-2010
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 and
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 is 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 temperatures particular 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,
Upto Ambient Percentage the starting capacity of a battery is seriously
oC _________________________
Temperature affected.
Water Antifreeze
The specific gravity of the electrolyte should
agent
be raised from 1.21 to 1.28 when operating at
All Temp. ranges 50 50 temperatures below -150C. 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.
16
S3.8 Engine 01-2010
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 t h e g r e a t er t h e am ou n t of
The two commonly used terms associated with
modif icat ion requir ed 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 information is
provided to engine owners, 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 object ives 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 Artic 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) -25° F (-32° C) -65° F (-54° C) Artic Specification refer to the design material and
Use antifreeze to Use ethylene glycol Use ethylene glycol specifications of components necessary for
satisfactory engine operation in extreme low
protect to antifreeze 5°% antifreeze 5°% temperatures to -65° F (-54° C). Contact Cummins
-2°° F (-29° C) water 5°% 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
17
S3.8 Engine 01-2010
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 600C, 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 indicated on the
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 unpainted parts 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
18
S3.8 Engine 01-2010
Section 5
MAINTENANCE OPERATIONS
Maintenance is the key to lower operating costs. A diesel engine requires regularly scheduled
maintenance to keep it running efficiently.
MAINTENANCE SCHEDULE
Preventive maintenance is the easiest and least 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 of the engine ndicate 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.
19
S3.8 Engine 01-2010
ENGINE MAINTENANCE SCHEDULE & MANDATORY CHECKS FOR ‘S’ SERIES

With Spin-on type Fuel & Lube Oil Filter
SYSTEM A – Check B – Check C - Check D - Check
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 Lube oil level & ▪ Repeat A Check ▪ Repeat B Check. ▪ Repeat C Check
top-up Lube oil upto ‘H’ ▪ Change Lube Oil * Check visually for ▪ Measure Blow Bye .
LUBRICATION mark on Dipstick * Use only CH4-15W40 metal particles in ( Max. 8 inches of H2O
SYSTEM * Use only CH4-15W40 Lube Oil used Lube Oil Water column with
Lube oil ▪ Change Spin-on Lube ▪ Clean Breather 0.221 inches Dia
Oil Filter. arrangement Orifice )
* Check for leaks. Rectify ▪ 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
COOLING * Check Coolant level in ▪ If required,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 / cm2 )
coolant up to H mark. * Check Cap,radiator for
seal. Change the Cap
if required.
* Check for fuel leaks. ▪ Repeat A Check ▪ Repeat B Check. ▪ Repeat C Check
* Rectify leak if any. In ▪ Change 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. T urbocharger.
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 adjust, if required mounting nut bolts.
& ▪ Run Engine, till coolant ▪ Clean Battery Leads ▪ Check AVMs condition. * Check Coupling bolts.
ENGINE attain minimum operating ▪ Secure all connectors Change if required
TESTING temp. 800 C). in Engine Electrical
* Record all Parameters system.
in Log Book.
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
20
S3.8 Engine 01-2010
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 connection on heat
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 hose
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 in the 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
21
S3.8 Engine 01-2010
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.
22
PRODUCT DAILY WEEKLY MONTHLY QUARTERLY
MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE
S3.8 Engine
6M-14 starter Check tightness of Check battery specific Top up *DE Shield Remove **CE cover and smear
Workshop Manual
(Lucas make) Battery and circuit gravity. reservoir with Molybdenum Sulphide grease
connections Multi grade 20W40 over CE 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.
23
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.
Check whether Warning Lamp ‘goes off’ when the engine is started.
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 Watt.
MAINTENANCE SCHEDULE FOR STARTER AND ALTERNATOR
01-2010
A030K288 (Issue 2)
S3.8 Engine 01-2010
NOTES
24
S3.8 Engine 01-2010
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 confirm to following 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 insufficient 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 is 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 least 24 hours to allow
up to 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 Percentage
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 up to -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 in 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.
25
S3.8 Engine 01-2010
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
Up to Ambient Heavy Duty Antifreeze

adverse effect using reclaimed oil will not be seen
temperature 0C Water agent

immediately, but the life of the components will
-40 50 50 be greatly reduced.
Recommended Antifreeze Agents It is difficult to recognise a poor quality oil.
Therefore, buy the recommended brands in sealed
Volvoline tins only from authorised dealers.
It is recommended that the entire cooling system The oil change periods recommended in
should be drained and filled with fresh mixture of maintenance schedule should be adhered to.
antifreeze agent and water in the ratio of 50:50

