Specification Book - Combined

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Cummins Diesel Sales and Service (India) Limited
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35/A/1/2, Erandwana, Pune 411 038.
Phones : (020) 020-25430066, 25431234, 25431703
Fax : (91) - 020 - 25439490 Bankers ____________________________________
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Bulletin No. AX 1001506
Printed October 2005
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Page-1 Page 2
GENERAL TABLE OF CONTENTS
FOREWORD
Contents Section
This manual provides certain specifications of N, V, K, QSK, S, B, C, X and Introduction ……………………………………………………….. i
CWC series of Cummins Diesel, Natural gas and Dual fuel engines and
Stamford Alternators. Maintenance practices and minor details of Engine Data -N, V, K, QSK ……………………………………… 0
troubleshooting and repairs, parts information have also been included.
Engine Data - Genset N, V, K, QSK …
…………………………… 1
For detailed operation / maintenance / troubleshooting procedures and Engine Data - Gas and Dual Fuel ............................................ 2
information, refer the respective engine (operation & maintenance,
shop and alternative repair) manuals. These additional manuals can be Engine Data - B Series............................................................. 3
procured from our Parts Department.
Engine Data - C Series ........................................................... 4
The data and part numbers compiled in this bulletin is subject to
change without notice and any obligation. Engine Data - S Series ............................................................ 5
The latest technology and the highest quality components are used to Engine Data - CWC Series...................................................... 6
manufacture Cummins engines. When replacement parts are needed,
we recommend using only genuine Cummins or Recon exchange Engine Data - X Series ........................................................... 7
parts.
Alternator Data - Newage ....................................................... 8
This book contains the specifications of obsolete products and Information - Parts .................................................................. 9
current products.
Information - General ............................................................. 10
Whilst every care has be taken in the compilation of information
contained in this book, legal liability cannot be accepted by Cummins Troubleshooting Charts ........................................................ 11
Diesel Sales & Service (India) Limited.
Index ...................................................................................... IN
All rights reserved.
No part of publication may be reproduced, stored in a retrieval system,

photocopied, transmitted in any form without prior permission of
Cummins Diesel Sales and Service (India) Limited.
Cummins
Customer Assistance Cell
Tel. : (020) 25436680 Call Toll Free

Fax : (020) 25445916
1 - 600 - 2332000
Contact for On line Help....
E-mail : [email protected]
Visit our Website : www.cumminsindia.com
Our Goal : Zero Engine Down

Compiled and published by Cummins “Service Training Center”
Section - i Introduction Page i-0 Section - i Introduction Page i-1
GENERAL SAFETY INSTRUCTIONS

IMPORTANT SAFETY NOTICE
Contents Page
General Safety Instructions WARNING

Important Safety Notices i-1
Improper practices or carelessness can cause burns, cuts,
Acronyms and Abbreviations i-3 mutilation, asphyxiation or other bodily injury or death.
Read and 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 the work area surrounding the product is dry, well lit,
ventilated, free from clutter, loose tools, parts, ignition sources
and hazardous substances. Be aware of hazardous conditions
that can exist.
• Always wear protective glasses and shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewellery

when working.
• Disconnect the battery cables first and discharge any capacitors

before beginning any repair work. Disconnect the air starting
motor if equipped to prevent accidental engine starting. Put a
“Do Not Operate” tag in the operators compartment or on the
controls.
• Use only the proper engine barring techniques for manually

rotating the crankshaft. Do not attempt to rotate the crankshaft
by pulling or prying on the fan. This practice can cause serious
personal injury, property damage, or damage to the fan blade(s)
causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the
engine to cool before you slowly loosen the pressure 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 pr oper stands to support the
product before performing any service work.
• Relieve all pressure in the air, oil, fuel and the cooling systems
before any lines, fittings, or related items are removed or
disconnected. Be alert for possible pressure when disconnecting
any device from a system that utilizes pressure. Do not check
for pressure leaks with your hand. High pressure oil or fuel can
cause personal injury.
Page i-2
Page i-3
Section - i Introduction
Ingress Protection – Dust-Protected & Splashing Water
Ingress Protection – Dust-Protected & Spraying Water
• To prevent suffocation and frostbite, wear protective clothing and

only disconnect fuel and liquid refrigerant (freon) lines in a
well.
Erasable Programmable Read Only Memory
G-Drive Original Equipment Manufacturer
• To avoid personal injury, use a hoist or get assistance when

lifting components that weigh 23 kg [50 lb.] or more. Make sure
all lifting devices such as chains, hooks or slings are in good
Environmental Protection Agency
condition and are of the correct capacity. Make sure hooks are
Electro-Magnetic Compatibility
positioned correctly. Always use a spreader bar when

Electro-Magnetic Interference
necessary. The lifting hooks must not be side-loaded.

High Coolant Temperature
Emission Control System
Engine Position Sensor
Ignition Control Module

Gross Vehicle Weight
• Corrosion inhibitor and lubricating oil, contain alkali. Do not get

Electro-Motive Force
the substance in your eyes. In case of contact, immediately flood

Fuel Shutoff Valve
Emergency Stop
eyes with large amounts of water for a minimum of 15 minutes.

Input / Output
immediately call a physician. Keep out of reach of children.

Horsepower
Fahrenheit
Avoid prolonged or repeated contact with skin. Do not

Mercury
Ground
swallow internally. In case of contact, immediately wash skin

Water
Hertz
Foot
with soap and water.

Inch
ACRONYMS AND ABBREVIATIONS
• To avoid burns, be alert for hot parts on product that have been
turned off, and hot fluids in lines, tubes, and compartments.
E-STOP
EPROM
GOEM
Ft (FT)
FSOV
• Always use tools that are in good condition. Make sure you
GVW
GND
EMC
EMF
ECS
IP53
IP54
HCT
EPA
EPS
ICM
EMI
H2O
I/O
Hg
Hz
understand how to use them before performing any service

hp
F
In
O
work.
• Always use the same fastener part number ( or equivalent) when

replacing fasteners. Do not use a fastener of poor quality if
replacements are necessary.
• Do not perform any repair when fatigued or after consuming

American Society of Testing and Materials
alcohol or drugs that can impair your functioning.
• Disconnect the positive (+) & negative (-) cables of battery and
California Air Resources Board
disconnect all electrical/electronic controls before welding.

American Petroleum Institute
Coolant Temperature Sensor
Electronic Control Module

Compressed Natural Gas
Cubic Inch Displacement
Electronic Control Panel

American Wire Gauge
Data Terminal Ready

Air Signal Attenuator
Alternating Current
Counterclockwise
Control Part List
Battery Positive
Data Set Ready

Communication
Air Fuel Control
Direct Current
Centistokes
Clockwise
Amperes
Section - i Introduction
Ampere
Celsius
AMPS
CARB
ASTM
C.I.D.
AWG
CCW
COM
CNG
ECM
DSR
AFC
ASA
ECP
DTR
CTS
CPL
CW
API
cSt
AC
DC
B+
C
A
O
Section - i Introduction ACRONYMS AND ABBREVIATIONS Page i-4
Kg Kilogram O/M Owner-Operator Manual
Km/l Kilometers per Liter OEM Original Equipment Manufacturer
KPa Kilopascal OPS Oil Pressure Sensor
KW Kilowatt OS Over Speed
Ib Pound PC Personal Computer
LCWL Low Coolant – Water Level P-P Peak to Peak
LED Light-Emitting Diode P/N Part Number
LLOP Low Lube Oil Pressure ppm Parts Per Million
LNG Liquid Natural Gas psi Pounds Per Square Inch
LTA Low Temperature Aftercooling PTO Power Takeoff
mA Milli-Ampere PWM Pulse Width Modulator
mW Milli-Watts Rpm(RPM) Revolutions Per Minute
mm Millimeter SAE Society of Automotive Engineers
MIP Mixer Inlet Pressure SCA Supplementary Coolant Additive
MPa Megapascal STC Step Timing Control
mph Miles Per Hour VS Variable Speed
mpq Miles Per Quart VSS Vehicle Speed Sensor
MPU Magnetic Pickup V Volts
N-m Newton-meter
NG Natural Gas
333 334
Section -11 Trouble Shooting Page 11-22 INDEX IN-01

PAGE NO.
FAULT CODE DIAGNOSTICS ECM, ECPG etc. contd...
Accessory Drive Timing Procedure on K-6 Engine -
1448 Generator AC Output Frequency Engine (N, V, K,QSK)....................................................................... 0 - 46
1449 Generator AC Output Frequency Acoustic Enclosures – Range - Genset (N, V, K, QSK).....................1 - 11
1451 Generator Circuit vs Bus Voltage Acronyms and Abbreviations - Introduction.......................................... i - 3
1452 Generator Set Circuit Breaker - Failed to Close Air Cleaner Assemblies and Elements And Kits - Parts.....................9 - 22
1453 Generator Set Circuit Breaker - Failed to Open Air Compressor Repair Kits - Parts......................................................9 - 5
1454 Generator Set Circuit Breaker - Failed Position Contact Air Exhaust System - Engine (N, V, K, QSK)....................................0 - 13
1455 Utility Circuit Breaker Position Contact - Incorrect for Air Intake System - Engine (N, V, K, QSK)....................................... 0 - 13
Application Air Intake System - B Series................................................................ 3 - 1
1456 Generator Circuit - Cannot Synchronize Air requirement, Part Numbers for air starter -
1457 Generator Set - Failed to Synchronize Genset (N, V, K, QSK)...................................................................... 1 - 48
1458 Generator Set - Cannot Synchronize Phase Air Starter Connection of Pilot Valve & Kit air starter -
1459 Reverse kW Genset (N, V, K,QSK)....................................................................... 1 - 48
1461 RevekrV
seAR Air Starting piping arrangement (Inertia engagement-N,K-1150) -
1462 High Current on Ground Genset (N, V, K,QSK)....................................................................... 1 - 50
1463 Generator Announces to LonWorks Network that it is Not Air Starting Piping arrangement (Preengagement type V, KV) -
in Auto Genset (N, V, K,QSK)........................................................................ 1 - 51
1464 Generator Announces to LonWorks Network that it a
Air System - CWC Series....................................................................6 - 5
"Load Dump" has Occurred Air System - S-Series...........................................................................5 - 6
1465 Generator Announces to LonWorks Network that it is Alternator Data - Newage - Contents...................................................8 - 0
"Ready to Accept Load" Alternator Product Designation - Alternator........................................ 8 - 1
1466 Modem - Lost Communication Alternator Tests, Checks - Alternator..................................................8 - 2
Alternators Range and Specifications - Alternator.............................. 8 - 3
1468 LonWorks Network - Lost Communication
Altronic III Name Plate Details - Gas & Dual Fuel................................2 - 9
1469 Measure Speed vs AC Output Frequency Altronic Installation Procedure - Gas & Dual Fuel..............................2 - 15
1471 AC Output Current - High Warning AVR Adjustments - Alternator............................................................. 8 - 1
1472 AC Output Current - High Shutdown B & C Series Engine Identification - B Series...................................... 3 - 1
1473 ECM Internal Watchdog Test Failed B Series Genset Specifications - B Series.........................................3 - 16
1474 Base Board - Extended I/O Software Mismatch B Series Specifications - B Series..................................................... 3 - 15
1475 Permission to Connect - Not Received B-check Kits Model Wise - Parts........................................................9 - 20
1476 Base Board - Not Responding to LonWorks Board Blow by Limits and Measurements - Engine (N, V, K, QSK)............0 - 15
1477 Crank Relay Contact Diagnostic Blow-By Readings - B Series...............................................................3 - 2
1478 Crank Relay Driver Diagnostic Detected an Error Break Up of filter Element & Seal Ring - Parts...................................9 - 18
1481 Voltage Regulator Driver Diagnostic C Series Checkpoint Information - C- Series....................................... 4 - 4
C Series Engine Maintenance Schedule - C- Series......................... 4 - 13
1483 One or More Fault Codes Have Not Been Acknowledged
Cable sizes for D. G. sets - Genset (N, V, K, QSK)........................... 1 - 13
1485 EFC Driver Diagnostic
CAC, Pre Mix Part Nos - Parts...........................................................9 - 35
1486 EFC Driver Diagnostic Capscrew Markings & Torque Values - General..............................10 - 16
1487 Not in Auto LED Driver Diagnostic Carburettor Models & Adjustments - Gas & Dual Fuel...................... 2 - 13
1488 Warning LED Driver Diagnostic Clamp T-Bolt Dia. Wise part Nos - Parts........................................... 9 - 35
1489 Shutdown LED Driver Diagnostic Component measure Limits Cylinder Blocks - Engine (N, V, K, QSK)0-42
1491 Ready to Load Output Relay Driver Diagnostic Compressor Application - B Series.................................................... 3 - 12
1492 Load Dump Output Relay Driver Diagnostic Conrod Bearings - Parts.................................................................... 9 - 17
1493 Operator Interface Panel Power Relay Driver Diagnostic Continuous Duty Generator Set Maintenance -
1494 Modem Power Relay Driver Diagnostic Genset (N, V, K,QSK)....................................................................... 1 - 56
1495 Common Shutdown Output Relay Driver Diagnostic Conversion Factors & Practices - General.......................................10 - 10
1496 Auto Mode Output Relay Driver Diagnostic Conversion Kits for Various Dual Fuel Engines - Gas & Dual Fuel....2 - 25
Coolant System - CWC Series........................................................... 6 - 5
1497 Manual Run/Stop LED Driver Diagnostic
Coolant System - S-Series...................................................................5 - 6
1498 Exercise LED Driver Diagnostic
Cooling System - Engine (N, V, K, QSK)......................................... 0 - 17
1499 Remote Start LED Driver Diagnostic Cooling System - B Series................................................................... 3 - 3
2111 Aftercooler Water Inlet Temperature Sensor Circuit Cooling Water Plain Hoses Dia. & Length wise Part Nos - Parts...... 9 - 34
2112 Aftercooler Water Inlet Temperature Sensor Circuit Crankshaft Dimensions - Engine (N, V, K, QSK).............................. 0 - 44
2113 Aftercooler Water Inlet Temperature - Engine Protection CSeries Design Features - C- Series.................................................. 4 - 1
2114 Aftercooler Water Inlet Temperature - Engine Protection Cummins Branded A.V. Mounts (GREB) - Parts............................... 9 - 40
Multiple Multiple Fault Codes on the Engine Harness Cummins Dual Fuel Engines Technology - Gas & Dual Fuel............ 2 - 10
335 336
INDEX IN-02 INDEX IN-03

PAGE NO. PAGE NO.
Cummins Engine nomenclature - Engine (N, V, K, QSK)................... 0 - 1 Fault Finding - CWC Series.............................................................. 6 - 12
Cummins Gas & Dual Fuel Engine Nomenclature - Gas & Dual Fuel..2 - 1 FIP removal & Fitment - S-Series........................................................ 5 - 7
Cummins Gas Engine Technology - Gas & Dual Fuel.........................2 - 1 Flex Master Coupling Part Nos. & Sizes - Parts................................ 9 - 33
Cummins Gas Engines Compressor & Irrigation - Gas & Dual Fuel....2 - 3 Flywheel Housing SAE Numbers - Engine (N, V, K, QSK)............... 0 - 46
Cummins Gas Engines Genset Application - Gas & Dual Fuel........... 2 - 2 Fraction, Decimal, Millimeter Conversion - General...........................10 - 8
Cummins genset size details - Genset (N, V, K, QSK)...................... 1 - 10 Fuel Oil & Recommended Properties - General.................................10 - 4
Cummins Part Numbers for Newage Alternator - Parts..................... 9 - 47 Fuel Pump Data Plate - Engine (N, V, K, QSK).................................. 0 - 2
Current at Various Power Factors - Genset (N, V, K, QSK)...............1 - 14 Fuel System - Engine (N, V, K, QSK)................................................0 - 27
Derating recommendations - Gas & Dual Fuel.................................. 2 - 11 Fuel System - B Series........................................................................ 3 - 5
Drive Belt Tension - General............................................................10 - 20 Fuel System - S-Series........................................................................ 5 - 6
Dual Fuel Engine Ratings & Specifications - Gas & Dual Fuel.......... 2 - 10 Fuel System and Settings - X Series.................................................. 7 - 4
ECPG Connector Details - Genset (N, V, K, QSK)............................ 1 - 23 Fuel System, FIP Fitment and Adjustments - CWC Series..................6 - 5
ECPG Datalink Adaptor Details - Genset (N, V, K, QSK).................. 1 - 31 Gas adjustment of Engines running on gas with different heat value -
ECPG List of Important Field Adjustments - Genset (N, V, K, QSK)..1 - 28 Gas & Dual Fuel................................................................................ 2 - 12
ECPG Overview, Software & Features, Part Numbers - Gas Engine Maintenance Schedule - Gas & Dual Fuel....................... 2 - 8
Genset (N, V, K,QSK)........................................................................ 1 - 24 General Safety Instructions - Introduction............................................i - 1
ECP-G retrofit Kits - Parts..................................................................9 - 13 Genset Allignment and coupling Torque Details -
Genset (N, V, K,QSK).........................................................................1 - 16
EFC controller Specification & Operation - Genset (N, V, K, QSK)... 1 - 20
Genset AVM Location & Weight - Genset (N, V, K, QSK)....................1 - 9
EFC governor description - Genset (N, V, K, QSK)........................... 1 - 18
Genset ratings & Specifications - S-Series.......................................... 5 - 2
EFC Introduction to parts - Genset (N, V, K, QSK)............................1 - 19
Governor Product Designation - C- Series.......................................... 4 - 3
Effective utilization of DG set - Genset (N, V, K, QSK)......................1 - 57 Heat Exchanger to Radiator - Parts..................................................... 9 - 8
Electrical System - B Series.................................................................3 - 9 Heat Recovery system - Genset (N, V, K, QSK)................................ 1 - 61
Electrical System - S-Series................................................................ 5 - 8 High Altitude Compensation Kits - Parts............................................9 - 12
Electrical System, Wiring Diagram - CWC Series.............................. 6 - 8 High Speed Diesel Requirements - General......................................10 - 5
Electronic Control Panel + Governor Fault Code Information - Hose Elbows Dia wise Part Nos - Parts.............................................9 - 21
Trouble Shooting.............................................................................. 11 - 16 How to use a digital volt / ohm meter - Genset (N, V, K, QSK).......... 1 - 17
Electronic Governor on 1150 & 1710 Gas Engines & Settings - Ignition Timing Procedure - Gas & Dual Fuel.....................................2 - 15
Gas & Dual Fuel................................................................................ 2 - 17 Important Basic Engine Design - C- Series......................................... 4 - 5
Engine Cranks But Does Not Start - Trouble Shooting...................... 11 - 1 Important Clearance Values - Engine (N, V, K, QSK)....................... 0 - 45
Engine Data - B Series - Contents...................................................... 3 - 0 Important Clearances - B Series........................................................3 - 13
Engine Data - C Series - Contents...................................................... 4 - 0 Important Clearances - C- Series...................................................... 4 - 13
Engine Data - CWC Series - Contents................................................ 6 - 0 Important Tips To Troubleshooting Systemwise - C- Series................ 4 - 7
Engine Data - Gas and Dual Fuel - Contents...................................... 2 - 0 Important Torque Values - Engine (N, V, K, QSK).............................0 - 47
Engine Data - Genset N, V, K, QSK - Contents................................... 1 - 0 Important Torques - B Series............................................................. 3 - 14
Engine Data - S Series - Contents.......................................................5 - 0 Important TorqueValues - C- Series................................................... 4 - 14
Engine Data - X Series - Contents.......................................................7 - 0 Important Turbocharger Specifications - Engine (N, V, K, QSK).......0 - 45
Engine Data -N, V, K, QSK - Contents.................................................0 - 0 Imported Lower Engine Gasket Set - Parts......................................... 9 - 4
Engine Data Plate - Engine (N, V, K, QSK).........................................0 - 2 Imported upper Engine Gasket Set - Parts.......................................... 9 - 3
Engine Firing Order - Engine (N, V, K, QSK).................................... 0 - 29 Index - Contents................................................................................. IN - 0
Engine Maintenance Schedule - S-Series........................................... 5 - 3 Indigenous lower Engine Gasket Set - Parts....................................... 9 - 2
Engine Nomenclature, Features - S-Series......................................... 5 - 1 Indigenous upper Engine Gasket Set - Parts.......................................9 - 1
Engine Not Taking Rated Load - Trouble Shooting............................ 11 - 3 Information - General - Contents........................................................10 - 0
Engine Overheating - Trouble Shooting............................................. 11 - 7 Information - Parts - Contents..............................................................9 - 0
Engine performance inspection report Genset - Introduction - Contents..........................................................................i - 0
Genset (N, V, K,QSK)........................................................................ 1 - 57 L.O. recommendations for Natural gas engine - Gas & Dual Fuel.....2 - 13
Engine specifications generator set application - LDO Operation - Genset (N, V, K, QSK)............................................ 1 - 58
Genset (N, V, K,QSK).......................................................................... 1 - 1 Load acceptance data - Genset (N, V, K, QSK).................................1 - 12
Engine Storage Procedures - General...............................................10 - 6 Locomotive and Rail Car Engine Specifications -
Engine Wiring Diagrams - Gas & Dual Fuel...................................... 2 - 22 Engine (N, V, K,QSK)........................................................................ 0 - 10
Engine Wiring Diagrams - S-Series..................................................... 5 - 9 Lubricating Oil & Recommendations - General..................................10 - 1
Engine, Alternator Specifications DXP Genset - X Series................. 7 - 1 Lubricating Oil Flow - X Series........................................................... 7 - 4
Engine, Alternator Nomenclature - X Series....................................... 7 - 1 Lubricating Oil System - Engine (N, V, K, QSK)................................0 - 28
Engine, Genset, Alternator Nomenclature - CWC Series................... 6 - 1 Lubricating Oil System - B Series........................................................ 3 - 4
Exhaust gas temperatures – Genset application - Lubricating System - CWC Series...................................................... 6 - 5
Genset (N, V, K,QSK)........................................................................ 1 - 15 Lubricating System - S-Series............................................................. 5 - 6
Exhaust System - B Series.................................................................. 3 - 1 Lucas Contactless Distributor Ignition System - Gas & Dual Fuel..... 2 - 16
Fault Code Diagnostics ECM, ECPG etc - Trouble Shooting...........11 - 19 Magtronic Installation Procedure - Gas & Dual Fuel..........................2 - 15
337 338
INDEX IN-04 INDEX IN-05

PAGE NO. PAGE NO.
Maintenance Schedule - X Series...................................................... 7 - 6 Stand-By Duty Generator Set Maintenance - Genset (N, V, K, QSK)1 - 55
Maintenance Schedule - B Series......................................................3 - 17 Switch Overspeed - Parts.................................................................. 9 - 31
Maintenance Schedule , NEPI - CWC Series................................... 6 - 11 Tachometer - Parts.............................................................................9 - 32
Maintenance Schedule for Industrial Fire pump Engines - Tap Drill Chart - General...................................................................10 - 22
Engine (N, V, K,QSK).........................................................................0 - 39 Technical Data CWC genset - CWC Series........................................ 6 - 2
Maintenance Schedule for Starter and Alternator - Thrust Bearings - Parts...................................................................... 9 - 18
Engine (N, V, K,QSK).........................................................................0 - 41 Torque Values - CWC Series.............................................................. 6 - 3
Maintenance Schedule other than Firepump engines - Torque Values - X Series.................................................................... 7 - 3
Genset (N, V, K,QSK)........................................................................ 1 - 52 Torque Values - S-Series..................................................................... 5 - 5
Marine Genset Engine Range - Engine (N, V, K, QSK)...................... 0 - 8 Torque Values & Critical Specifications for N Series -
Marine Main Propulsion Engine Range - Engine (N, V, K, QSK)........ 0 - 9 Engine (N, V, K, QSK)....................................................................... 0 - 48
Mechanical System - B Series............................................................. 3 - 7 Trouble Shooting of Engine - Trouble Shooting............................... 11 - 10
Modelwise Part Numbers - Gas & Dual Fuel..................................... 2 - 26 Troubleshooting Charts - Contents.....................................................11 - 0
Modelwise Recommendations - Gas & Dual Fuel............................... 2 - 7 Troubleshooting-EFC - Genset (N, V, K, QSK).................................. 1 - 21
Modelwise recommendations – genset - Genset (N, V, K, QSK).........1 - 4 Turbocharger Repair Kits - Parts......................................................... 9 - 6
Motorpal Pump Product Designation - C- Series................................. 4 - 3 Turbochargers - Parts.......................................................................... 9 - 9
Overhead Setting Adjustments - Engine (N, V, K, QSK)....................0 - 30 Valve Setting Procedure - S-Series..................................................... 5 - 7
Oversize Main Bearings - Parts......................................................... 9 - 16 Viscous Vibration Damper Specifications - Engine (N, V, K, QSK)...0 - 46
P.T. Pump Gasket Set - Parts.............................................................. 9 - 5 Water Pumps Repair Kits - Parts......................................................... 9 - 5
Parallel Operation - Alternator............................................................8 - 3 Wiring Diagram - B Series................................................................. 3 - 18
Part No. Structure Old and New - Parts.............................................9 - 19 Wiring Diagram - C- Series............................................................... 4 - 15
Part Nos. Information ECP - Parts..................................................... 9 - 37 Wiring Diagrams - X Series................................................................ 7 - 7
Part Nos. of Belts for Various Applications - Parts.............................9 - 38 Wiring Dual Delco Remy Starter & lucas alternator KV 12/16 -
Parts Common To‘B’ Series Engine - C- Series...................................4 - 1 Genset (N, V, K, QSK)....................................................................... 1 - 34
PCC retrofitting kits - Parts................................................................ 9 - 44 Wiring ECP with EFC governor & one starter : 4054714 -
PE Bosch Pump Product Designation - C- Series............................... 4 - 2 Genset (N, V, K, QSK)........................................................................1 - 41
Pipe Couplings - Parts....................................................................... 9 - 12 Wiring ECP with EFC governor & two starter :4054715 -
Pipe Plug Torque Values - General..................................................10 - 21 Genset (N, V, K, QSK)....................................................................... 1 - 42
Plain Air Hump Hoses - Parts............................................................ 9 - 21 Wiring ECP without EFC governor & one starter 4054713 -
Preliminary Engine Data Gas Engines - Gas & Dual Fuel................... 2 - 4 Genset (N, V, K, QSK)....................................................................... 1 - 40
Problem solving methodology - Trouble Shooting..............................11 - 1 Wiring ECPG with Two Starters - Genset (N, V, K, QSK).................. 1 - 32
Procedure For Installation of Fuel Pump - C- Series......................... 4 - 11 Wiring EFC governor Version I - Genset (N, V, K, QSK)................... 1 - 36
Procedure For Valve Setting - C- Series........................................... 4 - 12 Wiring Electronic instruments panel (Intenal & External) -
Properties of Hydrocarbons & gas fuels - Gas & Dual Fuel...............2 - 20 Genset (N, V, K, QSK)....................................................................... 1 - 38
PT (Type G) Fuel System Troubleshooting - Trouble Shooting........11 - 15 Wiring Engines with air starters - Genset (N, V, K, QSK).................. 1 - 35
PULSE Generators Starting Part Nos.& Guidelines - Parts...............9 - 52 Wiring Lucas/Delco Remy starter & Lucas alternator model N, V, K6 -
Radiator to Heat Exchanger - Parts..................................................... 9 - 8 Genset (N, V, K, QSK)....................................................................... 1 - 33
Rail Equipment Specifications - Engine (N, V, K, QSK).................... 0 - 12 Wiring PCC-1 genset system architecture - Genset (N, V, K, QSK).. 1 - 43
Ratings for Construction, Mining, Compressor applications - Wiring PCC-1 Terminal Strip Details - Genset (N, V, K, QSK)........... 1 - 44
Engine (N,V,K,QSK).............................................................................0 - 3 Wiring PCC-2 Terminal Strip Details - Genset (N, V, K, QSK)........... 1 - 45
Ratings of Fire Pump Engine Models by Respective rpm - Wiring Solid state potentiometer - Genset (N, V, K, QSK)................. 1 - 37
Engine (N, V,K,QSK)........................................................................... 0 - 6
Recommendations for Genset Installation - Genset (N, V, K, QSK).... 1 - 8
Recommended Battery Capacity for Cummins Engines -
Engine (N, V, K,QSK)..........................................................................0 - 28
Remote Radiators for Cummins Engine (Coil Coolers) -
Genset (N, V, K, QSK)........................................................................1 - 10
Replacement Parts ECPG - Parts..................................................... 9 - 36
Safety Controls Tripping Chart - Engine (N, V, K, QSK)................... 0 - 26
Short Block Assembly of Various Models - Parts...............................9 - 15
Sizes of Some Important Capscrews - CWC Series...........................6 - 4
SKO Operation - Genset (N, V, K, QSK)............................................1 - 59
Some Important values - Gas & Dual Fuel........................................ 2 - 13
Some Part / Repair Kit Nos - Gas & Dual Fuel.................................. 2 - 27
Special Features - CWC Series........................................................ 6 - 10
Special LDO Operation - Genset (N, V, K, QSK)............................... 1 - 60
Specifications & Product Information - C- Series.................................4 - 1
Standard dimensions - CWC Series................................................... 6 - 2
339 340
NOTES NOTES
Section - 0 Engine Data N, V, K, QSK Page 0-0
= Displacement in Litres
ENGINE DATA (N, V, K, QSK SERIES)
= Application Codes
Page 0-1
C = Construction
= Quantum Family
CONTENTS Page No.
= Engine Series
Cummins Engine nomenclature .......................................................... 0-1
= System
Engine Data Plate .............................................................................. 0-2
Fuel Pump Data Plate ........................................................................... 0-2
Ratings for Construction, Mining, Compressor applications ................. 0-3
Ratings of Fire Pump Engine Models by Respective rpm ........... ........ 0-6
Marine Genset Engine Range ................................................................ 0-8
Marine Main Propulsion Engine Range ................................................. 0-9
Locomotive and Rail Car Engine Specifications ............................. 0-10
Q S K 19 - C
Rail Equipment Specifications ............................................................. 0-12
Air Intake System ............................................................................. 0-13
Air Exhaust System .............,,,,,,,,....................................................... 0-13
CUMMINS ENGINE NOMENCLATURE (N, V, K, QSK SERIES)

Blow by Limits and Measurements .................................................... 0-15
Cooling System ................................................................................. 0-17
Safety Controls Tripping Chart ............................................................. 0-26
R = Railcar (Horizontal engine)

Fuel System ....................................................................................... 0-27
no alphabets = Automotive
Lubricating Oil System ...................................................................... 0-28
Recommended Battery Capacity for Cummins Engines .................. 0-28
Engine Firing Order ............................................................................ 0-29
= Application Code
Overhead Setting Adjustments .......................................................... 0-30
Bl = Off Highway
C = Construction
L = Locomotive
P = Power Unit
F = Fire Pump
Maintenance Schedule for Industrial Fire pump Engines ................. 0-39
G = Genset
Cubic Inches Litres M = Marine
Maintenance Schedule for Starter and Alternator ............................. 0-41
Component measure Limits Cylinder Blocks ..................................... 0-42
Crankshaft Dimensions .............. ........................................................ 0-44
Important Turbocharger Specifications .............................................. 0-45
Important Clearance Values .............................................................. 0-45
= Displacement in (cubic inches)
12
28
38
50
14
19
Flywheel Housing SAE Numbers ....................................................... 0-46
8
Viscous Vibration Damper Specifications ......................................... 0-46
Equivalent
Accessory Drive Timing Procedure on K-6 Engine .............................. 0-46
Litres
or
Important Torque Values ..................................................................... 0-47
1710
2300
3067
1150
495
855
743
Torque Values & Critical Specifications for N Series ........................... 0-48
The model name provides the following data

Section – 0 Engine Data N, V, K, QSK
= Turbocharged
= Aftercooled
(Family of engines)
____
= Series
3067 -
K T A
Fuel Pump Serial Number
Page 0-2
Fuel Pump Serial Number
Peak Torque
Page 0-3
R.P.M.
1200
1300
1400
1200
1500
1700
1500
1500
1500
1500
1500
1500
1500
1500
1500
Fuel Pump Code Number
Engine Speed
Fuel Pump Code Number
CUMMINS DIESEL ENGINES FOR CONSTRUCTION, MINING,COMPRESSOR & OTHER INDUSTRIAL APPLICATIONS
Peak Torque
811 (1149)
963 (1248)
Ft.Lb.(NM)
387 (524)
495 (660)
583 (790)
583 (784)
655 (898)
(1118)
FUEL PUMP DATA PLATE
(237)
(385)
(581)
(621)
532
662
990
Ç
É
S 1500
78363
73363
É
R.P.M.
2500
2300
2000
2300
2150
2800
2000
2100
2100
2100
2100
2100
2100
2000
2200
Ç
KA 361 A
É
KA 361
KCL
Maximum
BM 70486
H.P.
Ç
102
137
143
155
192
125
180
212
212
295
240
335
230
260
July 1st , 1988 onwards
80
Ê
N 495
X 113
(Prior to July, 1988)
GR.
Ê
Fuel Pump AR/BM
C.I.D. (Liter) Breathing

Type of Governor
Displacement Engine
Engine Model
CPL Number
N. A
N. A
N.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T
T
T
T
T
Number
743 (12.2)
743 (12.2)
743 (12.2)
743 (12.2)
495 (8.1)
495 (8.1)
495 (8.1)
(3.9)
(3.9)
(5.9)
(5.9)
(5.9)
(5.9)
(8.3)
(8.3)
5 1/8 X 6 (130 X 152)
5 1/8 X 6 (130 X 152)
5 1/8 X 6 (130 X 152)
5 1/8 X 6 (130 X 152)
5 1/8 X 6 (130 X 152)

5 1/8 x 6 (130 X 152)
5 1/8 X 6 (130 x 152)

Bore X Stroke
(102 X 120)
(102 X 120)
(102 X 120)
(102 X 120)
(102 X 120)
(102 X 120)
(114 X 135)
(114 X 135)
Inch (mm)
(1) Engine Serial Number (E.S.N.)
using the E.S.N. (2) The Control Parts

information about the engine. The
identifies the original engine parts list
standards for engine certification. The

List (CPL) identifies and helps in
improvements. (3) Engine Model tells

you the engine series, displacement
determine performance and emission
design
history and warranty data are recorded
up-to-date a Cummins engine with the

or major assembly parts. The engine
The engine dataplate shows specific
CPL can be considered as a guide to

locating the most current parts that

ENGINE DATAPLATE
and
of Cyl.
No.
technology
4L
4L
6L
6L
6L
6L
4L
4L
4L
6L
6L
6L
6L
6L
6L
and application.
latest
6CTA-8.3-C
6CTA-8.3-C
6BTA-5.9-C
6BTA-5.9-C
NTA-495-C
NTA-743-C
N-743-T-C
4BT-3.9 C
6BT-5.9 C
6BT-5.9 C
NT-495-C
NT-743-C
4B-3.9 C
N-495-C
N-743-C
Engine
Section – 0 Engine Data N, V, K, QSK Page 0-6
RATINGS FOR FIRE PUMP APPLICATION ENGINES AS PER RPM
Engine Model R.P.M. 2100 2000 1900 1800 1700 1600 1500
N-495-F H.P. - 107 104 103 101 96 92 Engine No. Bore X Stroke Displacement Engine Maximum R.P.M. Peak Torque Peak Torque
NT-495-F H.P. 155 150 145 140 134 127 119 of Cyl. Inch (mm) C.I.D. (Liter) Breathing m H.P. Ft.Lb.(NM) R.P.M.
NT-495-F1 H.P. 155 - - 154 - - 127
NTA-495-F H.P. 183 179 173 166 159 151 143 NT-855-C 6L 5 ½ X 6 (140 X 152) 855 (14.00) T 335 2100 921 1500
NTA-495-F1 H.P. 188 - - 195 - - 173 NTA-855-C 6L 5 ½ X 6 (140 X 152) 855 (14.00) T.A. 400 2100 1150 1500
N-743-F H.P. 182 179 174 168 161 153 144 NT-855-C240 (BC III) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T 240 2100 693 1500
N-743-TF H.P. 207 203 198 191 182 173 162
NT-743-F H.P. 255 250 244 237 229 219 207 NT-855-C295 (BC III) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T 295 2100 880 1500
NT-743-F1 H.P. 255 - - 257 - - 231 NT-855-C335 (BC III) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T 335 2100 997(1243) 1400
NTA-743-F H.P. 285 278 269 268 248 235 - NTA-855-C360 (BC III) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T.A. 360 2100 1076 1350
NTA-743-F1 H.P. 285 - - - - - 255
NTA-855-C400 (BC III) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T.A. 400 2100 1196 1400
NT-855-F H.P. 289 284 283 267 256 244 -
NTA-855-F (FFC) H.P. 345 343 337 327 315 301 268 NTA-855-C (BC) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T.A. 450 2100 (1331) 1500
NTA-855-F1 H.P. - - - - - - 306 NTA-14-C (BC) 6L 5 ½ X 6 (140 X 152) 855 (14.00) T.A. 525 2100 (2237) 1500
NTA-855-F2 H.P. 352 - - - - - -
KT-1150-C 6L 6 ¼ X 6 ¼ (159 X159) 1150 (18.9) T 450 2100 1350 (1831) 1500
NT-855-F (BC) H.P. 299 - - 395 - - 340
NTA-855-F (BC) H.P. 356 - - - - - 380 KTA-1150-C 6L 6 ¼ X 6 ¼ (159X 159) 1150 (18.9) T.A. 525 2100 1575 1500
NTA-14-F H.P. 480 - - 450 - - - KTA-1150-C 6L 6 ¼ X 6 ¼ (159 X 159) 1150 (18.9) T.A. 600 2100 1650 (2237) 1500
KT-1150-F H.P. 400 397 391 383 373 361 - KTTA-19-C 6L 6 ¼ X 6 ¼ (159 X 159) 1150 (18.9) T.A. 700 2100 2014 (2731) 1400
KT-1150-F1 H.P. - - - - 380
KTA-1150-F H.P. 534 526 512 495 465 450 - VTA-28-C 12V 5 ½ X 6 (140 X 152) 1710 (28.0) T.A. 900 2100 2200 1500
KTA-1150-F1 H.P. - - - - - - 450 KT-2300-C 12V 6 ¼ X 6 ¼ (159 X 159) 2300 (37.8) T 900 2100 2700 1500
KTA-19-F3-I H.P. - - - 620 - - 540
KTA-19-F H.P. - - - 680 - - 600
V-1710-F H.P. 415 413 407 396 382 364 342

Engine Model R.P.M. 2100 2000 1900 1800 1700 1600 1500 Section – 0 Engine Data N, V, K, QSK Page 0-5
VT-1710-F H.P. 548 532 515 499 479 458 -

Engine No. Bore X Stroke Displacement Engine Maximum R.P.M. Peak Torque Peak Torque
VT-1710-F1 H.P. - - - - 530
of Cyl. Inch (mm) C.I.D. (Liter) Breathing m H.P. Ft.Lb.(NM) R.P.M.
VT-1710-F2 H.P. - - - - - - 550
VTA-1710-F H.P. 691 670 651 626 605 573 -
KTA-38-C 12V 6 ¼ X 6 ¼ (159 X 159) 2300 (37.8) T.A. 1050 2100 3020 1500
VTA-1710-F1 H.P. - - - - - 614
VTA-1710-F3 H.P. - - - - - 700 KTA-38-C 12V 6 ¼ X 6 ¼ (159 X 159) 2300 (37.8) T.A. 1200 2100 3300 1500
VTA-28-F3 H.P. - - 730 - - 710 KTA-38-C 12V 6 ¼ X 6 ¼ (159 X 159) 2300 (37.8) T.A. 1200 2100 (4678) 1300
VTA-28-F5 H.P. - - - 815 - - 750 KTA-50-C 16V 6 ¼ X 6 ¼ (159 X 159) 3067 (50.3) T.A. 1600 2100 4400 (5966) 1500
KT-2300-F H.P. 801 800 792 780 755 723 -
KT-2300-F1 H.P. - - - - - - 750 K1800E 16V 6 ¼ X 6 ¼ (159 X 159) 3067 (50.3) T.A. 1800 1900 (7085) 1300
KTA-2300-F H.P. 1069 1047 1016 982 941 890 - K2000E 16V 6 ¼ X 6 ¼ (159 X 159) 3067 (50.3) T.A. 2000 1900 (7856) 1300
KTA-2300-F1 H.P. . - - - 890 KTA 3067-S-C 16V 6 ¼ X 6 ¼ (159 X 159) 3067 (50.3) T.A. 1200 1500 - -
KTA-38-F H.P. - - - 1030 - - 850
KTA-38-F1 H.P. - - 1220 - - 1080 QSK-60 16V 6.25 X 7.48 (159 X 190) (60) T.A. 2700 2100 (10631) 1500
KTA-38-F2 H.P. - - - 1350 - - 1180 QSK-78 18V (170 X 190) (78) T.A. 3500 1900 (13771) 1500
KTA-3067-F H.P. 1425 1390 1356 1306 1254 1194 1150
KTA-3067-F1 H.P. - - - - - - 1180
KTA-50-F H.P. 1447 - - 1742 - - 1541 NOTE:above performance ratings are for 300ft (90m) 25OC (77OF)
KTA-50-F1 H.P. - - 1855 - - 1735 * Following are the Equivalent Engine Models (based on units of displacement in C.I.D or liters.)
Notes : KT/KTA 1150 ... KT/KTA 19
* Above ratings are with guaranteed capability of 10% overload or one hour in every twelve hours running. V/VT/VTA171O ... V/VT/VTA 28 N.A.--- Naturally Aspired
* Nett HP to be arrived after deducting 2HP for DC battery charging alternator and HP required for fan (as applicable depending on engine rpm) in KT/KTA 2300 ... KT/KTA 38 T --- Turbocharged
case of radiator cooled engines. KTA 3067 ... KTA 50 T.A. --- Turbocharged Aftercooled
# Rating developed for special marinised application. Please refer CIL before offering the rating.
* Due to continuous improvement, specifications are subject to change without prior intimation.
Page 0-8
Page 0-9
Typical Generator output (kVA)
2000 - 2300 @ 1800 - 1900

750 - 1350 @ 1600 - 1950
140 - 2000 @ 1600 - 2050
500 - 700 @ 1800 - 2100
1000
1250
1750
100
140
180
320
380
440
500
625
750
75
Rating (BHP@rpm)
104 @ 2200
108 @ 1800
140 @ 2000
140 @ 1800
165 @ 1800
195 @ 1800
240 @ 1800
270 @ 1800
325 @ 1800
400 @ 1800
474 @ 1800
620 @ 1800
675 @ 1800
Rating (BHP@rpm)
MARINE MAIN PROPULSION ENGINE RANGE

1180 @ 1500
1470 @ 1500
2095 @ 1500
127 @ 1500
231 @ 1500
380 @ 1500
450 @ 1500
550 @ 1500
614 @ 1500
750 @ 1500
890 @ 1500
173 x 1500
93 @ 1500
MARINE GENSET ENGINE RANGE
Displacement (Ltrs)
Displacement (Ltrs)
* Engines are approved for Nox emission requirements of IMO.

12.2
12.2
12.2
12.2
* Engines are approved for NOx emission requirements of IMO.
8.1
8.1
8.1
5.9
8.1
5.9
8.1
14
19
19
28
28
38
38
50
60
14
14
14
14
19
28
28
38
50
60
Bore x Stroke (mm)
Bore x Stroke (mm)


159 X 190
140 X 152
159 X 159
159 X 159
159 X 190
130 x 152
130 x 152
130 x 152
130 x 152
140 x 152
159 x 159
159 x 159
140 x 152
140 x 152
159 x 159
159 x 159
159 x 159
102 x 120
130 x 152
102 x 120
130 x 152
130 x 152
130 x 152
130 x 152
140 x 152
140 x 152
140 x 152
159 x 159
159 x 159
140 x 152
KTA-19-D-(M1)*
KTA-50-D-(M1)*
KTA-38-M0/1/2*
KTA-38-D-(M1)
QSK-60-D (M)*
VTA-28-D (M)*
KTA-1150-MG
VTA-1710-MG
KTA-2300-MG
NTA-855-MG*
KTA-19-m3/4*
NTA-495-MG
KTA-1150-M
VTA-1710-M
NTA-855-M*
NTA-855-M*
KTA-50-M2*
NT-495-MG
NT-743-MG
VTA-28-M2
QSK-60-M*
N-743-T-M
N-495-MG
NT-495-M
NT-743-M
NT-855-M
6BT5.9M
N-495-M
N-743-M
6B5.9M
Model
Model
Section – 0 Engine Data N, V, K, QSK Page 0-10 Section – 0 Engine Data N, V, K, QSK Page 0-11
RAIL ENGINE SPECIFICATIONS

CUMMINS ENGINES FOR LOCOMOTIVE
RAIL EQUIPMENT
& RAIL CAR APPLICATIONS
Engine Displacement No. of Max Rating* OEM/MAKE MODEL HP-RATING APPLICATION

Model (Ltrs) Cylinders BHP @ RPM
ICF/BHEL VTA-1710-L 705 @ 1800 DETC/DEMU
LOCOMOTIVE
ENGINES BEML KTA1150-R 520 @ 2100 OHE-CAR
NT-855-L 14 6 335 @ 2100 PLASSER KTA1150-L 473 @ 2100 TIE-TAMPING

NTA-855-L 14 6 380 @ 2100 PLASSER KTA1150-L 473 @ 2100 POINT & CROSS
NTA-855-L 14 6 400 @ 2100
PLASSER KTA1150-L 473 @ 2100 RAIL STAB.
KT-1150-L 19 6 450 @ 2100
PLASSER NTA855-L 400 @ 2100 UNIMAT COPM
KTA-1150L 19 6 600 @ 2100
VTA-1710-L 28 12 800 @ 2100 PLASSER VTA1710-L 705 @ 1800 BALLAST CLN.
KT-38-L 38 12 900 @ 2100 SAN 2X NT-855-R 285 @2100 8-W OHE-CAR

KTA-38-L 38 12 1200 @ 2100 KPC 2X NTA-855-R 345 @ 1900 DHMU/ARTV
KTTA-38-L 38 12 1350 @ 2100
BHEL KTA-50-L 1400@1500 DEMU
KTA-50-L 50 16 1600 @ 2100
KTTA-50-L 50 16 2000 @ 1900
QSK-60-L2 (E) 60 16 2500 @ 1900 RAIL APPLICATION
RAIL CAR
(HORIZONTAL) Special Feature in DEMU Value Package:
ENGINES Roof Mounted Radiator (RMR) & Side Mounted Radiator (SMR)
NT-855-R 14 6 335 @ 2100 Technical Specifications:

NTA-855-R 14 6 400 @ 2100
Sr.No. Description RMR SMR
KTA-19-R 19 6 600 @ 2100
1 No of radiators 4 2
NTA-14-R3 14 6 475 @ 2100 2 No of radiator fans 2 1
NTA-14E-R3 19 6 750 @ 2100 3 Total weight of radiators 1250 Kg 1050 Kg
QSK-19-R 19 6 750 @ 2100 4 Total radiator capacity 80 litres 120 litres
5 System Pressure 7 PSI 7 PSI
POWER CAR
6 Maximum Water outlet temp. 95 Deg. C 95 Deg. C
ENGINES
7 Limiting Ambient Temperature 55 Deg. C 55 Deg. C
KTA-1150-G 19 6 450 @ 1500
8 Radiator core area (total) 24 Sq. Ft. 30 Sq. Ft.
KTA-19-G4 19 6 490 @ 1500 9 Maximum Fan Speed 2450 RPM 1750 RPM
NTA-14-RG1 14 6 450 @ 1500 10 Air Velocity across the core 1850 Ft/Min 1450 Ft/Min
NTA-14-G3 14 6 450 @ 1500 (unchoked)
11 Float Switch Specifications 24 V/NC type 24 V/NC type
Notes :
* Maximum intermittent traction rating. NA - Natuarally Aspirated
T - Turbocharged TA - Turbocharged Aftercooled
Above performance ratings are at Standard Conditions of UIC
Specifications are subject to change without notice for available /
delivery please contact Marketing.
Page 0-12
Hydrostatic Fan Drives

AIR INTAKE SYSTEM
705 @ 1800RPM
N.A.
KELA16122FM
Maximum Allowable Intake Restriction (at rated speed and load)
DETC(BHEL)
Diesel Electric
VTA-1710-L
TRC 1000
64.9 Tons
1.06 Tons
KRE 30 B
610 HP
x-Series s-Series s-Series All Engines All Engines Gas
167 W
BHEL
ELGI
KEL
KPC
ICF
CIL
100
Air
(Naturally (Turbo with Medium with Heavy Engine
Aspirated) charged) duty A/c duty A/c
N.A.
mm of water column (Inches of water column)
Clean filter 250 (10) 250 (10) 250 (10) 250 (10) 380 (15) 200 (8)
Choked Filter 400 (15.7) 380 (15) 500 (20) 635 (25) 635 (25) 380 (15)
Method of checking air Intake restriction
I) Naturally aspirated Engines.
Stand
216
216
79
(a) Minimum 30” water manometer to be connected to the INTAKE
705 @ 1800RPM
MANIFOLD adjacent to the mounting flange.
KELA16122FM
DEMU(NGEF)
Diesel Electric
VTA-1710-L
(b) Run the Engine at maximum speed and record the manometer
TRC 1000
9.49 Tons
60 Tons
630 HP
NGEF
reading.
ELGI
KEL
N.A.
N.A.
ICF
CIL
110
Air
Note:
Seats
108
108
(1) Mercury manometer cannot be sensitive enough for reading
79
RAIL EQUIPMENT SPECIFICATIONS
accurately.
(2) lf an engine is equipped with air compressor, do not connect
manometer adjacent to the air compressor connection of the
manifold.
II) Turbocharged Engine
(a) Connect a 30” water manometer to the air inlet pipe to the
Turbocharger.
Stand
216
216
705 @ 1800RPM
79
(b) The connection should be located in a straight section of air intake
KELA16122FM
DEMU(BHEL)
Diesel Electric
VTA-1710-L
9.49 Tons.
pipe to avoid of possible dynamic effect of the air stream.

TRC 1000
60 Tons
630 HP
167W
BHEL
ELGI
(c) Run the Engine at rated speed under full load and record the
N.A.
N.A.
KEL
ICF
CIL
110
Air
manometer reading.
AIR EXHAUST SYSTEM.
Seats
108
108
79
Limits for exhaust back pressure

Model mm (Inches) of Hg Maximum Limit
Old Installation New Installation
KTA50G8/QSK60/S Series /
Gas Engines 51 (2) 38(1.5)
Installed Power (as per UlC 623-OR)
KTA50G3/KT2300G/VTA28/
Engine Data N, V, K, QSK
K19/NT/N14/B/C/X Series 76 (3) 63(2.5)

Max. cruising speed (Kmph)
Manufacturer of Equipment
It is recommended to use ‘Schedule B’ MS pipes & long bend elbows.

Lighting Generator Model
Lighting Generator Make
If number of bends are more than 4 or pipe length is more than 10

Maximum Passengers:
Traction Motor Rating
meters then contact OEM/Cummins.

Traction Motor Make
Net Input to Traction
Compressor Model
Compressor Make
(A) System Restrictions (Back Pressure)

Equipment Type
Pay Load Weight

Exhauster Model
Exhauster Make
Cooling System
a) When engine pistons act against a back pressure in exhaust

Engine Model
Transmission
Engine Make
Tare Weight
system to expel exhaust gases, usable output of the engine is

lowered.
b) High back pressures indicates restrictions caused by foreign
Brake
DPC
DTC
objects/excessive bends/small sizes of piping.