Recommended grades of engine oils confirming to
for ambient temperature of up to -40 C. Coolant SAE API CF4 and MB 228.1 specifications and
should be drained and replenished in the grade selected according to range of ambient
recommended ratio every two years Or 1500 hrs temperatures are to be as given below :
which ever is earlier. Coolant

LUBRICANTS Coolant reservoir is to be filled externally, upto ‘L’ level
Please use only recommended brands of oil for with same coolant concentration.
getting optimum engine performance and life. Coolant is recommended to prevent corrosion of
There are several brands of lubricating oils in the engine & radiator and to increase boiling point of
market. Only some of these oils have been water. An ethylene glycol (type JIS K 2234-94,
approved by us for use in S-3.8-G engine. The class 2)
lubricating oils approved by us is volvoline which During initial fill of coolant in the engine 5 liter
conform to following specification : ethylene glycol is to be mixed with 5 liter of soft
SAE API CF4 Engine Oils water. And the mixture is to be poured in the
The recommended oils have certain vital properties radiator. Please note that colour of the ethylene
that help to reduce the wear and tear of the glycol supplied along with engine is green.
components. We have tested these oils for 50:50 water to ethylene glycol mixture is to be
thousands of hours in similar conditions your used for top up.
equipments is likely to encounter. The optimum
Change Coolant during every D Check.
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
26
S3.8 Engine 01-2010
CLEANING OF COOLING SYSTEM Cummins strongly recommends the use of

SAE 15W40 lub oil with API, CF4 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 cap.
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
27
S3.8 Engine 01-2010
in 5 Litre Can.
Premix Coolant Co o la n t is
‘Ethylene Glycol’
(Type JIS K 2234
94, Class 2)
Coolant is
recommended to
prevent Corrosion of
Engine & Radiator. I
t also broadens
th e O p er a t in g
Temperature range TIGHTENING OF CYLINDER HEAD NUTS
by Lowering the
coolant freezing After every remounting of cylinder head, the
point & by raising cylinder head nuts should be tightened in the
it’s boiling point. sequence as shown in the figure. Clean and oil
threads on the collared nuts as well as on the
NOTE
cylinder head studs prior to figment. Tighten evenly
This Premix Coolant Do-Not require, any addition in three stages till the maximum torque is
OR mixing of Raw Water. Coolant is to be used, achieved. A special socket must be used for
directly from Coolant Can (Ready To Use) tightening the nuts below the rocker arm shaft.
Coolant recovery Bottle is to be filled externally, Then adjust intake and exhaust valve clearances
with Coolant. Radiator is to be filled slowly, upto to specified valve.
bottom of Fill Neck.
Run the engine for approximately one hour,
Check Coolant Level Daily, before starting Gen-set.
thereafter, retighten cylinder head nuts and recheck
CAUTION valve clearances. Repeat the above procedure
Do-not add cold coolant to hot engine. after 5 to 16 hrs. of operating evertime a cylinder
Engine castings can be damaged . Allow engine head is refitted. Always fit a new cylinder head
0
to cool below 50 C, before adding Coolant.
gasket and ensure that the marking “TOP” is
Do-Not remove Cap, Radiator, from hot engine. towards the cylinder head side.
0
Allow engine to cool below 50 C, before adding
Coolant. Failure to do so, can result in personal For removing the cylinder head, loosen nuts in the
injury from steamy coolant. reverse order of tightening sequence.
Do-Not use sealing additives, to stop leaks in the

cooling system. This can result in coolant system
plugging & inadequate coolant flow, causing, 13
engine to Over heat.
Operating procedure 15
Again operate the engine for 5 mins. with the water

temperature above 80°C
Shut the engine and drain the cooling system.