TC
Section –0
(B) Measuring Exhaust Back Pressure

a) The point of measurement of exhaust back pressure must be as
Sr.No.
10.
13.
12.
11.
14.
15.
16.
17.
18.
19.
20.
close as possible to the exhaust manifold or turbocharger outlet flange

5.
1.
2.
6.
7.
8.
9.
3.
4.
area of uniform flow such as a straight section of pipe at least one pipe
diameter from any changes in flow area or flow direction.
Section - 0 Engine Data N, V, K, QSK Page 0-14 Section – 0 Engine Data N, V, K, QSK Page 0-15
b) Where it is impossible to locate the point of measurement in a

straight section, it is permissible to measure on the side of a bend BLOW-BY LIMITS & MEASUREMENTS
where flow is uniform and equivalent to flow along the centreline. DO
Normal Power cylinder wear results in a gradual increase in blow-by reading
NOT MEASURE ON INSIDE OR OUTSIDE RADIUS OF BEND AS over time. Sudden increase in blow-by reading indicates other problem.
FLOW IS NOT UNIFORM AT THESE POINTS. General Instructions for Measurement of blow-by :
1. Ensure that the correct blow-by tool for particular engine model is being
c) At the point selected, weld a 1/8 inch (3.17mm) diameter pipe used.
coupling to the exhaust tubing. Drill through tubing with a 1/8 inch drill.
2. In case of Naturally Aspirated engines, remove rocker cover & plug the
Remove all burrs. Mount 90 degree Weatherhead fitting to coupling.
vent holes in rocker housings before checking blow-by After checking the
Then use 3 feet (0.91m) of 1/8 inch inside diameter copper tubing, plug reading, remove the plugs from rocker housings to permit venting of
10 feet (3.05m) of 3/16 inch (4.76mm) inside diameter soft rubberhose crankcase.
to manometer. The manometer may be mercury filled or water filled. 3. While checking blow-by on 6 cylinder engines fitted with more than one
breathers, connect the blow-by tool to one of the breathers & plug remaining
breathers. Remove the plugs after checking the reading.
NOTE: It is important that line to manometer be as specified to
minimise variation in reading due to standing wave phenomenon which 4. While checking the blow-by, ensure that engine coolant & oil
occurs in manometer line. A change in length or material of this line temperatures are stabilized and maximum load is applied to the engine. In
case of variable load / speed applications, note down the maximum blow-by
can significantly change reading obtained. pressure reading for a complete load cycle.
d) Start engine and operate until oil temperature reaches 140 degrees 5. Sketches showing set up of blow-by tools on various engine models are
illustrated in this bulletin.
Farenheit (60 Degrees Centigrade).
BLOW-BY LIMITS (IN INCHES OF H2O)

e) Take backpressure readings when engine is developing its
maximum horsepower at maximum engine speed. Engine Model Orifice Size New/Rebuild Used engine
N-495 0.302” 5 8
NT/NTC/NTA-495 0.302” 8 12
f) Note difference in mercury level in both columns.
N-743/N-855 0.302” 8 12
NT/A-743 & NT/A-855 0.302” 12 18
NT/A-14 0.302” 12 18
Location of Silencer (in meters)
V/VT/VTA-1710 0.302” 12 25
In-line Engine 'V' Engine KT-1150:
Best 2 L/5 (4 L − 1.5 )/ 5 1500-1900 RPM Rating 0.354” 5 16
2000 & above RPM Rating 0.354” 6 17
Second best 4 L/5 (2 L − 4.5)/ 5
KTA-1150:
Worst Location L/5 or 3L/5 (3L − 10 ) / 5 1500-1900 RPM Rating 0.354” 7 19
2000 & above RPM Rating 0.354” 8 20
QSK 19 0.406” 5 13
Exhaust stack height : In order to dispose exhaust above building KTTA-19 0.406” 5 12
height, minimum exhaust stack height should be, KT/A-2300 0.406” 5 16
H = h + 0.2 x v KVA
KTA-3067/KTA-50 0.406” 7 19
Where H = height of exhaust stack h = height of building.
Section - 0 Engine Data N, V, K, QSK Page 0- 16 Section – 0 Engine Data N, V, K, QSK Page 0-17
COOLING SYSTEM
(BLOW-BY TOOL P/N 3822571 - ORIFICE SIZE : 0.406”)

Minimum Allowable Pressure cap 50 kPa [7 psi]
SET UP FOR KV-12/KV-16/KTA-50 ENGINES

0 0 0 0
Coolant Operating Range 167 F (75 C) to 203 F (95 C)
Raw Water Recommendations
BLOW BY TOOL
BLOW-BY CHECKING : Use distilled, deionised or equivalent clean water. If distilled or
deionised water cannot be used, the quality of water must meet
requirements listed below.
Parameter Limits Effects
PH - Higher levels will
Raw Water corrode aluminium,
TO GAUGE OR WATER
6.5 - 7.5
Engine Water 5-9 lead & promote scaling.
MANOMETER
Calcium/ Less than 170 PPM Excessive hardness
Magnesium (as CaCO3+Mg C03) will cause scaling
hardness problems
Chlorides Less than 40 PPM Excessive levels of
(as Cl). chloride / sulphates
Sulfates Less than 100 PPM cause corrosion of
cooling system
BLOW BY TOOL
components.
(BLOW- BY TOOL P/ N 38722566 - ORIFICE SIZE : 0.302”)
TDS (Total Less than 400 PPM High TDS increases

Dissolved conductivity of water
Solids) and accelerates
corrosion
SET UP FOR V- 12/ V- 28 ENGINES
Raw water meeting above specifications can be mixed with Cummins

BLOW- BY CHECKING :
Corrosion resistor/ coolant additive, which can effectively safeguard

CLOSED WITH PLUG
the engine against scaling and corrosion.

TO GAUGE OR WATER MANOMETER
Recommended Coolants for various engines
B/S/X Series 50-50 Water and Ethylene glycol

C Series (with alluminium radiator) Compleat EG
All other engines (including N14) CAC/(DCA2) + Water
Specifications For Treated Coolant

Coolant Additive concentrate limit should be 0.4 to 0.6 units/ltr
and pH should be 8.5 to 10
Effect: Higher levels will corrode aluminium lead & promote

KT/ KTA- 1150 : P/ N 3822570 (ORIFICE SIZE : 0.354”)
scaling Lower concentration levels will corrode cooling system

C/ NH/ NT : P/ N 3822566 (ORIFICE SIZE : 0.302”)
components & higher concentrations will form sludge, blocking

SET UP FOR C/ NH/ NT/ K- 6 ENGINES
KTTA : P/ N 3822571 (ORIFICE SIZE : 0.406”)
of coolant passages & water pump seal leaks

BLOW- BY CHECKING :
Water Temperature
Keep thermostats always in the engine, avoid long periods of idling,
and take necessary steps to keep water temperature up to a minimum
0 0
of 167 F (75 C).
BLOW-BY TOOL
BLOW- BY TOOLS :
Check Thermostats and Seals

Remove the thermostats from the thermostat housings and check for
proper opening and closing temperature. Most Cummins Engines are
0 0 0 0 0
equipped with either medium 170 to 185 F (77 to 85 C) or low 160 to
0 0 0 0 0
175 F (71 to 79 C) and in a few cases high-range 180 to 195 F
0 0
(82 to 91 C) thermostats, depending on engine application.
Section - 0 Engine Data N, V, K, QSK Page 0-18 Section - 0 Engine Data N, V, K, QSK Page 0-19
COOLANT ADDITIVE CONCENTRATE
CORROSION INHIBITOR (except Engines with Aluminium Radiators) Method
A. Coolant Additive Concentrate a. Remove the top tank cap of radiator/heat exchanger, use
Part Number Description Qty. dropper or open vent cocks in the cooling system & collect
coolant sample in the beaker.
3167214 Coolant Additive Concentrate 0.5 It.
b. Allow the coolant temperature to reach room temperature.
3167215 Coolant Additive Concentrate 1 lt. c. Remove ‘TEST STRIP’ from the pack. Dip the pad on the
3167216 Coolant Additive Concentrate 2 It. strip in coolant for 3 seconds.
3167217 Coolant Additive Concentrate 5 It. d. Remove strip & shake briskly to remove excess coolant.
3167218 Coolant Additive Concentrate 10 It. e. Wait for 45 seconds. Compare the colour of the pad with
3167219 Coolant Additive Concentrate 20 It. the colour chart within next 30 seconds.
It is supplied in plastic red colour containers having different part nos. f. Take action as shown in the colour chart.
for different volumes. The colour of the coolant additive concentrate Following action is required after checking COOLANT
is deep purple.
ADDITIVE CONCENTRATION
Below 0.4 units/lt Add B check quantity as per Operation &
B. Premixed Coolant
Maintenance manual. No need to add every B-Check.
It is supplied in plastic white colour containers having different part
or refer table part number 4912783
nos. for different volume. The colour of the coolant is pink.
From 0.4 to 0.6 units/lt OK, No action required.
Part Number Description Qty. Above 0.6 unit/ltr Add soft plain water by refering table part number
3167221 Premixed Coolant 5 It. 4912783
3167222 Premixed Coolant 10 It. For top up use only pre mixed coolant
3167224 Premixed Coolant 205 It.
b. pH of coolant
No special checking kit is required for this property. Special indicator
TestKit has bean added in the new corrosion inhibitor whose colour changes
Test kit (3167226) contasins test strip, correction table (4912783) with pH. This is only visual check. When colour of the coolant is pink
packed individually in a foil pack,. are required to check concentration. the pH is within limit.(8.5 to 10.0 pH)
Part Number Description If colour of corrosion inhibitor is colourless then it indicates, Gross
4912590 Test Strip undertreatment — Add precharge quantity, i.e. quantity of COOLANT
3167226 Test Kit ADDITIVE CONCENTRATE liquid as required for initial
Important Note : commissioning.
Shelf life for Coolant Additive Concentrate & Premixed Coolant
is 5 years & that of test strip/kit. is 18 months. Conversion of C.R. to C.A.C. on field engines:
Chromate and new liquid corrosion inhibitor are compatible. If engines
4. Coolant Checking -
having corrosion resistor are to be converted, use following method.
In normal operating condition with system maintained as per above, Cummins India Ltd. encourages field conversions.
the COOLANT will be maintained to the required specifications & no
checking is required. However coolant checking is suggested as 1. Drain coolant and remove corrosion resistor housing.
audit check or to take care of non use of recommendations for 2. Disconnect and remove corrosion connections. Plug the
service treatment and top up at 1500hrs/6 months. connections in block/water pump inlet.(Use following plugs as
Checking is also suggested at the following events, required, 1/4” NPTF-S910B, 1/2” NPTF-S915A, 3/4” NPTF-S995
- At the time of commissioning the engine, and 1” NPTF-S962).
- When coolant is totally replaced / excessive coolant loss occurs 3. Flush the coolant system with plain water twice to remove
- When concentration levels are unknown / doubtful. chromate from cooling system. This is r equired as chromate has
yellow colour & new coolant has pink colour.
Coolant checking is very easy with the use of ‘TEST STRIP’.
4. Precharge and maintain the coolant system as per instructions in
‘TEST KIT’, is designed and supplied with the engine to facilitate operation and maintenance manual.
coolant checking.
Following two coolant properties need checking.
a. Concentrating
This can be checked by ‘TEST KIT’.
Section – 0 Engine Data N, V, K, QSK Page 0-20 Section – 0 Engine Data N, V, K, QSK Page 0-21
Requirements of CAC Test Kit Part Number 3816985
System Present Genset First fill ‘B’ check

Capacity Engine Model requirement (lt.) requirement (lt.) Test Strip
(if below 0.4 units/lt)
Test strip is required to check coolant concentration. These are packed
40-60 495-H/E & Radiator 4 (2+2) 0.5 individually in a foil pack.
61-80 743 H/E & Radiator 5 1 Test Chart
855 H/E Test Chart is required to match colour on Test Strip & to decide coolant
81-120 855 Rad, K-6 Rad H/E 10 1.5 (1+0.5) concentration. Test instructions ar e given on the backside of test chart.
121- 175 No Genset Model at
present
176-225 V1710 H/E 15 (10+5) 2
Treatment Instructions
226-300 V1710-Radiator 20 (10+10) 3 (2+1)
KV12 & 16/1 MW-H/E
301-400 KV12 & 16 Radiator 25(10+10+5) 4 (2+2)
Check chemical concentration using colour chart and test strip supplied in Test
Cooled Kit Part No. 3816985. It should be in the range of 0.3 - 0.8 units/litre.
401-500 1 MW Radiator Cooled 30 (10+10+10) 5
Below 0.3 units/liter: Add 1 litres of DCA4 per 32 litres of coolant.

* Figures in bracket indicate combination of can sizes. 0.3 to 0.8 units/liter : OK
Above 0.8 units/liter: Remove adequate quantity of higher concentration
Coolant and add appropriate quantity of complete EG
ETHYLENE GLYCOL BASED COOLANT (COMPLEAT E.G) Premix Coolant to reduce concentration below 0.8 units
/ litre. Test at every B Check.
FOR CIL - C SERIES ENGINES WITH ALLUMINUM RADIATORS In order to maintain the coolant concentration it is must to top up the system
by Pre-mixed coolant only and not by water.
Cummins India has introduced a new Ethylene Glycol based coolant
(Compleat EG) for C-series engines with aluminum radiator. It will
replace DCA4 water-only product AL Plus Coolant. Coolant Replacement
Compleat EG 50:50 Premix is a fully-formulated antifreeze coolant from

Fleet guard based on DCA4 chemistry and Ethylene Glycol. At 6000 hrs of operation or after two years, it is necessary to replace the
coolant.
Self life for Coolant Additive Concentrate and Pre-Mix is 3 years and that of
Pre-Mixed Coolant
Test strip/ kit is 12 months.
Pre-Mix is supplied in plastic containers having different part numbers
for different volumes. The colour of the coolant is light blue.
Part No. Description Quantity

3816986 Pre-Mixed Coolant 5 lt.
Coolant Additive Concentrate (CAC)
It is supplied in 1 litre plastic container. The colour of the coolant additive

concentrate is blue. This is used to adjust coolant concentration without
any dilution.
Part No. Description Quantity

4104802 Coolant Additive Concentrate 1 lt.

Page 0-22
Coolant Recommendations and Specifications-SCA
Notes:
(blank filter without SCAs)
A. Consult the equipment manufacturer’s maintenance information

for total cooling system capacity.
SCA Units
B. When draining and replacing the Coolant, always pre-charge the

2200
SCA Units
200
20
Cooling system to a SCA level of 1.5 units per gallon. This

40
5
DCA (Fleetcool) Service Filters:
12
15
23
DCA (Fleetcool) liquid

2
6
4
concentration level Must never be allowed to go below 1.2 units and

must be controlled when the level is greater than 3 units. Action
needed when the level goes below 1.2 is a filter and liquid pre-charge;
from 1.2 to 3.0 units, filter only; above 3.0, test at every oil change until
[55 U.S. gal]
[1 U.S. gal]
[5 U.S. gal]
[1 U.S. pt.]
[2 U.S qt.]
level falls to 3.0 or below.
NOTE : When performing service which requires draining the cooling

Size
system, take special precautions to collect it in a clean container, seal

ENGINES FITTED WITH DCA FILTERS
it to prevent contamination, and save for reuse.

0.47
1.89
3.78
18.9
208
C. Change coolant filters at each oil change to protect the cooling

system. Consult the coolant c apacity chart to determine the correct
Not Available
Maintenance Interval
coolant filter for a given cooling system c apacity and oil drain interval.
WF2077
WF2050
WF2051
WF2052
WF2053
WF2054
WF2055
Part No.
Supplemental Coolant Additive (SCA)

Part No.
DCA30L
DCA35L
DCA50L
DCA40L
DCA45L
Fully formulated products contain SCAs and are required to protect the
cooling system from fouling, solder blooming, and general corrosion.
The coolant filter is required to protect the cooling system from
abrasive materials, debris, and precipitated coolant additives.
Fleetguard® DCA4 Service Filters and Liquid Precharge
(blank filter without SCAs)
Supplemental coolant additives, or equivalent, are used to prevent liner

SCA Units
2200
pitting, corrosion, and scale deposits in the cooling system.

200
20
40
5
Use the correct Fleetguard® coolant filter to maintain the

SCA Units
12
15
23
recommended SCA Concentration in the system.

2
4
6
8
DCA4 liquid
Section- 0 Engine Data N, V, K, QSK
DCA4 Service Filters:
Maintain the correct concentration by changing the service filter at

[50 U.S. gal]
each oil drain interval.

[1 U.S. gal]
[5 U.S. gal]
[1 U.S. pt.]
[2 U.S. qt.]
Note : The correct filter is determined by the total cooling system

Size
capacity and oil drain interval. Refer to the coolant Capacity Charts.
The SCA concentration must not fall below 1.2 units or exceed 3 units
0.47
1.89
3.78
18.9
208
per gallon of cooling system c apacity.

DCA60L
DCA65L
DCA70L
DCA75L
DCA80L
WF2070
WF2071
WF2072
WF2073
WF2074
WF2075
WF2076
WF2077
Part No.
Part No.
Page 0-24
Page 0-25
Install service filter(s) and/or liquid containing number of SCA units below
1329-1574
[351-400]
400
200
300
100
[16-20]
60-76
26
23
20
30
18
15
12
8
6
1139-1325
[301-350]
System Size in Liters [U.S. Gallons]
260
350
175
90
Maintenance Intervals for Cooling Systems up to 76 Liters [20 U.S. Gallons]
Maintenance intervals for Cooling System up to 1514 Liters [400 US. Gallons]
[11-15]
42-57
950-1135
[251-300]
23
15
12
12
10
4
8
6
6
225
300
150
75
19-38
[6-10]
[201-250]
761-946
12
12
4
4
2
8
6
6
6
250
125
190
65
4-19
[1-5]
[101-150] [151-200]
382-568 572-757
200
4
4
4
4
150
100
2
2
2
2
8
50
Install service filter(s) and/or liquid containing number of SCA units below :
1126-1250
1001-1125
150
110
876-1000
40
75
251-375
501-625
376-500
751-875
626-750
[Hours]
0-250
288-378
[76-100]
100
25
75
50
[45001-50000]
[40001-45000]
[35001-40000]
[30001-35000]
[25001-30000]
[20001-25000]
[15001-20000]
[10001-15000]
[0-10000]
[Miles]
Section –0 Engine Data N, V, K, QSK
193-284
[51-75]
40
20
80
60
Service Interval
Section- 0 Engine Data N, V, K, QSK
System Size in Liters [US. Gallons]
117-189
[31-50]
25
50
35
15
72001-80000
48001-56000
40001-48000
24001-32000
56001-64000
32001-40000
64001-72000
16001-24000
Kilometers
0-16000
[21-30]
79-144
25
20
15
10
751-1000
251-500
501-750
Service
Interval
Hours
0-250
Section– 0 Engine Data N, V, K, QSK Page 0 - 26 Section - 0 Engine Data N, V, K, QSK Page 0-27
SAFETY CONTROL TRIPPING CHART FUEL SYSTEM

Fuel Inlet Maximum Restriction
TEMPERATURE • Clean Fuel Filter 100 mm Hg [4.0 in-Hg]
Part Number Range Harness P.N & Qty
0
• Choked Fuel Filter 203 mm Hg [8.0 in-Hg]
194505 203 to 207 F
194517 198 to 202 0F Shutoff Valve Solenoid Coil Resistance 28 to 32 Ohms on 24 VDC
504043 193 to 197 0F Fuel supply & return line restriction for PT fuel system is max. 100 mm
4055076 203 to 207 0F Hg. For AMF Critical Start engines, minimum 0.45 m (18”) of gravity
0
4055979 198 to 202 F fuel feed needs to be provided to fuel pump at inlet connection.
4055654 193to 197 0F
Fuel Tank Design Requirements/Location
3062866 203 to 207 0F 3056356 , one
3062875 198 to 202 0F 3056357 , one • Size to suit atleast one shift operation or maximum 990 ltrs.
(Material MS for fuel tank and piping)
• Drain fittings to bleed water condensate at lowest point of tank.
LUBE OIL PRESSURE • Fill neck to be provided to allow min. 5% expansion space.
Part Number PRESSURE Harness P.N & Qty • Breather is mandatory.
194504 10 to 14 PSI
• Use pipe sealant loctite type 577 for all connections, for sealing.
194506 16 to 20 PSI No teflon tape to be used.
4055075 10 to 14 PSI • Suction Line and return line to be separated by at least 300 mm.
4055977 16 to 20 PSI • Galvanizing not recommended, inside fuel tank.
3056344 10 to 14 PSI 3056356 , one • Hand hole, Wire mesh filter screen at filling point.
3056345 16 to 20 PSI 3056356 , one • Fuel suction pipe should be 50 mm (2") inside the bottom of the
fuel tank for B Series and above engines. For S3.8 engine 25 mm
OVER SPEED STOP (1") is acceptable.
Part Number Tripping Range RPM Engine RPM Ratio O.S Setting • For PT fuel system, fuel return line should be on top of fuel level and
Indicator RPM for X / S / B / C series engines with high pressure fuel system fuel
500287 2500/2580 2100 2:1 1250 to 1290 return should be dipped in fuel.
500288 2150/2230 1800 2:1 1075 to 1115 FUEL SYSTEM FUEL TANK LOCATION
500289 1800/1880 1500 2:1 900 to 940 The objectives in locating a fuel tank are to make sure that the
500974 2150/2190 1800 1:1 2150 to 2190 supply and return restrictions are within the limitations and at the
505069 1640/1680 1500 1:1 1640 to 1680 same time to avoid hydraulic lock after the engine shut down.
3231354 1700/1740 1500 2:1 850 to 870 Typically fuel tank should be placed on the level as that of engine
3231688 2260/2300 1950 2:1 1130 to 1150 i.e. floor mounted. Locate fuel tank such that fuel outlet point (or
3233985 2050/2090 1800 2:1 1025 to1045 bottom of fuel tank) is maximum 1.8m (6 feet) below the fuel pump
3235575 2120/2160 1800 2:1 1060 to 1080 inlet or for top mounted fuel tank, top side of fuel tank is max 1.5 m
(5 feet) above fuel return line. In case of Top Mounted tanks non
3876193 1350/1410 1200 2:1 675 to 705
return valves are must in fuel supply and teturn lines of specified value.
3878441 1160/1240 1000 2:1 580 to 620
CONNECTION FLEXIBLE CABLE PART NO. IS 20/500464 A) When the tank can be located 8 to 20 inches below the fuel return
connection, the method meets the above requirements. In case of
fuel tank mounted above engine fuel connections special
arrangements are required.
1) In case of fuel return line connection is less than 8 feet above the
engine fuel connections, then use of one check valve (P/No.
178079) is recommended in injector line. And the other check
valve (P/No. 185505) is fitted at the fuel pump outlet to prevent
hydraulic lock due to gravity flow when engine is shut down.
2) In case return line cannot be restricted to less than 8 feet a float
tank arrangement should be provided.
B) In case of fuel tank below the fuel pump care should be taken to
keep a tank outlet connection not more than six feet from pump
inlet pipe. If this cannot be maintained it will be necessary to
employ a transfer pump and an auxiliary tank.
Section – 0 Engine Data N, V, K, QSK Page 0-28 Section - 0 Page 0-29
LUBRICATING OIL SYSTEM ENGINE FIRING ORDER

0 0
• Typical Engine Oil Pressure [with 15W-40 Oil at 221 F (105 C)]
2 MODEL FIRING ORDER CYLINDER COUNTING
• At idle (Minimum Allowable) 1 to 2 kg/cm
2
• At Rated speed 3 to 7 kg/cm
N495 / N-8 1-2-4-3 1234 FLYWHEEL
Engines Provided With Demand Flow Cooling System {DFC}
0 0
[with 15W-40 Oil at 221 F (105 C)]
2
• At idle (Minimum Allowable) 0.7kg/cm
• At Rated speed 2.4 to 3.1 kg/cm
2
N 743/855/14 1-5-3-6-2-4 123456 FLYWHEEL
K1150/19/QSK19
DFC SYSTEM REGULATES OIL FLOW AND OIL COOLING ONLY
ON DEMAND, RATHER than continuously at maximum capacity.
0 0 0 0
Oil Temperature Range 167 F (75 C) to 221 F (105 C)
0
Under full load conditions, an oil temperature of 240 F (116 C) for a
0 V1710/V28 1L-6R-2L-5R-4L-3R LB
short. 6L-1R-5L-2R-3L-4R 123456 FLYWHEEL
Engine oil pressure must be indicated on the gauge within 15
seconds after starting. If oil pressure is not registered within 15 123456
seconds, shut off the engine immediately to avoid engine damage. Bank angle 40
o
RB
Confirm the correct oil level in the oil pan.
RECOMMENDED BATTERY CAPACITY

FOR CUMMINS ENGINES.
K 2300/38/ 1 R-6L-5R-2L-3R-4L RB
Battery Cable Electrical
Model
Capacity AH Size mm2 System Volts QSK45 6R-IL-2R-5L-4R-3L 123456 FLYWHEEL
KV and above 360 70 24
123456
V28/K19 180 70 24
o
N14/855/N8/C 180 50 24 Bank angle 60 LB
B-5.9 150 50 12
S-3.8 120 50 12
X-Series 88 35 12
NOTE : The number of plates within a given battery size determines K 3067/K50 1R-1L-3R-3L-7R-7L-5R-5L RB
reserve capacity. Reserve capacity is the length of time sustained
8R-8L-6R-6L-2R-2L-4R-4L 1 2 3 4 5 6 7 8 FLYWHEEL
cranking can occur.
Battery Specifications : 12345678
o
The Batteries listed in table are the minimum capacity which must Bank angle 60 LB
be provided to crank the engines at the minimum engine
temperatures expected. Battery capacities are given in cold
cranking amperes and for reference in ampere-hours. Minimum
battery capacities based on engines with no externally connected K50Revised/ 1R-1L-3R-3L-2R-2L-5R-4L RB
parasitic loads. QSK60
8R-8L-6R-6L-7R-7L-4R-5L 1 2 3 4 5 6 7 8 FLYWHEEL
Battery (Specific Gravity) 12345678

o o o
Battery State of Charge Specific Gravity @ 27 C[80 F] Bank angle 60 LB
100% 1.260-1.280
75% 1.230-1.250
50% 1.220-1.220
25% 1.170-1.190
Discharged 1.110-1.130 NOTE: LB - Left Bank
RB - Right Bank
OVERHEAD SETTING ADJUSTMENTS Values - for NH/NT-495 (Dial Indicator)

Temperature Settings
Cold setting
Cold setting : The engine must have reached a stabilized oil temperature
0 0
of 140 F (60 C) or below Injector Plunger Intake Exhaust
It is recommended that valve and injector plunger adjustments be made travel inch (mm) Valve Valve
when engine is cold. Inch (mm) Inch (mm)
Adj. Recheck
Note / Caution Value Limit
1. Outer Base Circle procedure, is MANDATORY for engines fitted with Aluminium 0.170 0.169 to 0.171 0.011 0.023
STC or HVT injectors. Rocker housing (4.32) (4.29 to 4.34) (0.28) (0.58)
2. Before doing STC Injector Setting drain the lube oil from Injectors &
manifold by idle running the engine for 5 minutes with disconnected Cast Iron 0.175 0.174 to 0.176 0.013 0.025
lube oil connection to Injectors Rocker housing (4.45) (4.42 to 4.47) (0.33) (0.63)
Hold the torque wrench in a position that allows you to look in a direct
line at the dial. This is to make sure the dial will be read accurately. Torque Method - NH/NT-743/855
Make sure the parts are aligned, and squeeze the oil out of the valve
and injector train by tightening the adjusting screw. Bar in Pulley Set Cylinder
3. Two crankshaft revolutions are required to adjust all of the valves and Direction Position Injector Valve
injectors. Start A OR 1-6 VS 1 1
4. Do not use a click-type torque wrench for STC Injectors. Advance to B OR 2-5 VS 5 5
5. The feeler gauge must slide backward and forward with only a slight Advance to C OR 3-4 VS 3 3
drag. Advance to A OR 1-6 VS 6 6
6. The adjusting screw must not turn when the locknut is tightened. Advance to B OR 2-5 VS 2 2
Advance to C OR 3-4 VS 4 4
INJECTOR/VALVE SETTING PROCEDURES
Torque Method-NH/NT/NT-495/N-8 Values - for NH/NT-743 (Torque Method)

Bar in Pulley Set Cylinder
Direction Position Injector Valve Cold setting
Start A OR 1-4 VS 1 1 Injector Intake Valve Exhaust Valve
Advance to B OR 2-3 VS 2 2 In. Lbs.(N.m.) Inch (mm) Inch (mm)
Advance to A OR 1-4 VS 4 4
Advance to B OR 2-3 VS 3 3 Aluminium 72 (8.1) 0.014 (0.36) 0.027 (0.69)
Rocker housing
Values – for NH/NT-495 (Torque Method)
Cold setting Cast Iron 48 (5.4) 0.016 (0.41) 0.029 (0.74)
Injector Intake Valve Exhaust Valve Rocker housing
Aluminium In. Lbs. (N.m.) Inch (mm) Inch (mm)
Rocker housing Dial Indicator
– Method -NH/NT-743/855
72 (8.1) 0.014 (0.36) 0.027 (0.69)
Cast Iron 48 (5.4) 0.016 (0.41) 0.029 (0.74)
Direction Position Injector Valve
Rocker housing
Start A OR 1-6 VS 3 5
Values for N-8G1, G2 (Torque Method) Advance to B OR 2-5 VS 6 3
Valve and Injector adjustment limits Advance to C OR 3-4 VS 2 6
Injector 6 lb-ft (70 lb-in) OBC Method Advance to A OR 1-6 VS 4 2
Intake Valve 0.016” Advance to B OR 2-5 VS 1 4
Exhaust Valve 0.029” Advance to C OR 3-4 VS 5 1
Dial Indicator Method-NH/NT-495
Start A OR 1-4 VS 2 2
Advance to B OR 2-3 VS 4 4
Advance to A OR 1-4 VS 3 3
Section –0 Engine Data N, V, K, QSK Page 0-32 Section - 0 Engine Data N, V, K, QSK Page 0-33
Values - NH/NT-7-43/855 (Dial Indicator) Values for NTA-855/N14 WITH STC - OBC Procedure
Cold setting
Cold Setting
Injector Plunger Travel Intake Valve Exhaust Valve Injector Intake valve Exhaust valve
Inch (mm) Inch Inch inch-lb (N.m) Inch (mm) Inch(mm)
Adj. Recheck N-14 125 (14) 0.014 (0.36) 0.027(0.69)

Value Limit
Aluminium 0.170 0.169 to 0.171 0.011 0.023 NTA-855 125 (100 ) 0.014 (0.014) 0.027 (0.027)
Rocker housing (4.32) (4.29 to 4.34) (0.28) (0.58)
Cast iron 0.175 0.174 to 0.176 0.013 0.025 Torque Method-V-1710/28 (Top Stop & Non Stop Injectors)
Rocker housing (4.45) (4.42 to 4.47) (0.33) (0.63)
Values for NT-855 (Big Cam only - Non Top Stop)
0.228 0.227 to 0.229 0.011 0.023 Start 1-6L VS 1L 1L
(5.79) (5.76 to 5.82) (0.28) (0.58) Advance to 1-6R VS 6R 6R
Advance to 2-5L VS 2L 2L
Advance to 2-5R VS 5R 5R
NT-855-G5 Big Cam Ill NON STC IBC Method Top Stop Zero Lash Advance to 3-4L VS 4L 4L
Bar in Pulley Set Cylinder Advance to 3-4R VS 3R 3R
Direction Position Injector Valve Advance to 1-6L VS 6L 6L
Start A OR 1-6 VS 3 5 Advance to 1-6R VS 1R 1R
Advance to B OR 2-5 VS 6 3 Advance to 2-5L VS 5L 5L
Advance to C OR 3-4 VS 2 6 Advance to 2-5R VS 2R 2R
Advance to A OR 1-6 VS 4 2 Advance to 3-4L VS 3L 3L
Advance to B OR 2-5 VS 1 4 Advance to 3-4R VS 4R 4R
Values for 855 Big Cam. (Zerolash Method)
Values - VT-1710/28 (Top Stop & Non Stop Injectors)

Cold setting Injector Intake valve Exhaust valve
in-lb (N.m) Inch (mm) Inch (mm) Cold setting
Injector Intake Valve Exhaust valve
5 to 6 (0.6 to 0.7) 0.011(0.28) 0.023 (0.58) in-lbs (N.m.) Inch(mm) Inch (mm)
70 (8) 0.014 (0.36) 0.027(0.69)

NTA-855/N14 WITH STC INJECTORS – OBC Procedure
Bar in Pulley Set Cylinder Dial Indicator Method - KT/KTA-1150

Start A OR 1-6 VS 1 1 Direction Position Injector Valve
Advance to C OR 3-4 VS 3 3 Start A OR 1-6 VS 3 5
Advance to A OR 1-6 VS 6 6 Advance to B OR 2-5 VS 6 3
Advance to B OR 2-5 VS 2 2 Advance to C OR 3-4 VS 2 6
Advance to C OR 3-4 VS 4 4 Advance to A OR 1-6 VS 4 2
Values for QSK 19 OBC
Values for KT/KTA 1150
Cold setting in-lb(N.m) Inch (mm) Inch (mm)
Injector Plunger travel Intake valve Exhaust valve
250 (28) 0.014 (0.36) 0.032 (0.81)
inch (mm)
Adj Value Recheck Limit Inch (mm) Inch (mm)
0.304 0.303 to 0.305 0.014 0.027 Loosen Injector Set Screw by one turn
(7.72) (7.69 to 7.75) (0.36) (0.69) 165(19)
K 19 With STC or HVT Injectors - OBC Overhead Setting Procedure

Injector for QSK 19
The torque wrench must be calibrated, have a resolution of 0.28 N-m
Bar in Pulley Valves Set Cylinder [2.5 in-lb], and have a range of 17 to 23 N-m [150 to 200 in-lb].
Direction Position Closed on Injector Valve
Start A OR 1-6 VS 1 4 5 Be sure the parts are in alignment and squeeze the oil out of the valve
Advance to B OR 2-5 VS 5 1 3 and injector train while tightening the adjusting screw.
Advance to C OR 3-4 VS 3 5 6 Torque Value: 28 N-m [250 in-lb]
Advance to A OR 1-6 VS 6 3 2 Loosen the adjusting screw at least one revolution.
Advance to B OR 2-5 VS 2 6 4 Tighten the adjusting screw again.
Advance to C OR 3-4 VS 4 2 1 Torque Value: 19 N-m [165 in-lb]
Values for STC Injectors Dial Indicator Method- KT/KTA 2300

Cold setting Injector Intake Valve Exhaust valve Bar in Pulley Set Cylinder
in-lb (N.m.) Inch (mm) Inch (mm)
100 (11) 0.014 (0.36) 0.027 (0.69) Start 1 R-6 R VS 1R 1R
Advance to 1 L-6 L VS 6L 6L
Loosen Injector Set Screw by one turn Advance to 2 R-5 R VS 5R 5R
90 (10) Advance to 2 L-5 L VS 2L 2L
Advance to 3 R-4 R VS 3R 3R
Values for Non STC-Top Stop Injectors KTA-19-G3I CIL Make Advance to 3 L-4 L VS 4L 4L
Cold setting Injector Intake Valve Exhaust valve Advance to 1 R-6 R VS 6R 6R
in-lb (N.m.) Inch (mm) Inch (mm) Advance to 1 L-6 L VS 1L 1L
70 0.017 0.029
QSK 19- OBC Overhead Setting Procedure Advance to 3 L-4 L VS 3L 3L
Bar in Pulley Valves Set Cylinder Dial Indicator Method – KTA 3067
Direction Position Closed on Injector Valve Bar in Pulley Set Cylinder
Start A OR 1-6 VS 1 4 5 Start 1 R-8 R VS 1R 1R
Advance to B OR 2-5 VS 5 1 3 Advance to 1 L-8 L VS 1L 1L
Advance to C OR 3-4 VS 3 5 6 Advance to 3 R-6 R VS 3R 3R
Advance to A OR 1-6 VS 6 3 2 Advance to 3 L-6 L VS 3L 3L
Advance to B OR 2-5 VS 2 6 4 Advance to 2 R-7 R VS 7R 7R
Advance to C OR 3-4 VS 4 2 1 Advance to 2 L-7 L VS 7L 7L
Section -0 Engine Data N, V, K, QSK Page 0-36 Section – 0 Engine Data N, V, K, QSK Page 0-37
Values - for KT/KTA-2300 & KTA-3067 (Dial Indicator) KTA_50 (G3/G8) & QSK 60 Outer Base Circle Set
Revised Firing Order only.
Cold setting
Injector Plunger travel Intake valve Exhaust valve Bar in Pulley Valves Closed Set Cylinder
inch (mm) Inch Inch Direction Position on Cylinder Valve Injector
(mm) (mm) Number
Adj. Recheck Start 1 R-8 R VS 1R 1R 6R
Value Limit Advance to 1 L-8 L VS 1L 1L 6L
0.308 0.307 to 0.309 0.014 0.027 Advance to 3 R-6 R VS 3R 3R 7R
(7.82) (7.79 to 7.85) (0.36) (0.69) Advance to 3 L-6 L VS 3L 3L 7L
Advance to 2 R-7 R VS 2R 2R 4R
Advance to 2 L-7 L VS 2L 2L 5L
K-38/QSK 45 Outer Base Circle Set Procedure (with STC Injectors) Advance to 3 R-6 R VS 6R 6R 2R
Advance to 2 R-7R VS 7R 7R 5R
Bar in Pulley Valves Closed Set Cylinder Advance to 2 L-7 L VS 7L 7L 4L
Direction Position on Cylinder Valve Injector Advance to 4 R-5 R VS 4R 4R 8R
Number Advance to 4 L-5 L VS 5L 5L 8L
Start 1 R-6 R VS 1R 1R 2R
Values for KTA 50 G3/G8 OBC (STC Injectors)
Cold setting
Advance to 2 L-5 L VS 2L 2L 3L Injector Intake valve Exhaust valve
Advance to 3 R-4 R VS 3R 3R 1R in-lb(N.m) Inch (mm) Inch (mm)
Advance to 3 L-4 L VS 4L 4L 6L 100 (11) 0.027 (0.36) 0.014 (0.69)
Advance to 1 L-6 L VS 1L 1L 2L Loosen injector set Screw by one turn
Advance to 2 R-5 R VS 2R 2R 3R 90 (10)
Advance to 3 R-4 R VS 4R 4R 6R Values for QSK 45 / 60
Advance to 3 L-4 L VS 3L 3L 1L Cold setting
Injector Intake valve Exhaust valve
Values for K38 OBC (STC Inj.) in-lb(N.m) Inch (mm) Inch (mm)
248 (28) 0.014 (0.36) 0.032 (0.81)
K-38 in-lb(N.m) Inch (mm) Inch (mm) Loosen injector set Screw by one turn
168 (19)
100 (11) 0.014(0.36) 0.027(0.69)
Loosen Injector Set screw

by one turn
90 (10)

Page 0-39
EVERY ‘D’ CHECK

1500 HRS. AFTER
ALL STEPS OF
Adjust Injectors
C-CHECK AND
Replace rocker
Tighten the injector adjusting screw locknut:

cover gaskets
ADDITIONAL
Torque Value:
and Valves
With Adapter 47.5 N•m [35 ft-lb]

STEPS
Without Adapter 60 N•m [44 ft-lb]
There are two different methods use to set valve lash clearance: Torque
wrench method and feeler gauge method; both are described below.
Either method can be used; however, the torque wrench method has
proven to be the most consistent.
Nuts or Capscrews
Screen and Magnet
CheckTurbocharger
Calibrate injectors
Compressor and
Tighten Manifold
Replace rocker
Turbine wheel.
Method
cover gaskets
Replace Fuel
Repeat “A, B
D-CHECK
Make sure the parts are aligned, and squeeze the oil out of the valve
Pump Filter
if required.
Clean and
and the injector train by tightening the adjusting screw.

Fuel System
Air System
and C”
Loosen the adjusting screw at least one revolution.

Insert the feeler gauge between the rocker lever socket and the
crosshead.
Use torque wrench, Part No. 3376592, and tighten the adjusting screw.
Torque Value: 0.68 N•m [6 in-lb] Remove the feeler gauge.
CHECK PERFORMED
ENGINE SERIAL NO.
HOURS, CALENDAR
FOR INDUSTRIAL FIRE PUMP ENGINES ONLY
Clean Fuel Tank from
NOTE: The adjusting screw must not turn when the locknut is tightened.
as reqd. (Alternator/
Change if required.
Check Water Pump
Repeat “A” and “B”
Locknut torque can be applied with or without torque wrench adapter,

Check air cleaner
items and replace
Evacuator valve.
Inspect following
Other Maintenance
Exchanger Core
Part No. ST-669.

MAINTENANCE SCHEDULE
C-CHECK
Cooling System
Tighten the locknut.

Check Heat
Starter etc.)
Torque Value:
DATE
Fuel System
With Adapter 47.5 N•m [35 ft-lb]

inside
Without Adapter 60 N•m [44 ft-lb]

Attempt to insert a feeler gauge that is 0.03-mm [0.001-in] thicker. The
EQUIPMENT NO.________________________________________________
TIME SPENT ___________________________________________________

MECHANIC ____________________________________________________
valve lash is not correct if the thicker feeler gauge will fit.
Repeat the adjustment process until the proper lash is obtained.
ALL STEPS OF
C-CHECK AND
Replace rocker
Injector Adjustment
Adjust Injectors
FIRST 1500 HRS.
cover gaskets
ADDITIONAL
Use a dial-type torque wrench, Part No. 3824783, with 0.28 N•m [2.5 in-
and Valves
lb] resolution and a range of 17 to 34 N•m [12.5 to 25 ft-lb] to tighten the

CHECK
STEPS
injector rocker lever adjusting screw. If the screw chatters during setting,
repair the screw and lever as required.
Torque Value:
with Torque Wrench Adapter,
45 N•m [35 ft-lb]
Part No. ST-669 (1)
Clean Fuel Tank
without Adapter 60 N•m [45 ft-lb]

Change Engine
Change Engine
Check Throttle
Change Fuel
Full-Flow Oil
B-CHECK
Record Oil
Section –0 Engine Data N, V, K, QSK
Repeat “A”
Fuel System
Pressure
Breather
Linkage
Lubrication
Filters
Filter
Oil
Check Air Cleaner

Check Engine Oil
PARTS ORDER NO.
from Fuel Tanks

Drain Sediment
Check Coolant
from the Water
Cooling System
Drain Water
Check Fuel
A-CHECK
Separator
Fuel System
Lubrication
Air System
Supply
Level
Level
Daily
Section-0 Engine Data N, V, K, QSK Page 0-40
Section- 0 Engine Data N, V, K, QSK Page 0-42 A-CHECK B-CHECK FIRST 1500 HRS. C-CHECK D-CHECK 1500 HRS. AFTER
COMPONENT MEASUREMENT LIMITS CHECK EVERY ‘D’ CHECK
CYLINDER BLOCK SPECIFICATION Inch (mm) Other Maintenance Air System Check Turbocharger
Engine Camshaft Camshaft Main Cylinder Liner Cylinder Block Piston Pin Piston Pin Camshaft Check leaks and Clean / Change bearing clearance
Model bushing bushing brg counter Bore Lower Liner Bore O.D Journal Correct Crankcase Other Maintenance
I.D. Bore Bore I.D. Inside Dia. Bore I.D. O.D Check Engine Breather Steam Clean Engine
Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Lubricating Oil Check Air Cleaner Tighten Mounting
and Water Heater Restriction Bolts and Nuts
W 2.0015 2.1305 4.7505 2.0000 1.9978 1.996
Check Raw Cooling System (As Required)
(50.838) (54.115) (120.663) (50.800) (50.754) (50.70) Water Strainer Change Water
2 Check Crankshaft
495/743 Min 1.9990 2.1285 4.7485 6.124 5.7490 1.9987 1.9988 1.997 Check Starting Filter/Water Softner End Clearance
Batteries Check coolant
(50.775) (54.064) (120.612) (155.554) (146.025) (50.767) (50.770) (50.72) inhibitor. Add Check Vibration
Check belts, Damper
Max 2.0005 2.1295 4.750 6.126 5.7510 1.9990 1.9990 1.998 adjust if required coolant concentrate
if required. Check Air
(50.813) (54.089) (120.65) (155.600) (146.075) (50.775) (50.775) (50.75) Record Water Temp. Compressor
Record RPM Check Safety
W 2.0015 2.1305 4.7505 1.999 1.9985 1.996 Controls
(50.838) (54.115) (120.663) (50.775) (50.762) (50.70)
855 Min 1.999 2.1285 4.7485 6.5615 6.1240 1.9985 1.9988 1.997 Engine Interval B C D
(50.775) (54.064) (120.612) (166.662) (155.554) (50.762) (50.770) (50.72) Series Every 300 hours To be done at first Every 1500 Every 6000 hours To be done at 1500
All Hours Every 6 months 1500 hours only hours Every 1 Every 2 years hours after every
Max 2.0005 2.1295 4.750 6.5635 6.1260 1.9989 1.9990 1.998 Calendar year D Check
(50.813) (54.089) (120.650) (166.713) (155.600) (50.772) (50.775) (50.75) Notes: 1. Perform checks on operating basis of interval that occurs first.
W- Wear limit 2. Any time cooling system is completely drai ned and/or flushed, check coolant using coolant checking kit.
3. It is suggested to operate the engine at operating temperatures once in a week.
Section- 0 Engine Data N, V, K, QSK MAINTENANCE SCHEDULE FOR STARTER AND ALTERNATOR Page 0-41
PRODUCT DAILY MAINTENANCE WEEKLY MAINTENANCE MONTHLY MAINTENANCE QUARTERLY MAINTENANCE
Section -0 Engine Data N, V, K, QSK Page 0-43 BS5 Starter Check tightness of battery Check battery specific Top up *DE Shield reservoir with Remove **CE cover and smear
W 2.1295 2.2555 6.0965 2.000 and circuit connections gravity multi grade 20W40 (API-CD) oil. Molybdenum Sulphide grease over CE
(54.089) (57.290) (154.851) (50.80) bearing pin.
1710 Min 2.1245 2.2535 6.095 6.5615 6.1240 1.9985 1.9978 2.122 Check visually battery Clean the brush dust inside the starter and
(53.962) (57.239) (154.81) (166.662) (155.554) (50.762) (50.774) (53.85) electrolyte level. secure CE cover properly. Apply Elcoprine
sealing compound around cover.
Max 2.1283 2.2545 6.096 6.5635 6.1260 1.9989 1.999 2.123
(54.059) (57.264) (154.84) (166.713) (155.600) (50.772) (50.77) (53.92) Check the tightening torque of all fasteners
W 3.0035 5.8465 2.3990 2.398 2.995 SM130 PE Same as BS5 starter Same as BS5 starter Top up DE and CE Shield with Lubricate pinion on shaft with MOS2 grease
(76.276) (149.50) (60.935) (60.91) (76.07) Starter Multi grade 20W40(API-CD) oil OKS-410
1150/19 Min 3.000 3.2535 5.845 7.4915 6.9820 2.3985 2.3988 2.995 Check tightening torque of all
(76.200) (82.638) (148.46) (190.284) (177.343) (60.922) (60.929) (76.07) fasteners.
Max 3.002 3.2545 5.846 7.4935 6.9840 2.3989 2.399 2.997 AC5 Alternator Check belt tension ------ Check battery terminal voltage Check tightening torque of all fasteners
(76.250) (82.664) (148.49) (190.335) (177.394) (60.932) (60.94) (76.12) while charging.
W 3.0025 3.1895 6.8465 2.3990 2.398 2.995
(76.264) (81.013) (173.876) (60.935) (60.91) (76.07) Check tightness of output Clean and apply petroleum jelly Check the smoothness of ball bearings.
and WL terminal for battery terminals.
2300/ Min 3.000 3.1875 6.845 7.4915 6.9820 2.3985 2.3988 2.996
connections.
3067 (76.200) (80.962) (173.863) (190.284) (177.343) (60.922) (60.929) (76.09)
General DE-Drive end: Instructions *
38/50 Max 3.0015 3.1885 6.846 7.4935 6.984 2.3989 2.399 2.997 Ensure the panel switch is not sticky. ** CE – Commutator end
(76.238) (80.988) (173.884) (190.335) (177.39) (60.932) (60.94) (76.12) Do not crank the starter more than 20 seconds.
If the clutch slip noise is heard, do not try to start the engine.
W - Wear limit 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.
IMPORTANT TURBOCHARGER
Page 0-44
KT/KTA-2300
SPECIFICATIONS
KTA3067
Turbocharger Axial Play Radial Play at
Length
0.0035
Model Compressor End
0.008
0.008
0.003
0.012
0.015
Full
H2A/H1E* 0.004” to 0.0125” to
Alignment (TIR)
0.006” 0.0185”
HC3/4LGK 0.001” to 0.0074” to
0.004” 0.0208”
Flange
(Inch)
Rear
HC-5A/HX80/ 0.002” to 0.0191” to
0.001
0.001
0.001
0.001
0.001
HX82 0.005” 0.0294”
T-50/VT-50 0.006”to 0.003”to
ST-50 0.018” 0.033”
0.001
0.001
0.001
0.001
0.001
Nose
T-18A 0.004” to 0.003”

0.009” 0.007”
H1C 0.001” to 0.012”
0.003 0.018”
Hardness
HX40 0.0037 0.0128

45
45
45
45
45
52
52
52
52
52
0.0015 0.0195
RC
CRANKSHAFT DIMENSIONS
* H1E - Watercooled bearing housing turbo.
IMPORTANT CLEARANCE VALUES

Radius
(Inch)
0.172
0.195
0.172
0.195
0.172
0.195
0.230
0.270
0.230
0.270
Fillet
Engine Crank Liner Conrod Camshaft ACC Drive

Model Endplay Protusion Side Endplay Endplay
Clearance
Width (Inch)
V/VT/VTA 0.006” to 0.004” to 0.007” to 0.010” to 0.002” to

Crank Pin
1710 0.013” 0.006” 0.022” 0.015” 0.013”

2.375
2.378
2.125
2.128
4.049
4.051
2.748
2.751
4.798
4.802
KT/KTA 0.004” to 0.003” to 0.008” to 0.006” to 0.002” to

1150 0.016” 0.006” 0.014” 0.013” 0.012”
KT/KTA 0.005” to 0.005” to 0.012” to 0.006” to 0.002” to
2300 0.015” 0.007” 0.020” 0.013” 0.013”
3.1235
4.2470
4.2500
3.1250
3.1235
3.1250
3.7485
3.7500
3.9985
Crank Pin
Dia (Inch)
4.000
& KTA 3067

N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.018” 0.007” 0.013” 0.011” 0.012”
QSK 19 0.004” to 0.005” to 0.008” to 0.006” to 0.002” to
Section - 0 Engine Data N, V, K, QSK
0.016” 0.007” 0.014” 0.013” 0.012”

Dia (Inch)
QSK 45/60 0.005”to 0.006” to 0.012” to 0.006” to 0.005” to

Journal
4.4985
4.5000
4.4985
4.5000
5.7485
5.7500
5.4985
5.5000
6.4980
6.5000
0.020” 0.008” 0.020” 0.013” 0.011”
NOTE :
* Indicates with support
** Indicates with plate
MAX
MAX
MAX
MAX
MAX
N/NT/495/ MIN
MIN
MIN
MIN
MIN
For genset-app- “Acc drive endplay is 0 to 0.001”

KTA3067
NTA/855
VT/VTA
KT/KTA
KT/KTA
Model
N/NT/
2300
1710
1150
743
Section - 0 Engine Data N, V, K, QSK Page 0- 46

Hyd. Pump 180
Page 0-47
110 W. Pump
For Tapered Roller Bearings - End Clearance

flange head
59/122/207
with flange
Capscrew
Capscrew
Engine Model End Clearance

without
V- 28 0.003”- 0. 010”
head
Cam
180*
215
SHAFT
185
IDLER
K- 19 0.003”- 0. 016”
75
-
KV- 38 0.001”- 0. 008”

FLYWHEEL HOUSING
SIDE CAPS
MAIN BRGS
325-335
Flywheel housings are manufactured as per S. A. E. standards given

70-135
below. While confirming the SAE No., bore diameter and pitch circle
-
288
diameter (PCD) should be measured.

SAE NO. BORE PCD
35/145/340
FLYWHEEL
148/280/
0 25. 5” 26. 750”

110/210
155 imported 110/210
1 20. 125” 20. 875”

70 Indigenous /380
215
505
85/
2 17. 625” 18. 375”

3 16. 125’ 16. 875”
VIBRATION
VISCOUS VIBRATION DAMPER - INCH (MM)

DAMPER
92/122
Damper Maximum Recommended

105
120
Part No. Allowable Change interval

-
Thickness - Hours
Taper nose crank
IMPORTANT TORQUE VALUES
with single cap-
3037156 1.635(41. 53) 15000

CRANK FRONT
100/200/320
148/280/505
207531 2.574(65. 38) 15000

screw 475
211915 1.550(39. 37) 15000

160/290
160/290
FLANGE
50-55
217321 1.663(42. 24) 15000

/410
/320
* From ESN 25227693 - Tighten to 135 ft-lb then loosen & 45 ft.lb. + 90 (TPA.)
217322 1.663(42. 24) 15000

217323 1.663(42. 24) 15000
3873899 2.574(65. 38) 24000
o
INJECTOR
3015464 2.574(65. 38) 24000

133-140
3628651 2.574(65. 38) 24000

11-13
10-13
11-13
lb-in
3628649 2.574(65. 38) 24000

55
3628650 2.574(65. 38) 24000

/300/410
/275/310
/250/355
52/148/0
50/150/0
100/200
100/200
At any time the engine experiences the following problems, check

220+90
221+90
70/170
HEAD
CYL.
Vibration Damper. Replace if necessary

350
a. Gear train failure

b. Accessory drive shaft failure
70/140/220
70/140/220
75/150/250
75/150/250
c. Crankshaft failure
63 loosen
CONROD
All torque values listed below are in lbs.ft
Loosen
d. Damper mounting capscrew failure

Section - 0 Engine Data N, V, K, QSK
75/175
70/150
70/150
70/140
loosen
0
loosen
63+60
CAPS
/240
e. Flywheel mountin g capscrew failure
Accessory Drive timing procedure on K-6 engine with gear case

‘D’- KV16 250
letter ‘C’ KV12
250 +
Note : . TPA - Torque Plus Angle

*TPA method
blocks having
210/420-460
0
SN. with first
Loosen 200-
cover installed
90 advance
144/310+ 90
MAIN BRG
for cylinder
200-210/
230/260
420-460
200/450
200/450
200/450
210/450
If the accessory drive is removed with out the gear train in position or the
195/445
144/310
195/445
Loosen
Loosen
Loosen
Loosen
CAPS
loosen
engine is rotated after accessory drive is removed. Time the accessory

0
drive as follows
Remove the two pipe plugs from both timing holes in the front gear case
MODEL/SERIES
cover of cam shaft and accessory drive.

KT/A-1150
KT/A 2300
KT/A 3067
Bar the engine till the "X" mark on the camshaft gear is aligned and
QSK45/60
VT 1710
ENGINE
K38/50
centered in the upper timing plug hole.

QSK19
N8
Note: Need not to use any mark on idler gear for the accessory drive
alignment.
Install the accessory drive assembly so that the "A" mark on the
accessory drive gear is centered in the lower timing plug hole.
Torque Values & Critical specifications for N Series Section - 0 Engine Data N, V, K, QSK Page 0-48
Torque Values & Critical specifications for N Series
Part Name/ MODELS
Part Name/ MODELS
Characteristics NH NT NTBC N14
Accessory Drive Pulley Nut 270 to 310 ft.lb. 270 to 310 ft.lb. 270 to 340 ft.lb. 270 to 340 ft.lb.
Main Bearing Cap Torque 230-260 ft.lb. loose & 230-260 ft.lb. loose & 75 + 5, 145 + 5, 200 + 200 + 15 ft. lb., loose 2 Rev., 140 ft. lb.
Cylinder Head Torque 140-160/290-310/ 25/100/265-305 ft.lb. 100-220 ft.lb.rotate 225+5 ft.lb., rotate 90 Deg., + 3 Deg.
repeat repeat 15 ft. lb. loose ft. lb. and rotate 90 Deg.
460-480 ft.lb. 900 + 30 and rotate 90 Dec. +
Cross Head Valve Nut 30 to 40 ft.lb. 30 to 40 ft.lb. 30 to 40 ft.lb. ---- 3 Deg.
Injector Mounting 10 to 12 ft.lb. 133 to 140 ft.lb. One C/s.3/8:38-42 ft.lb. One C/s.3/8:38-42 ft.lb.
Two C/s.3/8:23-27 ftl.lb. Two C/s.3/8:23-27 ftl.lb. Crank End Play 0.007" to 0.018" 0.007" to 0.018" 0.004" to 0.018" 0.004" to 0.018
Rocker Shaft Bolt --- --- --- 110 ft.lb.
Rocker Housing 55 to 65 ft.lb. 55 to 65 ft.lb. 70 to 75 ft.lb. Cast Iron : 110-120 ft.lb. Linear Protrusion 0.004" to 0.007" 0.004" to 0.007" 0.004" to 0.007" 0.004" to 0.007"
Exhaust manifold 40 to 45 ft.lb. 40 to 45 ft.lb. 40 to 45 ft.lb. 55 to 60 ft. lb.
Cam End Play Plate : 0.001" to 0.005" Plate : 0.001" to 0.005" 0.008" to 0.013" 0.008" to 0.013"
Turbo V band clamp 75 inch Support:0.008" to 0.013" Support:0.008" to 0.013"
Air intake mtd./aftercooler 30-35 ft.lb. 30-35 ft.lb. 30-35 ft.lb. 30-35 ft.lb.
Piston cooling nozzle 6 to 9 inlbs. 100 to 140 inch. lb. 100 to 140 inch.lb. 100 to 140 inch.lb. RC plate Protrusion + 0.005" + 0.005" + 0.005"
Fuel pump mtg. 30 to 35 ft.lb. 30 to 35 ft.lb. 30 to 35 ft.lb. 30 to 35 ft.lb.
Intake valve lash setting 0.015" 0.015" 0.019" 0.014" RC Plate TIR 0.010" Max 0.010" Max 0.013" Max 0.010" Max
Exhaust valve lash setting 0.026" 0/026" 0.030" 0.027"
Injector travel(Non STC) 0.170+/-0.001" 170+/- 0.001" --- --- Gear Case Cover + 0.008" + 0.008" + 0.008" + 0.008"
Protrusion
Injector travel/Set screw --- --- 5 to 6 in.lbs. 5 to 6 in.lbs.
torque (IBC Method) (IBC Method) Gear Case Cover 50 to 55 ft.lb. 50 to 55 ft.lb. 50 to 55 ft.lb. 50 to 55 ft.lb.
Flywheel 185 to 215 ft.lb. 185 to 215 ft.lb. 185 to 215 ft.lb. 185 to 215 ft.lb. Mounting

Torque Values & Critical specifications for N Series
Part Name/ MODELS

Flywheel Housing 140 to 160 ft.lb. 140 to 160 ft.lb. 140 to 160 ft.lb. 140 to 160 ft.lb.
Front Engine Support ---- 50 to 55 ft. lb. 50 to 55 ft. lb. 50 to 55 ft. lb.
Con Rod Torque 70/75 - 140/150 ft.lb. 70/75 - 140/150 ft.lb. 70/80 - 160/174 ft.lb. 95 + 5 ft.lb. Rotate 60 Deg. + 5 Deg.
Loose 3 to 5 threads, Loose 3 to 5 threads, Loose & Repeat
25/30-70/75-140-155 ft.lb 25/30-70/75-140-155 ft.lb
Con Rod Side Clearance 0.0045" to 0.013" 0.0045" to 0.013" 0.0045" to 0.013" 0.0045" to 0.013"
Acc. Drive Mounting 40 to 45 ft.lb. 40 to 45 ft.lb. 40 to 45 ft.lb. 40 to 45 ft.lb.
Acc. Drive End Play 0.002" to 0.012" 0.002" to 0.012" 0.002" to 0.012" 0.004" to 0.009"
Gear Train Backlash 0.004" to 0.016" 0.004" to 0.016" 0.004" to 0.016" 0.004" to 0.016"
Oil Pan/Oil Pan Adaptor 7/16 c/s - 45 - 55 ft.lb. 7/16 c/s - 45 - 55 ft.lb. 7/16 c/s - 45 - 55 ft.lb. 7/16 c/s - 45 - 55 ft.lb.
5/16 c/s - 15 - 25 ft.lb. 5/16 c/s - 15 - 25 ft.lb. 5/16 c/s - 15 - 25 ft.lb. 5/16 c/s - 15 - 25 ft.lb.
Adaptor Vibration Damper 180 to 200 ft.lb. 180 to 200 ft.lb.
Vib. Damper 55 to 60 ft.lb. 55 to 60 ft.lb. 175 to 205 ft.lb. 175 to 205 ft.lb.
Contents
Air Starter
Section -1 Engine Data Genset N, V, K, QSK Page 1-2
Section - 1
CUMMINS DIESEL ENGINES FOR GENSET APPLICATION (PRIME POWER RATING) .... CONTD.
Alternate fuels
EFC Governor
Engine Model No. of Configuration Aspiration Displacement Bore & Stroke BHP(kW*) Typical Alternator Output
Wiring diagram for

Cycle (Lit) MM @1500rpm KVA (KW at 0.8 p.f.)
ECPG Control Panel

KT-1150-G ** 6 IN-LINE T 1150 (18.9) 6.25 x 6.25 (159 x 159) 380(283)
KTA-1150-G ** 6 IN-LINE TA 1150 (18.9) 6.25 x 6.25 (159 x 159) 450(336)
KTA-19-G4 ** 6 IN-LINE TA 18.9 159 X 159 600 500 (400)
VT-1710-G ** 12 VEE T 1710(28.0) 5.5 x 6 (140 x 152) 530(395)
VTA-28G ** 12 VEE TA 1710(28.0) 5.5 x 6 (140 x 152) 614(458)
Electronic engine controls information
KT-2300G ** 12 VEE T 2300(37.8) 6.25 x 6.25 (159 x 159) 750(560)

How to use a digital volt / ohm meter
KTA-2300-G 12 VEE TA 2300(37.8) 6.25 x 6.25 (159 x 159) 890(664)

KTA-3067G ** 16 VEE TA 3067(50.3) 6.25 x 6.25 (159 x 159) 1180(880)
KTA-50-G8 16 VEE TA 3067(50) 6.25 x 6.25 (159 x 159) 1933(1441)
NA – Naturally Aspirated Note : 1. * This is conversion of engine Horsepower to KW and not electrical output of alternator.
Engine Data Genset N, V, K, QSK
T- Turbocharged
How to measure current, voltage, resistance, internal
2. ** Currently new engines not available.

TA – Turbocharged Aftercooled 3. All the above ratings of engines for generator set conform to ISO 3046.
TAA = Turbocharged air to air aftercooled
CAC – Charge Air Cooler
Page
Current at Various Power Factors ......................................................... 1-14
Engine performance inspection report Genset ………………………….1-57

Effective utilization of DG set ………………………………………………1-57
PCC-1 Terminal Strip Details ........................................................ 1-44
PCC-1 genset system architecture……………................………… 1-43
Solid state potentiometer ……………………………………………1-37
Dual Delco Remy Starter & lucas alternator KV 12/16 ……………1-34
Lucas/Delco Remy starter & Lucas alternator model N, V, K6... 1-33
Overview, Software & Features, Part Numbers............................ 1-24
Connector Details ……………………………........………………. 1-23
resistance of meter, test for continuity, Connector checking ……1-17
Continuous Duty Generator Set Maintenance ……………………………1-56

Air Starting piping arrangement (Inertia engagement-N, K-1150).. 1-50
ECP without EFC governor & one starter 4054713……………….. 1-40
EFC governor Version I .......................……………………………..1-36
EFC controller Specification & Operation …………………………1-20
Air requirement, Part Numbers for air starter ...…………………... 1-48

Connection of Pilot Valve & Kit air starter ………………………….. 1-48
Electronic instruments panel (Intenal & External) …………………1-38
List of Important Field Adjustments .............................................. 1-28
EFC governor description…………………………………………….1-18
Genset Allignment and coupling Torque Details......….....……………….1-16
Stand-By Duty Generator Set Maintenance ………………………………1-55

PCC-2 Terminal Strip Details ........................................................ 1-45
Engines with air starters ………………………………………………1-35
Introduction to parts ………………………………………………….. 1-19
Exhaust gas temperatures – Genset application ………………………...1-15
Maintenance Schedule other than Firepump engines ………………….. 1-52

ECP with EFC governor & two starter :4054715………………….. 1-42
ECPG with Two Starters ............................................................. 1-32
SKO Operation ………………………………………………………1-59

Load acceptance data……………………………………………………….1 -12
Special LDO Operation …………………………………………….1-60

LDO Operation ………………………………………………………1-58
Remote Radiators for Cummins Engine (Coil Coolers) ......................... 1-10
Heat Recovery system ………………………………….……………….1-61

Modelwise recommendations – genset ……………………………………1-4
Recommendations for Genset Installation ………………………………...1-8
Genset AVM Location & Weight …………………………………………….1-9
Cable sizes for D. G. sets …………………………………………………..1-13

Cummins genset size details ……………………………………………. 1-10
Air Starting Piping arrangement (Preengagement type V, KV) .... 1-51

ECP with EFC governor & one starter : 4054714……….………… 1-41
Datalink Adaptor Details ............................................................... 1-31
Troubleshooting-EFC ………………………………………………… 1 -21
Engine specifications generator set application ……………………………1-1
Acoustic Enclosures – Range ……………………………………………. 1-11

Page 1
63 64
61 62
Section -1 Engine Data Genset N, V, K, QSK Page 1-1

CUMMINS DIESEL ENGINES FOR GENSET APPLICATION (PRIME POWER RATING)
Engine Model No. of Configuration Aspiration Displacement Bore & Stroke BHP(kW*) Typical Alternator Output
Section –1 Engine Data Genset N, V, K, QSK Page 1-3 Cycle (Lit) MM @1500rpm KVA (KW at 0.8 p.f.)
Bore & Stroke Displacement Prime Power Prime Power 6CT8.3-G2-I ** 6 IN-LINE T 8.3 114 x 135 175 140 (112)
No. of Engine 6CTA8.3-G1-I 6 IN-LINE TA 8.3 114 x 135 205 160 (128)
Engine Model ** Inch Cub. Inch Rating BHP (kW)* Rating BHP (kW)* 6CTA8.3-G2-I 6 IN-LINE TA 8.3 114 x 135 219 180 (144)
Cyl. Breathing
(mm) (liter) at 1500 R.P.M. at 1800 R.P.M. 6CTAA8.3-G1-I 6 IN-LINE TAA 8.3 114 X 135 245 200 (160)
NT-495-G 4 5 1/8 x 6 (130 x 152) 495 (8.1) 127 (95) 139 (104) T NTA-743-G ** 6 IN-LINE TA 12.2 130 X 152 200 225 (160)
NT-855-G4 (BC)** 6 IN-LINE T 14.0 140 X 152 280 225 (180)
NTC-495-G 4 5 1/8 x 6 (130 x 152) 495 (8.1) 154 (115) -- T NT-855-G5(BC) 6 IN-LINE T 14.0 140 X 152 306 250 (200)
NTA-495-G 4 5 1/8 x 6 (130 x 152) 495 (8.1) 173 (129) 200 (149) T.A. NT-855-G6(BC) ** 6 IN-LINE T 14.0 140 X 152 340 285 (228)
NTA-855-G2 (BC) 6 IN-LINE TA 14.0 140 X 152 380 320 (256)
N8 G1 4 5 1/8 x 6 (130 x 152) 495 (8.1) 202(151) -- T-CAC KTA-1150-G ** 6 IN-LINE TA 18.9 159 X 159 450 380 (304)
N8 G2 4 5 1/8 x 6 (130 x 152) 495 (8.1) 225(168) -- T-CAC KTA-19-G4 ** 6 IN-LINE TA 18.9 159 X 159 600 500 (400)
VTA-28-G3-I 12 VEE TA 28.0 140 X 152 710 600 (480)
NT-743-G1 6 5 1/8 x 6 (130 x 152) 743 (12.2) 205 (150) -- T VTA-28-G5-I 12 VEE TA 28.0 140 X 152 750 625 (500)
NT-743-G 6 5 1/8 x 6 (130 x 152) 743 (12.2) 231 (172) 257 (191) T KTA-2300-G(38G2I) 12 VEE TA 37.8 159 X 159 890 750 (600)
KTA-38-G5 12 VEE TA 37.8 159 X 159 1180 1010 (800)
NTA-743-G 6 5 1/8 x 6 (130 x 152) 743 (12.2) 255 (190) -- T.A. KTA-50-G3 16 VEE TA 50.3 159 X 159 1470 1250 (1000)
NTA-855-G1 6 5 1/2 x 6 (140 x 152) 855 (14.00) 280 (208) -- T.A. KTA-50-G8-1 16 VEE TA 50.3 159 X 159 1735 1500 (1200)
QSK-60-G3 16 VEE TA 60.0 159 X 190 2165 1875 (1500)
NTA-855-G 6 5 1/2 x 6 (140 x 152) 855 (14.00) 306 (228) 360 (268) T.A. QSK-60-G4 16 VEE TA 60.0 159 X 190 2319 2000 (1600)
NTA-855-G2 6 5 1/2 x 6 (140 x 152) 855 (14.00) 340 (253) -- T.A. QSK-78-G 18 VEE TA 77.6 170 X 190 3371 3000 (2400)
NT14-G1 ** 6 IN-LINE T 14.0 140 X 152 280 225 (180)
** Models discontinued for production. NT14-G2 ** 6 IN-LINE T 14.0 140 X 152 306 250 (200)
NTA14-G2 ** 6 IN-LINE TA 14.0 140 X 152 340 285 (228)
NTA14-G1 ** 6 IN-LINE TA 14.0 140 X 152 380 320 (256)
NTA14-G3 6 IN-LINE TA 14.0 140 X 152 450 380 (304)
Section – 1 Engine Data Genset N, V, K, QSKMODEL – WISE RECOMMENDATIONS - (DIESEL ENGINE) ... CONTD. Page 1-6
Total Air (ventilation + Section – 1 Engine Data Genset N, V, K, QSK MODEL – WISE RECOMMENDATIONS - (DIESEL ENGINE) Page 1-4
breathing) Total Air (ventilation +
Heat Exchanger
requirement for
breathing)
Genset Heat Exchanger
requirement for
Engine Model Genset
o
HxW
LxWxH
(H for HE,
o
Genset room
o
Rating (0.8 pf)

R for Radiator)
Engine Model
10 mtrs. Min. ID
Coolant Capacity
o
26 C)
room
HxW
Typical Room Size

Radiator Core Area
Bends Max. Length

upto 10 mtrs.Min ID
Typical
LxWxH
Min. ID
Radiator Fan flow in

o
Min. raw
Exh. Gas flow (No. of

o
o
o
(H for HE,
banks x flow per bank)

engine HE
Raw water
Exhaust pipe size max. 4

Lub Oil System Capacity
water flow at
Fuel supply /return Pipes

pipe Size (ID)
Capacity (wbt
cooling tower
Rating (0.8 pf)
40 C (rise 5 C)
flow per bank)
40 C (rise 5 C)
R for Radiator)
HE
Max. amb. below
Max. amb. Above

Coolant Capacity
Typical Room Size

Radiator Core Area
upto 10 mtrs.Min ID
Size (ID)
(rise 5 C)
o
Max. amb.
(wbt 26 C)
KVA m x m x m No. x mm No.xItr/sec mm ltr Itr Itr/sec Itr/sec Itr/sec mxm Itr/min TR mm
Above 40 C


flow at engine
Min. raw water
tower Capacity
*Raw water pipe
40 C (rise 10 C)
Bends Max. Length 10 mtrs.

Radiator Fan flow in Genset
*Typical cooling
Max. amb. below
Exh. Gas flow (No. of banks x

6CTAA8.3-G1-I 200 6.5 x 4.5 x 3.5 1 x 100 1 x 610 15 24 28 (R) 6245 3225 7385 0.7 x 1.0 N.A. N.A. N.A.
6CTA8.3-G2-I 180 6.5 x 4.5 x 3.5 1 x 100 1 x 550 15 24 27 (R) 6035 3115 5540 0.73 x 0.74 N.A. N.A. N.A. KVA mxmxm No. x mm No.xItr/sec mm Ltr Itr Itr/sec Itr/sec Itr/sec mxm Itr/min TR mm
6CTA8.3-G1-I 160 6.5 x 4.5 x 3.5 1 x 100 1 x 540 15 24 27 (R) 5565 2880 5540 0.73 x 0.74 N.A. N.A. N.A. QSK60-G4 2000 12.5 x 7.5 x 6.5 2 x 325 2 x 2885 50 400 550 (H) 750 (R) 41915 22090 32285 2.3 x 2.4 1760 200 125
6CT8.3-G1-I 140 6.5 x 4.5 x 3.5 1 x 100 1 x 470 15 24 27 (R) 4955 2555 5540 0.73 x 0.74 N.A. N.A. N.A.
6BTA5.9-G2-I 125 6.0 x 4.0 x 3.5 1 x 100 1 x 225 15 14.3 25 (R) 4920 2525 4000 0.7 x 0.7 121 - 45 QSK60-G3 1875 12.5 x 7.5 x 6.5 2 x 325 2 x 2700 50 400 550 (H) 750 (R) 38525 20310 32285 2.3 x 2.4 1760 200 125
6BT5.9-G1-I 82.5 6.0 x 4.0 x 3.5 1 x 100 1 x 225 15 14.3 22 (R) 3420 1760 2880 0.7 x 0.7 N.A. N.A. N.A. K1500EG/50G8-I 1500 12.0 x 7.0 x 6.5 2 x 250 2 x 2220 25 177 320 (H) 555 (R) 34955 18275 28400 2.2 x 1.95 1300 150 125
S3.8-G7 62.5 6.0 x 3.5 x 3.0 1 x 75 1 x 190 10 9 13 (R) 2450 1260 1880 0.6 x 0.6 N.A. N.A. N.A. KTA 50-G3 1250 12.0 x 7.0 x 6.5 2 x 250 2 x 1910 25 177 310 (H) 440 (R) 31475 16420 27375 2.1 x 2.0 1300 125 125
S3.8-G6 50 6.0 x 3.5 x 3.0 1 x 75 1 x 150 10 9 11 (R) 2090 1075 1880 0.5 x 0.5 N.A. N.A. N.A. KTA 38-G5 1000 11.0 x 7.0 x 6.5 2 x 250 2 x 1460 25 145 199 (H) 260 (R) 26980 14050 23855 1.9 x 1.8 900 100 100
S3.8-G5 45 6.0 x 3.5 x 3.0 1 x 75 1 x 150 10 9 11 (R) 2090 1075 1880 0.5 x 0.5 N.A. N.A. N.A.
KTA 38-G2-I (2300#) 750 9.0 x 6.0 x 5.0 2 x 200 2 x 1245 25 118 230 (H) 300 (R) 21795 11395 22655 1.9 x 1.65 625 70 100
S3.8-G4 40 6.0 x 3.5 x 3.0 1 x 75 1 x 150 10 9 11 (R) 1715 890 1880 0.5 x 0.5 N.A. N.A. N.A.
S3.8-G3 35 6.0 x 3.5 x 3.0 1 x 75 1 x 115 10 9 11 (R) 1420 730 1880 0.5 x 0.5 N.A. N.A. N.A. VTA 28-G5 625 8.5 x 6.0 x 5.0 2 x 125 2 x 945 20 95 212 (H) 250 (R) 17770 9270 22655 1.9 x 1.65 540 60 75
S3.8-G2 30 6.0 x 3.5 x 3.0 1 x 75 1 x 115 10 9 11 (R) 1240 640 1880 0.5 x 0.5 N.A. N.A. N.A. VTA 28-G3 600 8.5 x 6.0 x 5.0 2 x 125 2 x 930 20 95 210 (H) 240 (R) 17405 9060 18880 1.9 x 1.6 480 60 75
X2.5-G2 25 4.0 x 1.5 x 2.0 1 x 50 1 x 75 10 6.5 7.5 (R) 1060 542 1250 0.4 x 0.4 N.A. N.A. N.A. VT 1710 G# 450 8.5 x 6.0 x 5.0 2 x 125 2 x 800 20 95 210 (H) 14615 7595 11800 1.4 x 1.4 450 50 75
X2.5-G1 20 4.0 x 1.5 x 2.0 1 x 50 1 x 75 10 6.5 7.5 (R) 930 475 1250 0.4 x 0.4 N.A. N.A. N.A.
KTA 19 G4 500 8.5 x 5.5 x 5.0 1 x 200 1 x 1600 20 55 125 (H) 175 (R) 14410 7480 20280 1.48 x 1.58 **385+150 60 75+40
X1.7-G1 15 4.0 x 1.5 x 2.0 1 x 50 1 x 50 10 5 6 (R) 670 345 1050 0.4 x 0.4 N.A. N.A. N.A.
KTA 19-G3 450 8.5 x 5.5 x 5.0 1 x 200 1 x 1460 20 55 125 (H) 165 (R) 13110 6800 13000 1.48 x 1.58 385 45 75
* Typical Sizes, actual specifications may change as per site condition. ** Separate raw water connections for LTA & main circuit. NA=Not Applicable
KTA 1150 G 380 8.0 x 5.5 x 5.0 1 x 125 1 x 1095 20 55 80 (H) 115 (R) 12070 6255 10385 1.14 x 1.22 300 35 65
# Engines not in current production.
Note : Lub oil for C Series / N14 engines is CH4 15W-40 and for all other engines CF4 15W-40
67 68
65 66
Section – 1 Engine Data Genset N, V, K, QSKMODEL – WISE RECOMMENDATIONS - (DIESEL ENGINE) ... CONTD. Page 1-5
Total Air (ventilation +
Section – 1 Engine Data Genset N, V, K, QSK Page 1-7
breathing)
Heat Exchanger
requirement for
NOTES Genset
Engine Model
o
1. All the ratings of engines for generator sets are for prime power with variable load.
HxW
LxWxH
(H for HE,
Genset room
o
Rating (0.8 pf)

R for Radiator)
10 mtrs. Min. ID
2. The PH value of the engine coolant should be kept within 8.5 to 10.0
Coolant Capacity
26 C)
Typical Room Size

Radiator Core Area
Bends Max. Length

upto 10 mtrs.Min ID
Typical
Radiator Fan flow in

Min. raw
Exh. Gas flow (No. of

o
o
banks x flow per bank)

engine HE
Raw water

water flow at

pipe Size (ID)
Capacity (wbt
cooling tower
40 C (rise 5 C)
40 C (rise 5 C)
Max. amb. below
Max. amb. Above
3. Diesel fuel recommended as per IS 1460 1974 Grade ‘a’.

KVA m x m x m No. x mm No.xItr/sec mm ltr Itr Itr/sec Itr/sec Itr/sec mxm Itr/min TR mm
4. All engines have counter-clockwise rotation as viewed from the principal output end. KT 1150 G # 320 8.0 x 5.5 x 5.0 1 x 125 1 x 1100 20 55 75 (H) 110 (R) 10345 5370 10385 1.25 x 1.15 275 30 65
NTA14-G3 380 8.0 x 5.5 x 5.0 1 x 125 1 x 1055 20 39 45 (H) 76 (R) 11110 5750 10385 1.58 x 1.48 300 35 65
5. Total air requirement for radiator cooled engines would be addition of fan flow and forced ventilation air volumes.
NTA 855 G2BC 320 7.5 x 5.0 x 5.0 1 x 125 1 x 990 20 39 40 (H) 95 (R) 9385 4855 10070 1.18 x 1.22 **275+125 35 65+40
NTA 855 G # 250 7.5 x 5.0 x 5.0 1 x 125 1 x 950 15 36 55 (H) 80 (R) 8730 4530 10070 1.3 x 1.1 240 25 50
6. For the details of cooling tower please Contact nearest Cummins Office.
NTA 855 G1 # 225 7.5 x 5.0 x 5.0 1 x 125 1 x 850 15 36 55 (H) 80 (R) 7965 4135 10070 1.3 x 1.1 240 25 50
NTA 855 G6 BC 285 7.5 x 5.0 x 5.0 1 x 125 1 x 1160 20 39 47 (H) 80 (R) 8975 4650 10070 1.08 x 1.27 275 30 50
NTA 855 G5 BC 250 7.5 x 5.0 x 5.0 1 x 125 1 x 960 20 39 47 (H) 80 (R) 8285 4300 10070 1.08 x 1.27 240 25 50
NTA 855 G4 BC 225 7.5 x 5.0 x 5.0 1 x 125 1 x 860 20 39 47 (H) 80 (R) 7305 3795 10070 1.08 x 1.27 240 25 50
Performance Guarantee - NTA 743 G # 200 7.5 x 5.0 x 5.0 1 x 125 1 x 695 15 36 52 (H) 75 (R) 7430 3845 8025 1.1 x 1.1 175 20 40
NT 743 G # 180 7.0 x 5.0 x 5.0 1 x 125 1 x 660 15 36 50 (H) 70 (R) 6780 3510 8025 1.1 x 0.9 175 20 40
N8 G2 # 180 7.0 x 5.0 x 5.0 1 x 100 1 x 600 15 33 75 (R) 5850 3030 5710 1.0 x 0.95 NA NA NA
Engine output figures in this booklet conform with ES 5514/ISO 3074 for generator set applications. Turbocharged engine may be
operated without any
NT 743 G1 # 160 7.0 x 5.0 x 5.0 1 x 125 1 x 545 15 36 50 (H) 70 (R) 6050 3140 8025 1.1 x 0.9 175 20 40
loss in power up to 1500 m. elevation and 38 deg. C ambient temperature. Turbocharged engines require no deration in power output for humidity.
N8 G1 # 160 7.0 x 5.0 x 5.0 1 x 100 1 x 560 15 33 75 (R) 5250 2725 5710 1.0
x 0.95 NA NA NA
NTA 495 G # 140 6.5 x 5.0 x 4.0 1 x 100 1 x 485 15 27 43 (H) 62 (R) 5115 2640 3775 0.9 x 0.8 151 15 40
Cummins has always been a pioneer in product improvement. This specifications may change without notice.
NTC 495 G # 125 6.5 x 5.0 x 4.0 1 x 100 1 x 440 15 27 40 (H) 55 (R) 4575 2370 3775 0.8 x 0.9 151 15 40
NT 495 G # 100 6.5 x 5.0 x 4.0 1 x 100 1 x 410 15 27 40 (H) 55 (R) 3760 1950 3775 0.8 x 0.9 151 15 40
69 70
Section - 1 Engine Data Genset N, V, K, QSK Page 1-8
Page 1-9
3600
1700
2000
3700
KT
- Same foundation drawing for HE & Radiator cooled sets.
KS 84
KT/A 1150
RECOMMENDATIONS GENSET INSTALLATION
0.175
1.125
0.725
1.125
3.32
3.70
0.17
0.33
0.4
380/320
8
3900
1886
2142
4000
KTA
Room Layout :-
Typical 2-meter free space around genset is recommended for
- Max tilt 0.2 mm / meter of length of base rail

proper heat dissipation and ease of service.
(HE length?)
However, to avoid hot air recirculation radiator cooled engines may
KTA19G4
KS 84
0.350
0.200
0.900
0.500
0.900
0.900
4400
3.60
3.90
0.20
1927
0.35
4700
1927
500
have less space in front. Minimum 1.5 meter free space is a must for
10
GENSET WEIGHT AVM LOCATION (GERB MAKE) – SUMMARY
100 KVA and bigger gensets, for smaller gensets it should be 1
meter.
KS-FS1300
Room Ventilation
VTA28G5
For radiator cooled engines opening in front of radiator should be 1.5
0.275
6100
4.20
3050
3150
6400
4.20
0.28
0.35
1.05
1.05
1.05
625
0.2
0.5
10
times radiator core & at back 2.25 to 3 times radiator core. Ducting in
front of radiator is recommended, however it is not mandatory. If
opening exactly in the front of radiator is not possible then ducting
should be done to take out hot air. If opening in the back side of
KS-FS1300
KTA2300G
genset is not possible then opening on both sides of genset at the
0.325
1.000
0.700
1.000
0.950
0.625
4136
7400
7900
4196
4.80
4.80
0.20
0.33
KC6
750
0.2
rear of the alternator may be acceptable. In this case total openings
12
in two side walls should be atleast 3 times radiator core.
Additional ventilation arrangement may be required for radiator
- Max overhang of 350 mm for HE cooled sets

cooled engines installed in acoustic rooms enclosures. Radiator
KS-FS1300
KTA38G5
- Max distance between two AVM’s 1.2 m
cooled engines may create slight negative pressure inside the genset
0.525
0.975
1000
4600
8600
4600
9500
4.90
5.30
0.20
0.40
HC6
0.4
0.2
12
1
1
room/enclosure. Maximum static restriction should not increase 6-
mm water column.
Foundation.
KS-FS1300
KTA50G3
Do not install Genset on loose sand or clay. Foundation should be
10,600
10,000
HC6Z
1250
5662
5662
5.65
5.80
0.20
0.35
0.95
0.3
0.3
0.6
0.6
14
designed considering safe bearing capacity of soil. Vibration isolators
1
1
1
(AVMs) reduce generator set vibration and noise transmission to the
surrounding structure, hence they are recommended, however they
are not mandatory. The length and breadth of foundation should be
Distance between foundation holes / AVM’s in meters

at least 150-300 mm (6-12”) more than base rail length and breadth
KS-FS1300
1425/1500
KTA50G8
Section – 1 Engine Data Genset N, V, K, QSK
12,135
11,100
respectively.
0.275
5690
5690
5.75
5.96
0.25
0.38
HC7
0.2
0.5
0.5
0.9
0.7
0.7
16
1
1
Cooling System
Raw water inlet temperature should be 32 deg C with typical
temperature rise of 7-11 deg C. Cooling tower should be selected
based on this temperature difference and wet bulb temp. of site.
It is mandatory to install raw water temperature & pressure gauges at
Location selection criterion
Radiator
Radiator
inlet and outlet connections to H.E.
Base rail length Rad (m)
Rear Overhang Rad (m)

Front overhang Rad (m)
Recommended raw water pressure at inlet of heat exchanger should
Base rail length HE (m)
Rear Overhang HE (m)

Front overhang HE (m)
H.E.
H.E
Genset rating – KVA
2
be 3.5 kg/cm (50 psi) max.
AVM Model (Gerb)

Alternator Model
There should be positive pressure on suction of raw water pump.

Engine Model
Strainer, non-return valve should be used in cooling tower circuit

Engine only
Weight (kg)
Weight (kg)
Typical raw water Pump size, (20 m total head on Pump)
th
Quantity
nd
rd
9 & 10
th
th
th
th
th
Genset
Upto 380 KVA 2.2 kW (3 HP)
2 &3
1 &2
3 &4
5 &6
6 &7
7 &8
8 &9
400 to 625 KVA 3.7 kW (5 HP)
nd
rd
th
th
th
th
th
st
750 to 1500 KVA 5.5 kW (7.5 HP)
1875 to 2000 KVA 7.5 kW (10 HP)
71 72
Section – 1 Engine Data Genset N, V, K, QSK Page 1-10 Section - 1 Engine Data Genset N, V, K, QSK Page 1-11
QUICK SELECTION OF REMOTE RADIATOR THE RANGE OF CUMMINS ACOUSTIC ENCLOSURES

FOR CUMMINS ENGINE (COIL COOLERS) Model KVA Rating Length (mm) Width (mm) Height (mm)
ENGINE PRIME REMOTE RADIATOR S 3.8 30/40/50 3500 1200 1750
MODEL RATING PRIMARY SECONDARY
KVA S / 6BT 5.9 62.5/75/82.5 4000 1400 1750
CIRCUIT CIRCUIT
NT/C/A 495 100/125/140 4900 1600 2200
QSK60G4 2000 FCW-160(LT+HT) FCW-200
N 4.8 160/180 5200 1600 2400
KTA50G8-1 1500 FCW-140(LT+HT) FCW-180
NT/A 743 160/180/200 5400 1800 2400
KTA50G3 1250 FCW-120 FCW-140
NTA 855 250/285 6200 1800 2400
KTA50G3 1P2L 1250 FCW-120(LT+HT) FCW-140
K6 320/380 6900 2000 2600
KTA38G5 1000 FCW-100(LT+HT) FCW-120
K6 G4 500 7000 2200 2600
KTA2300 750 FCW-080 FCW-100
VTA 1710 500/590 7300 2500 3200
VTA28G5 600/625 FCW-060 FCW-080
KV 12 625/750 7600 2500 3500
KTA19G4 500 FCW-060(LT+HT FCW-080
KV 16 1000 8600 3000 3500
KV 16 G4 1250 9200 3000 3500
CUMMINS-GENSET SIZE DETAILS
Approx. Dry
Engine Model Total Dimensions of Set Weight of CIL APPROVED ACOUSTIC ENCLOSERS
Engine (Kgs.) Drawing no Description Length Width Height

L-mm H-mm W-mm 4926923 140-200 KVA 4500 1500 1850
N-495-G 2585 1495 940 890
4926924 100-125 KVA 4000 1150 1700
NT-495-G 2580 1740 940 940
4926925 75-82.5 KVA 3850 1150 1700
N-743-G 2950 1725 940 940
4950206 500 KVA 6500 2000 2300
NT-743-G/G1 3060 1880 1006 1140
NTA-743-G 3050 1880 1105 1190 4950207 250-380 KVA 5500 2000 2450
N-855-G 2985 1880 1006 1220 4950208 62.5 KVA 2950 1150 1575
NTA-855-G/G2 1945 1105 1105 1176 4950209 40-50 KVA 2800 1150 1575
KT-1150-G 3580 1840 1290 1255
4950210 30-35 KVA 2800 1150 1450
KTA-1150-G 3580 1840 1290 1255
4950211 20-25 KVA 2400 900 1375
VT-1710-G 4510 2052 1460 1634
4950212 15 KVA 2400 900 1375
VTA-1710-G 4510 2052 1460 1680
KT-2300-G 5070 2770 1780 2447 4950213 625 KVA 7000 2500 2925
KTA-2300-G 5070 2770 1780 2769 4950922 250 KVA 4650 1700 2050
KTA-3067-G 5635 2770 1894 3609
73 74
LOAD ACCEPTANCE DATA
TYPICAL CABLE SIZES FOR DG SETS
ENGINE MODEL ONE STEP FREQUENCY RECOVERY Earthing
KVA Amp. Cable size
(standby) LOAD IN % DIP (HZ) TIME (SEC.) Strip/Wire
Rating Rating (sq. mm) x runs (m)
(Copper)
N-495-G 100 1.5 3 15 (Single Phase) 63 25 x 2
N-495-G 80 3 4 20 (Single Phase) 80 35 x 2
NTC-495-G 70 4 4 25 (Single Phase) 125 50 x 2
N-743-G 100 1.5 3 15 32 6x4
NT-743-G 80 3 4 20 40 10 x 4
NTA-743-G1 80 3 4 25 40 10 x 4
N-855-G 100 1.5 3 30 42 16*1 8 SWG
NTA-855-G 70 4 4 50 70 25*1 8 SWG
NTA-855-G2 63 5 5 62.5 87 35*1 25 mm x 3 mm
NTA855G4 55 5 4.5 75 104 50*1 25 mm x 3 mm
NTA-14-G3 60 3.3 3 82.5 115 70*1 25 mm x 3 mm
KT-1150-G 65 5 5 100 139 95*1 25 mm x 3 mm
KTA-1150~G 65 5 5 125 174 120*1 25 mm x 3 mm
KTA19G3 57 8 5 140 195 150*1 25 mm x 3 mm
KTA19G4 57 5 5 160 223 185*1 25 mm x 3 mm
VT-1710-G 80 4.5 5 180 250 240*1 25 mm x 3 mm
VTA-1710-G 70 4 4 200 278 300*1 25 mm x 3 mm
VTA28G5 60 5 5 225 313 400*1 150*2 25 mm x 6 mm
KT-2300-G 80 4.5 6 250 348 400*1 185*2 95*3 25 mm x 6 mm
KTA-2300-G 65 5 4 285 396 225*2 120*3 70*4 25 mm x 6 mm
KTA38G5 50 5 5 320 445 300*2 150*3 95*4 25 mm x 6 mm
KT-3067-G 60 4 4 380 529 400*2 185*3 120*4 25 mm x 6 mm
KTA-50G3 55 5 6 450 626 240*3 150*4 95*5 25 mm x 6 mm
KTA50G8 67 5 4 500 696 300*3 185*4 120*5 32 mm x 6 mm
QSK60G4 58 4 3.2 600 835 240*4 185*5 120*6 32 mm x 6 mm
625 870 300*4 185*5 120*6 32 mm x 6 mm
Note : 650 904 300*4 225*5 150*6 50 mm x 6 mm
(1) Data based on engine operating at full working temperatures ( 85 750 1043 400*4 240*5 185*6 50 mm x 6 mm
deg.C), at 1500 rpm (50Hz) using Wood word Hydraulic / 1000 1391 300*6 225*7 50 mm x 6 mm
Cummins EFC governor zero droop.
1250 1739 400*7 300*8 240*7 50 mm x 6 mm
(2) Data may vary based on alternator and gen-set inertia, and typical
1500 2087 400*8 300*9 240*10 50 mm x 6 mm
alternator efficiencies.
1800 2504 400*10 50 mm x 6 mm
(3) Standby loads (KWe) are based on typical alternator outputs at 0.8
p.f 2000 2782 500*10 50 mm x 6 mm
(4) The above figures are representative of an single engine test only Notes :
and vary as per Fuel system Governor and AVR 1. Use 3-1/2 core armored power cables with aluminium conductor. (AYFY)o
adjustments. 2. Current rating of cables are taken based on operating temperature of 70 C.
3. For multiple runs of cables deration factor of 0.75 is considered i.e.
(5) Typical voltage dip on application of one step load is 25% deration applied.
20%. 4. AYFY conductor, PVC insulation, Steel strip armour, PVC outesrheath.
(6) All data shown is based upon ISO-3046, Part 1, Standard 5. Cable sizes mentioned are in square mm.
reference conditions of 100 kPa barometric pressure, 110m 6. For sets above 1000 kVA use of proper busbars in bus ducts is
altitude, 25oC air inlet temperature, and a relative humidity of recommended.
30%. 7. Also check IEC rules for earthing.
The above specifications are for reference only and are subject to
alteration without notice.
75 76
TABLE 4 : MAXIMUM CURRENT AT VARIOUS POWER EXHAUST GAS TEMPERATURE 100% LOAD
FACTORS FOR 415V ALTERNATOR (3 PHASE) O O
Engine Model kVA C F
Current @ 0.8 PF Current @ 0.85 PF Current @ 0.9 PF Current @ 0.95 PF Current @ 1.0 PF
SN KVA KW 100% Load 80% Load 100% Load 80% Load 100% Load 80% Load 100% Load 80% Load 100% Load 80% Load
NTA495G 140 504 940
NTA743G 200 476 889
1 2000 1600 2782 2226 2619 2095 2473 1979 2343 1875 2226 1781 6CT8.3G2-I 140 591 1096
2 1875 1500 2609 2087 2455 1964 2319 1855 2197 1757 2087 1669 6CTA8.3G1-I 160 561 1041
6CTA8.3G2-I 180 569 1057
3 1500 1200 2087 1669 1964 1571 1855 1484 1757 1406 1669 1336
6CTAA8.3G1-I 200 598 1108
4 1250 1000 1739 1391 1637 1309 1546 1237 1464 1172 1391 1113 6CTAA8.3G4 250 523 973
NT855G4 225 488 910
5 1000 800 1391 1113 1309 1048 1237 989 1172 937 1113 890
NT855G5 250 513 955
6 750 600 1043 835 982 786 927 742 879 703 835 668 NT855G5-I 250 543 1010
7 625 500 870 696 818 655 773 618 732 586 696 556 NT855G6 285 541 1005
NTA855G2 320 534 993
8 500 400 696 556 655 524 618 495 586 469 556 445 NTA855G2-I 320 502 936
9 450 360 626 501 589 471 556 445 527 422 501 401 NTA14G1 320 559 1038
NTA14G3 380 527 981
10 380 304 529 423 498 398 470 376 445 356 423 338
KTA1150G 380 537 999
11 320 256 445 356 419 335 396 317 375 300 356 285 KTA19G3-I 450 529 985
KTA19G4 500 538 1000
12 285 228 397 317 373 299 352 282 334 267 317 254
KTA19G9 500 489 912
13 250 200 348 278 327 262 309 247 293 234 278 223 VTA28G3 600 453 848
14 225 180 313 250 295 236 278 223 264 211 250 200 VTA28G5 625 457 855
VTA28G5-I 625 451 843
15 200 160 278 223 262 210 247 198 234 187 223 178 KTA2300G 750 447 836
16 180 144 250 200 236 189 223 178 211 169 200 160 KTA38G2-I 750 476 888
KTA38G3-I 800 481 899
17 160 128 223 178 210 168 198 158 187 150 178 142 KTA38G5 1010 500 931
18 140 112 195 156 183 147 173 139 164 131 156 125 KTA50G3 1250 529 985
KTA50G8-I 1500 481 897
19 125 100 174 139 164 131 155 124 146 117 139 111 QSK60G3 1875 442 827
20 100 80 139 111 131 105 124 99 117 94 111 89 QSK60G4 2000 429 804
21 82.5 66 115 92 108 86 102 82 97 77 92 73
Exhaust Gas Exhaust Gas
22 62.5 50 87 70 82 65 77 62 73 59 70 56 Engine Model Temperatures Engine Model Temperatures
23 50 40 70 56 65 52 62 49 59 47 56 45 Deg. F (Deg.C) Deg. F (Deg.C)
24 45 36 63 50 59 47 56 45 53 42 50 40 N 855-G 1000 (538) NT 743 G1 890 (477)
N495 1155 (524) NTA 855 G 895 (480)
25 40 32 56 45 52 42 49 40 47 37 45 36 N8 G2 860 (460) NTC 495 G 1040 (560)
26 35 28 49 39 46 37 43 35 41 33 39 31 NT 495 G 955 (513) VT 1710 G 1000 (538)
NT 743 945 (507) KT 1150 G 1050 (566)
27 30 24 42 33 39 31 37 30 35 28 33 27 NT 743 G 945 (507) KT2300 970 (521)
28 25 20 35 28 33 26 31 25 29 23 28 22
Data is based on operation under SAE standard J8 16b conditions of
29 20 16 28 22 26 21 25 20 23 19 22 18 500 feet (150m) altitude. (29.00 inch (736 mm) Hg. dry barometer) 85
30 15 12 21 17 20 16 19 15 18 14 17 13 Deg. f (29 Deg C) intake air temperature and 0.38 in (9.6 mm) Hg
water vapour pressure, using no.2 diesel or a fuel corresponding to
Note : 1. For H.T. alternators, please refer manufacturers * Data is based on operation under SAE standard J 1349
specifications. conditions of 300 feet (100 m) altitude. 29.61 inch Hg (100 kPa)
barometer, 77 Deg. F (25 Deg C) intake air temp; using No 2
2. Resistive and water loads have unity power factor. diesel or a fuel corresponding to ASTM D2.
77 78
Section– 1 Engine Data Genset N, V, K, QSK Page 1 - 16 Section - 1 Engine Data Genset N, V, K, QSK Page 1-17
GENSET ALIGNMENT
ELECTRONIC ENGINE CONTROLS -INFORMATION
1) Spider Type Coupling
GENERAL INFORMATION
1. Alternator hub to be shrink fitted on alternator shaft. The
interference between the coupling hub and alternator shaft should
be 0.0005" to 0.0015". How To Use A Digital Volt/Ohm Meter
2. Centre line of the keyway should be parallel to the axis of the bore On most meters, the negative (black) meter lead
within 0.002" on total length. For easy fitment hub should be heated must be plugged in the “COM” position and the
to approximately 300 degree celcius for 1/2 to1 hour . positive (red) meter lead must be plugged into
Alignment Reading: one of the positions marked for current,
1. Attach linkage of the dial gauge indicator to the flywheel and place resistance, or voltage. Refer to the
pointer of the dial on the face of the alternator hub The TIR should manufacturer’s instructions for more detail.
be within 0010"
NOTE: When measuring to a block ground, use
2. For bore TIR pointer of the dial gauge should be placed on outer
a clean unpainted metal surface to ensure a
side of the alternator hub, TIR should be within 0008”.
good measurement.
NOTE : After obtaining bore and face reading, crankshaft endplay should
be checked It should be within specified limit How To Measure Current
TIGHTEN ALL MOUNTING BOLTS OF THE SET
Make an open circuit at the place where the
2) Holset Flexible Coupling current needs to be measured.
1. Assembly instruction for rb series flywheel mounted coupling Select the AC current (A~) or DC current (A-)
2. Machine the hub (inner member) bore and key way to suit alternator function on the meter.
shaft Interference fit should be 00005" to 00015" per inch of Turn on the power in the circuit being measured.
O
diameter of shaft Inner member should be heated to 300 C. Put the leads of the meter across the open circuit
3. Insert cover if it is single piece Fit the hub on to the shaft c) Place to measure the current. Read the displayed
outer member in position resting on inner member Assemble two measurement.
halves of cover and torque bolt
4. Insert rubber blocks For easy assembly and to avoid damage to the How To Measure Voltage
rubber bloc ks use lubricant silicone fluid of viscosity between 300 to
1000 centistokes or jelly soap DO NOT USE PETROLEUM BASE
Select the AC voltage (V~) or DC voltage (V-)
LUBRICANT LIKE GREASE Apply lubricant to rubber blocks and function on the meter.
cavities Insert blocks in pairs using a non- metallic hammer (Use Turn on the power in the circuit being measured.
sequence shown in figure) Put the leads of the meter in parallel with the
5. FASTEN OUTER MEMBER TO FL YWHEEL TORQUE AS PER component to measure the voltage potential
TABLE AND CHECK ALIGNMENT difference between the two points of the
6. Check the bore (radial) and face (axial) reading The TIR should be component.
within 0.008" for bore and 0.010" for face
7. Check for crankshaft end play. Engine
- Controls
Details of Holset Couplings for Cummins Engines are as follows : How To Measure Resistance
Engine Models Type of Flexible Coupling Select the resistance function on the meter.
All "B" Series 0.37 ABSAE 14 Verify that there is no power to the components
N/NT/NTA495, NTC495,
N-743, N-743-T, N 855 being tested.
NT/NTA 743,NT/NTA855, NTA855G2 073ABSAE14 Put the leads of the meter in parallel with the
Meter
KT/KTA 1150, VNTNTA1710 1.15ABSAE14 component to measure resistance.

KT/KTA2300, KTA 3067 2.15 AB SAE 14
How To Find The Internal Resistance of The
Torque Specifications for Holset Coupling
Meter
Coupling Flange Bolts Cover Set Screws
Type
Grade Torque Tighten Grade Torque Tighten It is important to know the internal resistance of
8.8 Nm (FtLbs) 8.8 Nm (Ft.l.bs)
0.37 M 10 37 (27.29) M 10 37 (27.29)
the meter when measuring small resistances. To
0.73 M 12 64 (47.20) M 10 37 (27.29) accurately measure small resistances, the
1.15 M12 64 (47.20) M12 64 (47.20) internal resistance of the meter must be
2.15 M 12 64 (47.20) M12 64 (47.20) subtracted from the measured resistance.
NOTE : Turn the meter “ON”
1. A flexible coupling operating in correctly assessed system requires Set the meter to the lowest ohm scale. Measure
no maintenance If is recommended that the rubber blocks are the resistance across the meter test leads
inspected for every 5000 hrs. . (including special test leads if they are being
2. A small amount of rubber dust is normal. In initial running large
quantity of dust requires inspection on use of sufficient lubricants, used).
damages during assembly and proper torques “ZERO” the meter or subtract this value when
taking measurements.
79 80
Section - 1 Engine Data Genset N, V, K, QSK Page 1-18 Section - 1 Engine Data Genset N, V, K, QSK Page 1-19
How To Test For Continuity

INTRODUCTION TO EFC PARTS
Select the continuity function on the meter
(usually marked with a diode symbol). Make sure
there is no power to the component being A change in current in the actuator coil will
measured. Put the leads of the meter in parallel make the actuator-shaft rotate. The fuel flow
with the component to test continuity. Meter and the engine speed or power will change,
The meter will beep if the resistance is less than when the actuator shaft rotates.
150 Ohms. If there is an open circuit, the meter
will not beep.
Connector - Checking
When di sconnec ti ng connec tors duri ng 2) Introduction to Parts
troubleshooting, the pins must always be
inspected to make sure they are not the cause of The figure shows how various parts are
a bad connection. The three things to look for are functionally connected. Following major parts
bent, corroded and pushed back pins. are included in the EFC governor.
EFC GOVERNOR
1) EFC Governor Description

The Electric Fuel Controller (EFC) governor in
used on engine for controlling it's speed either in Magnetic Pickup 2a) Magnetic Pickup:
Actuator
an isochronous mode or with adjustable droop.

Housing
A magnetic pickup is an electro-magnetic
EFC governor is used on PT fuel system. The device. It is mounted on the flywheel housing
governor contains a magnetic pickup, actuator Governor
so that the ring gear teeth are sensed by a
mounted in housing, called as a housing actuator, Actuator
Controller
pickup. Sensing distance should be between
a governor controller, mounting parts, and a cable 0.028” - 0.042” from the flywheel gear tooth. A
harness for interconnections. pickup requires a hole with 5/8-18 UNF-2A
size tap for mounting. Three pin power- lock
connector is provided to connect the magnetic
pickup to the engine harness.
The magnetic pickup senses the engine speed at
the flywheel ring gear & generates an AC voltage Governor
Controller
with it’s frequency proportional to the engine Magnetic

Pickup
speed. The frequency also depends on number of

Flywheel
gear teeth on the flywheel. Signal from magnetic
pickup is sensed by a governor controller and is 2b) Actuator and Housing Actuator:
used as a speed feedback. The actuator is an electromagnetic rotary
solenoid valve. The actuator is housed in the
aluminium housing. This assembly is used as
The actuator mounted in the housing actuator is a valve for controlling the speed and horse
used to control the fuel flow from the fuel-pump to Governor
Controller
power of an engine.
the injectors. Actuator valve (When no current is Magnetic
Pickup
flowing in actuator coil) is normally closed. Actuator EFC

Actuator
valve opens depending on the amount of current Flywheel
through the actuator coil.
Reference Point
The governor controller compares the electrical

1500 RPM
signal from the magnetic pickup with a preset Governor

Controller
Magnetic Engine
speed reference point. If there is a difference in Pickup

EFC
Actuator
the two signals, the controller will change the Flywheel

Fuel
Pump
current to the actuator.