Cylinder head nut tightening sequence
If the water drained is still dirty, the system must
be flushed again until the water is clean.
28
S3.8 Engine 01-2010
Section 7
CHECKING VALVE TIMING
1. Attach suitable graduated disc to the vibration 1800 in order to bring No. 1 piston to BDC
damper pulley and mark ‘BDC’ position on
the periphery of the vibration damper pulley
by turning crankshaft by 180 from ‘TDC’
position. Fig. 7-1.
2. Remove cylinder head cover.
3. Adjust valve clearance (inlet 0.2 mm; outlet
0.3 mm). Eliminate No.1 inlet valve clearance
by inserting a 0.2 thick feeler gauge between
valve tip and rocker. Fig. 7-2.
4. Turn crankshaft to bring No. 1 piston to TDC.

(compression stroke). In this position, valves
Fig. 7-1
of the No. 6 cylinder will be overlapping.
5. Attach magnetic stand with dial gauge to the

cylinder head in such a way that the
plunger of the dial gauge rests on the
spring retainer of the 1st cylinder inlet valve
with a preload of about 10 mm. Position
plunger on the spring retainer as away as
possible from the centre to avoid fouling of
the rocker. Adjust dial gauge pointer
(bigger) to zero and also note down the
reading of the smaller needle.
6. Turn crankshaft clockwise slowly through. Fig. 7-2
3600 to bring No. 1 piston just to TDC II
II position (End of the suction stroke). Note
position (end of the exhaust stroke). Do not
down the dial gauge reading when the BDC
turn crankshaft in anti- clockwise direction to
position is just reached. The difference
adjust TDC position.
between this and the initial dial gauge reading
NOTE : Before reaching the TDC will give the valve lift in this position. The
position,
* preloaded plunger of the dial timing is correct if the lift is within the
gauge will move along the spring specified value of 3.9+ 0.3 mm.
retainer of the valve. Note down dial
gauge reading when the TDC position 9. Valve timing can also be ascertained by
is just reached. checking the lift of the exhaust valve. To be
doubly sure, it is preferable to check the lift
7.The difference between dial gauge readings of the exhaust valve of No. 6 cylinder. The
will give valve lift. The valve timing is correct valve lift at BDC I (end of power stroke) and
if the lift indicated by the dial gauge is within TDC II (end of exhaust stroke) should
the specified value of 0.8+ 0.2 mm. correspond to specifications.
8. The valve timing can be counter checked by 10. Valve lift readings beyond the specification
turning the crankshaft clockwise further by suggest wrong valve timing possibly on
account of worn out crankshaft - camshaft
29
S3.8 Engine 01-2010
gears/ damaged woodruff keys / mismatched
timing gears (i.e. ‘1’ mark on crankshaft gear
tooth is not matched with ‘3-3’ mark on
camshaft gear.
11. Identify the defect and rectify.

REMOVAL OF FUEL INJECTION PUMP
(Linkages, oil line etc. disconnected)
1. Disconnect accelerator linkage.
2. Remove timing gear housing plug,
3. Unscrew coupling nuts of injection lines with
a suitable spanner or socket, 000 589 0509
from fuel injection pump. Fig. 1.
4. Unscrew fuel line from feed pump and fuel Fig. 2
injection pump.
5. Remove high pressure lubrication oil line
between F.I.P. & oil filter.
6. Unscrew the screws holding fuel injection
pump on timing gear housing Fig. 2 and
remove fuel injection pump. Fig. 3.
(Preferably align the timing mark on F.I.P.
gear & pointer before removal of F.I.P.)
INSTALLATION OF FUEL INJECTION PUMP

AND TIMING ADJUSTMENT
1. Remove clutch housing inspection cover and
rotate crankshaft till 20 deg mark (yellow) on
flywheel coincide with pointer. Fig. 4. Ensure
that piston No. 1 is in compression stroke
by the feel of the push rods of No.1 cylinder
Fig. 3
which should be free.
2. Install fuel injection pump with new gasket
Fig.1 Fig. 4
30
S3.8 Engine 01-2010
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 smaller cover.
Fig. 5. Fit mounting bolts with spring washer
and tighten.
3. Remove clamps for Nos 1 and 2 valve