81 82
EFC CONTROLLER SPECIFICATIONS EFC TROUBLE-SHOOTING
OPERATION A) Three lamps are provided for diagnostics on EFC controller.
Governor Mode 0% (ISOCHRONOUS) TO 6-8%
1) Power OK Lamp : This lamp glows only when the supply voltage
Droop is within 18 to 30 Volts. If this lamp at any time does not glow,
Steady State Stability Less than + / – 1/ 2 % check for battery voltage or connections.
Idle Speed Setting (Frequency Range) 1 KHz to 4 KHz
2) Mag. Pickup OK : This lamp glows when the engine runs at a
Run Speed Setting (Frequency Range) Idle Setting to 6 KHz
speed above 200 rpm. If this lamp does not glow, it indicates that
POWER the pulses from pickup are not being received. Check the gap
Operation Voltage 24 Volts dc + / -6 Volts. between pickup and flywheel ring gear. If the gap is OK, check the
Power Consumption 60 Watt Max. connections. If the connections are also OK, replace the pickup.
Check Magnetic Pickup signal on the controller terminal no. 8 and
Normal Operating Current 1.5 Amps 9 with digital multimeter on AC voltage range during cranking. If it
ENVIRONMENTAL is more than 1.5 V AC then magnetic pickup is OK. If magnetic
Ambient Operating Temperature -10 to 55 degrees Centigrade pickup ok lamp still does not glow, replace the controller.
Relative humidity 0 to 90 %
3) Actuator OK : This lamp glows when actuator coil is taking
PHYSICAL current in the range of 0.5 to 1.8 amps. approx. i.e. lamp is off
Dimensions 12” x 8” x 3” when actuator is taking full current or zero current. This lamp is off
Weight 2.5 Kg (approx) when the engine is at standstill. At the time of cranking, this lamp
turns on momentarily. Lamp remains on when the engine speed is
PROTECTION
governed. If this lamp is not glowing, it indicates that, either
High Voltage Protection 36 V DC actuator is not properly connected or else the actuator is fully
Reverse Supply Polarity 36 V DC open but the sufficient fuel is not flowing. Check fuel input line or
Vibration Protection Controller sealed with EPOXY fuel filters.
Compound.
B) Following is the list of symptoms and checks to be performed.
Carry out all the checks or corrections in s equence till the problem
is rectified.
MAGNETIC PICKUP SPECIFICATIONS
SYMPTOM : 1) Engine cranks but will not start.
Proximity to gear teeth 0.028 min. - 0.042 max (inches)
CHECKS and CORRECTIONS:
(1/2 to 3/4 turn) i) Check for fuel in tank and fuel valve.
Thread size 5/8- 18 UNF-2A ii) Check whether fuel is reaching injector while cranking
engine.
Tap drill size 37/64
iii) Check whether fuel shutoff valve opens when the engine is
Temp. range -10 to 55 degrees centigrade cranked.
Output 2 V RMS minimum iv) Check for the RUN and IDLE pot. settings. If these are
disturbed, set them properly as per the procedure.
v) Check ‘Diagnostic lamps’ and take action accordingly.
OPERATION
vi) Check the voltage on the actuator terminals during cranking
1) ACTUATOR PART NOS.
the engine (Magnetic Pickup OK lamp should glow). It
Part No. Description should be more than 8 volts DC. If it is less then replace the
controller.
3085219 Actuator, 24 V, Normally Closed, LOW FLOW, for use on NT
- 855 and KTA- 19 engines.
3085220 Actuator, 24 V, Normally Closed, HIGH FLOW, for use on

VTA - 28, KT (A) 38 and KTA -50.
83 84
Section - 1 Engine Data Genset N, V, K, QSK Page 1-22 Section– 1 Engine Data Genset N, V, K, QSK Page 1-23
ECP - G (ELECTRONIC CONTROL PANEL – GOVERNOR )

SYMPTOM 2) Engine has rough performance or surge.
It is the combination of Electronic Control Panel, Electric Fuel Control and
CHECKS and CORRECTIONS: Solid State Potentio Meter
i) Install sight glass and check for air in fuel.
Connector Details
ii) Check whether controller is adjusted correctly. Pin Descriptions
Connector-A
iii) Check ac ripple voltage on 24 V dc supply by digital
A Battery (24 VDC) Negative
multimeter / oscilloscope . If ripple is more than 1 volts B Engine speed sensor return
remove the cause or ripple. Connect battery charger C Battery (24 VDC) Negative
directly to battery terminals. D Fuel shut off valve output
E Starter magnetic switch output
iv) Check the system voltage if it is below 19 Vdc charge the
F Fuel actuator output
batteries. G Lube oil pressure sensor supply
v) Remove connections going to controller and apply 24 V to H Lube oil pressure sensor signal
J Lube oil pressure sensor return
the actuator terminals. If the actuator does not click, as if it
K Data link start output relay driver
is not operating, or operating slow, loosen all of the L Battery (24 VDC) Positive
capscrews used for actuator mounting and tighten them M Fuel actuator return
again as per procedure. N Coolant temperature sensor signal
P Coolant temperature sensor return
vi) Remove actuator and check ‘O’ rings, springs and gasket. R Coolant level sensor signal
Replace defective parts. S Intake air temperature sensor signal
vii) Check whether the actuator is sticky. If found sticky, clean T Engine speed sensor signal
U Intake air temperature sensor return
with isopropyl alcohol. Reinstall the actuator as per the V Battery charging failure signal
procedure. Connector B
A Battery (24 VDC) Negative
B Speed raise / Alternate Frequency
SYMPTOM 3) Engine operates at high idle C Speed lower
D Remote Start
CHECKS and CORRECTIONS : E High intake air / Engine over speed alarm relay driver
i) Check whether run speed is adjusted too high. If so adjust F Low lube oil pressure alarm relay driver
G High coolant temperature alarm relay driver
the speed correctly. H Engine not ready to start alarm relay driver
ii) Check ‘O’ rings in the actuator. I Speed bias signal
J Remote stop
iii) Check Voltage at the actuator terminals, If it is more than Data Link Connecotor
17 V, inspite of 1 Data link positive
2 Data link negative
1) Putting run / idle switch on idle mode. 3 Not connected
4 Not connected
Or
5 Not connected
2) Decreasing Run speed in Run mode by rotating run pot. 6 Not connected
CCW. then check wiring, RUN/IDLE switch and it’s 7 Not connected
8 Not connected
connections, If these are OK replace the controller. 9 Not connected
Connector C (Future Use)
SYMPTOM 4) Engine operates at high idle A Electrical STC valve return
B Not connected
CHECKS and CORRECTIONS : C Not connected
D Fuel rail pressure sensor signal (output)
i) Check battery voltage. It is below 20 V charge the battery. E Fuel rail pressure sensor supply
F Fuel rail pressure sensor return
ii) Check voltage at actuator terminals. If it is less than 17 V, G Electrical STC valve output
change the controller.
iii) Calibrate the fuel pump al ong with the actuator and
housing actuator.
iv) Check the fuel system.
85 86
Section – 1 Engine Data Genset N, V, K, QSK Page 1-24 Section – 1 Engine Data Genset N, V, K, QSK Page 1-25
Governing Features
Controller Overview • Frequency bias
Reduce field failures related to Instrument Panels Analog 0-5V input for speed bias
Accuracy of measurement can interface solid state potentiometer
PC interface • Raise / Lower Contact inputs included in the OEM harness for
Built in diagnostics frequency adjustment
Adaptability to different sensors • Start up Black Smoke Limiting by controlling the initial fuelling
Minor changes to be accommodated quickly • Programmable ramp rate during engine start up
Common hardware for different engine models – Start to Idle mode
A specific “Calibration” (software) required for operating the controller, engine – Start to Rated mode
Software resides in controller memory • Rapid restart FSOV included to improve / eliminate start up issues
Released “Calibration” would available on Floppies / CD (no more EPROM’s!!) • Fuel Actuator command displayed on digital display
Engines would be shipped with “Calibration” loaded into the controller
A Separate PC based Service Tool required for : New features in ECP-G
– Monitoring engine parameters • Droop paralleling with built in software algorithm (programmable droop
– Changing values in controller feature)
– “Downloading” Calibration into the controller • Power Down Mode - ECP-G Controller powers down after preset
time if engine not running. This is to save the drain on the
Controller Overview - Software battery
Controller software can be divided into two parts: • Enhanced FSOV and magnetic switch driver design to with stand
short circuit
– Boot loader ( similar to Command.com for “DOS” based PC) • New plastic enclosure
– RTOP (Real time operating program) comprising of: • CECO Lube oil pressure sensor
– Actual software code residing in the ECP-G non volatile memory • Modular design to implement ESTC control capability
– Calibrations
– Stored in permanent memory C-VIEW – Steps in Software Usage
– Changeable only during development via PC based
Engineering tool. • Software Installation
– Trims • Obtaining Passcode for C-View
– Stored in permanent memory • Running C-View
– Changeable in the field • SITE CONFIGURATION
• By PC based Service tool • Creating Monitor Windows
• By embedded software (automatic trims, • Logging Data to a file
e.g., hour meter)
– Monitor Points
– Parameter values accessible to the user using the PC ECPG Sensor Specifications
based service tool
– Non changeable ALLTEMPERATURE SENSORS OIL PRESSURE SENSOR
Torque = 15 N•m [133 in-lb] Torque = 14 N•m [124 in-lb]
Service Tool Feature Groups
• Service Tool interfaces with the Controller using a RS 232 C Temperature Temperature Resistan ce Pressure Pressure Voltage
o o
Communication port ( C) ( F) (Ω) (kPa) (psia) (VDC)
• A RS 232 to RS 485 Data link converter with related harness required 0 32 30k to 36k 0 0 0.5
(same as the one used for ECP Remote monitoring software) 25 77 9k to 11k 207 30 1.5
• Service Tool can access the different Variables (Calibrations / Trims) 50 122 3k to 4k 414 60 2.5
75 167 1350 to 1500 621 90 3.5
• These Variables are grouped according to their functionality.
100 212 600 to 675 827 120 4.5
• Grouping simplifies user interface
• Following are some groups contain all ECP-G addressed variables -
intended for service tool use:
– Analog Input
– Discrete Input ENGINE SPEED SENSOR
– Engine Protection Torque = 34 to 47 N•m [25 to 35 ft-lb] Coil Resistance = 750 to 1600 Ω
– Engine Speed
– Governor …..
87 88
Operating, Electrical & Environmental Specifications LIST OF REPLACEMENT PARTS ECPG
Operation
Governor Mode .......................................... Isochronous to 6%
Sr. No. Part name P. Number
Droop ECP-G Assembly
Governor Gain Adjust.................................. 0.9 to 1.1
Frequency Adjust Range............................. ±4Hz 1 ECP-G Assembly 4083935
Power 2 Key switch 504975
Nominal Operating Voltage .........................+24VDC 3 Parameter selection push button 4071721
OperatingVoltageRange .............................+20 to +32VDC 4 Toggle switch (for Idle/Rated mode selection) 3875362
Maximum Continuous Voltage.....................+32VDC 5 Vibration Isolator 3229922
Ground Polarity ...........................................Negative Ground 6 Mounting bracket 4084240
Nominal Operating Current .........................1.5A @ +24VDC
Maximum Operating Current ......................4.5A @ +18VDC Sensors
Sleep Mode Operating Current ...................100mA (nominal)
Ready Mode Operating Current ................. 850mA (nominal) 1 Coolant temperature sensor 3865346
[ECPG On & Engine Not Running] 2 Air Intake temperature sensor 3408345
Environmental 3 Lube oil pressure sensor 3408560
Ambient ECPG Housing Operating Temp... 0° to 70°C (0° to158°F) 4 Coolant level sensor 4072714
Storage Temperature ..................................0° to 70°C (0° to158°F) 5 Adapter for Coolant temperature sensor 4084218
Vibration Limits ...........................................20-100Hz, 93.6mm/sec: 6 Adapter for Air intake temperature sensor 4084219
Physical 7 Magnetic pick up 3879986
Dimensions (Including Heat Sink;...............314 mm (L) x 264 mm (H) x 118 8 Lube Oil Pressure sensor adaptor (V 28 engine) 4104562
9 Lube Oil Pressure sensor adaptor 3814448
excluding mounting brackets)......................(12.34 x 10.37 x 4/64”) (495, 743, 855 series engines)
Weight ........................................................ 2.53 kg (5.596 lbs.)
Housing Enclosure ..................................... Glass Filled Plastic Actuator and Actuator housing
Heat Sink Metal........................................... Aluminum
Protection 1 Fuel Actuator with O ring 3330601
Reverse Polarity Protection ........................+28VDC Maximum 2 Fuel actuator housing 4071944
Electrical Interface Characteristics 3 Fuel actuator filter screen 3867393
Lamp/Relay Driver Supply 4 Fuel actuator ‘O’ rings (1) 3865398
Supply Voltage.............................................+12VDC Nominal @ 80 mA 5 Fuel actuator ‘O’ rings (2) 3642542
Lamp/Relay Drivers
DriverType. ............................. .... Low-Side (switched Harness
GND/Open)
DriverVoltageRating.....................................+24VDC Engine harness
Nominal Maximum Sink Current (Driver On).. 80mA
1 KT/KTA 1150/KTA 19 G4/G3 engines 4084232
Analog (Adjustable) Inputs
2 NT 495 4085697
Nominal Input Voltage Adjustment Range...0-5VDC
3 NTA 495 4085698
Maximum Input Voltage...............................5VDC
4 NT/NTA 743 4085700
Speed (Frequency) Bias Reference & Voltage Supply
5 NT/NTA 855 4085692
0-5 VDC Reference Voltage.........................+5VDC
6 VT/VTA 28 4085693
7 Extension harness 10 meters 4072993
Data link RS-485 serial communication standard
All continuity checks ok (no open circuit)
? if < 10
9 OEM harness 4054744
ECPG power supply 20 to 32 vdc
ECPG connector retaining capscrew torque=1 n•m [9 in-lb]
Short circuit to external voltage ok if < 1.5 vdc
All shorts to ground ESS circuits - ok (no short circuit)
? if > 10m
All other circuits - ok (no short circuit) if > 100k?
Parameter Description Feature Range Resolution Default Value Units List of Important Field Adjustments
Ramp Rate Speed should increase / decrease if the List of Field Adjustments
Raise / Lower Switch is kept pressed
continuously Parameter Description Feature Range Resolution Default Value Units
Speed Adjust Limit - Reference Speed -200 to 200 0.125 180 RPM Speed Bias Input Determines whether Speed Bias Analog Not Connected,
Analog Inputs - Not Connected -
Gives a selection between Speed Bias None, Connected Inputs is connected or not. Connected
Raise/Lower
Speed Adjust Source and Raise/ Lower Switches for Reference Speed Speed Bias Input, - - Data Link Start
Switches Serial Command to start the engine Data-Link Inactive, Active - Inactive -
reference Speed Adjustment Raise/Lower Switches Command
When Speed Override feature is Data Link Stop
Serial Command to stop the engine Data-Link Inactive, Active - Inactive -
Speed Override enabled, Reference Speed is set equal Reference Speed 0 to 1800 0.125 0 RPM Command
to this parameter. Calibration File Name Calibration File Name Data-Plate - - - -
Enables the Speed Override feature. Engine Build Date Engine Build Date Data-Plate - - - -
Speed Override
Reference Speed is set to Speed Reference Speed Disable, Enable - Disable -
Enable Engine Serial Number Engine Serial Number Data-Plate - - - -
Override value.
Common Warning,
Disable Powerdown,
Enable This trim configures the customer Common Shutdown,
Power Down Control Controls the Powerdown behavior. System Mode Enable Powerdown, - - Customer Output Discrete Outputs - Common Warning -
Powerdown selectable output driver. Engine Running,
Force Powerdown
Engine Not Ready To Start
Low Lube Oil Pressure Warning and Shutdown Thresholds Time required by the Engine to reach

Start to Idle Time Engine Crank 0 to 15 1 7 Seconds
Idle Speed after cranking it
Engine Models
Time required by the Engine to reach
N-495-G, NT-495-G, NTA-495-G, NTC-495-G, NT-743- Start to Rated Time Engine Crank 0 to 15 1 10 Seconds
KT-1150-G, KTA-1150-G, KTA-19-G3-I, KTA-19-G4, Rated Speed after cranking it
G, NT-743-G1, NTA-743-G, NT-855-G4 (BC), NT-855-
VTA-28-G, VTA-28-G3, VTA-28-G5, KTA-38-G5 High Coolant Temperature above which the High
Engine Speed (RPM) G5 (BC), NT-855-G6 (BC), NTA-855-G2
Low Lube Oil Pressure Low Lube Oil Pressure Temperature Coolant Temperature Shutdown Fault Engine Protection 95 to 100 1 96 Deg. C
Low Lube Oil Pressure Low Lube Oil Pressure Shutdown Threshold shall be activated.
Shutdown Threshold Shutdown Threshold
Warning Threshold (Bar) Warning Threshold (Bar) High Coolant Temperature above which the High
(Bar) (Bar)
0 0 0 0 0 Temperature Warning Coolant Temperature Warning Fault Engine Protection 90 to 95 1 93 Deg. C
500 0.4 0.3 0.5 0.3 Threshold shall be activated
1100 0.8 0.6 1.0 0.6 High Intake Manifold Temperature above which the High
Engine Protection 60 to 75 1 75 Deg. C
Page 1-28
Warning Threshold Intake Manifold Temperature Warning
Page 1-30
1500 2.1 1.8 2.7 2.4
91 92
89 90
Parameter Description Feature Range Resolution Default Value Units

Fault shall be activated.
Clear Snapshot Type 1 Buffer Clears the Snapshot Type 1 Buffer when set Active. Fault Handler Inactive, - Inactive -
ECP/ECPG to Datalink Adapter Cable Datalink Adapter to PC Com port Cable Datalink Adapter to Modem Cable Active
Section – 1
Engine Safety Override Flag When enabled, only engine overspeed and engine speed signal Fault Handler Disable, Enable - Disable -
P/N 4071852&4071853 P/N 4071851 P/N 4072074
lost faults shall shutdown the engine. All other faults
shall be ignored.
Fuel Actuator Cmd Override When Fuel Act Cmd Override feature is enabled, Fuel Act Cmd is Fuel System 2 to 95 0.01 2 %
ECP/ECPG Datalink Datalink PC Com Datalink PC Com set to this value when System Mode is READY.
Fuel Actuator Cmd Override Enable Enables the Fuel Actuator Cmd Override feature. Fuel Actuator Fuel System Disable, Enable - Disable -
DCD 1 1 DCD 1 1 DCD 1 1 DCD
Cmd is set to Fuel Actuator Override value.
RxD 2 2 RxD 2 2 RxD 2 2 RxD Governor Gain Adjust Governor Gain Adjust Governor 0.750 to 1.250 0.001 1.000 -
Governor Gain Scheduling It is the Coolant Temperature threshold below which the Coolant Governor 20 to 100 1 40 Deg. C
Txd 3 3 Txd 3 3 Txd 3 3 Txd Temperature Threshold Temperature based Gain scheduling takes effect
DTR 4 4 DTR 4 4 DTR 4 4 DTR Governor Gain Governor Gains get multiplied by this value when the Coolant Governor 0.5 to 1.5 0.001 0.700 -
Temperature Multiplier Temperature based Gain Scheduling takes effect.
Gnd 5 5 Gnd 5 5 Gnd 5 5 Gnd - -
Governor Load Governor Load Scheduling Enable Governor Disable, Enable Disable
Scheduling Enable

DSR 6 6 DSR 6 6 DSR 6 6 DSR
Engine Hours Since Reset Engine Hours Since Reset Hour Meter 0 to 100000 0.1 0 Hours
RTS 7 7 RTS 7 7 RTS 7 7 RTS Droop Droop value Reference Speed 0 to 6 0.5 3 %
CTS CTS CTS CTS Idle Speed The Speed at which the Engine should run when in Idle Reference Speed 800 to 1200 1 1100 RPM
8 8 8 8 8 8
Idle to Rated Time Time required for engine to ramp up / ramp down from Idle to Reference Speed 0 to 20 1 10 Seconds
RI 9 9 RI 9 9 RI 9 9 RI Rated and vice versa
Raise Lower Switch The rate at which the Adjusted Base Reference Speed 1 to 25 1 1 RPM/Sec
9 Pin M 9 Pin F 9 Pin M 9 Pin F 9 Pin M 9 Pin M
Page 1-29
Page 1-31
DRAWING NUMBER 0
38 REVESIONS ECPG WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS
3878916 REV DESCRIPTION REV BY DATE APPD
00 ER.-957053-000 23.2.95
SHUT DOWN COIL

FUEL SOLENOID VALVE
19 PIN CONNECTOR
NO 17
STARTING 12) SYSTEM :- ELECTRICAL F -VE A
17 16 SWITCH A
37 3
NC 26 25 11) SC. NO. :- VARIOUS Section -B1 B
R 18
HIGH WATER PUMP 10) CUSTOMER :- VARIOUS C
SAFETY CONTROL W
AMMETER 27 9) APPLICATION :- VARIOUS ECPC ACTUATOR D D
37 E E
1
8) ENGINE MODEL :- KV12/KV16 Cummins Ind.Inc
36 NC NO F F Page 1-30
7) THIS DIAGRAM WIRING TO BE USED WITH Electronic Control Panel

2 45V G
3 23 G
3 DUAL DELCO REMMY STARTER & LUCAS ALT. H
OVER SPEED STOP 4 24 24 18
OUTPUT H
4 J
5 25 6) BOTH THE STARTER EARTHING CABLES GND J
38 5
9 6 26 SHOULD BE OF EQUAL LENGTH. DATALINK K
ASSEMBLY LIGHT INDICATOR K
36 8 6 START L
NO 7 27 & DIODE 3875311 L
7 5) SIZE & LENGTH OF CABLE NO. 76 & 56
LOW LUB OIL PRESSURE 8 28 35 +Ve M
NC M
SAFETY CONTROL 8 SHOULD BE OF EQUAL LENGTH.
9 29 28 R N
9 36 N
4) SIZE & LENGTH OF CABLE NO. 57 & 55 MAG P
10 29 -Ve P
ICWI PICK-UP R
11 START PUSH BUTTON
SHOULD BE OF EQUAL LENGTH. R
SENSOR S
5 35 3) THIS DIAGRAM IS USED WHEN SAFETY S 2 TURN THE STARTING KEY SWITCH
+ 12
4 T TO START POSITION TO CRANK
W CONTROLS FOR LOW LUB. OIL PRESSURE T THE ENGINE.
+Ve U
-Ve 25 U
ALTERNATOR 35 HIGH WATER TEMPERATURE & OVERSPEED V 1 24 VOLT NEGATIVE GROUND SYSTEM.
W
AMPERAGE 33E V
7
CIRCUIT NO. CAPACITY WIRE GAUGE STOP ARE CONNECTED. V
ALTERNATOR
6 3, 8, 9, 23, 27 2) FOR STARTING THE ENGINE PUSH BUTTON

73 28, 29, 35, 36 20 44/0.3 MM AMP
CIRCUIT NO. WIRE GAUGE
54 37, 77, 79 SHOULD BE PRESSED BEFORE CRANKING & CAPACITY
MAGNETIC 78 P.V.C. IT SHOULD BE RELEASED AFTER LUB. OIL G, E, V, A, L, E, M
SWITCH
55, 56, 57, 76 200 14 1.5 SQ. MM.
56 95 SQ. MM DOUBLE. 39 E, D
54 4, 5, 6, 7, 24 PRESSURE BUILDS UP.
56 55 79 78 25, 26, 54, 73 30 65/0.3 MM 25, 33E, 38, 17 30 4.5 SQ. MM.
-VE GROUND ELECT. SYSTEM WITH 26 25 38 38
STARTER 74, 75, 78
+ + 35 36 C,H,J,N,P,S,U,R 11 1 SQ. MM.
55 1) ALTERNATOR 4
36 17 45 26, 45 200 P.V.C.95 SQ.MM.
17
+ + B, R SHIELDED 1 SQ. MM.
75 STARTER 45 35E 17 17 STARTER CABLE
79 73 39E
75 EARTH WIRE EARTH WIRE
76 74 26 E
76 BATTERIES 57 45
74
+ Ve - Ve 38 38
57 MAGNETIC WIRING DIAGRAM FOR DUEL DELCO REMY STARTER & - Ve + Ve
STARTER SWITCH MAGNETIC
LUCAS ALTERNATOR ENG. MODELS - KV-12/KV-16 SWITCH
THIRD ANGLE PROJECTION
BATTERY 24 V.D.C.
Section - 1
Page 1-32
Page 1-34
95 96
93 94
22
WIRING DIAGRAM FOR ENGINES WITH AIR STARTER CIRCUIT NO.
AMP
WIRE GAUGE 16 16 STARTING SWITCH
22 CAPACITY
2, 3, 8, 14, 22, 23, 6 5 B 3 14 01
AMP 20 44/0.3 MM B L R
CIRCUIT NO. WIRE GAUGE 28, 35, 36, 37 S
FUEL SOLENOID VALVE CAPACITY
2, 3, 8, 13, 14, 22, ---- 200 P.V.C. 95 SQ. MM AMMETER 2
20 40/0.3
Section – 1
23, 28, 35, 36, 37 01 FUEL SOLENOID VALVE 5,6,7,15,16,17,25,
3 14 30 65/0.3 MM
36 37 5,6,7,15,16,17,25, 14 26,27,33,34,38,39
NO 30 34/0.3 14
26,27,32, 33,34 3878917 3 36 37
NC 9 B NO
30, 29 200 485/0.5 B L 5 R
LOW LUB OIL PRESS STARTING S NC
2 1
SAFETY CONTROL AMMETER SWITCH 2 22
LOW LUB OIL PRESS 37 2
503881 504975 SAFETY CONTROL 2
23 3
36 3
22 1
35 NC 37 2
NO 2 36 4
23 3 25 5
3 NC 5
35 26 6
OVER SPEED STOP 4 NO 6
25 5 27 7
5 15 5 FOR ENGINE SHUT DOWN TURN THE 7
NO 6 OVER SPEED STOP 28
6 STARTING KEY TO STOP POSITION 8
27 7 7 8
NC 35 7 4 WATCH THE LUB OIL PRESSURE GAUGE
28 8 PUSH BUTTON 9 15
23 27 8 AND SHIFT STARTING SWITCH KEY TO RUN
29 9 NO 10
HIGH WATER TEMP. 9 POSITION WHEN OIL PRESSURE GAUGE 35 7
SAFETY CONTROL-194506 30 10 8 13 NC
10 INDICATES MORE THAN 1 Kg./Cm2. 23 11
ELEC.SOLENOID VALVE START PUSH BUTTON
FOR AIR STARTER 11 12 LAMP INDICATOR DIODE
25 ASSEMBLY LIGHT INDICATOR 3 RELEASE THE PUSH BUTTON AFTER ENGINE HIGH WATER TEMP.
3234239 12 SAFETY CONTROL 8 14
+ _ 33 & DIODE 3875311 FIRES.
28

W 2 TURN THE STARTING KEY SWITCH TO
33 8 SYSTEM ELECTRICAL. 25 YELLOW COLOUR
ALTERNATOR START POSITION TO CRANK THE ENGINE RED COLOUR
7 SO. NO. VARIOUS
33
3236504 SIMULTANEOUSLY PRESS THE STARTER + _ WIRE WIRE
28 02 LAMP INDICATING &
6 CUSTOMER - VARIOUS PUSH BUTTON. DIODE ASSY.
W
5 APPLICATION - VARIOUS 1 24 VOLT NEGATIVE GROUND SYSTEM 33 17 17 3875315
ALTERNATOR 26
4 ENGINE MODEL - VARIOUS 36 26
3 WATCH THE LUB. OIL PRESSURE GAUGE & 39 WIRING DIAGRAM FOR
SHIFT STARTING SWITCH KEY TO RUN 38 LUCAS SM130PE OR DELCO REMY STARTER
POSITION WHEN OIL PRESSURE GAUGE 02 34 MAGNETIC
INDICATES MORE THAN 1 Kg./Cm.2 & LUCAS ALTERNATOR
LUCAS SM 130 PE/ 34 SWITCH
2 24 VOLT NEGATIVE GROUND SYSTEM ENG. MODELS - N/NT/NTA-743, 855, VT/VTA-1710, KT/KTA-1150
DELCO REMY STARTER
29 1 TURN THE STARTING KEY SWITCH TO START
+ + POSITION TO CRANK THE ENGINE + +
30 SIMULTANEOUSLY PRESS THE STARTER
- - - -
PUSH BUTTON
Page 1-33
BATTERY 24 V.D.C.
BATTERY 24 V.D.C.
Page 1-35
52
37
Remote
speed
Adjustment
FUEL SOLENOID VALVE
P/NO.-134074
Open-run'
Close-idle
Actuator
24 VDC
Mag. pick up
35 19 PIN CONNECTOR
P/NO.-3878671
NC NO 40 Cummins Page 1-32
+Ve 26A CONTROLLER
36 A 1 2 3 4 5 6 7 8 9 10 11
24 V.D.C.FROM STARTER -Ve 45E E E
LUB OIL PRESS. B
SAFETY CONTROL 42
P/NO.-3056344 W/T. SENSOR 1
C
36 2 1185 1635
P/NO.-3392030 32
D 1170 1620
1155 1605
NC NO 41 1140 1590
1
E
O/T. SENSOR 1125 1575
2 31 VARIABLE TERMINAL
P/NO.-3392030 F 1110 1560
37 1095 1545
43 7 125 105
OVER SPEED S.OP. G 1080 1530 6.5 120 100
L.O. PRESSURE 1065 1515 TO BATTERY
P/NO.-500289 44 6 115 95
SENSOR H 1050 1500 5.5 110 90
1035 1485 5 105 85
24 VDC
NO 23 52 1020 1470
J 4.5 100 80
35 1005 1455 4 95 75
NC 27 990 1440
K 3.5 90 70 CONNECTOR PIN ASSIGNMENT (SEE NOTE)
975 1425 3 85 65
HIGH WATER TEMP. 40 960 1410 2.5 80 60
L 945 1395
SAFETY CONTROL 2 75 55
P/NO.-3062866 23 930 1380 1.5 70 50
M 915 1365 POTENTIOMETER
1 65 45 3 2 1
900 1350 1< 60 40
N 2
CONTROLLER
IDLE RPM RUN OIL PR. KG/CM OIL TEMP.OC WTR.TEMP.OC
MAGNETIC PICKUP 9 P HARNESS 6 5 4 3 2 1
P/NO.-3875360 2 1 3 6 5 9 7 8 9 Pole plug
8 R 9 8 7
28 IDLE RUN 2 1 3 6 5 9 7 8 9 Pole Receptacle
S
3 POLE PLUG
T PUSH IGNITION
9 POLE PLUG
6 FAILURE
U BUTTON SWITCH
-Ve +Ve 25
ACTUATOR
33E W V 1 2 3
7 EXTENSION CABLE
28
ALTERNATOR 4 5 6 1 2 3
P/NO.3236504 PANEL INSTRUMENT
HOUR METER P/NO.-3392379 7 8 9
P/NO.-3231403 2 1 3 6 5 9 7 8 9 Pole plug

OIL PRESS. On enginepanel

52 45E AMP.
EIP Wiring Diagram

CIRCUIT NO. WIRE GAUGE 2 1 3 6 5 9 7 8 9 Pole 9 POLE RECEPTACLE 3 POLE RECEPTACLE
KEY SWITCH 40 OVER CAPACITY
23C SPEED Receptacle
23WT 35 36 36 E 23,20A,27,28,35,36,
26A 14 1.5 SQ. MM 3 Pole 3 Pole 3 Pole 3 Pole
39E 26 25 37 37,39E,40,45E,52
38 Receptacle Plug Plug Receptacle
27 SHUT DOWN 25,33E,38,17 30 4.5 SQ. MM
17 COIL
MAG. SWITCH 6,7,31,41,32,42,43,44 11 1 SQ. MM 1 1 1 1
45E
26A 27 39 E
45 26,45 200 P.V.C. 89 SQ MM 2 2 2 2
C S
17 38 38 39E
STARTER 17 8,9 SHIELDED 1 SQ. MM
EARTH WIRE STARTER CABLE 3 3 3 3 PROBE
P/NO.-3018924 SM 130 PE/DELCO REMY 39E 27 26 45E
P/NO.-3873161/ P.NO.-3021038 RUN / IDLE SWITCH (MAG. PICKUP)
+VE M ENGINE HARNESS
26 45 39E 25 ( ON ENGINE PANEL ) (ON FLYWHEEL)
38
+Ve -Ve +Ve -Ve -VE
G 3 Pole Receptacle 1 2 3
MAGNETIC 33E
SWITCH W 3 Pole Plug 1 2 3 NOTE :
P.NO.-216537 28 1) Connector pin assignment is shown for looking
L the connector from pin (mating) side.
BATTERY 24 V.D.C.
2.3B 3879126 2) Please see the positions of circles & squares for
B
WIRING DIAGRAM FOR EFC GOVERNOR - VER 1
proper orientation of connector.

+VE -VE
ACTUATOR CABLE
Page 1-36
ACTUATOR
Page 1-38
( FUEL PUMP )
97 98
99100
STARTING SWITCH
3 - THIS WIRING DRAWING IS MADE FOR P/NO.504975
19 PIN CONNECTOR 26
P/NO.3878671 23A
INST. PANEL PART NO. - 3382379 26 26A B R 23A 01
ELECTRONIC GOVERNOR CONTROLLER CONNECTION DETAILS FOR SOLID STATE POTENTIOMETER
A S 23 1 01 PART NO. 3873853
- VE 42 MODULE
B 27 2
42 WTR.TEMP.
C 3 P/NO.3878675
32
Section – 1
32 4
D -VE
5 19 PIN
2 - TWO CORE SHIELDED CABLE OR 41
E 6 CONN
31 +VE 27
14/36 TO BE USED FROM F
43 1 CONTROL PANEL
TOGGLE SWITCH TO PIN 1 AND 2 G 41 MODULE
44 2 OIL TEMP.
H 3
OR RPM MODULE SHIELD TO BE HOUR METER 26A P/NO.3878674
52 31
J 45 E 4
-VE
CONNECTED 10 PIN 5 OF RPM K 27 START 5 19 PIN LOWER PUSH
PUSH BUTTON
01 CONN 1 2 3 4 5 6 7 8 9 10 11
40 40 6
MODULE. L P/NO.-504395 +VE 27 BUTTON
23 S-STARTER SOLENOID
M 1
MODULE M-STARTER MOTOR
N 2 OIL PRESS
43
9 3 P/NO.3878673 C-MAG. SWITCH COIL
P 44
8 4
R -VE B-BATTERY
5 19 PIN
1 - USE RED WIRES FOR ALL +VE 28 28 27A CONN
S 6
+VE 27 C-CHARGING ALTERNATOR
T INDICATING LAMP
RAISE PUSH
P/NO.-3225041 1 1 L-CHARGING FAILURE LAM BUTTON
6
U 2 2 MODULE
BLUE & BLACK FOR ALL -VE 7 01 8
V 3 RPM
(8 ON 19 PIN CONN.) 9 4 P/NO.3392023
5 1 -VE SOLID STATE POTENTIOMETER
5 19 PIN RAISE
4 6 CONN

2 +VE 27 E.F.C.
GREEN WIRES FOR ALL EARTH(E) TWO POLE LIMIT
3879125 TOGGLE SWITCH LOWER
P.NO.500278
EIP Inside Wiring Diagram

IO PIN CONNECTOR P/NO-3392023 4 5 6 7 8 9 -VE +VE
A
OUTPUT Kirloskar Cummins Limited
SYSTEM - STRING ENGINE 4 4 Kothrud, Pune 411 029. (INDIA)
B
5
C
5 TOGGLE SWITCH GND
6 6 KCL
D
7
E
7 ACTUATOR 2 CORE, 1.5 SQ. MM. +24 V.D.C.
S.O, NO. - VARIOUS 8 8 GROUND
SHIELDED CABLE WIRE SIZE
F PART NO. 3877372 SR.NO.
CUSTOMER - VARIOUS 9 9 MAG. PICKUP 1.0 SQ. MM. GND
G
-VE
H
23A 24 V SUPPLY TO 19 PIN CONN.
APPLICATION - GENSET +VE +
I
ENGINE MODEL - VARIOUS J OPEN
Page 1-37
24 VDC
Page 1-39
19 PIN CONNECTOR WIRING DIAGRAM
WIRING DIAGRAM WITHOUT E.F.C.
D -Ve A A WITH E.F.C.
B
B DETAILS OF 19 PIN CONNECTOR DETAILS OF 19 PIN CONNECTOR
EXTRA
C
DETAILS OF 7 PIN CONNECTOR
C D
SHUT DOWN COIL D A=PANEL -Ve A(23A)=EFC +Ve
D A=PANEL -Ve
E B(6)=
E B=
FUTURE
F EFC ACTUATOR B=
F MPU E.C.P. SHUT DOWN COIL
K NO C ECP ACTUATOR G T= } E(7)= }
G MPU E.C.P.
H C(10)= 19 PIN CONNECTOR T= }
NC H C= P/NO.-3878671
LLOP J EFC MPU
J E.C.P. PANEL SHUT DOWN -Ve A
SAFETY CONTROL K D= } G(11)= } A C=
K B
L B SHUT DOWN
L D(4)= EXTRA
FUTURE H= C
M OIL PRECURE RUN/IDLE C D=
*
35 +Ve
N
M
SENSOR SWITCH D
D
}
R ECP ACTUATOR J= } F(5)= }
36 N
E H=
-Ve P E
MAG. P FUTURE OIL PRECURE
LCWL R F(24)= EFC - Ve F
PICI-UP R G= F SENSOR
SENSOR LLOP NO
S K C ECP ACTUATOR G J=
S
K= }SAFETY CONTROL
H
G
}
T H
T NC
U LLOP J
-Ve +Ve 25 U J E.C.P. PANEL
W V L=PANEL +Ve SAFETY CONTROL K
G=
33E V LLOP
V K
L SAFETY CONTROL
ALTERNATOR N= L K= }
WATER TEMP. FUTURE
35 +Ve M
SENSOR M
P= } * R N
ECP ACTUATOR
36 N
MAG.
-Ve PICI-UP P L=PANEL +Ve
P
R=LCWL SIGNAL LCWL R
SENSOR R
S N=
S= S WATER TEMP.
AUX. T SENSOR
SENSOR T
U= } U
P= }
-Ve +Ve 25 U
7 PIN CONNECTOR W V
33E V

23A V='W' TERMINAL V
A
39E 26 6 ALTERNATOR R=LCWL SIGNAL
38 E.F.C. B
39E 26 25 L ACTUATOR 10
38 C
17 4 S=
35 D AUX.
A 23A RUN/IDLE 7
36 17 E
17 STARTER 45 SWITCH SENSOR
24 5
E.F.C. U= }
17 F
STARTER 45 EARTH WIRE 39E (VERSION II)
24 E 11
39E G 39E 26 25
EARTH WIRE 39E 38
E 38 V='W' TERMINAL
45 39E 35
26 38 L
AMP. 45 MAGNETIC A
+Ve -Ve +Ve -Ve
CIRCUIT NO. WIRE GAUGE SWITCH 36
CAPACITY MAGNETIC 17 AMP.
45 CIRCUIT NO. WIRE GAUGE
SWITCH CAPACITY
C,K,E,V,A,L STARTER 17
14 1.5 SQ. MM C,K,E,V,A,L
39E,D 24 39E E 14 1.5 SQ. MM
EARTH WIRE 39E,D
BATTERY 24 V.D.C.
25,33E,38,17 30 4.5 SQ. MM 39E 25,33E,38,17 30 4.5 SQ. MM
25 45 38
H,J,N.P,S,U,R 11 1 SQ. MM +Ve -Ve +Ve -Ve H,J,N.P,S,U,R 11 1 SQ. MM
MAGNETIC
26,45 200 P.V.C. 95 SQ. MM 26,45 200 P.V.C. 95 SQ. MM
SWITCH
SHIELDED
WIRING DIAGRAM B,T
SHIELDED
1 SQ. MM
Page 1-40
B,T 1 SQ. MM CABLE
Page 1-42
CABLE 4054715 BATTERY 24 V.D.C.
103 104
101 102
WIRING DIAGRAM
(PCC-1) POWERCOMMAND GENSET SYSTEM ARCHITECTURE WITHOUT E.F.C.
D
G21 DETAILS OF 19 PIN CONNECTOR
A=PANEL -Ve
SENSORS
CUSTOMER SHUT DOWN COIL
B=
INPUT/OUTPUT MPU E.C.P.
19 PIN CONNECTOR
MODEL
ENGINE
T= }
-Ve A
KTA19G4
VTA28G3
VTA28G5
KTA38G5
KTA50G3
A
KTA 50G8
KTA2300G
B C=
B
PCC CABINET EXTRA SHUT DOWN
C
C D= }
D
D
E H=
FIELD E OIL PRECURE
GCM A30 FUTURE
CT1 F
VOLTAGE F SENSOR
(optional) K NO C ECP ACTUATOR G J= }
G
REGULATOR H
NC H
400
500
500
600
800
KW
OUTPUT LLOP J G=
E.C.P. PANEL
1000
1200
CT2 J LLOP
SAFETY CONTROL K
Rating
MODULE K SAFETY CONTROL
PMG ANALOG L K= }
A37 ENGINE A33 CUSTOMER L
PT/CT FUTURE M
35 +Ve M
INTERFACE INTERFACE
A36 CT3 * R ECP ACTUATOR N L=PANEL +Ve
36 N
A31 A34 MAG.
-Ve PICI-UP P
P N=
LCWL R WATER TEMP.
L1 SENSOR R
S
SENSOR
GOVERNOR S P= }
L2 T
FILE
OUTPUT T
NAME
ACTUATOR DIGITAL -Ve +Ve 25
U
U
DFJB-50
DFLF-50
MODULE
DFJD-50
R=LCWL SIGNAL
DFLC-50
DFED-50
L3
DFGC-50
DFGC-50
A32 33E W V
V
A38 V
N ALTERNATOR S=

AUX.
SENSOR
U= }
7 PIN CONNECTOR
23A A V='W' TERMINAL
PARALLEL 6
E.F.C. B
CT
MAG ACTUATOR
DISPLAY BOARD A95 CIRCUIT BREAKER 39E 26 25 10 DETAILS OF 7 PIN CONNECTOR
38 C
PICK-UP
RATIO
1419/1
1893/1
1893/1
2141/1
2839/1
3867/1
4420/1
35 4 A(23A)=EFC +Ve
DETAILS FOR PCC1 (PCC 3100)

L D
A RUN/IDLE 7
L1 36 SWITCH E B(6)=
17 E.F.C.
23A 5
F (VERSION II) EFC ACTUATOR
L2 STARTER 45 17 11 E(7)=
BUS PT 24 G
}
L3 EARTH WIRE 39E E
A39 C(10)=
N 39E
25 45 38 EFC MPU
AMP. +Ve -Ve +Ve -Ve
CIRCUIT NO. WIRE GAUGE G(11)=
C,K,E,V,A,L
CAPACITY MAGNETIC
}
14 1.5 SQ. MM
SWITCH
39E,D D(4)=
NOS.
24
PART
25,33E,38,17 30 4.5 SQ. MM RUN/IDLE
BATTERY 24 V.D.C.
4104379
4107379
4107379
4084244
4084175
4084245
4084989
H,J,N.P,S,U,R 11 1 SQ. MM F(5)= } SWITCH
L1 L2 N L3 26,45 200 P.V.C. 95 SQ. MM WIRING DIAGRAM
SHIELDED
Page 1-41
Page 1-43
LOAD HERTZ VOLTS AMPS B,T 1 SQ. MM

CABLE F(24)= 4054714
105 106
PCC-II
MASTER START SENSOR/SYNC ENABLE

LOAD DEMAND/UTILITY SINGLE
PCC-II SIDE OEM/CUSTOMER
(FROM PCCII) TB3 RESPONSIBILITY
PRE-LOW OIL PRESSURE
CB OPEN/CLOSE INHIBIT
*TB14-2 OF BUS PT/
Common Warning (N/O)

Common Warning (N/O)
EXTERNAL LOAD SET -

EXTERNAL LOAD SET+
Common Warning (N/C)
Common Warning (N/C)
(N/O) READY TO LOAD
1 1 1 1 FIRST START SENSOR
LOW OIL PRESSURE
O/P From PCC to the main Panel
(N/C) LOAD DUMP
Breaker Trip (N/C)

Breaker Trip (N/C)
RUPTURE BASIN
2 2 2 2
UTILITY CB AUX
120 OR 240 VAC
GREEN (KVAR-)
*24VDCB+(20A FUSED) SUPPLY
CB POSITION
RED (KVAR+)
BLACK (KW-)
WHITE (KW+)
AVAILABLE FOR
3 3 3 3 CUSTOMER USE WHEN ENGINE IS
COMMON
COMMON
RETURN
SHEILD
RUNNING OR NOT RUNNING
4 4 4 4
B=IN
*24VDC SWITCHED B+(20A FUSED) SUPPLY IS AVAILABLE
5 5 5 5
6 6 6 6
} ONLY WHEN ENGINE IS RUNHNING. (CAN BE USED FOR
SWITCHING OFF BAT. CHARGER OR SWITCHING ON HEAT
EXCHANGER PUMP.)
}
7 7 7 7 *TB14-1 OF BUS PT/
FIRST START SENSOR
8 8 8 8 * GROUND (-VE) AVAILABLE
PCC-I-Terminal Strip TB1-1 Details at a Glance
FOR CUSTOMER USE.

9 9 9 9
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
10 10 10 10
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
11 11
} CUSTOMER SWITCH #2 (USE RELAY N/O
CONTACT FOR CUSTOMER FAULT I/P
A34-P1-22(GREEN)
12 12
A34-P1-15(WHITE)
A34-P1-8(BLACK)
A34-P1-23 (RED)
13 13
Into the PCC
CONT HTR1
CONT HTR2
} *LOCAL LOW FUEL SWITCH (USE LEVEL

A34-P1-19
A34-P1-20
A34-P3-19
A34-P1-18
A34-P2-14
A34-P2-13
A34-P2-12
A34-P2-16
A34-P1-17
A34-P1-11
A34-P2-15
A34-P2-23
A34-P2-8
A34-P2-7
A34-P2-5
A34-P2-6
A34-P3-9
A34-P3-1
A34-P2-2
A34-P1-3
A34-P1-4
A34-P1-1
SWITCH N/O CONTACT FOR FAULT I/P)
14 14
P12-9
15 15 *TB14-4 OF BUS PT/FIRST START SENSOR (RDY. TO LD)
16 16 LOAD DUMP (IN CASE OF U/F OR U/L OR BOTH)

REMOTE EMERGENCY STOP
17 17 *COMMON SHUTDOWN (ACTIVE FOR ANY S.D.FAULT)

SWITCHED B+(10A FUSED)
Common Shutdown (N/O)
PRE-HIGH ENGINE TEMP
18 18 RELAY COIL SOURCE

CUSTOMER FAULT 1
CUSTOMER FAULT 2
CUSTOMER FAULT 3
CUSTOMER FAULT 4
HIGH ENGINE TEMP
LOW ENGINE TEMP

Breaker Close (N/O)
Breaker Close (N/O)
19 19
}
REMOTE START
NET POWER (+)
LOW COOLANT
B+(20A FUSED)
NET POWER (-)
HEATER CONTROL (CONSULT H.O. FOR APPLI.)

O/P From PCC to the main Panel
NOT ON AUTO
FAULT RESET
OVERCRANK
ENGINE IDLE
OVERSPEED
20 20
NET DATA 1
NET DATA 2
LOW FUEL
LOW FUEL
GROUND
GROUND
21 21 # LOAD DEMAND S.D. (APPLY CUSTOMER RETURN)

(COM)
(N/C)
22 22 ** SYNC ENABLE (APPLY BATT. +VE FOR UTILITY PARA.)
** SINGLE MODE VARIFY (SHORT 23 & 26 TO VARIFY

23 23 SINGLE UTILITY PARA)
24 24 * RAMP LOAD/UNLOAD (APPLY CUST.RTN. TO LOAD DG)
25 25 *TB14-3 OF BUS PT/FIRST START (1st ST)
26 26 CUSTOMER RETURN (GND)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
+
27 27
} ** CONNECT 0-5 VDC SOURCE FOR EXT KVAR LOAD
CONTROL IN UTILITY PARALLEL APPLICATION.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
28 28
+
29 29
} ** CONNECT 0-5 VDC SOURCE FOR EXT KVAR LOAD
P12-1/A34-P1-9
CONTROL IN UTILITY PARALLEL APPLICATION.

P12-8(BLACK)
30 30
Into the PCC
P12-7 (RED)
TB BAT-F1
A34-P1-13
A34-P2-10
A34-P2-11
A34-P1-12
A34-P1-16
A34-P1-10
A34-P3-10
A34-P3-11
A34-P3-12
A34-P3-16
A34-P3-17
A34-P3-18
A34-P1-21
GND-ENG
GND-ENG
A34-P1-7
A34-P2-9
A34-P2-4
A34-P2-3
A34-P1-6
A34-P1-2
A34-P1-5
A34-P3-2
31 31 SHIELD DRAIN NOTE: USE SHIELDED CABLE ONLY.

P12-2
P12-5
P12-6
32 32 * COMMON WARNING (ANY WARNING FAULT)

CONNECT RELAY DRIVER RETURN FROM TB3-18
33 33
34 34
107 108
PCC-II
PCC-II
PCC II SIDE TB5(PARALLEL PCB) OEM/CUSTOMER

PCC II SIDE TB4 (GENSET PCB) OEM/CUSTOMER (FROM PCCII) RESPONSIBILITY
(FROM PCCII) RESPONSIBILITY +
1 1 UTILITY KVAR (0-50VDC ANALOG O/P TO MONITOR
1
2 2
1 MAIN (DAY) TANK LOW FUEL LEVEL SWITCH/P
2 2
} KVAR LOAD IN UTILITY PARA. APPLICATION)
200mA@ 24VDC O/P POWER FROM MODEM +
3 3 UTILITY KW (0-50VDC ANALOG O/P TO MONITOR
3
4
3
4
*GENSET CB INHIBIT (BATT.GND.I/P TO OPEN CB)
*GENSET CB POSITION (CONNECT DG BKR AUX N/O)
4 4
} KVAR LOAD IN UTILITY PARA. APPLICATION)
+
5 5
5
6
5
6
GENSET CB RTN
6 6
}
**UTILITY CB INHIBIT (BATT.GND.I/P TO OPEN CB)
7 7 7 7 *GROUND FAULT SWITCH (CONNECT N/O
**UTILITY CB POSITION (CONNECT DG BKR AUX N/O)
8 8 8 8 CONTACT OF GROUND FAULT RELAY)
UTILITY CB RTN
9 9 CUSTOMER SWITCH#1 (CUST. FAULT I/P CONFIGURABLE 9 9 CUSTOMER SWTICH RETURN (GROUND)
GROUND FOR WARN OR S.D.) CUSTOMER SW.#3 (CONFIGURABLE WARN/S.D.WITH
10 10 10 10
WAKE UP CONTROL CUST. FAULT I/P)
11 11 AUTO MODE O/P FOR CUSTOMER (24VDC 5AMP) 11 11 CUSTOMER S/W.$4(CONFIGURABLE CUST.WARN/S.D.CON
DG BKR + TO ACTIVATE THE CKT. EITHER OPEN OR CLOSE FAULT I/F
12 12
13 13
} NOT IN USE DG BKR
AUX N/C
Closing
Coil
12
13
12
13 } # LOAD SHARE KVAR (KVAR LOAD SHARE LINES)

*K1 K1 +
14 14 BATT.GND
15 15 BATT. +VE
}CLOSE
*GENSET CB
COMMAND
14 14
} # LOAD SHARE KVAR (KW LOAD SHARE LINES)
15 15
16 16 DG BKR
17 17
} NOT IN USE DG BKR Shunt Trip
AUX N/O Coil
16 16
+
SHIELD NOTE : USE OF SHIELDED CABLE IS MUST.
(LOAD SHARE LINES OF PCCI & PCCII ARE COMPITABLE)
*K2 17 17
18 18 BATT.GND
} *GENSET CB
OPEN COMMAND
K2
18 18
}
19 19 BATT. +VE
TB6(LONWORKS)
+
1 1
24 VDC SUPPLY FROM INLINE K CONNECTOR
2 2
3 3
4 4
TWISTED PAIR SHIELDED CABLE FOR NETWORK
5 5
6 6
* CONNECTIONS MANDATORY
7 7
# CONNECTIONS MANDATORY WHEN PARALLELED WITH OTHER DG SET
** CONNECTIONS MANDATORY WHEN PARALLELED WITH UTILITY 8 8
9 9
RELAY CONTACT
PUSH BUTTON
SWITCH
TB8(BASE PCB)
RELAY COIL OF 200mA @ 24 VDC
N/C
OUTPUT FROM PCCII 1 1 * REMOTE EMMERGENCY STOP PUSH BUTTON
INPUT FROM PCCII 2 2 * REMOTE START TYPE (IF CLOSED ENGINE WARMS
3
4
3
4
NO
NO
} UP AT IDLE & GOES TO RATED RPM/IF OPENED
ENGINE DIRECTLY GOES TO RATED RPM)
* REMOTE START (CONTL. CLOSE I/P TO RUN THE ENGINE)
5 5 RETURN GROUND
109 110
Kit Air Starter:
AIR - STARTER
CONNECTIONS OF PILOT VALVE & KIT AIR STARTER.
1. Inertia Engagement type starter P/N 3022692 has been specified
Pilot Valve Connections: on NH/NT and K-6 engine models. Kit air starter P/N AR-2141259
includes manual pilot valve P/N 3233856 whereas Kit air starter AR-
Pilot valve P/N 3234239 (for both electrical & manual operation) or P/N 3241325 includes electrical pilot valve P/N 3234239. Remaining
3233856 (only for manual operation) is used on all air starters. It parts in both these are listed below.
activates the main air line and the air starter.
AIR AIR AIR

S/N Part No. Description Qty.
1/4 (INCH) NPT
EXHAUST IN EXHAUST 5 HOLES
(OPEN) (OPEN)
5 1. 68705 Adapter
KNOB FOR 3 1
MANUAL
OPERATION
2. 112105 Elbow 4
3. 3022697 Valve air relay 1
4. 3026796 Elbow Plain Street 1
2 4 5. 3235030 Lubricator Air 1
5-HOLES FOR MOUNTING
5.0 DIA THRU. TO BE PLUGGED
6. 3235031 Filter Air 1
7. 3875667 Adaptor 2
Please refer above sketch. 8. 3237162 Adaptor 1
1. The air inlet should be connected to hole no. 1. The outlet from
9. 3237163 Coupler 1
hole no. 2 should be connected to the air starter pinion connection
(in case of pre-engagement type starters) and to main air valve (in 10. 3237164 Adapter 1
case of inertia engagement type starters). Please refer schematic 11. S-906-C Elbow for air start 1
diagrams on later pages.
12. S-911-C Elbow 1
When the knob is operated either manually or electrically, hole no. 13. S-913-C Nipple 1
1 & 2 get connected to each other and subsequently the air flow is 14. S-910-B Plug pipe 1
received at the main valve.
2. Hole no. 4 should be plugged.
3. Hole no. 3 and 5 should be kept OPEN as shown. These holes
are provided to release the pressurized air when the engine 2. Per-engagement type starter P/N 3026797 has been specified on
starting operation is completed. V-12 and KV engine models. Kit air starter P/N AR-3240892
4. This lay-out is applicable ONLY WHEN the pilot valve is includes manual pilot valve P/N 3233856 whereas Kit air starter P/N
connected for the air starter. AR-3241304 includes electrical pilot valve P/N 3234239. Remaining
parts in both these ARs are listed below.
CAUTION:
S/N Part No. Description Qty.
All connections to and from the pilot valve should be made as 1. 68705 Adapter 1
stated. Wrong connections may lead to malfunctioning of the 2. 112105 Elbow 5
starting system causing damage to the air starter pinion. 3. 3022697 Valve air relay 1
4. 3026796 Elbow Plain Street 3
AIR REQUIREMENT FOR AIR STARTER 5. 3235030 Lubricator Air 1
1. N-Series 8cft/Sec. (227 Lit/sec.) 6. 3235031 Filter Air 1
1. K6, V, KV-Series 18.6 cft/Sec. (527 Lit/sec.) 7. 3875667 Adaptor 3
8. 3237445 Coupling assembly 1
9. S-910-B Plug pipe 1
10. S-955 Bushing 1
11. S-1047-A Elbow male adapter 1
12. 3237170 Nipple 1
Please refer schematic diagram.
111 112
Section-1 Engine Data Genset N, V, K, QSK Page 1-50 Section - 1 Engine Data Genset N, V, K, QSK Page 1-53
TYPICAL AIR STARTING PIPING ARRANGEMENT (INERTIA ENGAGEMENT TYPE STARTER)

ENGINE MODELS - N/NT/NIC/NTA-495, N/NT/NTA-743, N/NT/NTA-855, KT/KTA-1150
TYPICAL AIR STARTING PIPING ARRANGEMENT (PRE ENGAGEMENT TYPE STARTER)

ENGINE MODELS - VT/VTA-1710(28), KT/KTA-2300(38), KTA-3067(50)
VALVE AIR PILOT ELBOW MALE ADAPTER
IN 3233856 OR 3234239 112105
IN VALVE AIR PILOT ELBOW MALE ADAPTER
OUT ELBOW MALE ADAPTER 112105
ELBOW PLAIN 112105 3233856 OR 3234239
STREET PIPE NIPPLE PIPE ELBOW PLAIN OUT
S-913-C FEMAL PIPE OUT
S 906-C ELBOW MALE ADAPTER
S-911-C OUT 112105
MOTOR AIR STARTING ELBOW MAIL ADAPTER
IN ELBOW MALE ADAPTER
3022082 112106 IN
50 1047-A
ADAPTER ELBOW PLAIN BUSHING PIPE MOTOR AIR STARTING
3237162 STREET PIPE NIPPLE S-955 3026797
3237170 ELBOW PLAIN
COUPLER 3026796
STREET PIPE
3237163
3025798
ADAPTER
3237164 COUPLER
3237445
VALVE AIR ADAPTER
112105
ADAPTER
VALVE AIR FLOW
3022887 3876667
ELBOW MALE ADAPTER ELBOW PLAIN

1
112105 1 -14 UNS THREADS STREET PIPE ELBOW MALE ADAPTER
8
3028788
BRACKET ADAPTER
112105
3875667 VALVE AIR RELAY
CONNECTOR MALE AIR LUBRICATOR 3022887
68705 3235030
ADAPTER ELBOW MALE
3875867 ADAPTER ELBOW PLAIN
112105 STREET PIPE
AIR FILTER ADAPTER3028788
3235031 BRACKET 3875667
ADAPTER
AIR PRESSURE GAUGE
(0-200 PSI) 3875867
HOUSING FLYWHEEL
CONNECTOR
1
1 8 -14 UNS THREADS MALE AIR
MINIMUM I.D. OF PIPE 1.5" 68705 AIR FILTER LUBRICATOR
FOR 1.5" B.S.P.CONNECTION 3235031
3235030
RELIEF VALVE 150 P.S.I.
AIR PRESSURE GAUGE AIR PRESSURE GAUGE

AIR PRESSURE
REDUCER VALVE (0-200 PSI)
SAFETY VALVE
CHECK VALVE
MINIMUM I.D. OF PIPE 1.5"
FOR 1.5" B.S.P.CONNECTION
AIR RECEIVER
RELIEF VALVE 150 P.S.I.
AIR PRESSURE GAUGE

AIR PRESSURE
DRAIN REDUCER VALVE
AIR COMPRESSOR
SAFETY VALVE
OIL & WATER SEPARATOR CHECK VALVE
AIR RECEIVER
DRAIN
AIR COMPRESSOR
OIL & WATER SEPARATOR
Section-1 Engine Data Genset N, V, K, QSK Page 1-54 Section - 1 Engine Data Genset N, V, K, QSK Page 1 - 52
MAINTENANCE SCHEDULE CUMMINS DIESEL ENGINES
A-CHECK B-CHECK FIRST 1500 HRS. C-CHECK D-CHECK 1500 HRS. (OTHER THAN INDUSTRIAL FIRE PUMP ENGINES)
B CHECK C D CHECK
Engine Series Interval FIRST 1500 HRS. C-CHECK D-CHECK 1500 HRS. AFTER
All(except Hours Every 300 hours At first 1500 hours Every 1500 hours Every 6000 hours To be done at 1500 A-CHECK B-CHECK
CHECK EVERY ‘D’ CHECK
NT/NTC-495-G) Calendar Every 6 months only Every 1 year Every 2 years hours alter every D
& N-8-G Check Daily / Weekly Repeat “A” All STEPS OF Repeat “A’ and Repeat “A” “B” & “C” All STEPS OF
C-CHECK AND “B” C-CHECK AND
(Big Oil Sump) Lubrication Lubrication ADDITIONAL
ADDITIONAL Lubrication Lubrication
Check Engine Check Engine STEPS
NT-495-G Hours Every 500 hours At first 1500 hours Every 1500 hours Every 6000 hours To be done at 1500 STEPS (None) (None)
Oil Level Oil
NTC-495-G Calendar Every 6 months only Every 1 year Every 2 years hours after every D Fuel System Fuel System
& N-8-G Check Fuel System Change Engine Adjust Injectors Change Hyd. Gov Clean and Calibrate Adjust Injectors
Drain Sediment Full-Flow Oil and Valves Oil Injectors if required. and Valves
(Big Oil Sump) from Fuel Tanks Filter Change Aneroid Replace rocker
1. Any time cooling system is completely drai ned and/or flushed, check coolant using coolant checking kit. Refer “Check Engine Coolant” details Air System Change By-Pass Replace rocker Oil cover gaskets Replace rocker
on Operation and Maintenance Manual Bulletin no. - 3243773 Clean Pre-Cleaner Filter cover gaskets cover gaskets
2. Under extremely dusty condition perform at more frequent intervals. Dust Pan Weekly Check Aneroid Replace Fuel Pump
Change Marine Adjustment Filter Screen & Magnet
“Note : B Check Maintenance schedule of NTC 495 big sump, QSK 60 engines is 500hrs” Gear Oil
115 116
113 114
Section – 1 Engine Data Genset N, V, K, QSK Page 1-53

A-CHECK B-CHECK FIRST 1500 C-CHECK D-CHECK 1500 HRS. AFTER
HRS. EVERY ‘D’ CHECK
Fuel
Main
Engine
Cooling
Exhaust
Engine
Electrical
Check Air Cleaner Replace Aneroid
lubricating
Record Oil Pressure Check Fuel Pump
Air Intake
Systems
Switchgear
Operational
Restriction Clean/ Fuel System Breather Calibration
Change Air Check Aneroid Oil Replace Aneroid
Drain
Clean
Check
Check
Check
Check
Check
Check
Drain :
Clean Fuel Tank
Clean :
Clean :
Torque
Generator Grease
Check :
Check :
Check :
Check :
Change
Perform
Cleaner Element Belows & Calibrate
Change:
Check Hyd. Gov. Oil From inside
Schedule
if required Air System
Check Throttle Linkage
Cooling System Cooling System Clean Turbocharger
Check / Coolant Lubricate ball Clean Radiator/ Compressor Wheel
Engine
Bearing
Level joints of the throttle Change Air Cooler and Diffuser if required
For leaks
For leaks
For Leaks
For Leaks
For Leaks
Check/Clean Generator
Engine Oil
Fuel Level
Capscrews
Resistance
Water Filter
Other Maintenance linkage of Hyd. governor. External Check Turbocharger
Coolant Level
By-Pass Filter
Full Flow Filter
Instrumentation
Engine Oil level
Transfer Switch
Cooling System
Change Fuel Filter Check Fan Hub/
Water Separator
Drain Air Tank Bearing Clearance
Condensate Trap
Governor Linkage
Clean Fuel Tank Breather idler and Water
Float Tank Breather

Crankcase Breather
Fuel Transfer Pump

Check & Correct Tighten Manifold
Sediment from Tanks

Hose and Connection
For Unusual Vibration
Power Circuit Breaker
Operational Load Test

Hydraulic Oil Governor
Air Cleaner Restriction

*Air System
Operation of Oil Heater

Pump / idler
For Exhaust Restriction

Piping and Connections
Motor operated Louvers
Service Tool Availability

Leaks 1
Nuts or Capscrews
Start Switch in Automatic

Battery Charging System
Generator Load Bank Test

Clean / Change Other Maintenance
Belt Condition and Tension

For Radiator Air Restriction
Fuel lines and Connections
Safety Controls and Alarms
Tighten Mounting Hardware

Cooling System
Hydraulic Governor Oil level

Drain Fuel Filter/
Operation of Coolant Heater

Crankcase Breather Inspect following
Or Change Air Cleaner Element

Water Separator Change coolant
Air Inlet and Outlet for Restriction

Check Air Piping parts & Replace
Heat Exchanger Zinc Anode Plugs

Daily Descale cooling
Exhaust Manifold and Turbocharger
Operation of Generator Heater Strips

Windings and Electrical Connections
Cooling System as Required
Fan Hub. Drive Pulley and Water Pump

Check Oil level system
Measure and Record Generator Winding

Change Water Filter/
Anti-Freeze and Concentration of Coolant

(Alternator/
Checks
Power Distribution Wiring and Connections

of marine gear & Other Maintenance
Battery Electrolyte level and Specific Gravity

Water Softener Starter, etc.)
Raw Wtr pump Check Vibration
l
Daily Check coolant inhibitor.
STAND-BY DUTY GENERATOR SET MAINTENANCE

Weekly Check belts, Damper
A
Add coolant concentrate, Check air Cleaner Check Air
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Monthly adjust if required if required.
Evacuator valve, Compressor
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6 Mos./300 Hrs.
B
Check Heat Exchanger Check Safety
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Annual Change if required
Page 1-55
Zinc plugs Controls

117 118
CONTINUOUS DUTY GENERATOR SET MAINTENANCE
Checks A B C D EFFECTIVE UTILISATION OF D G SET
1 Year/1500Hrs.
2 Yers/6000Hrs.
6 Mos./300Hrs.
Maintenance
Engine Schedul
Systems e Preventive Breakdown
Annual
Daily
Check :
For Leaks l l l l l
Operation of Oil Heater l DG Set
Engine Oil Level l l l l l
INPUT INSTALLED AS PER CUMMINS
Hydraulic Governor Oil Level l l l l l
Lubricating RECOMMENDATIONS
Change : Full Flow Filter l l l l Air
By-Pass Filter l l l l Output
Water
Oil Engine l l l l
Oil
Hydraulic Governor Oil l l l l
Check : For Leaks l l l l l
Fuel
For Radiator Air Restriction l l l l l Load OPERATE
Operation of Coolant Heater l
Hose and Connection l l l l l Load factor
Coolant Level l l l l l Unit Measurement diesel/units
Anti-Freeze and Concentration of Coolant l l l l kWH meter calibration
Cooling
Belt Condition and Tension l l l l l
Fan Hub. Drive Pulley and Water Pump l l l l
ENGINE PERFORMANCE INSPECTION REPORT - GENSET
Heat Exchanger Zic Anode Plugs l ESN:
Change: Water Filter l l l l
Clean : Water Separator l
Model:
Cooling System l Customer:
Check : For Leaks l l l l l Hours run
Air Cleaner Restriction l l l l l CT Ratio
Air Intake Piping and Connections l l l l
Clean : Crankcase Breather l l l l Ammeter reading AMPS.
Or Change Air Cleaner Element l l l l KW reading (√3 – V.I. Cos ∅) KWs
Check : For Leaks l l l l l
KWH
Governor Linkage l l l l
Fuel lines and Connections l l l l kWH meter last calibrated on / /
Drain : Sediment from Tanks l l l l l Frequency Hz.
Fuel Change : Fuel Filters l l l l
Clean : Float Tank Breather l l l l l Power factor
and calibrate injector l Units generated (Unit reading on kWH meter x CT ratio)
and/or Calibrate Fuel Pump l
Adjust Injectors and Valves l Average load factor = (Units generated / Hours run) x 100
%
Check For Leaks l l l l l KW (max.)
0
For Exhaust Restriction l l l Ambient temp. C
Exhaust Clean Turbocharger Comp. Wheel and Diffuser l 0
Check Turbocharger Bearing Clearances l Coolant temperature C
2
Torque Exhaust Manifold and Turbocharger Capscrews l l Oil pressure Kgs/cm
Check For Unusual Vibration l l l l l 0
Vibration Damper l Oil temperature C
Engine Crankshaft End Play l 0
Related Tighten Mounting Hardware l Raw water inlet to HE temp/Radiator bottom tank (T1) C
Clean : Engine l 0
Grease : Fan Pillow Bloc Bearings l l l l
Outlet from HE temp/Radiator top tank (T2) C
0
Check : Battery Charging System l Temperature differential T MAIN = (T2 – T1) C
Battery Electrolyte level and Specific Gravity l l l l
0
Engine Grow Plug l LTA HE Water outlet temp (Raw Water Circuit) (T3) C
Ang Clean Magnetic Pickup Unit l l
0
Safety Control and Alarms l l Temperature differential t LTA = (T3 - T1) C
Check :
Air Inlet and Outlet for Restriction l l l l l
Windings and Electrical Connections l l l l l Air restriction LB = “of H2O, RB = “of H2O
Main Operation of Generator Heater Strips l
Generator Grease : Bearing l l Coolant Quality pH = ppm = or Units/Lt.
Check/
Generator l Blow bye “of H20
Clean:
Check Power Distribution Wiring and Connections l l l l
Switchgear Power Circuit Breaker l l
Fuel pressure psi
Transfer Switch l l
Oil used (Brand & Grade)
Operational
Perform Generator Load Bank Test l
Procedures Base coolant (Add Water/Premix)
119 120
Section - 1 Engine Data Genset N, V, K, QSK Page 1-58 Section – 1 Engine Data Genset N, V, K, QSK Page 1-59
LDO OPERATION Details of Part Numbers (LDO Kit)
LDO PROPERTIES - SUBSTITUTE S/N Part Number Description

Higher Sulphur content : Oil with Higher TBN value. 1 AX1001334 LDO Additive 1 litre
Excessive suspended particles : Alongwith suitable Centrifuge. 2 AX1001335 Additive 5 litre
Higher Wax Content : Heater/s & Thermostatic Switch to maintain 3 AX1001332 Filtration Unit System
0
around 60 C Temp. of fuel 4 AX1001331 LDO Filtration Kit
LDO with following properties can be used on “G” Drive Engines. (LDO Filtration Unit System P/N
AX 1001332 + Duplex Fuel Filter
Properties of LDO : P/N AR3240256)
5 AX1001333 Service Kit for Filtration Unit
Sr. Recommended 6 AX1001336 Centrifuge Module
Parameter
No. Specifications 7 AX1001337 Intermittent Kit – Centrifuge
0 3
01 Density, @15 C Kg / m 880-900 8 AX1001338 Major Service Kit – Centrifuge
0 0 9 3226055 Thermostatic Switch – Day Tank
02 Flash Point (PMMC) C 66 C min.
10 3226053 Heater – Day Tank
0
03 Kinematic Viscosity, cSt @ 40 C 2.5 to 15.7 11 AR3240256 Duplex filter
0
0 Winter : 12 C
04 Pour point C 0
Summer : 21 C
SKO/ LOW SULPHUR FUELS (< 0.25%) OPERATION
05 Water content 2500 PPM Max. To improve lubricity of SKO and to enhance Cetene number,
suitable additive is selected with optimum dosage / ratio of 1:1000
06 Total Sulphur % wt. 1.8 % Max.
(Additive : SKO).
1. Additive - SKO with following properties can be used on all genset engines.
LDO is always with suspended, coagulated matter, which restricts
the flow. To disperse the coagulated matter an additive is
Sr. Recommended
required to be added in LDO. This additive is added to the bulk Parameter
No. Specifications
storage tank at the time of fill up in the ratio of 10000:1
0
(LDO:Additive). The additive will be s upplied by CDS&S under 01 Density, @15 C 0.785-0.825
the P/N – 0
02 Flash Point 35 C min.
Layout of LDO system 0
03 Viscosity, Cst @ 38 C 1.0-1.4
Positive Filtration Unit Day Tank with 04 Aromatic Content 18%

Primary Secondary Heaters +
Displacement
Filter 25 Filter 10 / 1 Thermostatic
Pump 05 Gross Calorific value 11,000 K cals / Kg
Switch
06 Cetane No. 38 min.
Bulk Storage 0 0
tank Engine fuel 07 Pour point C <0 C
(LDO+Additive) Filter
Centrifuge 08 Water content 500ppm max.
Module
09 Total Sulphur 0.25% max.
Additive in containers of 10, 20, 50, 100 liters of volumes and part
number are stated below for SKO & Low sulphur fuels :
01. AR 323844100 SKO ADDITIVE 10 LTS.

04. AR 323844400 SKO ADDITIVE 100LTS.
1:1000 (Additive : Fuel)

121 122
SLDO OPERATION HEAT RECOVERY THROUGH EXHAUST GAS BOILERS

Properties We offer :
• Exhaust Gas Steam Boiler
Sr. Parameter Recommended • Exhaust Gas Hot Water Generator or
No. Specifications • Exhaust Gas Thermic Fluid Heater
0 3
01 Density, @15 C Kg / m 880-900
0 0
Energy Balance
02 Flash Point (PMMC) C 66 C Min.
0
Without HRU
03 Kinamatic Viscosity, Cst @ 40 C 2.0 to 5.0 Electrical output - 34%
0 0
04 Pour point C Winter : 3 C Radiation loss - 3%
0
Summer : 15 C Coolant loss - 25%
05 Water Content 5000 PPM Max. Stack loss - 34%
06 Total Sulfur % wt. 0.35 % Max. Alternator loss - 4%
07 Sediments % wt. 0.05 % Max. With HRU

Electrical output - 34%
08 Carbon Residue % wt. 1.5 % Max.
Heat recovery - 20%
09 Ash % by Mass Max. 0.01 Radiation loss - 3%
Coolant loss - 25%
10 Cetane No. 34 to 35
Stack loss - 14%
11 Copper Strip Corrosion for 3 1b Alternator loss - 4%
Hours at 100 Deg. Cent.
12 Net Calorific Value 10,500 Kcal/Kg Approx. Advantages :
• Improved Efficiency
• Reduced Energy cost
• Recovery of heat upto 60% from the Waste Exhaust gases
The Special LDO Cetane number is very low i.e. 34 to 35. Hence
• Low Maintenance Cost
suitable additive with optimum dosage of ratio 1000 litres of Special
LDO to 1.5 litres of additive is needed to be blended. If the additive is • Attractive Payback Period
not used, engine power cylinder components will fail due to • 100% Depreciation in first year
detonation from poor combustion of fuel causing piston erosion.
Hence it is mandatory to blend Special LDO with additive in bulk Silencer
storage tank.
DG Set Gas Exh. Gas Chimney
CDS&S will supply additive as per details given below : Divertor Boiler
Damper
Additive Volume Part No. Special LDO Volume
15 Litre Container AX1002587 10 KL
Steam / Hot Water Generation at 75% load.
It is preferred that the additive is added in to bulk storage tank while Sr. DG set Steam generation in Hot Water
unloading the Special LDO tanker which will ensure proper mixing. No. Capacity kg/hr @ 10.5 kg/cm
2
generation in
It is necessary to use Centrifuge Kit to ensure the clean fuel supply (kVA) pressure(*)
0
kg/hr @ 80 C(*)
to engine at usage point and blending the Special LDO fuel with 1 250 110 1556
additive to improve it’s combustibility. 2 320 148 2086
3 380 164 2091
Note : Operating cummins diesel engines with alternate fuel other
4 500 180 2385
than diesel may cause to reduction in engine life / durability.
Engines may be operated considering the profit getting against break 5 625 230 3253
even point of fuel cost v/s engine repair cost. 6 750 271 3824
7 1000 404 5696
8 1250 499 7046
* Steam and Hot water generation figures are indicative.
These may vary with DG set operational conditions.
123 124
Section-2 Engine Data-Gas & Dual Fuel Page 2-0 Section -2 Engine Data-Gas & Dual Fuel Page 2-1
CUMMINS ENGINE NOMENCLATURE

Gas Engines
Contents Page G T A 855 -- G
Cummins Gas & Dual Fuel Engine Nomenclature ………….………..2-1 = Application Codes (G = Generating set)
Cummins Gas Engine Technology ………………………….…………2-1 = Displacement in Cu. in.

Cummins Gas Engines Genset Application...……………….………...2-2 = Aftercooled
Cummins Gas Engines Compressor & Irrigation ........…….…………2-3
= Turbocharged
Preliminary Engine Data Gas Engines ................................................ 2-4
= Gas engine
Modelwise Recommendations ............................................................. 2-7
Dual Fuel Engines
Gas Engine Maintenance Schedule ……………………..…………….2-8
Altronic III Name Plate Details……………………………..……………2-9 DG T A 855 -- G
= Application Codes (G = Generating set)
Cummins Dual Fuel Engines Technology ……………….………..…2-10
= Displacement in Cu. in.
Dual Fuel Engine Ratings & Specifications……………..…………...2-10
Derating recommendations ………………………………...………2-11 = Aftercooled
Gas adjustment of Engines running on gas = Turbocharged

with different heat value…………………………………….………
...…2-12
Some Important values …………………………………….…………2-13 = Natural Gas dual fuel engine (Diesel & Gas)
L.O. recommendations for Natural gas engine ………….………….2-13

Carburettor Models & Adjustments ……………………….………….2-13 CUMMINS GAS ENGINES TECHNOLOGY
Altronic Installation Procedure ......................................................2-15
Key Components
Magtronic Installation Procedure ..................................................2-15
• Carburettor
Ignition Timing Procedure .............................................................2-15 • Distributor / Altronic
• Ignition transformer
Lucas Contactless Distributor Ignition System ............................. 2-16
• Spark plug
Electronic Governor on 1150 & 1710 Gas Engines & Settings .... 2-17 • Pressure regulators
Properties of Hydrocarbons & gas fuels ………………….…………2-20 • Gas shut off valves
• Separate water circuit for after cooling circuit in case of
Engine Wiring Diagrams …………………………………….………...2-22 turbocharged aftercooled engines
Conversion Kits for Various Dual Fuel Engines ……………………2-25
Technology
Modelwise Part Numbers……………………………………………...2-26
A mixture of fuel and air enters the engine through a carburettor and
Some Part / Repair Kit Nos…………………………………………....2-27 is spark-ignited(Sl). The fuel injector is replaced by a spark plug in
the cylinder head and a fuel pump by a carburetor and ignition
distributor.
The gas induction through the carburettor requires low pressure gas
at 500 mm maximum water column at engine point. Most of the
components (including load bearing components) used in gas
engines are the same as those in standard, proven diesel engines.
Hence, Cummins gas engines are structurally more robust than
conventional SI engines. The peak cylinder pressure of Cummins
gas engines is designed such that it will be lower than diesel
engines. Hence, because of lower stress level, longer service life,
high reliability and maintenance-free operation are achieved.
Section –2 Engine Data-Gas & Dual Fuel Page 2-2 Section –2 Engine Data-Gas & Dual Fuel Page 2-3
Cautions
• Remove amphenol connector on altronic unit while carrying out
welding other wise Altronic unit will get dam aged.
1500-2200
1500-2200
1500-2100
1500-2100
1500-2100
1500-2100
1500-2100
1500-2100
• While installing the regulators ensure that the arrow is in the

SPEED
direction of gas flow.

RPM
• After the gas drain pipe welding/fabrication is complete ensure

that the entire line is flushed by air / gas / tested for leaks.
• Room should have opening or exhaust fan from roof or top most
CUMMINS GAS ENGINES FOR COMPRESSOR, IRRIGATION & REFRIGERATION APPLICATIONS
point of room for venting of natural gas as it is lighter than air.

CUMMINS GAS ENGINES FOR 50 Hz GENSET APPLICATION
1030-1200
Engine No. of Displa- Nominal Duty Est Natural

RATING
147-246
380-420
411-470
600-630
800-910
41-140
83-175
BHP
Model Cyli- cement Rating Cycle Consum-

nder (Lit) (kVA/kWe) ption
(SCuM/Hr)
G 6B 5.9G 6 5.9 45/36 P 16

G-495-G 4 8 70/56 P 21
G-743-G 6 12 100/80 P 31
Aspiration
NA/TA
NA/TA
NA/TA
G-885-G(BC) 6 14 125/100 P 37
TA
TA
TA
TA
TA
GTA-855-G (BC) 6 14 180/144 P 52

Note - Above performance ratings are for 90m (300 feet) altitude, 25 deg C (77 deg F)
G-1710-G 12 28 250/200 P 77
GTA-1710-G 12 28 380/304 P 103
GTA-1150-G 6 19 250/200 P 76
GTA-2300-G 12 38 500/400 P 135
Displacement
GTA-3067G 16 50 625/500 P 187

(Ltrs)
QSK-19-G 6 19 394/315 C -
5.9
8.3
14
19
19
28
38
50
QSK-38-G 12 38 713/570 C -
GQSK-60-G 16 60 1450/1160 C -
QSV-81-G (14 bar) 16 81 1711/1369 C -
QSV-81-G (16 bar) 16 81 1945/1556 C -
QSV-91-G 18 91 1923/1538 C -
Bore X Stroke
102 x 120
114 x 135
140 x 152
159 x 159
159 x 159
140 x 152
159 x 159
159 x 159
QSV-91-G(18 bar) 18 91 2188/1750 C -

(mm)
Notes :
(P) - Refers to Prime Power operation in island mode with variable
load where average load factor is about 80%. 10% overload is
available for 1 hour in every 12 hours of operation.
(C) - Refers to Base Load / Continuous Duty operation for unlimited
hours of operation at constant load. No overload is permitted
Configuration
TA -Turbocharged Aftercooled
over this rating.

V12
V12
V16
6-L
6-L
6-L
6-L
6-L
(-) - Kindly contact Marketing for more details.

NA - Naturally Aspirated
T - Turbocharged
KTA19-GC
G/GTA855
G/GTA5-9
G/GTA8.3
GTA19
GTA28
GTA38
GTA50
Engine
Section -2 Engine Data-Gas & Dual Fuel Page 2-4
l
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st
m3/hr
Name
PRELIMINARY ENGINE DATA FOR CUMMINS GAS ENGINES
1st state
2nd stage
(Electrical)
(MANUAL)
for inlet line

Component
stage regulator
DESCRIPTION / PARAMETER G-495- G-743- G-855- G-1710- GTA-855- GTA-1150- GTA-1710- GTA-2300- GTA-3067-
Assly Gas Filter
Gas flow m3/h 1st

1 stage regulator
Gas shut off valve
Gas Shut Off valve
Gas Flow/regulator
2nd stage Regulator
G(NA) G(NA) G(NA) G-(NA) G(TA) G(TA) G(TA) G(TA) G(TA)
durability
Repair kit P/No. Vanaz

Repair kit P/No. Vanaz
ENGINE
MODELS
Range of pressure gauge

ENGINE RATING BHP @ 1500 RPM 92(12), 86(10) 137(12),129(10) 157(12),157(10) 333(12),313(10) 242(10) 333(8.5) 480(10) 600(8.5) 800(8.5)
calorific value.
(COMPRESSION RATIO)
given separately
81(8.5) 121(8.5) 147(8.5) 293(8.5) 227(8.5) 313(7.5) 451(8.5) 570(7.5) 750(7.5)
G855
(2nos.) or radiator.
1 to 3
60-80
G743/
G495/
Qty. 1
kg/cm2
60 - 80
0 to 400
(25 mm)
(1" BSP)
(mill bar)
3875043
3875040
3872384
3392533
3872383
(1½" BSP)
AX1002319
0 to 1 Kg/cm
AX 1002316
2
NATURAL GAS CONSUMPTION FOR
GAS CALORIFIC VALUE
12.2(21) 18.5(31) 21.7(37) 44.2(75) 31(52) 46(77) 61(103) 80(135) 111(187)
970 BTU/CFT OR 8730 KCAL/CUB M
1 to 3
60-80
Qty. 1
kg/cm2
60 - 80
0 to 400
(50 mm)
GTA855
3875043
(1" BSP)
3875040
3875535
3392533
3875553
(mill bar)
depend on area of operation.
NOTES FOR PREVIOUS PAGE
(1½" BSP)
AX1002319
STD. CUB FT/MIN (STD.CUB M/HR)
2
NA-Naturally Aspirated engines
EXHAUST TEMPERATURE (STACK)
of desired pressures in the system.

1200(649) 1200(649) 1220(660) 1200(649) 932(500) 1030(555) 970(521) 1060(571) 1180(638)
1 to 3
Qty. 1
DEG.F(DEG.C)
kg/cm2
0 to 400
100-120
100-120
3875044
3875041
3392533
3873933
3872384
(mill bar)
GTA1150
(1½" BSP)
(1½" BSP)
(1½" BSP)
AX1002319
0 to 1 Kg/cm 0 to 1 Kg/cm
AX 1002316 AX 1002317
2
Section-2 Engine Data-Gas & Dual Fuel
TA-Turbocharged After cooled engines.

HEAT REJECTION TO WATER
Above data is preliminary and estimated.

3723(938) 6119(1542) 6702(1689) 14165(3570) 9904(2495) 14813(3733) 20455(5155) 28557(7197) 40731(10265)
JACKET BTU/MIN(KCAL/MIN)
1 to 3
60-80
Qty. 2
kg/cm2
G1710
0 to 400
100-120
3875043
3872384
3392533
3873933
(mill bar)
3875041
Presently Altronic is used in place of Magtronic
(1½" BSP)
(1½" BSP)
(1½" BSP)
AX1002319
0 to 1 Kg/cm
AX 1002317
HEAT REJ. TO AFTER COOLER NOT NOT NOT NOT
2
except 3067: LT magtronic 3067 TA: LT altronic.
1417(357) 1700(428) 2914(734) 3116(785) 3829(965)
Induced draft type cooling tower is recommended.

WATER BTU/MIN(KCAL/MIN) APPLICABLE APPLICABLE APPLICABLE APPLICABLE
Gas Pipe Line Component Details

For engine and HE exclusively for after cooler circuit.
HEAT REJECTION TO EXHAUST
1 to 3
Qty. 1
kg/cm2
0 to 400
100-120
100-120
(50 mm)
3875044
3875535
3392533
3875553
2732(689) 4521(1139) 4995(1259) 10305(2597) 6589(1661) 10679(2891) 13761(3468) 18897(4762) 25765(6745)
(mill bar)
3875041
GTA1710
(1½" BSP)
(1½" BSP)
AX1002320
0 to 1 Kg/cm
AX 1002318
2
BTU/MIN(KCAL/MIN)
AIR FLOW SCFM 120 198 214 450 400 558 800 997 1207
1 to 3
Qty. 2
kg/cm2
EXHAUST FLOW CFM 360 602 661 1372 1007 1504 2068 2739 3549
0 to 400
100-120
200-220
(50 mm)
3875044
(2" BSP)
3392533
3875553
3875535
(mill bar)
3875042
GTA 3067
(1½" BSP)
GTA 2300/
AX1002320
AX 1002318
0 to 1 Kg/cm2
Derating recommendations are same as NA and TA diesel engines.
Page 2-6
NA engines are available with both cooling arrangements
be monitored constantly for better performance and increased

Exhaust and aftercooler temperatures are critical and hence need to
Gas engine rating guidelines on account of gas composition are
Rating and gas consumption depends on gas composition /
Selection of gas engine components particularly ignition system

engines: HT Lucas / Magtronic optional 1710 NA. All TA engines
Following standard ignition systems are supplied. 495, 743, 855 NA
i.e. radiator or heat exchanger. TA engines are available with HE
Please supply reliable gas pressure gauges to ensure correctness
Please consider suitable derating as per the site conditions.
MODEL-WISE RECOMMENDATIONS (GAS ENGINE) Section -2 Engine Data-Gas & Dual Fuel Page 2-5
*Exh. Pipe Exh. Gas Total Air G-1710-G- GTA-855- GTA-1150- GTA-1710- GTA-2300- GTA-3067-
Heat Exchanger
Size Flow (Ventilation+breathing) DESCRIPTION / PARAMETER G-495-G(NA) G-743-G(NA) G-855-G(NA)
Typical Room max. 4 (No. of Gas Estimated Total Lub Oil Coolant requirement for Genset Radiator (NA) G(TA) G(TA) G(TA) G(TA) G(TA)
Engine Rating supply (Cal value
Size Bends banks x Gas System Capacity Max. amb. Max. amb. fan flow Typical Raw
Model (0.8 pf) 8730 in genset Min. Raw ENGINE WATER FLOW USGPM (LT/MIN) 48(174) 58(212) 69(261) 175(662) 92(348) 122(464) 190(719) 245(936) 370(1413)
Max. Length flow/bank line Consumption Capacity above below Cooling Water
Kcal/m3) room Water
LXWXH 10 mtrs. 40OC 40OC Flow at tower Pipe
min capacity Size AFTER COOLER WATER FLOW NOT NOT NOT NOT
(rise 5O C) (rise 10OC) engine HE 35(133) 30(114) 40(151) 70(266) 86(327)
min. ID ID (wbt 26OC) (ID) USGPM (LT/MIN) APPLICABLE APPLICABLE APPLICABLE APPLICABLE
KVA mxmxm No. x mm No. x lt/sec mm SM3/Hr K Cal/min lt lt lt/sec lt/sec lt/sec lt/min TR mm RAW WATER FLOW FOR ENGINE HE
51(193) 83(314) 91(344) 192(727) 135(511) 200(757) 278(1052) 400(1552) 560(2120)
@92 DEG. F/32 DEG C USGPM (LT/MIN)
GTA3067-G 625 12.0 x 7.0 x 6.5 2 x 250 2 x 838 65 187 27209 177 320 25873 13221 NA 1300 200+20 125
RAW WATER FLOW FOR AFTERCOOLER NOT NOT NOT NOT
GTA2300-G 500 11.0 x 7.0 x 6.5 2 x 200 2 x 647 65 135 19643 118 260 18918 9695 NA 1300 150+15 125 40(151) 50(190) 80(333) 85(320) 120(454)
HE @ 92 DEG.F/32 DEG. C USGPM (LT/MIN) APPLICABLE APPLICABLE APPLICABLE APPLICABLE
GTA1710-G 380 8.5 x 6.0 x 5.0 2 x 125 2 x 488 50 103 14987 95 250 14398 7388 NA 1052+333 100+15 100 COOLING TOWER CAPACITY (TR)
G1710-G 250 8.5 x 6.0 x 5.0 2 x 125 2 x 324 50 76 11058 95 210 7578 3885 NA 727 75 100
ENGINE & AFTERCOOLER 20 30 30 75 60 80 100 150 200
Section-2 Engine Data-Gas & Dual Fuel

GTA1150-G 250 8.5 x 5.5 x 5.0 1 x 125 1 x 710 50 77 11204 55 125 11125 5693 NA 757+190 80+10 100
AFTERCOOLER ALONE NOT APPL NOT APPL NOT APPL NOT APPL 10 10 15 15 20
GTA855-G 180 7.5 x 5.0 x 5.0 1 x 125 1 x 475 50 52 7566 36 75 7824 4006 NA 511+151 80+10 65
MAIN GAS PIPELINE SIZE INCH (MM) 1(25) 1.5(40) 1.5(40) 2(50) 2(50) 2(50) 2(50) 2.5(65) 2.5(65)
G885-G 125 7.5 x 5.0 x 5.0 1 x 125 1 x 312 40 37 5384 36 80 5486 2793 10070 344 30 NA
MAIN LINE GAS PRE PSIG (KG/SQ.CM) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4)
G743-G 100 7.5 x 5.0 x 5.0 1 x 125 1 x 284 40 31 4511 36 75 4578 2336 8025 314 30 NA GAS PRESSURES
AFTER 1st REGULATOR PSIG (KG/SQ.CM) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5)
G495-G 70 6.5 x 5.0 x 4.0 1 x 100 1 x 170 25 21 3056 27 62 3293 1675 3775 193 20 NA
AFTER 2nd REGULATOR INCH WC(CM.WC) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20)
* Typical Sizes, actual specifications may chagne as per site condition.
NA = Not Applicable. Note : Lub oil for Gas engines is GEO 15W-40. PLEASE CONTACT CDS&S FOR ANY SPECIAL REQUIREMENT
Page 2-7
The gas engine requires special oil with low ash content. Ensure that proper oil is used for initial fill as well as for regular use. The oil specification is GEO (Gas Engine oil) API CD 15 W 40.
OTHER LETTERS=ODD FIRING PATTERN

Page 2-8
Page 2-9
Inspection’ where some
signs of wear should be
Cummins India Limited.

for wear to determine if
check. Wear limits and

Check is often referred
GN=HORIZ. FL-GEAR FLEX COUPLING

bearings are checked
Distributor/Dealers of
operated for another
• Repeat ‘A’ ‘B’ ‘C’ ‘D’
analyzed during the
other information is
pressure and other
the engine may be
key parts, such as
• This Maintenance
to as ‘In-Chassis
GV=HORIZ.FLANGE TWO SLOTS

consumption, oil
GL=HORIZ. FL-FLEX COUPLING

service period.
available from
and ‘E’ Check
J=ROUND FLANGE - 3 SLOTS
2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16
Likewise, oil
A=EVEN FIRING PATTERN

15000 Hours
S= EXTRA OUT PUT UNIT

BEL= ADJUSTABLE BASE
G=HORIZANTAL FLANGE
T=ELECTRONIC TIMING
F-CHECK
H=HIGH OUT PUT UNIT

EL=BASE MOUNT
A=VERTICAL
• Clean Auxiliary Coolant
• Tighten Mounting Bolts
• Check Engine Blow-By
D=FLANGE
• Check Crankshaft End
• Repeat ‘A’ ‘B’ ‘C’ and
• Clean Radiator Core
0-9 NOS.
5=2.5:1
6=1.5:1
• Check Thermostat
• Change Vibration
1=1:1
2=2:1
3=3:1
4=4:1
• Clean Engine
NAME PLATE DETAILS

(externally)
Clearance
‘D’ Check
6000 Hours
and Nuts
E-CHECK
Damper
Heater
NO OF CYLINDERS
STATOR WINDING
FIRING PATTERN
Vent Tube Connections
• Clean / Replace Spark
GEAR RATIO
• Change Fan Hub and
MOUNTING
• Repeat ‘A’ and ‘B’ Check • Repeat ‘A’ ‘B’ and ‘C’
• Check Air Piping and
• Clean or Replace Air
• Check Gas Pressure

Damper Alignment
• Clean Tray Screen
OPTIONS
• Check Oil Bath Air
2000 Hours / Yearly
Compression and
Cleaner Element
• Check Vibration
• Check Cylinder
To Carburetor
Drive Pulley
MAINTENANCE SCHEDULE
-BEL
CUMMINS GAS ENGINES
D-CHECK
Cleaner
(Paper)
Record
Check
Plugs
T
• Adjust Valve / Crossheads
• Clean Crankcase Breather

• Check Inlet Air Restriction
H
• Change Engine Oil Filter
• Adjust Throttle Linkage

• Lubricate Water Pump/
Electrical Connections
• Check Auxiliary Water
1000 Hours / 6 Months
ALTRONIC III
• Check Engine Oil Level • Change and Adjust Belt • Record Oil Pressure
• Change Oil Bath Air
Note : Maintenance Schedule of Dual fuel engine is same as Diesel engine.

and Corrosion Resistor • Lubricate Electrical
• Check Heat Exchanger • Change Engine Oil
9
• Clean and Tighten
• Change Hydraulic
2
Governor Oil
Cleaner Oil
Equipment
(GV-1710)
Fan Hub
C-CHECK
A
Pump
16 A-B-C-D-E-F-H-J-K-L-M-N-P-R-S-T A-T-S-R-P-N-M-L-K-J-H-F-E-D-C-B
• Check Pre-Cleaner Dust • Check Connection and
• Check Gas Leaks and • Check Engine Coolant
• Check Generator for

500 Hours / 3Months
A-M-L-K-J-I-H-F-E-D-C-B
• Check Operators Report • Repeat ‘A’ Check
Section 2 Engine Data-Gas & Dual Fuel
Zinc Plugs
SECTION - 2 Engine Data-Gas & Dual Fuel
A-F-E-D-C-B
B-CHECK
Cautions : Remove amphenol connector

on altronic unit while carrying out welding
other wise Altronic unit will get damaged.
Tension
CW Rotation
Gauges
A-D-C-B
Dust
The Firing order of Altronic III is as Follows

• Lubricate PTO Bearing
• Check Coolant Level
Governor Oil Level

• Check Air Cleaner
• Check Leaks and
• Check Hydraulic
12 A-B-C-D-E-F-H-I-J-K-L-M
A- CHECK
Element
Correct
Correct
No.of CCW Rotation
Orange
A-B-C-D-E-F
White
Black
DAILY
Wiring Color Code

Pan
A-B-C-D
-
-
Other -
Cyl.
G
N
4
6
Section - 2 Engine Data-Gas & Dual Fuel Page 2-10 Section -2 Engine Data-Gas & Dual Fuel Page 2- 11
CUMMINS DUAL FUEL ENGINES
l Engine rating and consumption figures depend on gas quality.
Technology Hence, please furnish gas composition by volume, calorific value,
A dual fuel engine is basically a diesel engine with conversion kit to run
gas pressure and gas flow rate at engine point, and get confirmation
the engine with diesel and any suitable gas. This works on the diesel
from Cummins for engine rating.
cycle. Gaseous fuel is added to the air which is inducted at air intake
manifold or before turbocharger. This mixture of air and gas is
compressed in the cylinder just as air is compressed in normal I.C. l Presently all TA engines are Heat Exchanger cooled.
engine. At the end of compression, diesel is injected through a
conventional fuel system. This pilot injection acts as a source of ignition. l Standard engines are available with electric starting arrangement.
The engine can run either on diesel or on diesel+gas. Adequate controls However optional air/gas starting arrangement could be made
are provided for dual fuel operation. available with extra cost. Specifications are subject to change
without notice.
Key Components
• Gas control valve Derating Recommendations
• Gas pressure regulators NA - Naturally Aspirated
• Gas shut off valves Engine performanc e is based on operation at 500 feet altitude and
• Separate water circuit for aftercooler in case of turbo charged 29.40C ambient temperature.
aftercooled engines a) 3.5% per 1000 feet above 500 feet altitude.
• Fuel pump throttle and gas control valve linkage
b) 2% per 5.50C above 29.40C ambient temp.
c) derating on account of humidity as per BS- 5514
• Two solenoid valves for diesel flow restriction
• Selector switch for diesel and dual fuel modes
TA - Turbocharged Aftercooled
• Modified air intake manifold
Engine performance is based on operation at 5000 feet altitude and
• Gas piping 380C ambient temperature Derating recommendations
a) 4% per 1000 feet rise above 5000 feet.
DUAL FUEL ENGINE MODELS AND THEIR SPECIFICATIONS
b) 2% per 1 itc rise above 388C.
Engine Bore Stroke No.of Displa- Aspira- Engine Rating kWe (for c) No derating on account of humidity.
Model (mm) (mm) Cylin- cement tion rating kWe Propane 2-
ders (Lit) 10% and Butane Derating guidelines with reference to gas composition
BHP (Prime) 0.2 to 5%)
(Natural gas engines)
(cont.) (Prime)
DG-495-G 130 152 4 8.1 N.A. 85 56 50 Compression Max. permissible combustibles Derating guidelines
DG-743-G 130 152 6 12.2 N.A. 130 80 68 Ratio other than Methane and Ethane
DG-855-G 140 152 6 14 N.A. 145 88 75 Naturally aspirated gas engines
DG-1710-G 140 152 12 28 N.A. 300 - - 12:1 Propane up to 2% }
DGTA-855-G 140 152 6 14 T.A. 275 180 160 Butane up to 0.2% }
DGTA-1150-G 159 159 18.9 T.A. 405 Pentane +} up to 0.1% }
6 280 256
Hexane }
DGTA-1710-G 140 152 12 20 T.A. 550 360 340
DGTA-2300-G 159 159 12 37.8 T.A. 800 540 500 10:1 Propane up to10% Propane >5%, 0.5% per 1% Propane
DGTA-3067-G 159 159 16 50.3 T.A. 1060 680 640 Butane up to 100% Butane >2%, 0.5% per 1% Butane
Pentane up to 1 % Pentane >0.1%, 4% per 1% Pentane
NOTES: Hexane up to 1 % Hexane >0.1%, 4% per 1% Hexane
l Rating @ 1500 RPM @ 0.8 p.f. 8.5:1 Propane up to 100%

l Prime power refers to operation in island mode with variable load where Iso Butane up to 80% i Butane >50%, 0.5% per 1% Ibutane
N Butane up to 30% N Butane >15%, 1% per 1% Nbutane
average laod factor is 80%. 10% overload is available for 1 hour in every
Pentane up to 3% Pentane > 0.1%, 4% per 1% Pentane
12 hour of operation. Hexaneup up to 3% Hexane > 0.1%, 4% per 1% Hexane
l The ratings are based on natural gas and diesel as feed fuel.
Turbocharged Aftercooled gas engines
l For any other gaseous fuel please check ratings with Marketing.
10:1 Propane up to 2% }
l Above are continuous ratings for both NA and TA engines with following
Butane up to 0.2% } No derating
gas analysis (By Volume) Pentane up to 0.1% }
Methane (CH 4 ) 75- 99% Nitrogen (N 2 ) 0- 8%, Butane 0.2% Hexane up to 0.1% }
Ethane (C 2 H 6 ) 0- 15% Carbon Monoxide (CO) 0- 1%
Ethane (C 2 H 4 ) 0- 2% Carbon Dioxide (CO 2 ) 0- 12% 8.5:1 Propane up to 10% Propane >5%, 0.5% per 1% Propane
Hydrogen (H 2 ) 0- 1% Sulphur Content 0.1 Max. Butane up to 5% Butane >2%, 0.5% per 1 % Butane
Propane (C 3 H 8 ) 0- 2% Hydrogen Sulphate 0.001% Max. Pentane up to 1% Pentane >0.1%, 4% per 1% Pentane
Hexane up to 1% Hexane > 0.1 %, 4% per 1 % Hexane
Section - 2 Engine Data-Gas & Dual Fuel Page 2-12 Section -2 Engine Data-Gas & Dual Fuel Page 2-13
Notes: SOME IMPORTANT VALUES