holders. Unscrew No. 1 delivery valve holder
and remove delivery valve spring and peg.
Fig. 6.
4. Refit delivery valve holder without delivery
valve, spring and peg and tighten to specified
torque.
5. Install swan neck tube, 312 589 0223, on Fig. 6
this holder. Fig. 7
6. Connect diesel bowl pipe to the fuel injection
pump gallery. Fig. 7
7. Set control lever to full throttle position.
8. Loosen mounting bolts of the fuel injection
pump to intermediate plate and swivel pump
towards engine when fuel should start flowing
freely through swan neck. Fig. 8. Swivel
pump away from the engine. Fuel flow should
completely cut off. Fig. 9. 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. If the pump is correctly
mounted, proceed as follows:
Swivel fuel injection pump towards engine, Fig. 7
when the flow of fuel will resume. Now swivel
Fig. 5 Fig. 8 Fig. 9
31
S3.8 Engine 01-2010
pump away from the engine slowly when the
flow of fuel decreases. Fig. 10 and ultimately
the flow nearly stops, giving a drop in 15
to 20 seconds. Fig. 11. Check flywheel
position once again to make sure that the
yellow mark (18 before TDC) on the
flywheel aligns with the pointer.
9. Tighten fuel injection pump bolts (4 numbers)
carefully so as not to disturb the position
of the fuel injection pump.
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 Fig. 10 Fig. 11
stops and a drop forms on the swan
neck in 15 to 20 seconds.
The position should coincide with 20 degrees
before TDC mark on flywheel aligning with
the pointer. Fig. 12. This check confirms that
the fuel injection timing has been correctly set.
11. Disconnect swan neck and fit back delivery
valve, spring and peg after cleaning them.
Fig. 13. Tighten delivery valve holder to 4.5
mkg. Fit delivery valve holder clamps.
12.Refit timing gear housing plug and clutch
housing inspection cover.
13.Disconnect diesel bowl from the fuel injection
pump gallery.
14. Connect fuel hoses to the feed pump and Fig. 12
fuel injection pump main gallery.

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. If necessary, align high pressure lines
with special tools, Part No 312 580 0085.
16.Bleed the fuel system as follows. Unscrew
and operate hand primer (up and down
strokes) until resistance is felt. Loosen the
bleeding screw on the fuel filter and allow air
to escape. Operate the primer slowly with the
bleeding screw open till bubble free fuel starts
flowing. Tighten the bleeding screw. Bleed the
fuel injection pump gallery in the same
manner and tighten bleeding screw. Operate
the hand primer for a few strokes. Check for Fig. 13
32
S3.8 Engine 01-2010
leakages if any and screw on the hand
primer knob fully.
17.Connect accelerator linkage.
Caution : Ensure adequate tightness on feed
pump fuel inlet banjo to avoid fuel starvation.
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 Fig. 15
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.
6. Unscrew leak off line banjo bolts along with
sealing washer and remove leak off line
assembly Fig. 14. Unscrew and remove
pressure screw holding nozzle holder to the
cylinder head with the help of socket,
000 589 0209. Fig. 15.
7. Remove nozzle holder with puller, 000 589
0119. Fig. 16.
8. Loosen protective sleeve in cylinder head
with adaptor, 000 589 0309. Fig. 17. Fig. 16
9. Remove protective sleeve and its sealing ring
from cylinder head.
Fig. 17
Fig. 14 3
9
33
S3.8 Engine 01-2010
INSTALLATION
1. Apply a light 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, 000 589 0309 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, 000 589 0209 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, 312 580
0085. Tighten high pressure lines 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 starts opening. If the opening
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
34
S3.8 Engine 01-2010
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 lever down slowly until
needle on pressure gauge shows 20 kg/cm’
below opening pressure. The nozzle is leak
proof if no drop comes out of nozzle tip
within 10 seconds.
In the event of leak, disassemble injection 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 otherwise gauge may get
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 test oil will emerge in the
shape of a non-atomized cone until the
buzzing range is attained.
DISASSEMBLY, REPAIR AND ASSEMBLYOF
NOZZLE HOLDER AND INJECTION NOZZLE
Fig. 23
(Nozzle holder removed)
1 Insert nozzle holder in to holder 403 589 00
31 00 and unscrew pressure nut with special
wrench 000 589 01 13 00 from nozzle body.
Fig. 23.
2 Clean nozzle externally and internally in
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 000
589 00 68 00. Fig. 24.
Fig. 24
35
S3.8 Engine 01-2010
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 403 589 00
31 00.
6. Tighten pressure nut with special wrench 000
589 01 13 00 to specified torque. Fig. 26.
Fig. 26
Fig. 27
36
S3.8 Engine 01-2010
SECTION 8
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
2 Counterweight
. bolts on crankshaft 3+1 tightening
3. Connecting rod bearing by 90o
cap bolts M 15 x 1.5 10 +1 + 20o)
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 Nozzle
. in nozzle holder 8
8 Nozzle
. 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 - M 8 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
37
S3.8 Engine 01-2010
NOTES
38
S3.8 Engine 01-2010
Section 9
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.
Th e s t ar t e r m ot o r t e rm i n al o r 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
d a m a g e d l i n e s o r l o os e l i n e 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, the 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 teeth are very Thoroughly clean or smoothen burr