l Gas Pressure near engine skid - 15 to 20 psig Ignition transformer
l Low compression ratio should be selected, when any one of 1. Primary resistance - 0.2 to 0.3 OHMS.
composite gas exceeds its permissible limit, in case of gas engine. 2. Secondary resistance - 4500 to 5500 OHMS.
l Calculate derating due to individual composite. Sum up to find out
net derating, Deduct net derating from power corresponding to SPARK PLUG
selected compression ratio to find out brake horse power of a gas Spark plug gap - 0.018 inch.
engine. Spark plug torque 28 to 30 ft-lb.
l Rating and diesel substitution depend on gas composition in case of Check for centre electro continuity
Socket size – 13/16 inch.
dual fuel engine.
l Gas shuld be perfectly dry, clean and free from liquid hydrocarbons, Adaptor spark plug Torque - 70/80 ft-lb.
foreign particles, dust etc.
l Sulphur content in the gas should not exceed 0.1%
l Derating on account of site conditions is applicable.
l Please contact Cummins Marketing Department for more details. NATURAL GAS ENGINE OIL RECOMMENDATIONS
The use of quality engine oils combined with appropriate oil and filter
GAS ADJUSTMENT OF ENGINES RUNNING ON GAS WITH change intervals are critical factors in maintaining engine performance
DIFFERENT HEAT VALUE and durability
• Run the engine at rated speed with 10-20% load.
• Fix the throttle valve. Cummins India Ltd. recommends the use of a high quality SAE 15W-40
• Adjust the pressure regulator till the engine runs at its highest speed engine oil for natural gas engines. The specifications meeting Cummins
• Lower the pressure till the speed has dropped 3% recommended Volvoline GEO15W-40 oil blends for natural gas engines
• Run the engine at rated speed with 100% load. are
• Adjust the carburettor power mixture valve till the CO percentage is
between 0.5 and 1.0% API CD Quality Phosphorous - 250 - 350ppm
When it is not possible to measure the CO percentage adjust till the
SAE 15W40 Viscosity Zinc - 250 – 350ppm
highest vacuum in the inlet manifold is obtained.
Initial timing of the Magtronic is made by turning the engine to place Less than 0.5% Sulfated Ash Calcium - 1200 ppm
No.1 cylinder on magtronic side of engine on top dead centre of its TBN (ASTM D2896) - 5/5.5
compression stroke, rotating the drive coupling of the Magtronic by TAN (ASTM D 664) - 0.5 - 0.7
hand to locate the red painted timing finger visible in the timing window
and installing the Magtronic to the engine drive coupling.
A sulfated ash limit of 0.5 percent mass has been placed on all engine
Final timing is made by attaching a timing light to No. 1 cylinder primary lubricating oils recommended for use in Cummins natural gas engines.
lead. If a low voltage timing light is not available, it will be necessary to Higher ash oils can cause valve and/or piston damage, spark plug
connect an additional ignition transformer in parallel with the No. 1 fouling, and lead to excessive oil consumption and degradation of the
cylinder ignition transformer to allow use of a high voltage timing light. catalyst.
The timing light directed at the timing marks on the accessory drive
pulley will indicate the firing position of No. 1 cylinder. Rotating the IMPCO CARBURETOR MODELS FOR DIFFERENT
Magtronic clockwise when viewed at timing window advances the timing CUMMINS ENGINE MODELS
on G 495/743/855 engines and retards timing on G 1710 engines. With ENGINE CARBURETOR
final timing adjusted. Secure the base mounting bolts. G/GTA-495 200
N-743/855 225
GV-1710 2 X 225
GTA-855 200 T
GTA-1710 600-3
GTA-2300 2 X 200 T
GTA-3067 2 X 600 - 3
Section – 2 Engine Data-Gas & Dual Fuel Page 2-14 Section – 2 Engine Data-Gas & Dual Fuel Page 2-15
CARBURETOR FIELD ADJUSTMENTS & POSITION
Low Pressure Regulator is blue in color. Adjust the outlet pressure of
Naturally aspirated engines carburetor is mounted on intake manifold this regulator to 3 - 8" of H O by rotating plug inside the top cap counter-
2
(after air cleaner), where as in turbocharged engines, carburetor clockwise to decrease the outlet pressure. Check the LPR flow direction
mixture unit is fitted in between air cleaner and the turbo, the throttle unit is in line with arrow.
is fitted between turbo and after cooler intake manifold. Exhaust gas temperatures of duel fuel engines are same as diesel
It is recommended to connect 2nd stage PRV as near as possible to engines.
carburetor. Note : While installing the regulators ensure that the arros is in the
The power mix adjustment valve is to be adjusted to middle position. direction of gas flow.
The idle screw is required to be adjusted (tight fully and loose for 2.5 After the gas train pipe welding / fabrication is complete ensure
turns) when the engine speed is less than 650 rpm. that the entire line is flushed by air / gas / tested for leaks.
Procedure : Intake manifold vacuum on the natural Gas Engine is one
of the most important factors on gas engine operation. This vacuum Altronic Installation Procedure
should be measured by a suitable gauge or column containing to use a Rotate engine so that No. 1 Cylinder is at the ignition firing point (Ignition
dial type gauge. The dial type vacuum gauge is calibrated in inches of angle BTDC), so that, No. 1 cylinder is at firing point (both the valves
mercury, 0 inch to 30 Inch Hg. Intake & Exhaust are closed).
1. Close main gas supply valve. Caution : For GV-1710-G/GTA-1710-G engine take No. 1 RB. (Altronoc
2. Set carburetor power mixture adjustment valve at centre between Side Bank)
“R” (Rich) and “L” (Lean) marks. Fig. 5-9. Determine the rotation of the Altronic III unit (looking at the drive end of
3. Close the idle adjustment; then open two and one-half turns. Fig. the Altronic unit) for the engine being equipped. (For all
5-10. inline Gas Engine-CW, ForGV-1710/ GTA-1710-G -CCW, For GTA-
4. Remove pipe plug from intake manifold and install a vacuum 2300 /GTA-3067- CW)
gauge. Rotate the drive coupling until the red marking on on shaft is aligned with
5. Open the main line gas supply valve. proper marking on housing (CW or CCW) as per the
6. Adjust line gas pressure to the regulators. altronic rotation on engine.
7. Start the engine, using normal starting procedure. Mount the unit to engine, keeping the two red lines together as close as
8. Start the engine, using normal starting procedure. possible.
9. Adjust gas pressure to carburetor to 3 inches of water with engine Final timing should be checked using a timing light with the engine at
running at 600 to 700 rpm. This adjustment is very important and operating speed.
must be accurately accomplished as the engine fuel economy and Magtronic Installation Procedure
power output are directly affected by any variation in iniet gas
Rotate the Magtronic drive until red rotor arm is centered in timing
pressure at the carburetor.
window
10. After engine coolant attains operating temperature (140° to
160°F), operate the engine at rated rpm and system load. a. Rotate engine so that No. 1 Cylinder is TDC of compression stroke (both
Check the carburetor inlet gas pressure. This pressure must the valves Intake & Exhaust are closed).
remain between 2 to 3 inches [50 to 76 mm) of water when the Mount the Magtronic unit to engine.
engine rpm and load varies from rated load and speed to no-load Final timing should be checked using a timing light with the engine at
at idle. If gas pressure to carburetor falls below 2 inches [50 mm] of operating speed.
water at full load, this may indicate excessive pipe length, flow Ignition Timing Procedure
restriction between the main line pressure regulators, b. With
Ensure Proper installation procedure is followed for fitment of ignition
engine running at rated rpm and load, move the carburetor power
units. Check the connections as per the wiring diagrams of the
mixture adjustment valve slowly toward the “L” position.
respective engine drawings The timing light works on a very high
Any and all final adjustments on the engine should be to obtain and voltage supply.
highest amount of manifold vacuum. Any adjustment that cause a drop
1. Connect one extra ignition transformer in parallel with the No. 1
or less vacuum is an incorrect adjustment. Final adjustments must be
cylinder ignition transformer.
made with the engine operating at its rated load and speed.
2. Connect the timing light between the high voltage terminal of
11. Shut down engine.
external ignition transformer and the spark plug (which is
12. Close the main gas supply valve. externally mounted).
Note : High Pressure Regulator is red in color. Correct the inlet pressure 3. Mark a line at the desired degree BTDC of no. 1 cylinder (on
to HPR for 20 psi with another regulator (if reqd.) Adjust the outlet accessory drive pulley) by means of a chalk (say 25 deg BTDC).
pressure of this regulator to 7psig by rotating counter. Clockwise to
decrease the outlet pressure Check the HPR flow direction of arrow
mark is in line with flow.
Section - 2 Engine Data-Gas & Dual Fuel Page 2-16 Section - 2 Engine Data-Gas & Dual Fuel Page 2-17
4. Start the engine and observe timing with the timing light directed transferred to the Distributor from where it is supplied to the Spark
towards the timing mark on the accessory drive pulley at the timing plug of appropriate cylinder.
pointer. • This arrangement has entirely eliminated the existing mechanical
5. Final ignition timing is to be adjusted with the engine at rated speed C. B. point.
and load. After the final adjustments tighten the cap screws. • Additional Feature: Ignition coil will not be energized unless the
Note: Rotating the housing of magtronic / altronic / distributor in the Ignition module receives the engine RPM signal. This will not allow
opposite direction of its shaft rotaion on engine to advance the the Ignition coil to remain energized when engine is not running
timing and vice-a-versa. and will improve the Ignition coil durability and battery life.
Advanced timing lowers the exhaust temperatures, better fuel Air Gap between tip of the magnetic pick-up and tip of the Splines
consumption but results in excessive engine knocking. on the Distributor Shaft: 0.012" - 0.016" (0.3 mm - 0.4 mm).
Retarded engine timing reduces the tendency of engine knocking but Summary of Parts in Contact less Distributor Ignition System
increases the exh temperatures and fuel consumption.
Timing varies as per the composition of natural gas & ambient Sr.No. Part Number Description Quantity
temperatures, load factor.
1 3814895 Distributor 1
2 3814520 Gasket 1
SECONDARY
TIMING LIGHT Hardware for mounting the Distributor in Dive Distributor
ACC DRIVE H.T.COIL 3 3759526 Screw Hex Head Cap 2
CYL.NO.1
IGN TRANSFORMER 4 181466 Washer, Lock 2
5 70704 Washer, Plain 2
SPARK PLUG
PRIMARY 6 3814896 Module, Ignition Control 1
7 3814897 Coil, Ignition 1
FROM ALTRONIC/MAGTRONIC
8 4105997 Mounting, Ignition Coil 1
Includes bracket and hardware required for mounting the ignition coil
and Module Ignition Control
Connections for Checking Engine Ignition Timing 9 3814967 Harness, Wiring 1
For connection between Ignition Coil and Distributor
Lucas Contactless Distributor Ignition System : 10 3875379 Harness, Wiring 1
For connections between Distributor and Spark Plugs
Ignition secondary voltage to
spark plugs through distributor Woodward Electronic Governor on 1150 & 1710 Gas Engines.
Woodward Electronic Governing System works on 24 V DC
supply. It includes three basic parts:
l A magnetic pick-up (MPU) which senses speed from flywheel ring
Splined Distributor Ignition Module gear.
Shaft
l A speed control, which senses the speed from MPU, compares it
+ to a reference signal, and generates a control signal, which the
control sends to the actuator. This control also includes a load
Magnetic Pick-up sensor and provides droop control for generator sets.
mounted inside
Distributor Ignition l An actuator, which receives the signal from the control and
Coil
positions its output shaft according to this signal. This output shaft
is connected to the throttle lever by a linkage.
12 V Battery Electronic Over-speed protection system works on 24 V DC
supply. It includes three basic parts:
• Engine RPM signal is generated using the distributor splined shaft 1 Magnetic pick-up (MPU) senses speed from flywheel ring gear
and a magnetic pick up housed inside the Distributor. This signal 2 Over-speed safety control gets the speed feedback from MPU,
is then processed in an Ignition Module and fed to the Ignition coil compares it to a reference over-speed signal (1800 rpm).
for actuation. 3 If the engine crosses the reference over-speed rpm, the control
• Ignition coil, on receiving the signal from Ignition module, sends a control signal to the Gas Shut-off Valve and shuts it off.
generates secondary high voltage. This high voltage is then
Section - 2 Engine Data-Gas & Dual Fuel Page 2-18 Section - 2 Engine Data-Gas & Dual Fuel Page 2-19
Component Part numbers : 2. To decrease ringing (will increase settling time) after a transient, turn
Assembly Control Box (Part No. 4084895) the GAIN pot counter clockwise slightly, then turn the STABILITY pot as
required to eliminate oscillations and to obtain desired response.
Electronic Over-speed Control (Part No. 4084890) Repeat if necessary.
Panel Wiring Harness (Part No. 4084891) This completes the Governor setting on the engine for Isochronous -
Woodward Speed Control (Part No. 4084889) Solo operation.
Fuses (Refer appendix III for fuse ratings) Droop Adjustment for Droop / Parallel Operation :
Harness for CT / PT Feedback (Part No. 4084892) Adjustment of the droop potentiometer is necessary when droop mode
operation of the control is required. Droop can be set with either of the
Magnetic Pick-up (Part No. 3875360) following methods. Droop is usually expressed as a percentage and
Actuator (Part No. 4084884) calculated by:
Woodward Speed Control (Part No. 4084889) %Droop = [(No Load Speed - Full Load Speed) / No Load Speed] *100.
Engine-Governor Wiring Harness (Part No. 4084887) Droop setting on an isolated load:
Panel Wiring Harness (Part No. 4084892) l Start and operate the genset independently for this setting.
l Run the engine at no load rated speed.
l Apply load, 100%, if possible.
Important Note :
l Adjust droop potentiometer to give the desired rated speed.
1. Disconnect battery connections before connecting Governor Turning the droop potentiometer clockwise will increase the droop
wiring harness. and turning counter-clockwise will decrease the droop. Example:
2. Disconnect amphenol connectors of Governor-wiring harness, Operating at 50 Hz (no load), 47.50 Hz at full load indicates 5%
Altronic ignition harness before carrying out any welding. droop. If only 50% loading is possible, 48.75 Hz would indicate 5%
droop.
Droop setting with a system operating into Parallel Bus :
Engine Start-up (For Isochronous - Solo Operation)
l With the generator not paralleled, adjust the Rated Speed POT to
l Put the Idle - Run toggle switch on IDLE position. give a speed setting above 50 Hz by the percent droop required.
l Start the engine. (For example, 4% droop would require raising the speed to 52.0
l Note Low Idle RPM. It should be between 1080 - 1120. This is pre- Hz). Mark the potentiometer position and return to 50 Hz.
set RPM value. l Turn the Droop Pot fully clockwise (for maximum droop).
l Put the Idle - Run switch to “RUN” position. l Using the high idle Speed Trim Pot adjust the engine speed to be
equivalent to the frequency of Bus
l If at rated speed, there is oscillations / hunting, adjust the GAIN
l Close the generator breaker and it is ready for taking load.
pot to the stable region between oscillations / hunting.
(Synchronize to the bus and parallel to the line).
l If there is a oscillations / hunting which does not stop when the l Now slowly start turning the Rated Speed Pot towards the mark
GAIN pot is adjusted. Turn the STABILITY pot slightly clockwise made in step (a). The set will start taking the load. Simultaneously
and adjust GAIN pot again. Continue this procedure, until the note the kW reading.
engine runs at a steady rated speed.
l Note the kW reading when the rated speed pot has reached the
l If at rated speed, there is a oscillations / hunting which does not mark made in step (a). If it is less than the desired load on the
stop, even when the GAIN pot is fully counter clockwise, adjust the engine, rotate the Droop pot slowly, counter-clockwise to obtain
STABILITY pot slightly counter clockwise until the high frequency the desired load on the engine.
oscillation stops.
Woodward Speed Control (Droop mode)
l Set the engine high idle speed to 1500 RPM by adjusting the
RATED SPEED pot for Isochronous - Solo operation. 24 VDC Actuator MPU RUN/IDLE PT CT
+ - - + switch L N P1 P2
l Put load on the Engine gradually in the steps of 25%, 50%, 75%,
and available maximum Load or 100% whichever is lower. 1 2 3 4 5 6 7 8 9 10 11 12
Following are the guidelines to adjust the transient response, if Speed
trim POT
required: 2KOhms
Fuse Fuse
1. To decrease settling time (may increase ringing) after a transient, turn 10 Amps
6.8
KOhms 2 Amps
the GAIN pot clockwise slightly, then turn the STABILITY pot as
required to eliminate oscillations and to obtain desired response. For Run/Idle Switch
Idle - Open
Repeat if necessary. + Run - Close
From
PT From
24 V Battery CT
MPU R
Y
Actuator B
N
From
Bus Bar
Section - 2 Engine Data-Gas & Dual Fuel Page 2-20 Section – 2 Engine Data-Gas & Dual Fuel Page 2-21
OEM Instructions for making connections to CT / PT : Methane Ethane Propane Butane
Connection Colour Function Formula C 1 H4 C 2 H6 C 3 H8 C 4 H10
A Orange Current Transformer (C.T.) Normal State

Gas Gas Gas Gas
Primary P1 or S1 @ NTP
B Red Potential Transformer (P.T.) Boiling Pt. of
-256 F O -127 F O -43 F O 31OF
Live -1 15-230 VAC Liquid @ NTP
C Grey Current Transformer (C.T.) BTU/Cu.Ft. HHV 1,012 1,783 2,558 3,354
Primary P2 or S2 Cu. Ft. of Air to
9.53 16.67 23.82 30.97
D Green Potential Transformer (P.T.) Neutral burn 1 Cu. Ft. Gas
Lower / Upper limit
5/15 3/10 2.2/10 1.8/9
Important: CT should be sized to produce 5A secondary current, with Flammability
maximum engine (current) rating, i.e. CT Rating must be : Maximum Self Ignition Temp. 650 OC 515OC 470OC 365OC
engine (current) rating / 5A. CT burden is essentially 0 VA.
Max air + gas temp at the end of compression = 2400 OF
Maximum temperature of exhaust = 1300 OF
PROPERTIES OF HYDORCARBONS / GAS FUELS 1. Natural Gas
Mixture of different hydrocarbon gases.
Higher Heat Value (H.C.V)-Total heat evolved by complete Methane rich gas with Ethane, Propane, Butane etc.
combustion of fuel when the products of combustion cooled down to Minimum 70% Methane is required. More the methane content,
better the performance.
15 deg. C
If Propane, Butane, Ethane percentage is higher than 2% by
Lower heat Value (L.C.V) - It is (HCV – Total heat absorbed by the volume, can cause detonation. Hence lower C.R. Pistons are to be
combustion gases (steam etc.)) at the combustion temperatures. used .
Subsequent de-ration in power.
Octane value of Natural gas apx. 130, higher the octane value -
Available piston C.R. 12:1, 10:1, 8:5:1, 7:5:1
better the anti knocking qualities.
Available forms of Natural Gas
Octane should not be more than 4% Piped Natural Gas
1 Gallon =3.78litres=0.833 Gallons (UK) Compressed Natural Gas (CNG)
Boiling Pt. of Liquid @ NTP - Temperature at which liquid state of Liquified Natural Gas (LNG)
matter converts to gaseous state. 2. Bio-gas / Sewage
BTU / Cu. Ft. HHV (1 BTU = 252 cal) Methane 60-65%, Carbon Dioxide 25-30%.
Due to recent advance in Biotechnology, Digester gas is produced
9.5 Cu. Ft of Air to burn 1 Cu. Ft. Natural Gas at STP by anaerobic bacteria from organic waste.
Lower / Upper limit Flammability - Minimum / Maximum air to gas Sulfur/Hydrogen sulfide should be less than 0.1% by volume. If in
ratio for better combustion. excess, can cause damage to the engine components.
Self Ignition Temp – The temperature the gas ignites. 3. L.P.G. :
Propane can be liquified by pressurizing it at 100 PSIG (LPG) Liquified Petroleum Gas (LPG)
Mixture of Butane and Propane (3:2 by Volume)
Proprane should not be more than 1.7%
Pistone C.R. 8.5 : 1.
Caloric Value
Natural Gas 850-970 BTU/CFT = 7562 - 8629 kcal/Cu.m
LP G 2769 BTU/CFT = 24635 kcal/Cu.m
Bio Gas 540 -600BTU/CFT = 4804-5338 kcal/Cu.m
Weight to Volume ratio (at 70deg F and 30” of mercury) is

0.458lbs./SCF=923.7BTU/SCF
140 SCF Natural gas = 1 gallon of diesel = 129,575 BTUs/Gallon

Specific gravity of Natural Gas = 0.695 (wrt. air as 1)
Page 2-23
Page 2-22
4. WATCH THE LUB OIL PRESSURE GAUGE AND
3. RELEASE THE PUSH BUTTON AFTER ENGINE

EARTH ‘P’ CONNECTION FROM MAGTRONIC.
SWITCH IN OFF POSITION TO DISCONNECT

5. TURN STARTING SWITCH TO ‘OFF’ POSITION
2. TURN THE STARTING KEY SWITCH TO START
MAGTRONIC ‘P’ TERMINAL FROM ‘EARTH’

SIMULTANEOUSLY PRESS THE STARTER
TO SHUTDOWN THE ENGINE THEN TURN
POSITION WHEN OIL PRESSURE GAUGE
DURING STARTING & RUNNING OF ENGINE.
4. WATCH THE LUB OIL PRESSURE GAUGE AND

PUSH BUTTON KEEP IGNITION TOGGLE
TOGGLE SWITCH’ TO ‘ON’ POSITION TO
6. THIS DIAGRAM REFERS TO THE 12 VOLT H.T.
3. RELEASE THE PUSH BUTTON AFTER ENGINE

THIS IS ESSENTIAL FOR DISCHARGING
TURN THE STARTING KEY SWITCH TO START

POSITION TO CRANK THE ENGINE
- KEEP THE IGNITION SWITCH ON TO GIVE

SHIFT STARTING SWITCH KEY TO RUN
- THEN TURN IGNITION SWITCH (TOGGLE
POSITION WHEN OIL PRESSURE GAUGE

DISTRIBUTOR TYPE LUCAS IGNITION
- THIS ESSENTIAL FOR PREVENTING
SHIFT STARTING SWITCH KEY TO RUN
- PRESS THE STARTER PUSH BUTTON.
1. 24 VOLT NEGATIVE GROUND SYSTEM.

INDICATES MORE THAN 1 Kg/cm2
INDICATES MORE THAN 1 Kg/cm2

SYSTEM USED ON GAS ENGINE.
12 V SUPPLY TO IGNITION COIL

1. 24 VOLT NEGATIVE SYSTEM.
SWITCH) TO OFF POSITION.

- TURN STARTING SWITCH
2. TO START THE ENGINE :-

5. TO STOP THE ENGINE :-
IGNITION COIL DAMAGE

TO ‘OFF’ POSITION
‘MAGTRONIC’.
POSITION
FIRES.
FIRES.
STARTING SWITCH
STARTING SWITCH
3
R
START PUSH BUTTON

B
13
S
ENGINE WIRING DIAGRAMS
2
R 3
16
15
START PUSH BUTTON
16
S
B
15
15
13
INDICATING LAMP
7
13
15
7
AMMETER
L
8
5
AMMETER
16
INDICATING LAMP
B
B L
16
13
PVC 95 SQ. MM
6
WIRE GAUGE
6
IGNITION SWITCH
44/0.3 MM
65/0.3 MM
TOGGLE SWITCH
DOUBLE
8
9
TOGGLE
SWITCH
0.2
CAPACITY
AMP.
1
200
20
30
12
1
2
3
5
6
7
8
9
PVC 95 SQ. MM
WIRE GAUGE
12
2
5
3
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
44/0.3MM
65/0.3MM
DOUBLE
5, 6, 7, 15, 16, 42,
25, 26, 27, 33, 34
11
12
10
1
CIRCUIT NO.
4
5
3
6
7
8
9
21
41
23
25
26
27
28
40
2, 3, 8, 13, 9,
41
22, 23, 28,
35, 36, 37
39, 40, 41
22
37
0.2
23
25
26
27
28
40
43
CAPACITY
43
AMP.
40
200
22
20
30
37
FROM MAGTRONIC
40
-
Section - 2 Engine Data-Gas & Dual Fuel
COIL
12V
IGN
25,26,27,33,34
5,6,7,15,16,42
P
CIRCUIT NO.
3 8 7 4 6 4 2
2,3,8,13,9
MAGNETIC
MAGNETIC
27
22,23,28
35,36,37
39,40,41
SWITCH
27
SWITCH
26
26
34
42
42
40
40
34
+
41
-
BATTERY 24 V.D.C.
34
40
41
42
BATTERY 24 V.D.C.
41
41
39
SM 130 PE
STARTER
41
39
+
33
SM 130 PE
STARTER
39
GAS SOLENOID VALVE
+
LOW LUB OIL PRESS
OVER SPEED STOP
HIGH WATER TEMP.
ALTERNATOR
40
SAFETY CONTROL
SAFETY CONTROL
35
28
33
22
37
NO
NC
NC
NC
NO
NO
W
+
25
GAS SOLENOID VALVE

23
36
33
36
35
LOW LUB. OIL PRESS
OVER SPEED STOP

22
40
35
HIGH WATER TEMP.
33
SAFETY CONTROL
28
SAFETY CONTROL
37
25
ALTERNATOR
-
NO
NC
NO
NO
NC
NC
W
+
36
35
23
36
Section – 2 Engine Data-Gas & Dual Fuel PART NUMBER DETAILS Page 2-26 Section - 2 Engine Data-Gas & Dual Fuel Page 2-24
I. Engines having Magtronic and Internal mounted ignition transformers :
HIGH TENSION CABLES
Engine model Spark Plug Ignition coil Magtronic/ Pressure regulator Carburettor
Altronic Stage I Stage II
G-495 199148 166836 168175 3875040 3875043 179765
G-743 199148 166836 168144 3875040 3875043 191864
G-855 199148 166836 168144 3875040 3875043 191864
GTA-855 199148 166836 168144 3875040 3875043 3232503
G-1710 199148 166836 168145 3875041 3875043 (2) 191718(2)
GTA-1710 199148 166836 168145 3875041 3875044 3232502 1
2 1 2 3 4 5 6
II Engines having Magtronic/Altronic and External mounted Ignition transformers: 3
4 TO ENGINE
5
Spark Magtronic/ Pressure regulator Carburetor CAP, PROTECTION
Engine model Ignition Coil 6
Plug Altronic Stage I Stage. II 7
8
G-495 3873431 3873589 168175 3875040 3875043 179765 9

10
11 1 - THIS DIAGRAM REFERS TO THE
G-743 3873431 3873589 168144 3875040 3875043 191864 43 12
12
G-855 3873431 3873589 3392709 3875040 3875043 191864 H.T. LUCAS DISTRIBUTOR TYPE
Diagram No.3875376 IGNITION SYSTEM ON 6 CYLINDER
GTA-855 / 1150 3873431 3873589 3392709 3875040 3875043 3232503 - + (BAT) GAS ENGINE
G-1710 3673431 3873589 3392710 3875041 3875043(2) 191718 (2) - + 43 41 12
6 12V TOGGLE SWITCH
GTA-1710 3873431 3673589 3392710 3875041 3875044 3232502
40
GTA-1150 3873431 3873589 3392709 3875041 3875044 3232503 IGNITION COIL (12V)
2 3 MOUNED ON ENGINE
GTA-2300 3873431 3873589 3876325 3875042 3875044(2) 3232503 (2)
(MOUNT IN INCLINED
GTA-3067 3873431 3873589 3392712 * 3875042 3875044(2) 3876533 (2) POSITION)
* Altronic
H.T.
39 + 41
Ill. Engines having High Tension Distributor drive system Pressure regulator 4 ROTOR 5 + +
Carburettor 12V 12V 40
Engine model Spark Plug Ignition coil Distributor 1 Stage. I Stage II - -
G-495 3873431 3812217 3875380 3875040 3875043 179765 1 12 VOLT -VE GROUND SYSTEM
G-743 3873431 3812217 3812219 3875040 3875043 191864 DISTRIBUTOR COVER
G-855 3873431 3812217 3812219 3875040 3875043 191864
FIRING ORDER 1-5-3-6-2-4
Refer SPT No 3242600-Dec. 2001 for new cyl head spare parts.
Section -2 Engine Data-Gas & Dual Fuel Page 2-25

CONVERSION KITS FOR VARIOUS DUAL FUEL ENGINES
SR. CONVERSION KIT CONVERSION FROM RELEASE COOLINGTOWER RAW WATER
Gas Engine
Gas Engine
Gas Engine
NO PART NO TONNAGE FOR CIRCULATING PUMP FLOW
DIESEL TO DUAL FUEL AFTERCOOLER
ENGINE ENGINE
1 AR 3879769 - 01 N-495-G DG-495-G ER 907102-000 -- --
Butterfly valve – G 855

ER 917234-000
Regulator P/No. 3870544

Repair Kit – Gas Pressure

Butterfly Valve – GTA 1710
Butterfly Valve – GTA 1150
2 AR 3880008 - 00 NTC-495-G DGTA-495-G SP-4019 5 TON 20 US GPM
3 AR 3879738 - 02 N-743-G DG-743-G
ER 907078-000 -- --
ER 917234-000
AR 3879766 - 01 NTA-855-G DGTA-855-G ER 907102-000 10 TON 40 US GPM
4

ER 917234-000
R6106K
R6102K
R2304K
R2301K
R2304KB
5 AR 3879755 - 01 KTA-1150-G DGTA-1150-G ER 907010-000 (WITH HC5) 20 TON 80 US GPM
ER 917234-000 (WITH 4LGK)
Each
Each
Each
Each
Each
Each
Each
Each
6 AR 3880190 - 00 VTA-1710-G DGTA-1710-G ER 928039-000 20 TON 80 US GPM
7 AR 3880084 - 00 KTA-2300-G DGTA-2300-G ER 927181-000 30 TON 120 US GPM
8 AR 3880072 - 00 KTA-3067-G DGTA-3067-G ER 927144-000 30 TON 120 US GPM
SOME AX PART / REPAIR KIT NUMBERS OF GAS ENGINES
AX1002315
AX1002314
AX1002313
AX1002320
AX1002319
AX1002318
AX1002317
AX1002316
Page 2-27
Section - 3 Engine Data - B Series Page 3-0 Section - 3 Engine Data - B Series Page 3-1
ENGINE IDENTIFICATION (B & C SERIES)

Contents Page
Cummins Engine Nomenclature (B & C Series)
B & C Series Engine Identification……………………………………... 3-1
The model name provides the following data
Air Intake System………………………………………………………… 3-1
6 B T A 5.9 - G
Exhaust System …………………………………………………………. 3-1
= Application Codes (G-Genset)
Blow-By Readings……………………………………………………….. 3-2
= Displacement in Litres
Cooling System …………………………………………………………. 3-3
= Aftercooled
Lubricating Oil System ………………………………………………….. 3-4
= Turbocharged
Fuel System ……………………………………………………………… 3-5
= Series (Family of engines)
Mechanical System ……………………………………………………. 3-7
= Number of cylinders
Electrical System ………………………………………………………3-9
Compressor Application .................................................................. 3-12 AIR INTAKE SYSTEM

1) Check air inlet service indicator for signs of choking. Air inlet
Important Clearances ……………………………………………… 3-13
restriction should not exceed 635 mm (25”) of water. Inspect/clean air
Important Torques …………………………………………………….. 3-14 cleaner element every 250 hours of engine operation. Excessive
intake restriction will lead to
B Series Specifications ……………………………………………….. 3-15
a) Engine hard starting
B Series Genset Specifications ……………………………………… 3-16
b) Engine not taking load with black smoke.
Maintenance Schedule ……………………………………………… 3-17 c) Excessive injector carboning leading to early injector failure.
d) Excessive blow-by.
Wiring Diagram .............……………………………………………… 3-18 e) Engine oil dilution.
I) Engine over heating etc.
g) Turbocharger failure / leakage
EXHAUST SYSTEM
1) Check turbocharger end play and radial clearance at every 1000
hours, Permissible turbo end play is .10 to .16mm (.004” to .006”) and
radial clearance is .30 to .46mm (.012” to .018’) failure to check turbo
will lead to similar problems as mentioned above and premature turbo
failure.
2) In case of excessive lengths & bends in exhaust piping - check

exhaust back pressure during installation. It should not exceed 76.2
mm (3”) of mercury.
Section - 3 Engine Data - B Series Page 3-3

Page 3-2
COOLING SYSTEM
1) Ensure equipment is in level. Coolant radiator fill rate of

approximately 11.5 litres/minute (3 U. S. GPM) should be
maintained during initial fill. This will ensure complete system
deaeration. Air in the system causes water pump impeller
cavitation resulting in reduced coolant flow, hence overheating -
(Orifice Size 0.221”)
Resulting in head gasket burning.

BLOW BY TOOL
To ensure complete system deaeration run the engine for 05/10

minutes at low idle with radiator cap removed - stop the engine,
check & top up the system.
2) Added coolant must be clean and treated as follows:
Mixture of water : Ethylene glycol (1:1) = 50% + 50%.
If the coolant is not clean it will lead to entry of foreign particles

and rust formation. This may clog the coolant passages,
resulting in overheating - subsequently leading to piston rings
block damage and head gasket burning.
BLOW-BY READINGS
3) Stop all cooling system external leaks and ensure that the
pressure cap is sealing and in good working condition. An
engine operated with external leaks/pressure cap missing, leads
to system aeration and over heating.
4) Never operate the engine without a thermostat. If done so

(Inches of H2O)
Used Engine
engine will overheat. A missing or defective jiggle pin of the

thermostat can cause engine to run cold . Thermostat operating
21
10
13
17
28
2
6
3
0 0
range is 83 C to 88 C. (Differ as per part number)
5) Every 1000 hours or 32,000 Kms. (20,000 miles) check fan hub,
belt tension bearing and belt tension. This will ensure proper
cooling system operation. If any of the three are defective, it will
(Inches of H2O)
New/Rebuild
lead to engine over heating leading to other serious progressive

damages. The belt tension is to be checked at the longest span
1
5
1
7
1
1
4
of the belt. The maximum permissible deflection is 9.5 to

12.7mm (3/8” to 1/2”). With the belt tensioner checking tool ST -
Section - 3 Engine Data - B Series
1293 the value is 36.32 to 49.94 Kgs. (80 to 110 Lbs).
6) To identify a head gasket blown condition, for engine not

6B-5.9 upto 2200-2500 RPM
4BT/A-3.9 above 2500 RPM
6BT/A-5.9 above 2500 RPM

4BT/A-3.9 :2200-2500 RPM
4BT/A-3.9 up to 2200 RPM
starting. Check the compression of each of the cylinders. Normal

6BT/A5.9 upto 2200 RPM
6-B-5.9 above 2500 RPM
4 B-3.9 above 2500 RPM
4 B-3.9 up to 2500 RPM
6B-5.9 upto 2200 RPM
compression is 2068 kPa. (300 psi) at 150 cranking RPM. A

689.5 kPa (100 psi) difference between cylinders indicates a
B Series:
compression seal problem. If the compression is found low on

adjacent cylinders and the pressure cannot be increased by
oiling the rings, the head gasket is probably leaking between the
cylinders.
LUBRICATING OIL SYSTEM b) Water in oil can be caused by
a) The pressure regulating valve is designed to keep the oil (i) Cup plugs leaking.
pressure from exceeding 414 kPa. (60 psi). (ii) Damaged cylinder head gasket
b) The bypass valve is designed to open when the pressure drop (iii) Oil cooler element leaking
across the filter is more than 138 kPa. (20 psi). When a filter (iv) After cooler element leaking.
becomes plugged, and oil pressure decrease of 69 kPa. (10 psi)
or less from the normal operating pressure can be observed on
5) If the lube system is not maintained, it will also lead to
the vehicle oil pressure gauge. The pressure will return back to excessive oil consumption.
normal when the filter bypass valve will open.
a) Worn or damaged seals in the turbocharger can allow
c) Minimum oil pressure at low idle (625 to 725 RPM) is 69 kPa (10 the oil to leak into the air cross over pipe and burn in
psi). Minimum oil pressure at rated speed is 207 kPa. (30 psi) the combustion chamber, or leak past the engine
exhaust casing and burn inside the exhaust piping.
1) Check the engine oil level daily - and maintain the level upto ‘H’ b) Inadequate sealing of the piston rings will result in oil
mark. Oil level above ‘H’ will cause hard starting & over heating a being blown out of the breather tube and/or consumed
level below ‘L’ mark may cause engine seizure. Make sure the by the engine. A blow by check / compression check
equipment is in level. A slight angle may give you a false reading can confirm the same.
on the dipstick. c) Oil can also be lost through a worn or malfunctioning air
compressor. Look for carbon build up and oil deposits
2) Change engine oil and filter every 250 hours, replace with new
in the air line from the compressor to the air tank.
filter and use recommended engine oils only. Failure to do so will
cause severe engine damage.
FUEL SYSTEM
3) A loose suction tube, damaged gasket or crack in the suction 1) Drain water and sediments from fuel tank and fuel water
tube can cause a temporary loss of prime for the oil pump. The separator filter daily. This will ensure trouble free service
engine will have low oil pressure or no oil pressure at starting from the fuel pump and injectors, as diesel alone acts as a
followed by normal oil pressure. Under such a condition stop the lubricant for the moving parts of the fuel system.
engine immediately and rectify the fault. 2) Replace fuel filter, clean strainer and replace ‘O’ ring every
4) Check the condition of oil. 500 hours. If not done - will lead to low power, engine not
starting etc. The fuel suction restriction should not exceed
a) Thin black oil is an indication of fuel in the oil. 152.4 mm (6”) of mercury.
b) Milky discolouration is an indication of water in the oil.
3) The fuel drain line restriction should not exceed 34.5 kPa. (5
a) Fuel in the oil can be caused by : psi), and the return line must be connected to the bottom of
i) Injection pump shaft seal leaking/defective. the fuel tank, to prevent pump housing drain back by the
ii) Fuel leaking by the rings/Faulty injectors. process of syphoning. In case of a sudden unexplained shut
down, engine restarts on cranking, check fuel return line for
iii) Defective lift pump.
restriction.
iv) A crack in the cylinder head from the fuel filter location
to the air intake. In case of stationary applications or wherever possible, it is
advisable to install the base of the diesel tank slightly above
v) Restricted fuel drain line. the top of the engine -
a) Use the following logic to identify fuel in the lube oil. a) Eliminate the problem of drain back.
Power normal : Replace the fuel pump b) Eliminate the fitment of a lift pump.
Lower power - : Replace the c) Eliminate air from the fuel system & priming will be very
increased white injectors easy.
smoke during d) Eliminate the problem of hard starting caused due to
start up system aeration.
Low power - : Verify the rings are e) Maintain solid fuel in all lines at all times.
increased blac k sealing by
smoke performing a 4) Procedure for bleeding air from the fuel system
compression a) Check and tighten all connections from the diesel tank
check. to the lift pump.
b) Loosen bleeding screw on top of the banjo nut of the fuel c) Spray pattern.
filter head, prime by lift pump till a positive flow of fuel is d) For a used injector chatter test is not necessary.
observed - tighten the bleed screw.
In a running engine to check for satisfactory injector
c) Switch on the switch key to energise the coil & keep the oil operation - loosen the supply lines to each injector and
pressure By Pass switch button pressed (if provided) and
notice drop in engine rpm. If on loosening supply, the
continue priming by lift pump. For a Robert Bosch VE
Pump do not loosen any screw on pump for bleeding. In engine rpm does not fall - this indicates that this injector
case of Lucas CAV DPA Pumps-loosen the bleeding is defective.
screw on top of the fuel pump housing.
CAUTION:
d) Release the high pressure supply lines at the injectors and
Do not bleed a hot engine as this could cause fuel to spill on to
crank the engine till squirts of diesel is observed at all a hot exhaust manifold creating a danger of fire.
injectors. Tighten the supply and start the engine.
9) To determine a worn or malfunctioning injection pump -
5) Tighten all suction lines regularly. This is done to prevent air visually check fuel delivery with an externally connected
entering the fuel system. Air in the system will cause engine tested injector to one of the pump outlets. Replace the pump if
hard / not starting problems. the fuel is not being delivered/sprayed.
For air, check at the following points.
a) Elbow connections and hose from tank to strainer. NOTE
b) Strainer ‘O’ ring. a) While checking for spray, do not put your hand under the
c) Elbow connections and hose from strainer to lift pump. nozzle spray. The fuel Injection pressure is high enough to
After lift pump the system is under pressure. penetrate your skin and blood vessels to cause blood
poisoning.
6) For a problem of engine not taking load or engine not starting, b) Do not attempt any adjustments on the fuel pump in the
the lift pump can be one of the reasons. To check the lift pump field, as this may result in fuel pump malfunction.
for proper operation only after confirming that the system does
not draw in air. Check for : MECHANICAL SYSTEM
a) Volume delivered by lift pump within 30 seconds of 1) If any of the cylinder head capscrews are loosened for
cranking should be 0.75 litres. any work- all the capscrews must be retorqued to the
b) Pressure should be 21 to 49 kPa (3 to 7 psi) specified value and in sequence. If not done this may
lead to blown head gasket between consecutive
If the above two checks are not satisfied, this indicates that cylinders.
a) Lift pump lever may be worn out.
b) Lift pump inlet/outlet valves may be defective. 2) Valve setting must be carried out every 1000 hours o r
c) Lift pump diaphragm may be ruptured. If so diesel will leak 32,000 Kms (20,000 miles) of engine operation. If not
out the weep hole in the housing. done it will lead to low power, black smoke, over heating,
d) The camshaft lobe is worn out. hard starting etc.
NOTE : The procedure is as follows:

Frequent filter replacement to get full power from the engine indicates a) Remove the valve covers.
a worn lift pump or a worn camshaft lobe. This occurs because even
with a little flow restriction due to partially choked fuel filter, the b) Locate TDC for cylinder No. 1 by barring engine slowly
required quantity of fuel will not be delivered - resulting low power. while pressing the engine timing pin, till the pin engages
in the slot of the camshaft gear. Disengage the timing
7. Check solenoid coil for operation, an inoperative coil will lead to pin.
engine not starting. To restart the engine - remove the valve,
from the coil and refit the coil. In this condition the mechanical c) Check / set valves with engine cold - below 60 deg.
shut off levers is to be operated to shut off the engine. Safety centigrade. (140 Deg. F). Oil temperature.
controls will not be functioning.
Intake clearance to be set to : .254 mm (.010”).
8. To determine whether the injector is operative, check the Exhaust clearance to be set to: .508 mm (.020”).
following
a) Opening pressure. (Also called as pop pressure).
b) Leakage test.
4 CYLINDER ENGINE 6 CYLINDER ENGINE d) Bar the engine in the direction of rotation until the dial
1. Intake* Exhaust* 1. Intake* Exhaust* reads maximum and starts back. The maximum dial
2. Intake* Exhaust$ 2. Intake* Exhaust$ reading should be equal to or above the following
3. Intake$ Exhaust* 3. Intake$ Exhaust* specifications.
4. Intake$ Exhaust$ 4. Intake* Exhaust$ Intake- 16.154 mm (0.636”) and exhaust- 11.532 mm
5. Intake$ Exhaust* (0.454”)
* - Set the values. 6. Intake$ Exhaust$ NOTE:
$ - Do not set the values. Any time a new camshaft is installed, new tappets should also be
installed.
d) Mark the crankshaft pulley and gear case cover or 7) A rod knock occurs when the engine is not loaded. Verify
flywheel and flywheel housing. Rotate through 360 by first applying load and then unloading and listening for
degrees to realign the marks. the knock.
e) Set the remaining cylinders. ($ marked) 8) A main bearing knock will be heard when the engine is
loaded.
NOTE: 9) For a problem of hard starting check engine blow by after
For a new / overhauled (with valves replaced) / recon engine or confirming that air/exhaust system and fuel system are
reconditioned cylinder head the intake clearance is .30mm (.012”). ok.
and exhaust valve clearance is 0.022".
ELECTRICAL SYSTEM
These values are kept higher than normal to provide for initial
setting in. The electrical system consists of battery, starting motor; alternator,
fuel shut off valve, low lubricating oil pressure safety control, high
f) Install the valve covers and torque capscrews to 24 N.m water temperature safety control, starting switch, push button,
(18 Ft. Lbs). indicating lamp, amp meter, toggle switch, air discharge temperature
safety control in IR P450, P600 and P450 compressor, etc.
3) Valve sealing : If the compression is low on one or more
1) Battery
nonadjacent cylinder and the pressure cannot be
increased by oiling the rings, poor valve sealing is to be Make sure the battery terminals are not loose or corroded.
suspected. Valve leakage is often audible from the intake Voltage across the battery terminals should be 12 V or 24 V
and exhaust manifold. according the system.
2) Starting Motor
4) Worn valve seals can be identified by excessive smoke (1) Engine does not Crank :
at idling or when the engine unloaded when the vehicle
is going down the hill. Verify the c ondition by removing * If the solenoid (magnetic switch) does not make an audible
the valve spring and inspecting the seals. sound check for loose wiring connections.
* Check the voltage at the solenoid.
5) If frequent valve setting is required - and if rocker lever, No voltage - check the condition of the battery. Check the
valve stem, and push rods do not show excessive wear connections at the battery, engine and solenoid.
then the tappets and/or the camshaft lobes are worn out.
If the camshaft lobe is worn out, low power and unusual • If 12 V at the solenoid - Check the voltage at the S (switch)
noise from the intake/exhaust manifold will be observed. terminal on the solenoid. The ignition switch must be at the
START position.
To confirm whether the camlobes and tappets are worn The solenoid is at fault if the check indicates 12V at the S
out, check the valve lift as follows. terminal.
a) Check the rocker levers, valve stems, push rods for The trouble-shooting procedure is the same for 24V system.
wear. The values are 24V.
b) Adjust the valve lash to zero clearance with the engine in If no voltage is indicated at the S terminal of the ignition switch check:
the valve set position for the subject cylinder. An * Fuses
approximation can be achieved by observing the * Voltages to the ignition switch
adjusting screw length out of the rocker lever. * And if the vehicle is so equipped, voltage to clutch switch,
c) Set up a dial indicator on top of the valve spring retainer neutral safety switch and engine safety shut off system.
and adjust the dial indicator to zero. If the solenoid does make an audible sound turn the switch
off and attempt to bar the engine in both directions, as
follows.
1) Direction of engine rotation Switch ON, lamp ON. Engine RUNNING

2) Direction opposite engine rotation. Check the drive belt and alternator pulley to be sure that
3) Direction of engine rotation. the alternator is rotating.
If the engine will bar at step 3 - attempt to start the engine. Disconnect the leads to Alternator – If the lamp stays on,
If the starter cranks the engine, check the starter pinion there is a short to ground on the alternator side of the
gear & flywheel ring gear for damage. lamp.
If the lamp goes off, replace the alternator.
4) If engine does not rotate - check for internal malfunction of
Engine / Equipment. 5) Abnormal charging system operation
If the engine bars and the starting motor does not crank, Check the battery and all wiring connections. Inspect the
check the voltage between the solenoid and starting motor. wiring for defects. Check all connections for tightness and
The ignition switch must be in the start position. cleanliness.
With ignition switch ON and all wiring harness leads
No voltage - starter is at fault.
connected, connect a voltmeter from :
Normal voltage - The solenoid is at fault. A : Alternator “BAT” terminal to ground.
When troubleshooting a 24 V system, the value is 24 volts. B : Alternator No.1 terminal to ground.
3) Engine Cranking Speed too Low C : Alternator No.2 terminal to ground.
* Make sure the wiring connections are clean, tight and not A zero reading indicates a break between the voltmeter
damaged. connection and the battery. Locate and repair the open
* Check the battery voltage. circuit.
If the engine is free, check the voltage at the starter With all accessories turned off, connect voltmeter across
during cranking. If the voltage drops more than 2.4 volts the battery. Operate engine at moderate speed. If
check that all connections are tight. The limit for 24 volts voltage is 15.5 or more, replace the alternator or repair.
system is 4.8 volts. If the cables are correct and the The limit for 24 volts system is 25 volts.
Voltage drop exceeds the limits, replace the starter.
6) Checking Fuel Shut Off Valve
If the engine requires more than a normal effort to bar,
check for excessive load from the driven units and Check all connections for loose or corroded connections and
accessories. for broken wires. Remove the valve. Ground the valve and
connect 12 volts DC to the terminal and observe plunger
4) Alternator movement. Use 24 volts for 24 V system (Hold the valve
Trouble with the charging system may be indicated by the carefully while checking. The valve may fly off when supply
indicator lamp or ammeter. disconnected.)
7) Low lub oil pressure Safety Control
Check the indicator lamp for normal operation as shown
below: Check all connections for loose or corroded connections and
for broken wires. Connect the wires to ‘N.O.’ contact.
Abnormal Indicator Lamp Operation
When oil pressure reaches more than 10 PSI the micro switch
Engine Switch Lamp Ammeter reading within the safety control operates. It makes ‘N.O.’ contact.
STOPPED OFF OFF 0 When oil pressure reaches more than 10 PSI the micro switch
STOPPED ON ON - Ve within the safety control operates. It makes ‘N.O.’ out side
RUNNING ON OFF + Ve
contact to “N.C.” internally.
Switch OFF, Lamp ON. Engine STOPPED If the engine does not start. Short the “N.O.” terminal & start
* Disconnect the lamp lead at the ignition switch. the engine. If the engine starts, the safety control is defective.
* If the lamp stays on there is a short to a positive wire on Replace the safety control.
the ignition side of the lamp. 8) High Water Temperature Safety Control
* If the lamp goes off there is a short in the switch. Check for loose or corroded connections and for broken wires.
Connect the wires to “N.C.” contact.
Switch ON, lamp OFF, Engine STOPPED
This condition can be caused by a break in the circuit. To If engine does not start, check continuity of “N.C.” contact with
determine where a circuit break exists - Check for a the help of ohmmeter. If the continuity is not shown, the safety
blown fuse, a burned out bulb, defective bulb socket, or control is defective, replace the safety control.
a break in lead circuit between alternator and ignition 9) Starting Switch and Push Button
switch. Check all connections for tightness and cleanliness.
10) Indicating Lamp IMPORTANT CLEARANCES

Check all connections for tightness and cleanliness. Check bulb. CHECK POINT SPECIFIED
Crankshaft endplay 0.005” / 0.010”: Assly.
After test
11) Ammeter Free rotation with turn torque 0 to 15 N-m.
Check all connections for tightness & cleanliness. Con. Rod side clearance 0.004”/0.012”
Sr. No. on Exh. side
Piston protrusion 0.020”/0.027” (NA)
12) High Air discharge temp. Safety control
W.R.T.Block Deck 0.012”/0.027” (TC)
In IR HP 450, P600 & P450 compressors this switch is provided at Air
Camshaft endplay 0.005”/0.0135”
end. Check for continuity of this switch similar to engine High water
temperature safety control. GEAR TRAIN BACKLASHES
Crank to Camgear 0.003” / 0.013”
Crank to lub pump drive 0.004” / 0.010”
NOTE: FOR IR HP 450, P600 & P 450 COMPRESSORS
Lub pump gears 0.004” / 0.010”
When Engine Cranks/starts and still if it is felt absolutely necessary to
Camgear to fuel pump gear 0.003” / 0.013”
decouple the engine the following points are to be checked prior to
For Inline Pump
decoupling the compressor to rule out compressor/engine problem.
Key is not used in between FIP gear & shaft as such pump gear need
not to be timed but needs to match timing pins of FIP pump & Engine
COMPRESSOR APPLICATION cam gear.
For Rotary Pump
Compressor Side This table must be used to make sure of proper fuel injection pump to
1 Drop across separator element. The allowable drop is 15 psi. Kits for engine timing.
checking the pressure drop are available with the nearest IR branch Key must be used between pump shaft & gear.
office. Letter on Engine Injection
2. If the engine starts and the drop in pressure across separator is less Pump Gear Model Pump
than 15 psi, then decoupling the engine and showing that it achieves A 4B3.9, 4BT3.9 Stanadyno
rated rpm does not prove anything as the engine is supported to drive
A 4B3.9, 4BT3.9, 4BTA3.9 Lucas CAV DPA Pump
compressor at the rated HP.
B 4B3.0, 4BTA3.0 Robert Bosch VE Pump
3. If engine takes load but high/low idle is not achieved the actuating
cylinder stroke is to be checked which should be between 25 -30 mm If C 6BT6.0, 6BTA5.9 Rober Bosch VE Pump
movement is less, then the hose to be checked for blockage/cylinder to D 6B5.9, 6BT5.9 Stanadyno
be serviced. If fuel pump lever is manually operated for checking rpm D 6B5.9, 6BT5.9, 6BTA5.9 Lucas CAV DPA Pump
then the service valves are to be open. E 6BT5.9, 6BTA5.9 Rober Bosch VE Pump
4. If engine cranks but fails to start then the high air .discharge F 4BT3.9, 4BTA3.9 Rober Bosch VE Pump
temperature safety switch malfunction to be checked.
G 6BTA5.9 Lucas CAV DPA
Engine Side
RUNOUT
1. Air in fuel line/choked fuel filters.
Rear cover seal bore 0.020”
2 Compression of all the cylinders
Flywheel housing face 0.008”
3. Choked air filters
Bore 0.008”
4. Blow by exceeds limit
5. Turbo.
Precaution to be taken while decoupling:
1. Compressor to be supported at the bottom side to prevent
deformation of mounting bolts/Anti vibration mounts of compressor.
2. Compressor coupling selling not to be disturbed. Decoupling is
advisable only when there is absolutely no rotation.
IMPORTANT TORQUES B SERIES SPECIFICATIONS

Important N-m Important N-m MIN MAX
Torque Values S.S. Torque Values S.S. DATA
mm (Inch) mm (Inch)
Main bearing 60/120/ Gear cover mtg. 24, 13 mm
capscrews 160, 23 mm capscrews or 12 mm CYL BORE 102.00 (4.0157) 102.116(4.0203)
Connecting 35/70/100, Injector nozzle 60, 24 mm MAIN JRNL BORE 83.106 (2.2730)
Rod 12 mm nut Deep Well
Cyl.Head Mtg. 40/85/126, Lift pump mtg. 24, 12 mm CAM BORE 54.164 (2.1324)
capscrews 18 mm capscrews
Fuel, Dual filter 32, 24 mm CAM BORE NO. 1 54.089 (2.1295) 54.139 (2.1314)
Engines Manufactured after 1991. head nut torque
CRANK MAIN JRNL DIA 82.962 (3.2662) 83.013 (3.2682)
Tighten all Capscrews 90N-m Lub oil filter head 80, 19 mm
(66 ft-lb) OUT OF ROUNDNESS 0.050 (0.002)
Recheck to 90N-m Pressure regulator
(66 ft-lb) LO. Cooler mtg. capscrews 24, 12 mm TAPER 0.013 (0.0005)
Long Capscrews Rkr 120N-m
BEARING CLEARANCE 0.119 (0.00475)
Assly only (89 ft-lb) Lub Oil filter head 24, 12 mm
Recheck Long 120N-m PISTON PIN BORE 40.006 (1.5750) 40.025 (1.5758)
Capscrews (89 ft-lb) Alternator pulley nut 80, 22
Advance all 90 degrees PISTON PIN DIA 39.990 (1.5744) 40.0032 (1.5749)
For detailed procedures refer to T & R Cover intake/ 24, 12,
Manual Bulletin No. : 3810486 Aftercooler 13 mm CRANK ROD JRNL DIA 68.962 (2.7150) 69.013 (2.7170)
Belt tensioner 43, 15 mm OUT OF ROUNDNESS 0.050 (0.002)
G.E.Hsg.Mtg. 24, 12 mm
Camshaft thrust 24, 13 mm 14 mm TAPER 0.013 (0.0005)
plate mounting capscrews Belt tension bracket 24, 5 mm
BEARING CLEARANCE 0.089 (0.0035)
Lub pump mtg capscrews 24, 13 mm ALLEN PISTON RING CLEARANCE
Wtr pump mtg.capscrews 24, 13 mm Fan hub mtg. 24, 13 mm
Rear cover plate 9, 10 mm TOP (TURBOCHARGED) USE KEYSTONE GAUGE
Crankshaft pulley 137, 15 mm
TOP (N. ASPIRATED) 0.075 (0.003) 0.150 (0.0059)
Suction tube and Brace 24, 13 mm
Mounting capscrews Vibration damper 137, 15mm INTERMEDIATE 0.075 (0.003) 0.150 (0.0059)
Oil pan mounting 24, 10 mm
capscrews 12 mm Exhaust mfd. mtg. 43, 14 mm OILCONTROL 0.040 (0.0016) 0.130 (0.0051)
Drain plug on oil pan 43, 17 mm capscrews
PISTON RING GAPS
Rocker cover mtg. torque 24, 15 mm Turbocharger nuts 32, 15 mm
Fuel pump drive shaft 65, 22mm TOP (TURBOCHARGED) 0.40 (0.0160) 0.70 (0.0275)
Nut BOSCH/MICO with Flywheel housing 60, 18 mm
spring washer CAV 81, 22 mm mtg. C/s TOP (N. ASPIRATED) 0.25 (0.0100) 0.55 (0.0215)
Fuel pump mtg. nuts 24, 12 mm INTERMEDIATE 0.25 (0.0100) 0.55 (0.0215)
Fuel pump lock 30, 10 mm Flywheel mounting 137, 19mm
screw with Hex capscrews OIL CONTROL 0.25 (0.0100) 0.55 (0.0215)
special washer Bosch CAV Starter mtg. 43, 17 mm
capscrews.
REMARKS :-
Lifting Hook 24 Nm 12mm Front
Lifting Hook 77 Nm 18mm Rear
S.S. = Socket Size
Page 3-16
cooled, Water cooled

Turbocharged, After
1015 x 598 x 946

154 HP/100kWe
Mechanical A2
MAINTENANCE SCHEDULE - B SERIES
6BTA 5.9 G2 I
12 V 150 Ah
Engine Only
102 x 120
125 kVA
+/- 1.5%
17.3 : 1
A-Check B-Check C-Check D-Check
3.0”Hg
In line
149
90
H
6
-
-
-
q 0-50 hrs/ q 225-250hours/ q 475-500hours/ q 950-1000hours/
0-30 days every 3 months. every 6 months. every 12 months.
Cooling System q Repeat all A q Repeat all A & B q Repeat all A, B &
q Fill coolant and Checks. Checks. C Checks.
recommended Lubrication q Check tappet q Check Fan belt
ensure proper q Change engine clearances and tension, replace if
venting. oil. adjust, if necessary.
cooled, Water cooled

Turbocharged, After
q Check coolant q May be necessary. q Fuel tank
1015 x 598 x 946

124 HP/80 kWe
Mechanical A2
6BTA 5.9 G1 I
level in switched over to Lubrication cleaning.
12 V 150 Ah
Engine Only
equivalent oil of q Check dipstick
102 x 120
Radiator. q Check operating
+/- 1.5%
17.3 : 1
100 kVA
3.0”Hg
In line
Fuel System CF-4, Grade clamping and parameters &
150
90
H
6
-
15W40 correct if
-
q Clean fuel record.
-
strainer, fuel including required. Cooling System
tank breather. Cummins q Clean condition q Replace the
q Check fuel shut Volvoline Oil. of hoses. coolant.**
off mounting & q Change engine Cooling System q Check radiator
tighten the fulll flow oil filter. q Check condition fins and radiator
mounting screw. Record all of hoses and fan blades for
q Adjust the pressure. replace if faulty. damage.
2175 x 807 x 2060

speed control Cooling System q Check fan drive Fuel System
105 HP/66 kWe
Mechanical A2
Turbocharged,
Water cooled
lever if required. q Check coolant belt. q Check fuel lift

12 V 150 Ah
6BT 5.9 G1
102 x 120
14.3 ltrs.
level & top up if Fuel System
B Series Genset Specifications
82.5 kVA
Air System pump diaphragm.

+/- 1.5%
17.5 : 1
UC22G
3.0”Hg
In line
22.00
q Check plugs in necessary.* q Check fuel shut q Clean and check
155
90
H
6
intake pipe for q Check the off mounting & fuel injector
proper sealing. condition and tighten the nozzles.
q Check function tension of mounting screw. Lubrication
of vaccum radiator drive q Check fan drive System
indicator. belt. belt. q Check leakage
q Check hoses q Check the q Check fuel pipes and replace
and clamp for radiator fins for and replace if hoses if required.
2175 x 807 x 2060 proper sealing. contamination required. Air System
Other or blockage. Air System q Check hump
105 HP/60 kWe
Mechanical A2
Turbocharged,
Water cooled
q Check leaks if Fuel System q Check air

12 V 150 Ah
hose and replace

6BT 5.9 G1
102 x 120
14.3 ltrs.
any. q Change fuel/ cleaner sealing. if required.

+/- 1.5%
17.5 : 1
UC22W
75 kVA
3.0”Hg
In line
22.00
q Check G/Set water separator q Check sealing of

155
Mechanical
90
H
6
and G/set room. element. radiator. System

Exhaust System q Clean fuel Mechanical q Adjust valve
q Ensure smoke strainer, fuel System lashes as
level is normal tank breather. q Adjust valve recommended.
and no leak q Check fuel shut lashes as Electrical System
from piping. off mounting & recommended. q Check battery
q Check for tighten the Electrical System switches and
proper support mounting screw. q Clean battery replace if
Fuel Consumption at 1500 RPM (gms/bhp-hr)
to Exh. pipe. q Adjust the terminals. required.

q Check and throttle lever if q Check wiring qCheck
record exhaust required. harness for starter/battery
(L x B x H) in mm. With S. B. alternator
back pressure Air System tightness of charging

Coolant Capacity – with Radiator (ltrs)
q Clean element
150 mm exhaust manifold out flange
(inches of Hg) terminal alternator and

Section - 3 Engine Data - B Series
Exhaust gas back pressure max. at

Noise Level at 3 mts Distance (dB)
Electrical System in reverse clamping. repair if required.

Prime Power Rating at 1500 RPM
Approx. Dimensions of D. G. Set
q Check battery direction with q Check wiring

condition clean dry air harness and
Alternator Voltage Regulation
pressure. connections and

Alternator Insulation Class
Electrical System tighten if

Lubrication Oil Capacity
q Check battery required.

Alternator Size (Prime)
terminals.
Engine Configuration
Bore & Stroke in mm

Aspiration & Cooling
Compression Ratio
Battery Capacity
No. of Cylinders
Governor Class
Note : For more information refer respective operational maintenance

Engine Model
manual.
Parameter
* Add treated coolent during top up.

** Drain complete cooling system and flush the entire system.

GAUGES AND INDICATING LAMPS TO BE USED AS PER 12V OR 24V
OIL PRESSURE
WATER TEMP.
HOUR METER
RPM METER
GAUGE
GAUGE
45
45
45
23 +B -T 43
23 +B -T 32
LOP FAIL/ALARM
48
+
45
45
INDICATOR
36
45
23
37
48
INSTRUMENT PANEL WIRING
45
HWT FAIL/ALARM
23
INDICATOR
45
SWITCH
KEY
2
3
1
31
FOR B SERIES INDUSTRIAL APPLICATIONS (WITH SD. COIL)
28
ASSY. INDICATOR
23
P.B.
27
28
40
45
31
32
28
45
27
40
23
28
38
37
43
12 46
10
11
1
2
3
4
5
6
7
8
9
28
27
40
23
28
31
32
38
37
43
45
46
43
SENDER
OIL PR.
32
WTR. TEMP.
SENDER
31
40
37
26
28
27
23
36
45
EMGINE WIRING
+VE
45
12V/24 BATTERY
STARTER
27
26
-VE
L.O.P. SAFETY
33E
36
31
37
W.T. SAFETY
40
35
37
28
25
SWITCH
WL
SWITCH
ALTERNATOR
W
+
SHUT DOWN
35
23
46
COIL
Section- 4 Engine Data C- Series Page 4-0 Section- 4 Engine Data C- Series Page 4-01
ENGINE SPECIFICATIONS
Contents Page
Engine Series : C
01 Specifications & Product Information………………………...…4-01
Bore : 114 MM
02 ‘C’ Series Design Features ………………………………………4-01 Stroke : 135 MM
03 Parts Common To ‘B’ Series Engine……………………………4-01 Displacement : 8.3 LITERS
Firing Order : 1-5-3-6-2-4
04 PE Bosch Pump Product Designation ………………………..4-02
Number of Cylinders : 6
05 Governor Product Designation………………………………….4-03 Configuration : Inline
06 Motorpal Pump Product Designation………………………...…4-03
PRODUCT INFORMATION
07 ‘C’ Series Checkpoint Information …..………………………….4-04
Model BHP @ RPM KVA e @ 0.8 pf
08 Important Basic Engine Design ………………………………..4-05
6 CTA 8.3 C 230 @ 2000
09 Important Tips To Troubleshooting Systemwise .…………… 4-07
6 CTA 8.3 205 @ 1500 160
10 Procedure For Installation of Fuel Pump ……………………4-11 6 CT 8.3 G2-I 175 @ 1500* 140
11 Procedure For Valve Setting …………………………………4-12 6 CTA 8.3 G1-I 205 @ 1500* 160
12 ‘C’ Series Engine Maintenance Schedule …………………….4-13 6 CTA 8.3 G2-I 219 @ 1500* 180
6 CTAA 8.3 G1-I 245 @ 1500* 200
13 Important Clearances …………………………………………4-13
14 Important Torque Values ………………………………………4-14
‘C’ SERIES ENGINE DESIGN FEATURES
15 Wiring Diagram ............………………………………………4-15 • Single Piece Cylinder Head
• Replaceable Guides
• Wet Cylinder Liners - Mid Stop Design
• Short Water Jacket
• Gerotor Lube Pump
• Forged Steel Crankshaft
• Steel Camshaft
• Two Valves Per Cylinder
• High Swirl Combustion
• Helical Intake Port
• Inline Fuel Injection Pump
PARTS COMMON TO ‘B’ SERIES ENGINE

.. Crankshaft Seals (Rear)
.. Valve Tappets
.. Engine Timing Pin Assembly
.. Fuel Pump Drive Access Cover
.. Belt Tensioner
.. Fuel Filters
.. Camshaft Thrust Plate
BOSCH PE PUMP PRODUCT DESIGNATION GOVERNOR PRODUCT DESIGNATIONS
A typical inline pump will have the following name plate. ‘RSV’
RS V 400-1100 A0C 2190 8R
BOSCH R = Flyweight Governor

made in Germany
S = Swivel Lever Model
02256063 SERIAL
NUMBER V = Variable Speed Governor (all speed)
ALPHA PES6A 100D 320/3 400 = Low Idle Pump Speed
NUMERIC RS2697
1100 = Full Load Pump Rated Speed
PRODUCT
DESIGNA- 9 400 230 097 A = Fits On “A” Size Pump
TION __________________ TEN 0 = Numerical Code For Percent of
DIGIT Regulation (flyweight and spring combination)
PART
C = Governor Model (version)
NUMBER
2190 = Application Number
The product designation for the above name plate can be broken into R = Located On Right End Of Pump
sections as follows.
MOTORPAL PUMP PRODUCT DESIGNATION

PE - Inline Pump With Camshaft
A typical motorpal Mf injection pump details are as follows
S - Flange Mounted
PP6M 10K 1 f N10812
P = stands for fuel injection pump
6 - Number of High Pressure
Outlet (Pumping Elements) P = stands for flange type mounting
A - Pump Size; MW = Pump Size 6 = represents No. of injection units
Mf = Size of pump, depending on the plunger stroke

100 - Plunger Diameter (multiply times 1/10 mm) 10 = Diameter of the plunger (mm)
K = Plunger head shape with constant beginning of injection

D - Execution; /=Original;
1 = Rotation of Camshaft (Clockwise from drive end)
A = first change;
B = second change; N10812 = Assembly document number
C = third change; etc
320/3 - Construction information
R - Direction Of Rotation
(R = Right; L = Left)
S2697 - Application Information

‘C’ SERIES ENGINE
CHECKPOINT INFORMATION VIBRATION DAMPER
- Check alignment marks at proper service checks
OIL TEMPERATURE AT OIL SUMP
- Range -99 to 127 Degrees Centigrade 8 RIB POLYVEE K SECTION BELT
OIL PRESSURE AT MAIN RIFLE - Proper belt tension – 80 to 140 lbs – ST – 1293 Gauge
- min 10 psi idle - 30 psi rated
- Typical 30 psi idle - 60 psi rated
CRANKCASE VENT
TURBOCHARGER I AIR MANIFOLD PRESSURE
- Pressure 27-40 in. Hg at rated - Engine blow by
Note : Pressure subject to engine HP and design. - New engine after break in 0.8 in. of water
FUEL INJECTION PUMP - Used engine max. 18 in. of water
- Fuel Gallery Pressure - 20 psi. min. Note : Blow by reading at rated RPM with 0.302” orifice restriction
Note : Regulated by fuel drain connection
- Fuel Drain Restriction -20.4 in. Hg.
COMPRESSION PRESSURE AT CRANKING SPEED OF
FUEL SHUT OFF SOLENOID - TWO COILS – PULL AND HOLD
- min. Operating Voltage -24 V; Peak Amps-2 - New engine - 350 psi. min
Resistance Ohms Across Coil - 29.5 – 2.5 ; Peak Amps – 1
- Used engine - 300 psi min
Dipstick litres
- Low Level - 15.3 Note : Difference between pressures of 2 adjacent cylinders
- High Level - 18.9 indicates cylinder head gasket damaged.
Note: Level may change with oil pan option

IMPORTANT BASIC ENGINE DESIGN
OIL PRESSURE REGULATOR
- Regulator plunger starts to open at 60 psi 01. # 4 MAIN UPPER THRUST BEARING
pressure and returns oil back to sump. 02. PISTON COOLING NOZZLES IN # 1,2,4,5,6 & 7 MAIN
BEARING SADDLES.
WATER TEMPERATURE 03 ALL UPPER MAIN BEARINGS SAME PART NUMBER
- Min 70 Degrees Centigrade EXCEPT #4, WHICH IS A THRUST.
- Max 95 Degrees Centigrade 04. ALL LOWER MAIN BEARINGS SAME PART NUMBER.
05. CONNECTING RODS NOT PRESSURE LUBRICATED AT
TURBOCHARGER UPPER PIN BORE. NOTE: OILED BY PISTON COOLING
- Turbocharger Outlet Restriction - 2.0 in Hg. (max. at rated load) NOZZLE.
- Turbocharger inlet Restriction 06. CONNECTING ROD BEARING, UPPER & LOWER
6C8.3 - 20 in. of water BEARINGS SAME PART NUMBER.
6CT8.3 / 6CTA8.3 - 25 in. of water 07. TAPPETS SAME PART NUMBER AS USED ON ‘B’ SERIES,
MUSHROOM TAPPET OR TOP HAT STYLE.
WATER MANIFOLD 08. CAM THRUST, METAL CONSTRUCTION. ACCESS TO
- Upper manifold CAPSCREWS, WHEN TIMING MARKS ARE ALIGNED.
- Cold side of system 09. CAM BUSHINGS IN ALL CAM BORES.
- Higher pressure side
- PROPER ALIGNMENT IS WHEN OIL HOLE IN BUSHING
- Upper manifold pressure - IS ALIGNED WITH OIL SUPPLY PASSAGE.
12 to 25 psi (rated) with 7 psi pressure cap
- OIL FEEDS OVERHEAD FROM #7 CAM BUSHING
Note: Engine RPM and temperature,
- OIL FEEDS FUEL PUMP SUMP FROM # 1 CAM
pressure cap will cause pressure difference.
BUSHING
- Lower manifold
10. NO TIMING MARKS ON FUEL PUMP DRIVE GEAR.
- Hot side of system
- Lower pressure side 11. WATER PUMP CAN ONLY BE INSTALLED IN ONE
POSITION.
IMPORTANT TIPS ON TROUBLE
12. ONE PIECE HEAD DESIGN SHOOTING – SYSTEMWISE
AIR SYSTEM
NOTE : CAPSCREWS UNDER INJECTOR HOLD-ON 1. Air flow restriction will result in excess smoke and low
CAPSCREWS power.
13. ROCKER LEVER OIL SUPPLY TUBE CAN ONLY BE 2. Entry of non filtered air will result in damage to cylinders.
INSTALLED IN ONE POSITION AS REMOVED, AS TUBE 3. Excess smoke and low power can result if there are leaks
WILL TAKE A SEATED POSITION, BECAUSE OF on the pressurised side and/or exhaust leaks.
PRESSURE OF THE CLAMPING FORCE OF THE 4. A malfunctioning turbocharger can result in :
ROCKER LEVER SUPPORT.
- low power & black smoke
14. LINERS MID STOP DESIGN 0.0005” TO 0.0045” LINER - High lubricating oil consumption and blue smoke
PROTRUSION
- Unusual noise
15. HIGH PRESSURE INLINE PUMP WILL BE ROBERT Engine Model Orifice size Blow by limits Inch of water
BOSCH ‘A’ OR ‘MW’ TYPE OR MOTORPAL PUMP.
New/Rebuild Used engine
16. A FUEL PUMP POSITIONER OR TIMING PIN IS 6 CT/A-8.3 0.302” 4 18
PROVIDED FOR PUMP INSTALLATION. FUEL PUMP
INSTALLATION WILL REQUIRE ENGINE TO BE FUEL SYSTEM
POSITIONED AT T.D.C. OF COMPRESSION STROKE 1. The lift pump should deliver a volume of 0.75 litres within
FOR # 1 CYLINDER. 30 seconds of cranking.
17. TWO PISTION COOLING NOZZLES PER CYLINDER. CAUTION : Make sure the wire to the fuel solenoid is
disconnected before performing this check.
C-Series Conventional Block V/s Rationalized Block Residue fuel in the injection pump may allow the
engine to start.
Feature Conventional Block Rationalized Block
CIL Make Serial 2525____ 2575____ 2. Frequent fuel filter replacement to get full power from the
Number starts with engine can indicate a worn lift pump.
Thermostats Two One 3. For a problem of low power, if the lift pump delivers the
Coolant Flow Cylinder Head to Liner Liner to Cylinder Head required volume, check for restrictions on supply leaks in
Belt Tension Pulley Mounted Up Mounted Down the fuel circuit to the lift pump.
FIP Make Robert/Mico Bosch Motorpal a. Tank vent
FIP Oil Supply Through Gear case Separate oil supply pipe
b. Supply tank
Breather provision On rocker cover On rocker cover or on
c. Supply line
block
d. Pre filter
Coolant filter At thermostat At water header
e. Supply line
Location
Bosses on block No bosses for ECM Bosses for ECM 4. Air in the fuel system will result in engine hard to start, run
mounting mounting. rough, misfire, produce low power.
5. Filtration and separation of water from the fuel is important
for troublefree operation and long life of fuel system.
6. A restricted travel of the fuel control lever (Throttle Lever)
can cause low power.
7. The high idle screw of the fuel injection pump is set at the
factory and should not be adjusted in the field.
8. Partial actuation of the mechanical shut down lever will
affect fuel flow and engine power.
9. Fuel injection pump timing with respect to engine is

NOTE : An increase in white smoke during the first start of the
extremely critical. Pump timing that is off by only a few
crankshaft degrees will cause day is a symptom that an injector is leaking.
1. Poor performance - Starting and power COOLING SYSTEM
2. Excessive smoke and emissions
1. Overheating of the engine may result due to
3. Poor fuel economy - water temperature gauge malfunction
10. The length, internal size and rigidity of the high pressure - less coolant level
- oil level more than “H” mark
fuel lines is critical to smooth engine operation. DO NOT
- air in cooling system
WELD OR SUBSTITUTE LINES. USE ONLY THE
- restricted water pump suction line
SPECIFIED PART NUMBER FOR THE ENGINE.
- belt tensioner malfunction
WARNING : THE PRESSURE OF THE FUEL IN THE LINE - choked radiator
IS SUFFICIENT TO PENETRATE THE SKIN - damaged fan hub bearings
AND CAUSE SERIOUS BODY HARM. - thermostat malfunction
- overfueling
11. For removing air in high pressure line, bleed at the fitting - over loading
that connects the injector. Bleed one line at a time, until the - incorrect fan shroud
engine runs smooth. - damaged fan
12. To ascertain a malfunctioning injector; operate the engine

and loosen the fuel line nut one at a time at injector end and
listen for a change in engine speed. A drop in engine speed
indicates the injector was delivering fuel to the cylinder and COOLANT LOOP OF CONVENTIONAL AFTERCOOLING
vice versa. SCHEMATIC OF COOLANT LOOP
OF 6 CTA 8.3 WITH
CONVENTIONAL AFTERCOOLING
LUBRICATING SYSTEM LOWER WATER

85 DEG.C
MANIFOLD
THERMOSTAT
1. A pressure regulator, stuck in closed position will result in LINER

CAVITIES
COOLANT
high oil pressure. FILTER
AFTER
COOLER
CYLNDER RADIATOR
HEAD
2. Low oil pressure may be a result of UPPER WATER

MANIFOLD
a. Oil pressure gauge faulty. OIL COOLER
b. Low engine oil level CAVITY
76
c. Loose suction tube WATER PUMP DEG.C
d. Choked oil filter

e. Pressure regulator stuck in open position COOLANT FLOW RATIONALISED BLOCK
f. Oil dilution
g. Excessive worn oil pump UPPER WATER
85 DEG.C.
h. Worn bearings & bushings MANIFOLD

THERMOSTAT
3. Coolant in the oil results from a crack or leak between the CYLINDER
HEAD
coolant and oil circuits from following components. COOLANT AFTER
FILTER COOLER
- oil cooler LINER RADIATOR
CAVITIES
- aftercooler
- core plugs in cylinder head LOWER WATER
MANIFOLD
- cylinder liner seal
OIL COOLER
- headgasket CAVITY
- cylinder liner (crack) 76
- cylinder head (cracked passage) WATER PUMP

DEG.C.
- cylinder block (cracked passage)

AFTERCOOLER UNDER PRESSURE
4. Fuel diluting oil is limited to four sources
- lift pump
- malfunctioning injector
- inadequate piston ring sealing
- a worn or damaged injection pump
PROCEDURE FOR INSTALLING FUEL PUMP

ELECTRICAL
1. For a problem of engine not cranking, the possible reasons
may be A typical PES6A Robert Bosch Pump/Motorpal Pump
- battery terminals loose or corroded 1. Bring cylinder no. 1 to TDC of compression stroke, by using
- discharged batteries engine timing pin.
- loose electrical wiring
- damaged starter pinion and flywheel ring gear 2. Remove access plug of fuel pump governor housing timing pin.
- electrical starter faulty
3. Remove the pump timing pin.
4. Rotate fuel pump shaft, till timing tooth is in centre of access
2. Engine cranking speed too low may be due to plug hole.
- low battery voltage 5. Reverse position of timing pin, so that timing pin engages in
- starter faulty tooth and locks the fuel pump shaft.
- excessive load from drive units 6. Fit access plug.
- internal engine malfunction
7. Make sure the "O" ring seals are correctly installed and are not
damaged. Lubricate the mounting flange.
3. Trouble with the charging system may be indicated by
indicator lamp or ammeter. 8. Slide the pump shaft through the drive gear and position the
pump flange on to the mounting studs.
In case ignition switch is off, lamp is on, when engine is
stopped, then the reason may be 9. Install the mounting nuts. Torque value - 43 N.m. (32 ft. lb.)
- short to the positive wire of ignition side of lamp 10. Install the retaining nut and washer. Torque value 10-15 N.m.
- short in the ignition switch (7-11 ft.lb.)
11. Disengage the timing pin.
In case of ignition switch on, lamp off, with engine stopped,
the reason may be 12. Remove the fuel pump timing pin plug. Reverse the position of
- blown fuse the pin and install the pin, plug and sealing washer.
- burned out bulb 13. Tighten the fuel pump drive nut.
- defective bulb socket Torque values - FES6A - 93 N.m.
- open circuit between alternator and ignition switch PES6MW - 105 N.m.
Motorpal MI - 105 N.m.
In case of ignition switch on, lamp on, engine running, the
reason may be 14. Install the gear case cover access cap. Hand tight.
- belt slippage 15. Install the fuel lines, control linkage and fuel shutoff solenoid.
- short circuit to ground, on the alternator side of lamp Note : (1) Brand new pumps from factory and serviced pump from
- faulty alternator service shop are always in locked condition.
(2) Both the Robert Bosch and Motorpal fuel pumps have a
4. Abnormal charging system operation may be due to timing pin for looking the fuel pump shaft, during fitment,
- loose connections however the timing pins are different.
- defective wiring
- faulty alternator
5. For checking of fuel shut off valve, activate the ignition

switch and check the plunger travel
A = 86.6 mm (3.4 in.) - Ignition switch in off position

B = 60.2 mm (2.4 in) - Ignition switch activated
Note : The solenoid must operate without binding

PROCEDURE FOR VALVE SETTING C Series Engine Maintenance Schedule : (CIL Make Rationalised
Block Engines)
1. Use timing pin to locate Top Dead Centre of compression stroke
A-CHECK DAILY B-CHECK C-CHECK D-CHECK
for cylinder no. 1.
300 HOURS OR 1500 HOURS OR 6000 HOURS OR
6 MONTHS 1 YEAR 2 YEARS
CAUTION : Be sure to disengage the pin after locating TDC.
Maintenance Check/Inspect/ Change/Replace/ Check/Inspect/
Check Replace Inspect Replace
2. Check / adjust valves for cylinder as follows:
l Check fuel- Repeat a Check Repeat A, B Repeat A, B & C
F water separator. l Change Check Check
CYL CYL CYL CYL CYL CYL l Check lubricating oil l Adjust overhead l Drain cooling
L lubricating oil l Replace fuel set. system.

level filters l Check drive l Inspect vibration
1 2 3 4 5 6 Y l Check coolant l Replace belts. damper.
level lubricating filter.
# # # # # # W l Check cooling l Clean fuel
fan strainer
I E I E I E I E I E I E H l Check drive l Inspect air
E belts. intake piping.

l Inspect charge
E air cooler
- Clean charge
L oil cooler
- Check air
cleaner
restriction
# - Valves to be set l Vent fuel lines
l Vent injector
3. Mark on the vibration damper and correspondingly on the gear supply lines
l Check coolant
case cover. Rotate the crankshaft by 360 degrees in clockwise parameters.
direction.
Note :
4. Set the remaining valves as follows: 1. Refer specific Operation & Maintenance Manual for other C-Series
F engines.
CYL CYL CYL CYL CYL CYL L 2. Lube Oil recommended is API CH4, SAE 15W40 (Valvoline Premium
blue/equivalent)
Y 3. Coolant to use - compleat EG for all Alluminium Radiators.
1 2 3 4 5 6
W For more details refer Page No. 0-20
* * * * * * H IMPORTANT CLEARANCES
I E I E I E I E I E I E E CHECK POINT INCH
Crankshaft endplay 0.006/0.013
E
Con rod side clearance 0.004/0.012
*Valves to be set L Camshaft end clearance 0.0047/0.0134
Liner protrusion 0.0005/0.0043
Min. clearance between 0.009
lower block edge & bottom of liner
INTAKE VALVE CLEARANCE - 0.012” R C plate protrusion +0.006
EXHAUST VALVE CLEARANCE - 0.024” GEAR TRAIN BACKLASHES
Crank to cam gear 0.006/0.010
Crank to lube pump idler 0.003/0.013
Lube pump gears 0.003/0.013
Cam gear to fuel pump gear 0.006/0.010
RUNOUT
Flywheel housing face 0.008
Flywheel housing bore 0.008
IMPORTANT TORQUE VALUES WIRING DIAGRAM ECP-II C-Series

N-m Socket Size
Main brg C/s 50/95/170 21 mm
Connecting rod 40/80/120 19 mm
Cyl. Head Mtg C/s (Mfg. before 1991) 40/150/220 16 mm
DETAILS OF 19 PIN CONNECTOR
Cylinder Head Torque Manufactured after 1991.

H= LLOP PRESSURE
Tighten all Capscrews 70 N-m (52 ft-lb)

WATER TEMP
V= 'W' TERMINAL
D= SHUT DOWN
MPU ECPG
L=PANEL +VE
Recheck to 70 N-m (52 ft-lb)

A=PANEL -VE
J= SENSOR
P= SENSOR
SHIELD SHOULD BE CONNECTED TO COMMON

COIL
Long Capscrews only 145 N-m (105 ft-lb)

4. SHIELDED CABLES CAN BE STRIPPED FOR
OR SIGNAL RETURN ON THE EQUIPMENT
1. THIS WIRING DIAGRAM IS FOR C SERIES
Recheck Long Capscrews 145 N-m (105 ft-lb)

}
}
}
G=
N=
B=
T=
2. 24 VOLT NEGATIVE GROUND SYSTEM

CONNECTIONS UPTO 3 INCHES MAX.
ENGINES WITH ECP II CONTROLLER
Advance all 90 degrees

3. TURN THE STARTING KEY SWITCH
TO START POSITION TO CRANK
For detailed procedures refer to T and R Manual Bulletin No : 3666003

G.E.hsg. mtg C/s 24 12 mm
SYSTEM - ELECTRICAL
Pan rail 60 19 mm
THE ENGINE
Camshaft thrust plate 24 12 mm

SIDE ONLY.
Lube Pump Mtg C/s 5/24 24 mm

Wtr Pump mtg C/s 24 13 mm
Rear Cover Plate 9 10 mm
P.V.C. 85 SQ. MM
WIRE GAUGE
Suction tube and Brace mtg C/s 9 10 mm

1.5 SQ. MM
4.0 SQ. MM
1 SQ. MM
1 SQ. MM
Oil Pan mtg C/s 24 13 mm

19 PIN CONNECTOR
Drain Plug on Oil Pan 80 3/8”

SHIELDED
CAPACITY
M
G
H
U
C
D
R
E
B
S
A
V
K
F
T
J
CABLE
AMP.
Rocker Cover Mtg C/s 55 10 mm

200
14
30
11
M
G
H
U
D
R
E
B
S
-Ve A
V
K
F
T
L
J
WATER TEMP.
Rocker Cover Mtg C/s 24 15 mm

SENSOR
CIRCUIT NO.
25, 33E, 38, 17
Fuel Pump drive Shaft nut PES 6 A 93 14 mm

G, E, V, A, L
G,H,J,N,P
26, 45, 27
39 E.D
PES 6MW 105 11/16”

B,T
PICK-UP
Motorpal mf Pump 105 11/16”

MAG.
40 AMPS.
Fuel Pump mtg Nuts 43 14 mm

0 HOLDING COIL
27
MAGNETIC
PULLING COIL
Gear Cover mtg C/s 24 12 mm

SWITCH
17
FUEL SHUT-OFF VALVE
38
39E
Lift Pump C/s 24 12 mm

39E
DATALINK
START
27
Fuel Dual Filter 32 24 mm

L
Lub Oil Pressure regulator 80 22 mm

-Ve
25 38
17
45
45
L.O. cooler mtg C/s 24 13 mm

STARTER
EARTH WIRE
BATTERY 24 V.D.C.
OUTPUT
39E 26
+Ve 25
GND
+5V
ALTERNATOR
-Ve +Ve
Cover intake 24 12 mm
v
A
LLOP PRESSURE
Belt Tension 43 15 mm
w
-Ve
Belt Tension Bracket 24 5 mm allen

SENSOR
33E
25
+Ve
Fan Hub Mtg C/s 24 12 mm

Fan Hub pulley 43 17 mm
Vibration Damper 200 18 mm
Exh mfd mtg C/s 43 17 mm
Turbo nuts 32 15 mm
Flywheel Hsg Mt C/s 60 19 mm
Flywheel 137 18 mm
Starter 77 19 mm
Injector nozzleHold Down C/s 24 12 mm
Section 5-Engine Data S-Series S-SERIES GENSET RATINGS AND SPECIFICATIONS Page 5-2
Parameter 30 kVA 35 kVA 40 kVA 45 kVA 50 kVA 62.5 kVA
Engine Model S 3.8 G2 S 3.8 G3 S 3.8 G4 S 3.8 G5 S 3.8 G6 S 3.8 G7
Contents
Prime Power Rating at 1500 RPM 37 HP/24 kWe 43 HP/28 kWe 52 HP/32 kWe 58 HP/36 kWe 65 HP/40 kWe 76 HP/50 kWe
No. of Cylinders 4 4 4 4 4 4
Engine Configuration In line In line In line In line In line In line
Governor Class Mechanical A2 Mechanical A2 Mechanical A2 Mechanical A2 Mechanical A2 Mechanical A2
Natural, Natural, Turbocharged, Turbocharged, Turbocharged, Turbocharged, After
Aspiration & Cooling
Water cooled Water cooled Water cooled Water cooled Water cooled cooled, Water cooled
Bore & Stroke in mm 97 x 128 97 x 128 97 x 128 97 x 128 97 x 128 97 x 128
Engine Maintenance Schedule
Compression Ratio 17:1 17:1 17:1 17:1 17:1 17:1

Section 5-Engine Data S-Series
Battery Capacity 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah

Alternator Size (Prime) UC22C UC22C UC22C UC22T UC22D UC22V
Alternator Voltage Regulation +/- 1.5% +/- 1.5% +/- 1.5% +/- 1.5% +/- 1.5% +/- 1.5%
Alternator Insulation Class H H H H H H
Lubrication Oil Capacity 7-9 ltrs. 7-9 ltrs. 7-9 ltrs. 7-9 ltrs. 7-9 ltrs. 7-9 ltrs.
Coolant Capacity–with Radiator (ltrs) 11.00 11.00 11.00 11.00 11.00 11.00
Noise Level at 3 mts Distance (dB) 90 90 90 90 90 90
Exhaust gas back pressure max. at
2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg
150 mm exhaust manifold out flange
Approx. Dimensions of D. G. Set
1700 x 620 x 1436 1700 x 620 x 1436 1700 x 620 x 1100 1700 x 620 x 1100 1700 x 620 x 1100 2070 x 773 x 1206
(L x B xH) in mm. With S.B. alternator
Electrical System..........................……………………………….5-8
Engine Nomenclature, Features ………………………………..5-1
Valve Setting Procedure ………………………………………….5-7

Genset ratings & Specifications ………………………………….5-2
Engine Wiring Diagrams ..............……………………………….5-9

FIP removal & Fitment…………………………………………….5-7
Fuel System ……………………………………………………….5-6
………………………………..5-3
Torque Values ……………………………………………………5-5
Coolant System ……………………………………………………5-6

Air System ………………………………………………………….5-6
Lubricating System………………………………………………...5-6
Dry / Oil Bath Type Dry / Oil Bath Type

Page
Page 5-0
Air Cleaner Dry Type Dry Type Dry Type Dry Type
Section 5-Engine Data S-Series Page 5-3

MAINTENANCE SCHEDULE S-3.8-G ENGINES
Intake
Cooled
Exhaust
Features
A Check B Check C Check D Check
Thermostat
G - Genset
Four Stroke
❏ Daily 300 hours/every 3 months 600 hours/every 6 months 1200 hours/every 12 months
Firing Order :
Bore x stroke
Water Cooled
Industrial silencer
Inline 4 Cylinders
Lubrication ❏ Repeat all A checks ❏ Check battery mounting. Clean battery ❏ Repeat all A, B, & C Checks
Metric Dimensions
Example : S-3.8-G
Compression Ratio
❏ Check oil level, top up Lubrication posts and terminals. Tighten terminals ❏ Check tightening of Oil Pan
Length x width x height
if necessary ❏ Change oil in sump, drain off while still and apply Vaseline/petroleum Jelly. mounting Cap Screws.
Displacement 3.785 litres
97 x 128
hot and clean magnetic drain plug. Check level of electrolyte and top up ❏ Check fan belt tension,
0
1-3-4-2
3.8 - Displacement in liters
Oil bath / dry type air cleaner
❏ Lubricate the FIP linkage by using oil with distilled water, if necessary. replace if necessary.
S - Small end horsepower
Fuel System
0
Caution: Don't use CAC/DCA

can. ❏ Remove and clean air ducting hoses. ❏ Apply grease to fan hub & Capacity with radiator - 11 litres
17:1
❏ Check fuel level in

Dry weight engine only 360 kgs.
fuel tank and secure ❏ Check oil level in FIP and governor and ❏ Remove and clean engine breather cap belt tensioner.
0
top up if necessary. (strainer) in kerosene oil, blow air in

Engine water pump - centrifugal type
❏ Clean the fuel tank for the

Thermostat fully open - 83 C to 87 C
the tank cap.

Direct Injection Mico Pump & Nozzle
Minimum exhaust pipe size is 50 mm.
❏ Clean engine oil filler housing. Replace reverse direction and refit. Replace dirt and the sediments. Operating temperature - 750 C to 950 C
Thermostat start to open - 72 C to 76 C
A Holset make turbocharger, model H1C
AIR SYSTEM
oil filter cartridge and ‘O’ ring. Fill oil filter rubber gasket, if necessary.
Cooling system pressure - 0. 5 bar ( 7 psi)
Cooling System
❏ Check coolant level in housing with recommended engine oil. ❏ Check valve clearance and adjust, if
Maximum exhaust backpressure is 2.0//of Hg.
COOLANT SYSTEM
Coolant - Water : Ethylene Glycol -- 50: 50 (1:1)

S-3.8-G NOMENCLATURE
radiator and top up if Fuel System necessary (engine warm).

1054 x 628 x 995 mm
necessary and ❏ Change both fuel filters. ❏ Lubricate water pump with bearing
Aluminum core radiator without deaeration system.
secure the cap. ❏ Remove drain plug of fuel filter bowls grease.
Oil bath air cleaner pan capacity 0. 600 to 0. 650 litre
and drain off sediment.

0
Flow ---- Thermostat ----- Water pump / Radiator ----- Water

Naturally Aspirated / Turbocharged / Turbocharged & After
Contd...
pump ----- Oil cooler ----- Cylinder block ---- Cylinder head ------
5-1
0
Dry type air element max allowable restriction is 25” of water column.
Maximum exhaust gas, temperature range at full load is 407 C to 565 C

Page 5-4
1200 hours/every 12 months

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.
i
Description Torque (Kgf-m)
D Check
Engine
1. Main bearing cap bolts 5 Plus "90 to110" deg
2. Counterweight bolts on crankshaft 3 Plus "90 to110" deg
element No. 1. Remove the drain plug of
Check engine for trouble-free operation

functioning and operating temperature.
3. Connecting rod bearing
fuel filter No. 2 and drain off sediment.
Clean fuel filter bowl and replace filter
(colour of exhaust gases and nozzle

Short thread bolts M14/M 15 x 1.5 or nuts 10 Plus "90 to110" deg
Long thread bolts M 15 x 1.5 5 Plus "90 to110" deg
Check the thermostat for proper
4. Cylinder head nuts -

MAINTENANCE SCHEDULE S-3.8-G ENGINES – CONTD…..
Tighten cylinder head 1st stage 6

in 3 stages as per sequence 2nd stage 9
3rd stage 11
5. Screw plug in cylinder head 10 to 20
Bleed the system.
6. Protective sleeve in cylinder head M14 x 1 6

7. Nozzle in nozzle holder 8
8. Nozzle holder in cylinder head 7
operation).
9. Cap nuts on high pressure lines 2.5

10. Rocker arm support bolts M12 11
C Check
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
❏
operating condition, showing red signal. ❏
14. Oil cooler bolts on Cyl. Cr. case M8 3.5

coolant, fuel and lube ❏ Clean air cleaner element for dry type air
15. Timing gear housing on crankcase M10 4.5

❏ Clean radiator core with compressed air.
indicator. Please take up the element for

❏ Check coolant concentration, replace or
❏ Check connections of starter motor and
❏ Tighten cylinder head nuts (with engine

❏ In case, red signal shown in restriction
16. Timing gear nut (Injection pump) M14 x 1.5 8

❏ Check oil condition and oil level in air
❏ Check restriction indicator-whether in
cleaner oil bath. Add oil if necessary.
❏ Check valve clearance and adjust, if
17. Timing gear housing cover M6 0.8

alternator and tighten if necessary.
18. Bolt for timer on Camshaft 30

warm) and in correct sequence.
19. Vibration damber lock bolt M24 x 1.5 50 to 55

20. Flywheel mounting bolts M12 10
necessary (engine warm).
add Coolant if necessary.
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
Cooling System
26. Oil sump drain plug 4 to 6

27. Screw on water pump pulley hub 3.5
cleaning.
cleaner.
Air System
28. Exhaust manifold bolts M10 3.5

B Check
29. Starter motor on clutch housing M10 5

Others
30. Clamping bolt for altenator 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
❏ Check for leakage of
34. Banjo bolt of leak oil line 2.5

35. Centre bolt of oil filter housing 6
Instruments are
oil and rectify.
36. Oil Filter on crankcase M10 6

functioning.
❏ Check if all
37. Oil pump cover on oil pump M8 3

Instruments
38. Suction pipe on oil pump cover M8 6

❏ Daily
A Check
39. Screw plug oil pressure relief valve M24 1.5 to 2.5
Others
Section 5-Engine Data S-Series Page 5- 6 Section 5-Engine Data S-Series Page 5-7
AIR SYSTEM FUEL INJECTION PUMP- REMOVAL & FITMENT

Intake Removal
Oil bath / dry type air cleaner 1. Remove all Fuel connections of Fuel Pump
Oil bath air cleaner pan capacity 0. 600 to 0. 650 litre
2. Remove mounting capscrews on fuel pump mounting flange
Dry type air element max allowable restriction is 25” of water column.
mounted on Cylinder Block
Exhaust
Industrial silencer Fitment by Spill cut adjustment
A Holset make turbocharger, model H1C 1. Rotate Crankshaft in clockwise direction and bring # 1 piston to 200
Maximum exhaust backpressure is 2.0 //of Hg. B T D C. (achieved by aligning yellow mark on flywheel with pointer
Maximum exhaust gas, temp range at full load is 407 o C to 565 o C in inspection window of flywheel housing)
Minimum exhaust pipe size is 50 mm. 2. Slide Fuel Pump in position ensuring that ‘notched gear teeth’ on
COOLANT SYSTEM F I P Cam gear aligns with pointer (can be viewed by removing
Flow ---- Thermostat ----- Water pump / Radiator ----- Wate r breather fitted on Cylinder Block.)
pump ----- Oil cooler ----- Cyl block ---- Cylinder head ------ 3. Follow ‘spill cut adjustment procedure’ for fine adjustment of Fuel
Thermostat Pump
Thermostat start to open - 72 0 C to 76 0 C 1. Fuel line from Fuel pump.
Thermostat fully open - 83 0 C to 87 0 C 2. Remove delivery valve holder, peg, spring and delivery valve of #
Engine water pump - centrifugal type 1 Cylinder
Aluminum core radiator without deaeration system. 3. Connect 'swan neck pipe’ to # 1 delivery valve holder to measure
Capacity with radiator - 11 liters fuel drop correctly.
Coolant is - Water : Ethylene Glycol -- 50: 50 (1:1) 4. Connect Diesel container to supply connection of Fuel Pump
Cooling system pressure - 0. 5 bar ( 7 psi) (container should be two feet above Fuel pump)
Operating temperature - 75 0 C to 95 0 C
5. Loosen mounting bolts of Fuel Pump body to mounting flange.
Grease for water pump 70 gms
Caution : Don't use CAC/DCA. 6. Swivel Fuel Pump body either away, towards the engine to
ensure one drop of fuel from Swan neck pipe in approximately 20
LUBRICATING SYSTEM
seconds
Flow
Oil Pan ------ Strainer ----- Oil Pump Relief / regulator valve 57psi 7. Tighten fuel pump body cap screw in above position
Full flow filter --- filter By pass valve 1.8 to 2.6 kgs/ sq cm ----- Heat 8. Turn crankshaft in Reverse direction by app. 300 . The fuel will start
exchanger ---- Cooler By pass valve 1.5 to 2 kgs/ sq cm ------ Main oil flowing freely. Then slowly turn the crankshaft in direction of
rifle -------- Cam, main bearings ----- Rocker lever assly shaft. rotation till fuel flow nearly stops.
Engine mounted lube oil pump and cooler. 9. Remove swan neck pipe and diesel container. Connect all
Lube oil filter - Replaceable paper Element connections.
A stamped steel front sump oil pan to reduce engine weight 10.Ensure proper fitment of delivery valve holder / peg / spring and
Oil pan capacity for all rating of engines is low 7 ltrs. – high 9 ltrs. delivery valve.
Oil filter capacity 1 litre 11.This completes the timing.
Minimum Engine Oil pressure Valve setting procedure
@ rated speed - 4 bar (58.0 psi) 1. Open inspection window on top of flywheel housing.
@ low idle - 1 bar (14.5 psi) 2. Rotate crankshaft in clockwise direction to align red- mark on
Oil change at 300 Hours or 3 months which ever is earlier flywheel with pointer (in inspection window)
Recommended Oil is SAE 15W40, API CF4
3. This will bring either # 1 or # 4 piston in T D C of compression stroke
Maximum lube oil consumption is 1. 5% of fuel consumption.
4. For Valve setting # 1 piston has to be in T D C of compression stroke.
FUEL SYSTEM
Confirm by checking that both pushrods of Cylinder No. 1 are free.
Priming fuel system by Fuel feed pump
Maximum Suction lift - 1 meter 5. Adjust clearance of intake and exhaust valves serially for valve
Maximum fuel head 4 meters Numbers (Not the Cylinder Numbers) 1,2,3, 5 ( viewed from
Maximum fuel inlet temperature 71 C
0 engine front end)
MICO pump, MICO injector 6. Rotate Crankshaft 3600 and set remaining valves.
Fuel filter -Replaceable paper Element Cold setting (50 0 max cooling system temperature)
Nozzle Pressure - 200 + 10 bar Tappet clearance Inlet 0.20 mm
Old nozzle at least - 180 bar (183.5 Kg/ cm2 ) Tappet clearance Exhaust 0. 30 mm
Max. variation in nozzle pressure - 5 bar (5. 1 Kg/ cm2 ) Sequence of valves E I I E E I I E
Note : Ensure fuel return line is dipped into the diesel to prevent air Clearances
lock (air entry into fuel system during shut down) Crank axial play 0.19 –0.29 mm
Con rod end play 0.10 – 0.40 mm
Cam Shaft axial play 0.11 –0.39 mm
Permissible Radial run out of Fly wheel 0.05 mm
PAGE 5-9
MICO FIP combination Numbers of S-3.8 Gensets
Sr. Engine kVA Telco Part MICO Combination
TURN THE STARTING KEY SWITCH TO START

No. rating number number
GENSET (30-62.5 KVA) DOT

WITHOUT DIGITAL TACHO
12 VOLT NEGATIVE GROUND SYSTEM.
1. 497 NA engine, 37 PS 30 KVA 2527 0710 01 27 E 030 9521 00
POSITION TO CRANK THE ENGINE

@ 1500 rpm for generator
HOUR METER
set application.
ENGINE MODEL - S 3.8 C2-C7

2. 497 NA engine, 43 PS 35 KVA 2527 0710 01 82 E 040 1190 00
44
L.O.T. GAUGE
APPLICATION-
set application.
B T
+
SYSTEM -
3 497 NA engine, 49 PS 40 KVA 2527 0710 01 84 E 040 1206 00
45
23A
set application.
:
4 497 NA engine, 55 PS 45 KVA 2527 0710 01 85 E 040 1187 00
STARTING SWITCH
23A
WATER TEMP
43
23
T
set application.
40
GAUGE
+
26
B
45
5 497 NA engine, 61 PS 50 KVA 2527 0710 01 77 E 040 1187 00
23A
AMP CAPACITY WIRE GAUGE

4.5 SQ. MM
1.5 SQ. MM
32
set application.
L.O.P.GAUGE
ENGINE MODEL - S 3.8 G2-G7
45
B T
40
3 497 NA engine, 76 PS 62.5 KVA 2527 0710 01 88 E 040 1221 00
45
23A
27
30
14
set application.
ASSY. INDICATOR
HOUR METER
45
23
ELECTRICAL SYSTEM & INSTRUMENT PANEL (12 V)
25,26,27,33E,45,52
52 +
CIRCUIT NO.
Electric L O pressure gauge
28
Electric Water temp gauge
32,43,28
Electric Hour meter
Starting switch
DIGITAL TACHO
Battery Charging indicator12 V
HOUR METER
9 8 45 52
+
MAGNETIC PICKUP
12 Volts, - ve earthing
WATER TEMP.
Battery - 12 Volts, 120 AH
LUB OIL PR.