Pinion does not disengage dirty or damaged : release spring at the flywheel 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 ) E n g i n e d o e s n o t s t a r t has been completely emptied, at first
although the starter motor is vent the fuel system.
operating.
Engine is too cold. Follow the instruction for winter
Inadequate venting of fuel system. operation. Vent system once more.
When doing so, Check the fuel pipes
for leaks and the filler for dirt.
39
S3.8 Engine 01-2010
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 cleaned by MICO
dealer.
B) Engine suddenly s tarts Injection nozzle has got stuck.

Remove load from the engine.
knocking heavily Repeatedly shift from idling to full
load for a short time. If the knocking
does not stop, have the entire fuel
system cleaned as soon
as possible.
C) S om e C yl i n d er s f ai l t o 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 Ha v e t his r ep a ir ed at MI CO
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 leaks Check gasket. When fastening
( c an be no t ic e d b y g as cylinder head again pay attention
bubbles in the cooling water) to the tightening sequence.
40
S3.8 Engine 01-2010
Trouble Cause Remedy
G) Oil pressure suddenly drops. Lack of oil in crankcase. Refill
Cau t io n : In ca s e o f 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 at a 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, then 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) Oil pressure increases, There is water in the oil due to
Find out and eliminate leakage.
vapours and m ois t a ir leakage in cylinder head or
escapes through the breather. crankcase
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 Defective regulator or alternator.
regulator. 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 commutator.
Loose or damaged lines.

Repair or replace lines, tighten
connections.
41

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What steps should be taken if the engine oil pressure suddenly drops?

Workshop Manual

English – Original Instructions 01-2010 A030K288 (Issue 2)

Should you require further assistance contact:

Cummin India Limited

Tel: +91 2030248600

DESCRIPTION PAGE NO.

To the Owner and Operator ........................................................................... 6

To the Owner and Operator

maintenance schedule outlined in this manual.

Keep records of regularly scheduled maintenance.

Routine Service and Parts

• Engine model and serial number

10 MAINTENANCE STEPS FOR CUMMINS ENGINES

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.

Check Air Connection

Check Engine Coolant Supply

Remove the radiator cap and check engine coolant

Check and top up radiator with Specified coolant

the oil can immediately flow to the bearings

Fig. 1-3 Cross-section of Lub-oil Filter

faulty injection nozzle operation may be the cause.

Oil Pressure before shutting it down to allow lubricating oil and

SPECIAL OPERATING CONDITIONS

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

the atmospheric pressure and density. To ensure

ENGINE OPERATION IN COLD WEATHER

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 Artic 6. Proper external heating source available.

MAINTENANCE OF ENGINE LAID UP FOR LONG PERIOD

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

maintenance to keep it running efficiently.

ENGINE MAINTENANCE SCHEDULE & MANDATORY CHECKS FOR ‘S’ SERIES

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

be done after 5 to 10 hours of every

(c) Oil pressure

Check the tightening torque

**DE - Drive end

Do not crank the starter more than 20 seconds

MAINTENANCE SCHEDULE FOR STARTER AND ALTERNATOR

LUBRICANTS, FUELS & COOLANT

FUELS a small and cheap private filling station. Before

which depends upon ambient temperature is be mixed.

They have already lost their vital properties. The

Up to Ambient Heavy Duty Antifreeze

temperature 0C Water agent

-40 50 50 be greatly reduced.