OIL TEMP.
SENSOR
SENSOR
SENSOR
BLOCK TERMINAL
Alternator - 12 V DC 35 Amps
26
27
23
28
52
45
32
43
44
Starter Motor - 12 V Flange Mounted
10
11
12
13
14
1
2
3
4
5
6
7
8
9
26
27
23
28
52
45
32
43
44
36
31
32 43 44 8 9
8
45
+ 27
26
25
BATTERY 12V
33E
+
OIL PRESSURE
40
SHUT DOWN COIL

37
ALTERNATOR
33E
WATER TEMP
36
37
31
SAFETY
SAFETY
35
+
25
28
35
23
PAGE 5-10
ENGINE MODEL - S 3.8 G2-G7 (DOT)
ITEM NUMBER
Section – 6 Engine Data - CWC Series Page 6-0 Section – 6 Engine Data - CWC Series Page 6-01
Genset Model - Nomenclature

Contents Page
Example : CWC 15
Engine, Genset, Alternator Nomenclature 6- 01 CWC Engine Series
15 kVA Rating
Technical Data CWC genset 6- 02
Genset Serial Number - Nomenclature
Standard dimensions 6- 02 Example : 81030200005
8 CWC Series
Torque Values 6- 03 1 15 kVA, (2 = 20 kVA, 3=25 kVA)
03 Year of Manufacture
Sizes of Some Important Capscrews 6- 04 02 Month of Manufacture
00005 Serial Number of DG Set
Air System 6- 05
Engine Model - Nomenclature
Coolant System 6- 05 LPA2 and 3 – two and three cylinder, direct injection, naturally aspirated
axial
Lubricating System 6- 05 fan cooled diesel engines.
LPW2, 3 and 4 – two, three and four cylinder, direct injection, naturally
Fuel System, FIP Fitment and Adjustments 6- 05 aspirated
water cooled diesel engines.
Electrical System, Wiring Diagram 6- 08 LPWT4 – Four cylinder, direct injection, turbocharged water cooled
diesel
Special Features 6- 10 engine.
LPWG2, 3 and 4 – two, three and four cylinder, gas fuelled, naturally
aspirated
Maintenance Schedule , NEPI 6- 11
water cooled diesel engines.
LPWS2, 3 and 4 – two, three and four cylinder, indirect injection,
Fault Finding 6- 12 naturally
aspirated water cooled diesel engines.
Engine Serial Number - Nomenclature
The engine serial number is stamped on a plate attached to the engine.
It is necessary to identify the type and build of each engine to enable the
correct
maintenance procedures, as described later in this publication, to be
carried out.
01011987 LPW3 A 09
01………….. Year of manufacture
011987…… Consecutive number of engine
LPW3 LPWG3 Model(T-Turbocharger, S-Indirect injection G=gas
fuelled)
A………….. Anticlockwise rotation (Looking from flywheel end)
09………… Build of engine
Alternator Serial Number - Nomenclature
Wuxi Newage (Stamford)
Example : YYYYWWNNN
YYYY - Year of manufacture
WW - Week of manufacture
NNN - Serial number of alternator produced in the week
NEIL Ahmednagar (Stamford)
Example : L03030072
L - Supplied to Cummins entities
03 - Year
03 - Month
0072 - 72nd machine manufactured during the month
Section - 6 Engine Data - CWC Series Page 6-02 Section – 6 Engine Data - CWC Series Page 6-03
TORQUES VALUES
TECHNICAL DATA CWC SERIES, 50HZ GENSETS The tolerance for all torque settings is + 10% except those marked with a *
when it is +5% -0%. For practical purposes the figures have been rounded.
Generating Set CWC 15, 3 CWC 20, 3 CWC 25, 3
Model Phase Phase Phase
Description of Component Nm lb. ft
Set Output 380-440 V 50 Hz 380-440 V 50Hz 380-440 V 50 Hz
Stop/run control assembly screw
Rated Output 12 kWe 15kVA 16 kWe 20kVA 20 kWe 25kVA 7 5
1, 2
Engine Make Lister Petter Lister Petter Lister Petter Crankshaft pulley stud
Model LPW3 LPW3 LPW4 Front End cover nuts or bolts
Cylinder (firing order) 3 (1-2-3) 3 (1-2-3) 4 (1-3-4-2) Fuel filter bracket screw
In-line (four In-line (four In-line (four
Engine Build (Cycle) Inlet and exhaust manifold bolts
Stroke) Stroke) Stroke)
Governor / Class Mechanical/A2 Mechanical/A2 Mechanical/A2 Oil pump setscrew
9 6.5
Natural Natural Natural Camshaft thrust plate screws
Aspiration
Aspiration Aspiration Aspiration Governor weight plate screws
Cooling Water Water Water
Cylinder head cover nut
Bore & Stroke in mm 86 x 80 86 x 80 86 x 80
Compression Ratio 18.5:1 18.5:1 18.5:1 Crankcase door bolt 8 6
Cubic Capacity 1.395 ltr 1.395 ltr 1.860 ltr Alternator adjusting link
Battery 12V/55Ah 12V/55Ah 12V/55Ah Fixing bolt to backplate 16 12
RPM 3000rpm 3000rpm 3000rpm
Water pump studs (not bolts)
BHP 27 27 36
Mean piston Speed at Fuel filter union plug 20 15
3000 rpm 7.99m/sec 7.99m/sec 7.99m/sec
Fuel lift pump nuts
Engine Block Coolant Injector clamp nut
Capacity (Incl. 2.5 ltrs (6.5) 2.5 ltrs (6.5) 3 ltrs (7.0)
Radiator) Axial fan bracket bolt – LPA
Exhaust Gas Flow 82.8 ltr/sec 82.8 ltr/sec 110.4 ltr/sec Alternator bolt 21 15.5
(Pipe dia) (44mm) (44mm) (44mm) Water pump bolts and nuts
Exhaust Gas
520 deg C Deep sump bolts 3
Temperature (Max 520 deg C 520 deg C
Back Pressure) (760mm H2O) Centre bearing housing bolts
Alternator Make Stamford Stamford Stamford Glow plug – LPWS
Oil Strainer tube nut 27 20
Alternator Model BCA 162 E BCA 162G BCA 162J
Main bearing housing nuts
Alternator Voltage
Regulation + 2% + 2% + 2% Injector pipe nuts – LPA, LPW 28 21
1
Radiator fan nut – LPW, LPWS 30 22
Alternator Insulation F F F Fuel Pump clamp
34 25
Single Load step to Valve rocker nut
100% 100% 100%
NFPA 110 Connecting rod bolt *
35 26
Dry Weight engine 157 kg 157 kg 189 kg Radiator fan spacer – Build 70
Dry Weight DG Set 383 383 420 Starter motor bolt
Oil pump relief value 41 30
STANDARD DIMENSIONS Oil filter adaptor bolt – LPWT4
Injector nozzle nut – LPA, LPW 46 34
Model Length (mm) Width (mm) Height (mm)
LPW-3 595 482 574
LPW-4 695 482 574
CWC-15 kVA DG Set 1255 612 955
CWC-25 kVA DG Set 1255 612 955
Section– 6 Engine Data - CWC Series Page 6-04 Section– 6 Engine Data - CWC Series Page 6-05
AIR SYSTEM
Fuel pump delivery valve holder 47 35
Maximum allowable intake restriction 254 mm H20
Flywheel bolt LPW 41 30
Air System Flow : Atmosphere – Air Cleaner – Intake manifold – Cylinder
Flywheel housing screw 68 50 head – Combustion Chamber – Exhaust manifold – Silencer – Tail Pipe –
Cylinder head bolt – LPW, LPWT, LPWS * Atmosphere
Stage 1 8 6
COOLING SYSTEM
Stage 2 48 35 Max. allowable coolant temp 103 Deg. C at engine outlet
Stage 3 88 65 Minimum radiator opening : 750 mm x 750 mm
Crankshaft pulley 1, 2 or pulley bolt 1 300 221 Coolant recommendation 50:50 (Water : Ethylene Glycol)
Thermostat starts to open 72-76- C
Notes : Thermostat fully open 85-88 – C
1 – Left hand thread Cooling system pressure 10 psi pressure cap
2 – Early engines Capacity with radiator 6.5/7.0 liters
3 – Builds 28, 51, 52, 57, 58, 59 The maximum permitted ambient temperature (LAT) is 50°C (125°F).
4 – The lower torque figure is used on earlier engines and the higher figure for Cooling System Flow : Water pump –Cylinder Liner – Cylinder Head –
Thermostat – Radiator – Suction pipe – Water Pump ; Thermostat – Bypass
later ‘High Boss’ cylinder barrels. On earlier barrels the bosses and threads are line – Water pump
below the top fin. On the ‘High Boss’ arrangement the bosses and threads are
at the top of the barrel
Starter Motor Terminal Torques

LUBRICATING SYSTEM
Starter Motor Battery + Terminal 1 Link Terminal 2 Lube oil Recommended 15W 40, CF-4
Lucas / Magnetti Nm 4.0-4.2 3.1-3.2 Oil & filter to be changed at 250 hrs / 3 month
lbf ft 2.95-3.01 2.3-2.4 Oil pan capacity LPW-3/LPW-4 3.75/ 5.5 liters
Marrelli
Minimum oil pressure @ rated speed & load 2 bar
Denso Starter Nm 5.89-11.77 5.89-11.77 Minimum oil pressure @ low idle 1 bar
lbf ft 4.34-8.68 4.34-8.68 Lube Oil System Flow: Oil Pan – Strainer – Oil Pump Pressure Regulator
– Full Flow Filter (Bypass valve) – Oil Passages in Side cover – Cam
Bushes ; Oil Passages in Side cover – Main bearing Housings of Crank
Sizes of Some Important Cap screws Shaft ; Oil Passages in Side cover – Hydraulic tappets – Push rods –
Rocker levers and valves
Fan Nut 1.5” (Left hand thread)
Pulley Crank 24mm (Left hand thread)
Connecting Rod 0.5"
Exhaust and Inlet bolts 10mm / 3/8"
FUEL SYSTEM
Conrod Cap screws 12mm
Fuel System: Fuel Tank – Fuel pump – Fuel Filter – Fuel Piping – Individual
Cylinder Head 17mm
FIP Pumps – Nozzles – Tank; Fuel Filter – Fuel Piping - Tank
Bearing Hsg Allen key size 7/16"
Maximum Suction lift 3048mm
Fly wheel hsg 17mm X 5nos
Maximum fuel head 600mm
Fly wheel 19mm X 6nos
Max. fuel inlet temperature 71 deg. Centigrade
Lube oil Strainer 19mm
Fuel tank Capacity 100 liters
Pressure regulator 24mm
Present LPW Engine Nozzle 240 bar
Side cover 10mm X 13nos
Early LPW Engine Nozzle 205-225 bar
Injector Capscrew 14mm
Old nozzle at least 200 bar
Tappet cover 13mm
No Tappet Setting is Required.
Lube oil pump 13mm
Inspection cover 10mm
Main bearing Housing 6mm Allen key
Section– 6 Engine Data - CWC Series Page 6-06 Section – 6 Engine Data - CWC Series Page 6-07
Valve Setting Fuel Injection Pumps -Fittment
These engines are fitted with hydraulic tappets and therefore no Before refitting a fuel pump, the governor must be correctly adjusted. If it
adjustment is necessary has been removed or is known to be out of adjustment, refer to "Setting
Caution: It is required to compress the rocker levers with special tool for the Governor”
squeezing oil from hydraulic tappets, only if the valve train parts are If the fuel pump tappet has been removed it must be replaced with the
removed for service purpose longer slot (A) facing outwards.
This will ensure it is correctly located over the end of stud (B) which is
Working of Mechanical Governor Assly fitted inside the crankcase.
The tappet can be placed into the crankcase with the aid of long-nosed
The rack operates the fuel pump for the max. and min. fuel delivery. pliers held open against the top inside edge of the tappet recess.
The rack is operated by Governor lever assembly which in turn 1. Hold the engine control in the stop position.
maintains the position of rack, as per the balancing forces of speeder 2. Press down on the top of the fuel pump tappet, and slowly turn the
spring and fly weights (fitted on cam gear). crankshaft until the fuel pump tappet is felt to be at its lowest position.
Increased tension of speeder spring with speed adjusting lever 3. Using the fuel pump rack setting gauge, 317- 50114, clamp the pump
increases the operating speed of the engine. rack
The rack can be separately operated by external control lever (not (C) with the end protruding 55.5mm (2.18in) from the crankcase end
shown in fig).for stopping the engine with the help of shut down coil. face
Load increase example: Load increase causes a drop in engine speed 4. Replace the correct original shim pack to the fuel pump.
5. Gently insert the fuel pump, and shims into the crankcase taking care
means fly weights (fitted on cam gear )force decreases, which is less to ensure that the fuel pump rack engages with the slot in the governor
than spring tension, allows the rack to move towards max fuel position. rack.
This increase in fuel stabilises the speed back to normal (until fly weight 6. Carefully turn the fuel pump anticlockwise until the pump rack is felt
force equals to speeder spring force) speed . against the stop. Hold the pump in this position, and replace the fuel
Load decrease example: Load decrease causes an increase in engine pump clamp with the beveled face of the nut towards the clamp finger
speed means fly weights (fitted on cam gear )force increases, which is tight. Take care to ensure the pump does not move.
more than spring tension, allows the rack to move towards min/ stop(no Caution: It is possible that the engine will not stop when required if the
fuel) position. This decrease in fuel stabilises the speed back to normal pump is not turned anticlockwise before tightening down or it moves
(until fly weight force equals to speeder spring force) speed . before or while, being tightened.
7. Torque the nut to 34.0 Nm (25.0 Ib-ft).
8. Install the fuel pipes.
Fuel Injection Pumps 9. To ensure the control lever is positively stopped by the control lever
The individual fuel pumps(main cam & rack actuated) are located at the stop screw and not the fuel pump stops refer to "6.18 Setting the
side of the engine, between the push rods. They are secured to the top Stop/Run Lever".
of the crankcase by a clamp and nut.
Each fuel pump is timed individually, using appropriate flywheel timing Fuel Injection Pump -Spill Cut Adjustment
degree marks. When an existing or new fuel pump is refitted, it is only It will only be necessary to carry out pump timing if the original shims
necessary to refit the existing shim pack, or a new pack of the same have been lost or mixed with those of another cylinder.
thickness as the original. 1. Remove High pressure fuel line, delivery valve holder, spring and
delivery valve of one of the pumps.
2. Connect `swan neck pipe’ to 1 delivery valve holder to see the fuel
Fuel Pumps Removal dropping correctly. Ensure the control lever of rack in full delivery
While removing Fuel Pumps leave one fuel pump in position to retain position.
the governor setting . 3. Connect Diesel container to supply connection of one fuel pump
1. Isolate the fuel supply. (container should be two feet above Fuel pump).
2. Using a pair of pliers, squeeze the tails of the flexible fuel pipe clip at 4. Bring the particular cylinder in compression stroke observe the
the pump end together sufficiently to enable the clip to be moved continuous fuel flow from swan neck.
sideways along the pipe. 5. Rotate the engine in clock wise direction until the fuel flow from the
3. Pull the pipe off the fuel pump. swan neck is just stopped (spill cut ) as per the required angle mark of
4. Turn the engine control anticlockwise to the stop position. the respective cylinder on the fly wheel.
6. If the spill cut takes place in advanced / retarded angle than the
5. Remove the fuel pump holding clamp. required correct the shims as below:
6. Lift out the fuel pump. To advance the timing - remove shims. ;To retard the timing - add shims
Caution: If more than one fuel pump is being removed extreme care 7. Tighten fuel pump body with the clamp in position.
must be taken to ensure that the shim pack is kept with the relevant 8. Repeat the procedure 4, 5 to confirm or until to achieve the correct
pump and cylinder. timing.
Under no circumstances must any attempt be made to remove the fuel 9. Remove the swan neck and diesel container. Connect all
pump tappet stud from the crankcase. connections
The shims fitted between the steel plate and the fuel pump flange must 10. Ensure proper fitment of delivery valve holder / spring and delivery
not be removed or added to. valve
No attempt to dismantle the fuel pump, other than to replace the delivery 11. This completes the timing
valve, must be made.
Whenever the delivery valve holder is removed a new joint must be
fitted before it is reassembled and the holder torqued to 47.0Nm
(35.0 Ib-ft).
Section – 6 Engine Data - CWC Series Page 6-08 Section– 6 Engine Data - CWC Series Page 6-09
Wiring Diagram
Engine Fixed Speed adjustment Procedure
The speed of the engine is controlled by tension of the speeder spring.
The spring is attached to the speed control lever, (which can be
operated either by a cable, rod, lever or solenoid for variable speed) .
The set-screw is adjusted until it makes contact with the speed control
lever, at the required maximum speed, and then locked in position with
the lock-nut.
The minimum full load speed for all engines and builds is 3000 r/min.
The two set-screws are adjusted until at the required speed both make
contact with the speed control, both are then locked in position with the
lock-nuts.
Rotating the set-screw (B) in anti-clock wise and (A) in clock wise
increases the engine speed.
Setting the Stop / Run lever

To ensure the control lever is positively stopped by the control lever stop
screw,and not the fuel pump stops the following sequence must be
carried out with the end cover in position.
Caution:: In some engines the tamper proof screw must be fitted to
prevent changes being made to the engine stop run control settings. In
these cases adjustment is not possible.
Turn the engine control lever A anticlockwise towards the STOP
position until the fuel pump stop is just felt with gentle finger pressure.
Slacken the nut and adjust the screw until it just touches the control
lever
Adjusting the 'G' Setting

The 'G' setting is made to ensure the fuel pumps deliver the correct
amount of fuel as dictated by the engine build number.
Caution: On some engines a tamperproof set screw nut is fitted to
prevent
changes being made to the engine stop/run control settings. In these
cases adjustment is not possible.
The following instructions only apply to engines not fitted with
tamperproof nuts.
Any adjustment should not be made until the engine control lever has
been correctly set.
1.Move the engine control to the run position.
Caution: The settings given below are the initial settings. Resetting may
be necessary to achieve optimum running and performance.
2. Insert a gauge of the appropriate 'G' dimension between the head of
the upper set-screw and the top of the radi used part of the engine
control
LPA, LPW, LPWS: All Builds 23mm
LPWT4: Builds 01,02, 51, 84 23mm AII others 27mm
3. Adjust the lower set-screw until the engine control just touches the
setting gauge. Tighten the set-screw lock-nut
4. Remove the gauge.
ELECTRICAL SYSTEM
Charging 12 V - 35/45 amps (Denso Make)
alternator
Self Starter 12 V-1.4 kW / 2 kW Flange Mounted (Denso Make)
Cable Core 35 sq.mm
Electrical System 12 Volts, - ve earthing
Battery 12 Volts, 120 AH
Section – 6 Engine Data - CWC Series Page 6-10 Section– 6 Engine Data - CWC Series Page 6-11
Special Features
Cylinder Block : Alloy cast Iron with dry cylinders, single piece, Maintenance Schedule
Integrated oil pan, crank removal from rear of block, Place for mounting A-Check-Daily B-Check - C-Check - D-Check -
Injection pumps Internal mounted Mechanical Governor. Every 225-250 Every 475-500 Every 950-1000
Cylinder Head: The cylinder head is a one piece deign with two valves Hours/3 Hours/ 6 Hours/ 12
per cylinder. The cylinder head includes valve guides, valve seats months months months
surfaces and valve stem seals. The Intake valves are larger than
Exhaust valves for better volumetric efficiency. Lubrication Note : First B- Repeat all Repeat all steps
Cylinder Head: Intake ports of each cylinder are connected to crank System check (NEPI) steps of A,B - of A, B, C-
case for sucking blow by gasses through tappet cover. No breather is Check oil level, to be done at Checks Checks.
provided on the crank case for air venting. Pressure compensation of fill if required. 100 hrs/3 Lubrication Lubrication
crank case takes place through air cleaner only Cooling months which System System
Crankshaft : High tensile strength steel forging with induction System ever is earlier. Clean breather Clean breather
hardened pins and journals for high fatigue resistance. Dynamically Check & fill the Repeat all if provided . if provided.
balanced in all planes. Thrust washers are incorporated in rear and front coolant level. steps of A- Cooling Cooling
main bearings of the crank shaft as shown in figure (observe the Fuel System Check. System system
position of protrusion at both ends) Check the Lubrication Check coolant Drain, flush and
Dismantling - Crankshaft : supply and System level & topup. refill the
1. Remove the gear end cover. Use a suitable three legged puller to level of fuel. Change engine Fuel System coolant. Check
remove crankshaft pinion. Drain water oil with grade Clean fuel tank fan hub
2. Remove the pistons and connecting rods. from fuel water 15W-40 breather. bearing, belt
3. Remove the flywheel, flywheel housing and main bearing housing. separator. Change lube Air System tension, replace
4. Screw a suitable new or clean M6, or inlet manifold bolt into the Clean fuel oil filter. Check all if necessary.
dowel. Pull the bolt and dowel out of the crankcase and leave the bolt in strainer, fuel Record oil external nuts, Fuel System
the dowel until it is refitted to ensure the dowel is refitted the correct way tank breather. pressure after bolts and Clean fuel tank.
round. Check fuel starting. unions for Check the
5. Gently withdraw the crankshaft through the flywheel end of the shut of Cooling tightness. engine and
crankcase along with center main bearing housings. mounting & System Ensure that all speed controls
6. Remove the two socket screws and dismantle the center bearing tighten the Check Coolant guards are for free
housing/s. mounting level. firmly attached movement.
7. Remove the thrust washers from the gear end of the crankcase and screw. Adjust Fuel System and not Air System
the flywheel end main bearing housing. the linkage if Change damaged. Renew the air
In a 3 cylinder engine crank is fitted with 4 main bearings (shell type) required. fuel/water cleaner element
Front (No.1) main bearing is incorporated in the block. No 2,3 main Air System separator
bearing are incorporated in the bearing housings fitted on the crank Check plugs in element. Clean
shaft. No 4 mainbearing is fitted on the rear bearing housing. No 2,3,4 intake piping fuel strainer,
bearing housings are incorporated with drills for piston cooling for proper fuel tank
Camshaft : Two valve and one Injection pump lobes per cylinder are sealing. Check breather.
incorporated on the cam shaft. One slightly offset lobe is added to the function of Air system
cam shaft at the last cylinder for operating Fuel feed pump. One cam vaccum Check
bush is incorporated in the cylinder block only for No.1 bore. indicator. restriction
Cam Gear should be marked with crank pinion while cam shaft fitment. Check hoses & indicator, clean
Camshaft along with gear should be replaced since there is no key fitted clamps for the air cleaner.
between cam shaft and gear. Never dismantle cam shaft & gear proper sealing. Open pre
The valve train consists of camshaft, tappets, push rods and rocker cleaner dust
levers. Push rods are used for more strength and longer durability. If the pan, clean by
fuel pump tappet has been removed it must be replaced with the longer air.
slot facing outwards. NEPI Checks
Connecting Rod: Drop forged, I beam section, alloy steel with easy "A"(NEPI) 0-50 hrs or 30 days whichever is earlier.
engine in-frame overhaul capability. Small end bushing is splash "B"(NEPI) 100 hrs or 3 months, whichever is earlier from NEPI(A).
lubricated. Big end needs to be matched with cap with reference to the (first B-Check at 100 hrs. and subsequent after every 250 hrs.)
number, towards cam side.Piston’s combustion chamber bowl off-set "C"(NEPI) 500 hrs or 6 months whichever is earlier from NEPI(A)
should be towards intake side. "D"(NEPI) 1000 hrs or 12 months, whichever is earlier from NEPI(A)
Section– 6 Engine Data - CWC Series Page 6-12
Fault finding
Overheating Engine Stops

Radiator fan belt too slack. Lack of fuel.
Overload. Air or water in the fuel system.
Lubricating oil level too low. Choked air or fuel filter.
Radiator fan inlet obstructed. Overload.
Re-circulation of exhaust gasses Overheating.
or cooling air. Loss of compression.
Radiator cooling fins blocked. Loss of electrical supply to the fuel
Low level of coolant. injector pump’s solenoid.
Cooling system obstructed Automatic shutdown, if protective
devices are fitted.
Loss of Power Exhaust Smoke
Loss of compression. White smoke - generally as a result
Choked air filter. of water entering the cylinder.
Choked exhaust system. Faint blue smoke - generally the
Fuel injector dirty. result of light load.
Choked fuel filter. Heavy blue smoke - caused by
Worn engine lubricating oil passing the piston
ringsdue to:Stuck, worn or broken
rings.Worn cylinder bore.Overfull
oil sump.
Black smoke due to incomplete
combustion can be caused
by:Overload.Choked air filter. Inlet
temperature too high.
Unsuitable fuel, or water in it.
Difficult Starting Excessive Carbon Deposits

Unsuitable lubricating oil (too Choked air filter.
heavy). Choked exhaust system.
Incorrect fuel. Unsuitable fuel oil.
No fuel in the tank. Unsuitable lubricating oil.
Choked fuel filter. Continuous idling.
Air lock in the fuel system.
Discharged battery.
Poor battery connections.
Section – 7 Engine Data - X Series Page 7-0 Section– 7 Engine Data- X Series Page 7- 01
Genset Model - Nomenclature
Example : D X P 15 - 5
Contents Page D Fuel (Diesel)
X Engine Series
Engine, Alternator Nomenclature 7- 01 P Prime Power
15 kVA Rating
5 Frequency(5 - 50Hz , 6 - 60Hz)
Engine, Alternator Specifications DXP Genset 7- 01
Engine Model - Nomenclature
Torque Values 7- 03 Example : X -1.7 – G1
X = X Series
Lubricating Oil Flow 7- 04 1.7 = Displacement(Litre)
G1 = Application (Genset)
Genset Serial Number - Nomenclature
Fuel System and Settings 7- 04
Example : 81030200005
Maintenance Schedule 7- 06 8 X Series
1 15 kVA, ( 2 = 20 kVA, 3=25 kVA)
Wiring Diagrams 7- 07 03 Year of Manufacture
02 Month of Manufacture
00005 Serial Number of DG Set
Alternator Serial Number - Nomenclature
Wuxi Newage (Stamford)

Example : YYYYWWNNN
YYYY - Year of manufacture
WW - Week of manufacture
NNN - Serial number of alternator produced in the week
NEIL Ahmednagar (Stamford)

Example : L03030072
L - Supplied to Cummins entities
03 -Year
03 -Month
0072 -72nd machine manufactured during the month
Engine Specifications – X - Series

-
Generating Set DXP15 5, 3 DXP20-5, 3 DXP25-5, 3
Model Phase Phase Phase
Genset Rating kVA 15 / 12 20 / 16 25 / 20
/ kW
Current Amps 21 28 35
Fuel Consumption
gms/bhp/hr 173 173 173
Length (mm) 1200 1400 1400
Width (mm) 655 695 695
Height (mm) 1031 954 954
Weight (kg) Dry 400 480 480
380-440 V 50 380-440 V 50 380-440 V 50
Set Output Hz Hz Hz
Section– 7 Engine Data- X Series Page 7- 02 Section– 7 Engine Data - X Series Page 7-03
Engine Make CUMMINS CUMMINS CUMMINS

Model X1.7G1 X2.5G1 X2.5G2
Torque Values: X 1.7 & X2.5 engines:
Cylinders 2 3 3
Engine Build In-line In-line In-line
Description Value
Governor/Class Mechanical/A2 Mechanical/A2 Mechanical/A2
Aspiration Natural Natural Natural Cylinder head nut & Setscrews 80 lbft – 3/4 “ and 11/16 “
Bore & stroke (mm) 91.44 x 127 91.44 x127 91.44 x 127 ( Non re-torque type ) – 3 cyl engine Sockets
Compression Ratio 18.5 : 1 18.5 : 1 18.5 : 1 (Retorque type Gasket) – 2 Cyl engine 70 lbft
Cubic Capacity 1.7 ltr 2.5 ltr 2.5 ltr Cylinder head nut & Setscrews
Battery & Starting 12V/55Ah 12V/55Ah 12V/55Ah Copper Asbestos type
RPM 1500 rpm 1500 rpm 1500 rpm Connecting rod nuts 45 lbft - Cadmium plated
HP 20 32 32 60 lbft - Phosphated – 11/16”
Mean piston socket
Speed@1500 rpm 6.35m/sec 6.35m/sec 6.35m/sec Main bearing setscrews 115 lbft – 7/8” Socket
Balance weight setscrews 55 lbft
Fuel HSD 2 HSD 2 HSD 2
Idler gear retaining setscrews 50 lbft
Fuel Consumption 4.0 ltr/Hr 7 ltr/Hr 7.5 ltr/Hr
@100 %Load * Camshaft gear retaining screws 21 lbft
Specification 15W- 40 15W- 40 15W- 40 FI Pump adaptor to pump nut 55 lbft
Lube Oil CF4 CF4 CF4 FI pump gear to adaptor setscrews 21 lbft
Lube Oil Sump Flywheel setscrew 80 lbft
Capacity(Ltrs) 5 6.5 6.5 Flywheel Adaptor 45 lbft
L.O Consumption 0.03 ltr/Hr 0.04 ltr/Hr 0.04 ltr/Hr Crankshaft Flange bolt 110 lbft
at Full Load ** Nozzle holder 12 lbft
Coolant Capacity Rocker shaft 60 lbft
(Engine+Radiat or) 6 ltrs 7.5 ltrs 7.5 ltrs Intake manifold 8 lbft
Exhaust Pipe Size Drain plug coolant 60 lbft
(mm) 50 50 50 Exhaust manifold 21 lbft
Exhaust Gas Flow 50 ltr/sec 75ltr/sec 75 ltr/sec Adaptor Gear case cover 55 lbft
Exhaust Gas 450 deg C 400 deg C 400 deg C Gear case cover – 16 & 10 mm 21 lbft
Temperature Gear case cover – 10 mm 8 lbft
Alternator Make Stamford Stamford Stamford Water pump to block 21 lbft
Alternator Model BC 164 D BC 184 E BC 184 F Rear seal plate 21 lbft
RPM / Frequency 1500 / 50 1500 / 50 1500/50 Lube oil filter head 45 lbft
(rpm / Hz) Oil pan – 13 mm 21 lbft
Alternator Voltage ±1.5% ± 1.5% ± 1.5% Oil pan – 24 mm 21 lbft
Regulation Front Support Mounting 18 mm 35 lbft
No of Phases 3 3 3 Front Support Mounting 24 mm 21 lbft
Power Factor 0.8 lag 0.8 lag 0.8 lag Lube pump 21 lbft
Insulation Class H H H Strainer support 8 lbft
Single Load Step 100% 100% 100% Except following remaining threads are metric:
Battery Rating (AH) 88 AH 12V 88 AH 12V 88 AH 12V
Stud / nut / set screw Cyl block to head 7/16” - 20 UNF
* SFC with in +5% and specific gravity 0.8 Bolt & nut connecting rod 7/16” -20 UNF
** Considering specific gravity 0.89 Balance weight set screw 7/16” - 20 UNF
Bridge piece timing case 5/16” - 24 UNC
Coolant recommendation - 50:50 water: Ethylene Glycol (Don’t Use CAC /DCA) Plug cylinder head 1/2” - 14 PTF
Maximum allowable intake restriction 15” of H20 (Dry Type air cleaner) Thermostat fixing hole in int. manifold 7/8” - 14 UNF
Coolant temp range at engine outlet 75 to 98 Deg. C Union rocker oil feed in cylinder head 1/8” - 27 NPSI
Lube oil temp range 75 to 105 Deg. C Oil pressure gauge connection 1/4” - 18 NPSI
PISTON
Alfin - Aluminiun alloy with Ferrous insert, Three ring pack
X1.7 : Alfin Toroidal cavity on top of piston
X2.5 : Alfin Re-entrant bowl on top of piston
Section – 7 Engine Data - X Series Page 7- 04 Section – 7 Engine Data - X Series Page 7- 05
Lubrication Oil Flow : Oil Sump — Lube Pump -- PRV-- Filter – Main Valve Time checking - X 1.7 :
Oil Gallery – Main Bearing – Connecting Rod Big end ; Main Oil Gallery
1. Turn the engine in clockwise direction and obtain 2nd cylinder
– Idler Gear – Cam shaft bearing -- Rocker Assembly
inlet valve in just fully closed position
Cooling System 2. Set tappet clearance of 0.030” at the valve stem side.
l System capacity - X1.7-4 litre; X 2.5-4.8 litre. 3. Turn the engine in the normal direction till clearance reduces to 0
l Thermostat:Wax filled type - 77 to 82 deg C (Operating temp) 4. At this point the 1st piston should be at TDC. The TDC mark on the
Fully open at 90 deg C flywheel and the pointer should coincide. If it coincides, then the
l Coolant reservoir is to be filled externally with correct coolant valve timing is correct.
concentration.
l Use Valvoline Koolant Concentrate Cummins (EG Water-1.1)
Valve Time checking - X 2.5 :
Caution : Don't use CAC/DCA
1. Turn the engine in clockwise direction and obtain 3rd cylinder
Exhaust valve in just fully closed position
Removal of Fuel Pump : 2. Set tappet clearance of 0.031” at the valve stem side.
1. MICO inline pump with mechanical governor; Fitted on timing 3. Turn the engine in the normal direction till clearance reduces to 0
case retained by three 13mm nuts 4. At this point the 1st piston should be at TDC. The TDC mark on
2. Turn engine to #1 Cylinder TDC on compression the flywheel and the pointer should coincide. If it coincides, then
3. Disconnect pump connections the valve timing is correct.
4. Remove cover from timing case front cover
5. Remove three capscrews of gear TAPPET SETTING :
6. Remove nuts & washers of pump mounting Three Cylinder Engine - Cold Intake and Exhaust Clearance is -
7. Remove the pump 0.012”
Fuel Pump Side
Fitment of fuel Pump : Valve Sequence: Rear 3E 3I 2I 2E 1E 1I Front
1. Check that the slot in the fuel pump shaft is in approximate (I - Intake E - Exhaust valve)
position to the dowel in the gear and install the pump on the three
studs on rear of gear cover- do not tighten the nuts Procedure I:
2. Ensure alignment of dowel in slot 1. Rotate engine. See that
3. Tighten the gear to the pump using three set screws No. 3 cyl. exh. valve fully opens, then set valves of No. 1 cyl.
4. Tighten the pump mounting nuts 2. No. 1 cyl. exh. valve fully opens, then set valves of No. 2 cyl.
5. Replace inspection covers 3. No. 2 cyl. exh. valve fully opens, then set valves of No. 3 cyl.
6. Refit all connections
7. Fill Lube oil in FIP before engine startup Procedure II:
1. No. 3 cyl. exh. valve fully opens, then set valves of first three
Spill Cut – Off: levers.
1. Remove clamp & unscrew #1 Delivery Valve holder 2. No. 1 cyl. int. valve fully opens, then set valves of rear three
2. Remove the peg, spring and delivery valve (Don’t remove delivery rocker levers.
valve guide)
3. Refit only the delivery valve holder and swan neck tube, connect Two Cylinder Engine - Cold Intake and Exhaust Clearance is - 0.012”
diesel bowl pipe to pump gallery Fuel Pump Side
4. Align Spill cut-off mark (BTDC) on crank pulley with indicator. Set Valve Sequence: Rear 2I 2E 1E 1I Front
control lever to full throttle position
(I - Intake E - Exhaust valve)
5. Loosen pump mounting bolts and swivel pump to obtain a drop in
15-20 seconds
Procedure I:
6. Remove and refit the delivery valve holder along with delivery
valve, spring & peg 1. Align Mark – Set all free valves
X2.5 - Clockwise ( One idler between crank & cam) 2. Rotate 360 deg – Set all remaining valves
(Move pump towards block to spill cut-off for Reducing fuel) Procedure II:
X1.7 - Anti clockwise ( Two idler between crank & cam) 1. Align Mark – TDC Compression of No 1 Set valves of Cyl No 1
(Away from block to spill cut-off for Reducing fuel) 2. Rotate 180 deg Clockwise – Set valves of Cyl No 2
Section- 7 Engine Data - X Series 7- 06 Section- 7 Engine Data - X Series Page 7-07
Maintenance Schedule
A Check B Check C Check D Check

0-50 hrs/ q 225-250 hours/ q 475-500hours/ q 950-1000hours/
30 days every 3 months every 6 months every 12 months
Cooling system (first 'B' check to q Repeatall A & B q Repeatall A, B & C
be done at 100 Checks. Checks.
q Fill coolant as and
hrs./3 months q Check Fan belt
recommended Lubrication
which ever tension, replace if
ensure proper q Check dipstick
occures earlier. necessary.
venting. clamping and
q Repeat all A
q Check coolant correct if required. q Fuel tank cleaning.
Checks.
level in Radiator. q Checkcondition of q Check operating
Lubrication
Fuel System Hoses. parameters &
q Change engine
Clean fuel Cooling system record.
q oil.
strainer, fuel tank q May be switched q Check condition of Cooling system
breather. over to equivalent Hoses and replace q Replace the coolant.
q Check fuel shut oil of CF-4, Grade if faulty. q Check Radiator fins
on mounting & 15W40 including q Check fan drive and Radiator Fan
tighten the Cummins belt. blades for damage.
mounting screw. Volvoline Oil.
Fuel system Fuel system
q Adjust the speed q Change engine
full flow oil filter. q Check fuel shut off q Check fuel lift pump
control level if
required q Record oil
mounting & tighten diapragam.
pressure. the mounting q Clean & Check fuel
Air System screw.
Cooling system injector nozzles.
q Check plugs in q Check fan drive
intake pipe for q Check coolant Lubrication System
level & top up if belt.
proper sealing. q Check leakage and
necessary. q Check fuel pipes
q Check function of replace Hoses if
q Check the and replace if required.
vacuum indicator. required.
condition and
q Check hoses and Air System
tension of radiator Air System
clamp for proper drive belt. q Check Hump Hose
q Check air cleaner
sealing. q Check the
and replace if
sealing. required.
Other Radiator fins for
q Check sealing of
q Check leaks if contamination or Mechanical System
blockage. radiator.
any q Adjust valve lashes
Fuel system Mechanical System as recommended.
q Check G/set and
q Change fuel/water q Adjust valve lashes Electrical System
G/set room.
separator. as recommended.
Exhaust System q Check battery
q Clean fuel Electrical System
q Ensure smoke switches and
strainer, fuel tank q Clean battery replace if required.
level is normal breather.
and no leak from terminals. q Check starter/
q Check fuel shut off
piping. q Check wiring Battery charging
mounting &
Check for proper Harness for alternator and
q tighten the
support to Exh. tightness of replace if required.
mounting screw.
pipe. Terminal Clamping.
q Adjust the throttle
q Check wiring
q Check and lever if required.
Record Exhaust Harness &
Air System
back pressure connections and
q Clean element in
(inches of Hg) tighten if required.
reverse direction
Electrical System with clean dry air
q Check Battery pressure.
condition. Electrical System
q Clean battery
terminals.
Section- 7 Engine Data - X Series Page 7-08
CT
Section – 8 Alternator Data – Newage Page 8-0 Section – 8 Alternator Data – Newage Page 8-01
Contents Page
PRODUCT DESIGNATION
Alternator Product Designation 8- 01 H C . I 4 4 4 C 2
H C . M 5 3 4 F 1
H C K I 6 3 4 Z 2
AVR Adjustments 8- 01
GENERATOR TYPE HC
Alternator Tests, Checks 8- 02 SPECIFIC TYPE

K = VOLUTED ADAPTER AND
UNIDIRECTIONAL FAN
Parallel Operation 8- 03
INDUSTRIAL (I)
MARINE (M)
Alternators Range and Specifications 8- 03
FRAME SIZE
EXCITATION SYSTEM
SERIES 3, MX341, MX321
SERIES 4, SX440, SX421
NUMBER OF POLES 2,4 OR 6
CORE LENGTH C/D/E/F….
NUMBER OF BEARINGS 1 OR 2
AVR Adjustments
AVR POTS FUNCTION, DIRECTION

VOLTS To adjust generator voltage, Clockwise increases
output voltage
Stability To prevent voltage hunting, Clockwise increases
damping effect
UFRO To set Under Frequency Roll Off point, Clockwise
reduces knee point frequency
Droop To set generator voltage droop, Clockwise increases
voltage droop
Trim To match AVR input to Accessory (PFC3) output,
Clockwise allows more control of accessory over AVR.
Exc Trip To set over excitation cut off level., Clockwise increases
excitation cut off level
Dip To set initial frequency related voltage dip, Clockwise
increases voltage dip
Over / V To set over voltage cut off level, Clockwise increases
over voltage cut off level
I / Limit To set maximum short circuit current, Clockwise
increases short circuit current
Dwell To set under frequency related voltage recovery,
Clockwise increases voltage recovery time.
RMS Set and Sealed at Factory.
Section - 8 Alternator Data -Newage Page 8-02 Section-8 Alternator Data - Newage Page 8-03
continuity. Check PMG stator resistance between output leads. This

should be balanced & within +10 % of specified value:
Insulation Test
• UC22 / 27: ?
l Minimum acceptable value of Insulation to earth is 1 M-Ω . • HC4 / 5 : ?
l Meggar the Main stator Main rotor Exciter Stator and Exciter Rotor • HC6/7 : 2.3Ω
l The AVR must be disconnected before the test.
• If resistance is unbalanced and/or incorrect the PMG stator must be
Exc. Trip replaced. If voltages are balanced but low and PMG stator winding
l In order to protect the generator windings AVR incorporates an over resistance is correct – the PMG rotor must be replaced.
excitation circuit which detects high excitation and removes it after a
pre-determined time i.e. 8 – 10 seconds.
Parallel Opeartion: Difficulties:
l Correct setting is 70V ? 5% between terminals X & XX.
Some of the paralleling problems that can occur are detailed below. Probable
Over Voltage causes are also shown:
l Over voltage protection circuitry is included in AVR type SX421, MX321 l Oscillating kW meter, ammeter and voltmeter.
to remove generator excitation in the event of loss of AVR sensing Cause: Engine governing:
input.
l In-correct setting would cause generator output voltage to collapse at l Unbalance ammeter readings, kW meters balanced and stable
No Load or on removal of load, and LED is illuminated. Cause: Circulating current through incorrect voltage setting, droop kit
l Correct setting is 300V ? 5% across terminals E1 – E0. Clockwise connections reversed or insufficient droop.
adjustment of over voltage control potentiometer will increase voltage at
l Unbalanced ammeter reading on no load or rapidly rising currents as
which circuit operates.
soon as breaker is closed
Cause: Incorrect voltage setting or droop kit connections reversed.
Ramp
l The RAMP potentiometer enables adjustment of the time taken for l Unbalanced kW and ammeter reading as load increased or decreased.
generator’s initial voltage build up to normal rated voltage during each Cause: Dissimilar governor speed regulation.
start & run up to speed.
l The potentiometer is factory set to give a ramp time of three seconds, l Unbalanced ammeter reading as load increases, kW meter balanced.
which is considered to be suitable for most applications. Cause: Droop circuit settings not identical or one droop kit reversed.
l This time can be reduced to one second by turning pot fully anti
clockwise and increased to eight seconds by turning pot fully clockwise. Parallel Operation Neutral Interconnections:
l Normally while operating same rating sets in parallel, neutral of one set
Excitation Check
is ground and others are isolated by Neutral Isolator Switch. In case of
l The no load DC excitation voltage across X (F1 / + ve) & XX (F2 / – ve) machines with different ratings Neutral of largest operating set should
is very important. be earth and others should be floating.
l For future fault finding it is advisable to keep a record of this voltage in
logbook for each generator. This should be done when generator is
being commissioned. If a fault occurs in future this exact voltage can be Alternators Range and Specifications
supplied into the exciter stator and machine should give an output equal Brush less Stamford Alternators Range
to original output voltage at the time of commissioning. All Ratings for Industrial Application at 3 Phase,415 Volts,
50 Hz on 40o C Ambient Temp & 1000 Metre Altitude
Example
Common Features for All Range
GeneratorVoltage Engine RPM Load Excitation Voltage
NOMINAL NOMINAL ZERO 9 – 12 Voltage Series Star (Y) : 415 Volts Line Voltage & 240 Volts Phase
415 1500 ZERO 9 – 12 Voltage at 50 Hz
o
Insulation Class : H ["H" Class insulation can withstand up to 180 C
Checking PMG on machines with PMG. o o
temperature (40 C ambient & 125 Rise with
l Start the set & run at rated speed. 15oC Temperature Margin)]
Ingress Protection : IP 23 [Enclosure is Designed as Per "IP23" to
l Measure voltage at AVR terminals P2, P3 & P4. These should be protect from ingress of Moisture & Dust where "2" stands
balanced and within following ranges: for protection against soild object greater than 12mm & "3" stands for
– 50Hz generator: 170 – 180V o
protection against spraying water upto 60 from vertical].
– 60Hz generator: 200 – 216V Rated Power Factor : 0.80 Lag
Winding Pitch : 2/3
l Should the voltages be unbalanced stop the set, remove the PMG Overload Capacity : 10 % Overload for 1 hours Once in Every 12 Hours
sheet metal cover from non drive end bracket and disconnect the multi- Maximum Over speed : 2250 Rev / Min.
pin plug in the PMG output leads. Check leads P2, P3 & P4 for
- Continue to next seven pages.
Frame Base Height Rated Rated AVR AVR (Optional) Stator Winding DE NDE Weight Complete % Effici- Frame Base Height Rated Rated AVR AVR (Optional) Stator Winding DE NDE Weight Complete % Effici-
with Kva of centre Excitation Excitation (Standard Winding Leads Bearing Bearing Alternator (in Kg.) ency with Kva of centre Excitation Excitation (Standard Winding Leads Bearing Bearing Alternator (in Kg.) ency
Core Rating of shaft from Voltage (V) Amps (A) Scope of Self Excited Separately Single Double @ 0.8 P.F. Core Rating of shaft from Voltage (V) Amps (A) Scope of Self Excited Separately Single Double @ 0.8 P.F.
Length foot (MM) Supply) (No PMG) Excited (PMG) Bearing Bearing & 100% Length foot (MM) Supply) (No PMG) Excited (PMG) Bearing Bearing & 100%
load load
UC27C 100 270 58 2.3 SX421 MX321/MX341 NA Double Layer Lap 12 6315 6310 409 422 90.6 BC16A 5 160 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 88 91 77.5
UC27D 110 270 58 2.3 SX421 MX321/MX341 NA Double Layer Lap 12 6312 6309 428 446 91.2 BC16A 7.5 160 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 88 91 76.9
UC27V 125 270 60 2.5 SX421 MX321/MX341 NA Double Layer Concentric 12 495 509 92.5 BC16B 10 160 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 95 98 80.1
UC27E 140 270 58 2.3 SX421 MX321/MX341 NA Double Layer Lap 12 495 509 92 BC16C 12.5 160 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 103 106 81.1
UC27F 160 270 58 2.3 SX421 MX321/MX341 NA Double Layer Lap 12 533 547 92.55 BC16D 15 160 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 109 112 82.1
(ISO)
(ISO)
UC27G 170 270 58 2.3 SX421 MX321/MX341 NA Double Layer Concentric 12 600 600 92.8 BC18E 20 180 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 128 131 85.9
BALL 6309-2RS (ISO)
BALL 6306-2RS (ISO)
UC27G 180 270 58 2.3 SX421 MX321/MX341 NA Double Layer Concentric 12 600 600 92.7 BC18F 25 180 52 2.2 SX460 SX440/SX421 NA Double Layer Concentric 12 151 154 86.9
Section - 8 Alternator Data -Newage
BALL 6315-2RS
BALL 6310-2RS
UC27H 200 270 58 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 629 643 93.5 UC22C 30 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 274 281 88.9
HC4C 210 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 860 885 93.7 UC22C 32.5 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 274 281 88.6
HC4C 225 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 860 885 93.5 UC22C 35 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 274 281 88.35
HC4C 237.5 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 860 885 93.25 UC22C 40 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 274 281 87.7
HC4C 250 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 860 885 93 UC22C 42.5 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 274 281 87.5
HC4D 275 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 950 950 93.8 UC22D 45 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 287 291 89
HC4D 285 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 950 950 93.5 UC22D 50 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 287 291 88.5
HC4E 300 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 1035 1030 94.12 UC22E 55 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 314 331 89.5
BALL 6312-2RS (ISO)
BALL 6309-2RS (ISO)
HC4E 320 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 1035 1030 94 UC22F 62.5 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 340 351 90.85
BALL 6317-2RS (ISO)

BALL 6314-2RS (ISO)
HC4F 350 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 1265 1275 94 UC22G 75 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 384 400 90.9
HC4F 380 315 48 2.3 SX421 MX321/MX341 MX321/MX341 Double Layer Lap 12 1265 1275 93.9 UC22G 82.5 220 58 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 12 384 400 90.5
Page 8-06
Page 8-04
Frame Base Stator Rotor Excitor Excitor Cummins No. of Cyl. / BHP Power Full PM Stator QDCT QDCT RTDs BTDs Space Space Frame Base Stator Rotor Excitor Excitor Cummins No. of Cyl. / BHP Power Full PM Stator QDCT QDCT RTDs BTDs Space Space
with Kva Winding Winding Stator Rotor Engine Configuration @1500 Output Load Resistance Resis- (2 per Heaters Heater with Kva Winding Winding Stator Rotor Engine Configuration @1500 Output Load Resistance Resis- (2 per Heaters Heater
Core Rating Resistance Resistance Resistance Resistance Model RPM in KW Current in Ohms tance PHASE) Ratings Core Rating Resistance Resistance Resistance Resistance Model RPM in KW Current in Ohms tance PHASE) Ratings
O O
O at 22 C O O at 22 C O
Length (L-L) at at 22 C at 22 C at at (if fitted) at Length (L-L) at at 22 C at 22 C at at (if fitted) at
O for AVR O O for AVR O
22 C OHMS OHMS 0.8 PF 0.8 P.F. @ 20 C 20OC 22 C OHMS OHMS 0.8 PF 0.8 P.F. @ 20OC 20 C
Controlled Controlled
OHMS OHMS
UC27C 100 0.118 1.14 0.156 NT-495-G 4 (In-Line) 127 80 139 NA Optional Optional Optional BC16A 5 3.24 0.44 0.26 - - - 4 7.0 NA NA NA Optional Optional Optional
UC27D 110 0.09 1.25 0.156 - - - 88 153 NA Optional Optional Optional BC16A 7.5 3.24 0.44 0.26 - - - 6 10.4 NA NA NA Optional Optional Optional
UC27V 125 0.062 1.4 0.0426 NTC-495-G 4 (In-Line) 154 100 174 NA Optional Optional Optional BC16B 10 2.04 0.48 0.26 - - - 8 14 NA NA NA Optional Optional Optional
UC27E 140 0.062 1.4 0.182 NTA-495-G 4 (In-Line) 173 112 195 NA Optional Optional Optional BC16C 12.5 1.58 0.52 0.26 - - - 10 17.4 NA NA NA Optional Optional Optional
24.3
UC27F 160 0.048 1.6 0.182 N8-G1/NT-743-G1 4(In-Line) / 6(In-Line) 202/205 128 223 NA Optional Optional Optional BC16D 15 1.29 0.56 0.26 - - - 12 21 NA NA NA Optional Optional Optional
of Winding
Kindly Refer
O/M Manual
O/M Manual
UC27G 170 0.0416 1.7 0.182 - - - 136 237 NA Optional Optional Optional BC18E 20 1.40 0.64 0.21 - - - 16 28 NA NA NA Optional Optional Optional
Depends on Type
25 W, 230 V AC 1 Ph
Depends on Type of
N8-G2/NT-743-G 4(In-Line) / 6(In-Line)
Winding Kindly Refer

UC27G 180 0.0416 1.7 0.182 225/231 144 250 NA Optional Optional Optional BC18F 25 0.5 0.74 0.23 - - - 20 35 NA NA NA Optional Optional Optional

UC27H 200 0.03 1.92 0.182 NTA-743-G 6 (In-Line) 255 160 278 Optional Optional Optional Optional UC22C 30 0.362 0.59 0.142 S3.8-G2 4 (In-Line) 37 24 42 Optional Optional Optional Optional
HC4C 210 0.034 0.91 18 OHMS 0.136 - - - 168 292 Optional Optional Optional Optional UC22C 32.5 0.362 0.59 0.142 - - - 26 45 Optional Optional Optional Optional
5.2
HC4C 225 0.034 0.91 18 OHMS 0.136 NTA-855-G1 6 (In-Line) 280 180 313 Optional Optional Optional Optional UC22C 35 0.362 0.59 0.142 S3.8-G3 4 (In-Line) 43 28 49 Optional Optional Optional Optional
HC4C 237.5 0.034 0.91 18 OHMS 0.136 - - - 190 330 Optional Optional Optional Optional UC22C 40 0.362 0.59 0.142 S3.8-G4 4 (In-Line) 52 32 56 Optional Optional Optional Optional
HC4C 250 0.034 0.91 18 OHMS 0.136 NTA-855-G 6 (In-Line) 306 200 348 Optional Optional Optional Optional UC22C 42.5 0.362 0.59 0.142 - - - 34 59 Optional Optional Optional Optional
120 W, 230 V AC 1 ph
12
5.2
HC4D 275 0.028 1.04 18 OHMS 0.136 - - - 220 383 Optional Optional Optional Optional UC22D 45 0.258 0.64 0.142 S3.8-G5 4 (In-Line) 58 36 63 Optional Optional Optional Optional
36
of Winding
HC4D 285 0.028 1.04 18 OHMS 0.136 NTA-855-G2 6 (In-Line) 340 228 396 Optional Optional Optional Optional UC22D 50 0.258 0.64 0.142 S3.8-G6 4 (In-Line) 65 40 70 Optional Optional Optional Optional
Kindly Refer
O/M Manual
Depends on Type
HC4E 300 0.022 1.17 18 OHMS 0.136 - - - 240 417 Optional Optional Optional Optional UC22E 55 0.202 0.69 0.156 - - - 44 77 Optional Optional Optional Optional
120 W, 230 V AC 1 ph
NTA-855-G1
HC4E 320 0.022 1.17 18 OHMS 0.136 (BIG CAM)KT-1150-G 6 (In-Line) 380/380 256 445 Optional Optional Optional Optional UC22F 62.5 0.13 0.83 0.156 S3.8-G7 4 (In-Line) 76 50 87 Optional Optional Optional Optional
HC4F 350 0.02 1.35 18 OHMS 0.136 - - - 280 487 Optional Optional Optional Optional UC22G 75 0.11 0.94 0.156 6BT 5.9-G 6 (In-Line) 98 60 104 Optional Optional Optional Optional
HC4F 380 0.02 1.35 18 OHMS 0.136 KTA-1150-G 6 (In-Line) 450 304 529 Optional Optional Optional Optional UC22G 82.5 0.11 0.94 0.156 6BT 5.9-G1 6 (In-Line) 105 66 115 Optional Optional Optional Optional
Page 8-07
Page 8-05
S. AVR Appli- Voltage Sensing Input Power Input Power Output Control Feature Availability (Adjustment POT) Protection Feature Availability Frame Base Height Rated Rated AVR AVR (Optional) Stator Winding DE NDE Weight Complete % Effici-
No. cation Regulation Stability Volts Droop Trim Dip Dwell Rms Ramp Over Exci- Over S/C I UFRO with Kva of centre Excitation Excitation (Standard Winding Leads Bearing Bearing Alternator (in Kg.) ency
kit tation Trip Voltage Limiting Core Rating of shaft from Voltage (V) Amps (A) Scope of Self Excited Separately Single Double @ 0.8 P.F.
1 SX460 +/- 1.5% 85-125 Vac or No separate Max.90V dc Yes Yes No No No No No No No No No Yes Length foot (MM) Supply) (No PMG) Excited (PMG) Bearing Bearing & 100%
170-250 Vac power input, Continuous 4 A load
(Jumper Selectable), sensing is used
50-60 Hz, 2 Phase as power input Double Layer Lap
HC5C 400 355 48 2.3 SX440 SX421 MX321/MX341 24 1265 1265 94.75
2 SX440 Self +/- 1% 170-250 Vac 170-250 Vac Max.90V dc Yes Yes Yes Yes No No No No No No No Yes Double Layer Lap
HC5C 437.5 355 48 2.3 SX440 SX421 MX321/MX341 24 1265 1265 94.5
Excited 50-60 Hz, 2 Phase 50-60 Hz, 2 Phase Continuous 4 A HC5D 475 355 48 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 24 1395 1395 94.85
Generator
3 SX421 170-250 Vac 50-60 170-250 Vac Max.90V dc Yes Yes Yes Yes Yes No Yes No No Yes No Yes HC5D 500 355 48 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 24 1395 1395 94.8
(Non +/- 0.5%
PMG) Hz, 3 Phase 50-60 Hz, 3 Phase Continuous 4 A HC5E 520 355 48 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 24 1545 1535 95.5
HC5E 550 355 48 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 24 1545 1535 95.2
4 SA 465 +/- 1% 100-130 Vac or 100-250 Vac Max.105V dc Yes Yes Yes No No No No No No No No Yes Double Layer Lap
HC5E 570 355 48 2.3 SX440 SX421 MX321/MX341 24 1545 1535 95.1

170-250 Vac 50-60 Hz, 2 Phase Continuous 4 A
BALL 6320-2RS (ISO)
BALL 6314-2RS (ISO)
HC5E 600 355 48 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 24 1545 1535 95
(Jumper Selectable),
HC5F 625 355 48 2.3 SX440 SX421 MX321/MX341 Double Layer Lap 24 1685 1690 95.4
50-60 Hz, 2 Phase
HC6W 750 400 52 2.5 MX321 - - Double Layer Lap 24 1963 1969 94.6
HC6Y 800 400 52 2.5 MX321 - - Double Layer Lap 24 2333 2335 95.8
5 MX341 Separately +/- 1% 170-250 V ac, 140-220 V ac,3 Phase , Max.120V dc Yes Yes Yes Yes Yes No No No Yes No No Yes
2 Phase, 50 Hz 100-120 Hz from PMG Continuous 2.7 A HC6Y 900 400 52 2.5 MX321 - - Double Layer Lap 24 2333 2335 95.6
(ISO)
(ISO)
Excited
Generator HC6Y 1000 400 52 2.5 MX321 - - Double Layer Lap 24 2333 2335 95.4
BALL 6324-2RS
BALL 6317-2RS
6 MX321 (With +/- 0.5% 170-250 Volts , 170-220 V ac,3 Phase , Max.120V dc Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes HCK6Z 1250 400 62 3.1 MX321 - - Double Layer Concentric 24 2553 2591 95.5
PMG) 3Phase, 50-60 Hz 100-120 Hz from PMG Continuous 3.7 A HC7F 1500 450 63 3.6 MX321 - - Double Layer Lap 24 2984 3069 96.26
5. Excitation Voltage at No load :for all UC & HC6 Range : 11-12 Vdc at 1560 RPM & for HC4 & HC5 Range : 8 - 9 Vdc at 1560 RPM HC7H 2000 450 63 3.6 MX321 - - Double Layer Lap 24 3784 3864 96.6
6. Excitation Voltage at full load :for all UC & HC6 Range : 2.5 Amp, 52 Vdc max. at 1500 RPM, 0.8 P.F. & for HC4 & HC5 Range : 2.0 Amp ,38 Vdc Max. at 1500 RPM,0.8 P.F.
These Figures are for General Guidance only and are not to be taken for inspection & hence for acceptance or rejection.
The Voltage Regulation and Temperature rise are not applicable for Non-Linear Load & Unbalanced Load Conditions.
Page 8-10
Page 8-08
Frame Base Stator Rotor Excitor Stator Excitor Cummins No. of Cyl. / BHP Power Full PM Stator QDCT QDCT RTDs BTDs Space Space
with Kva Winding Winding Resistance Rotor Engine Configuration @1500 Output Load Resistance Resis- (2 per Heaters Heater
O Ratings
Core Rating Resistance Resistance at 22 C Resistance Model RPM in KW Current in Ohms tance PHASE)
O O
Length (L-L) at at 22 C for AVR at 22 C at at (if fitted) at
O O
22 C OHMS Controlled OHMS 0.8 PF 0.8 P.F. @ 20 C 20OC
OHMS OHMS
HC5C 400 0.0136 1.55 17 0.174 - - - 320 556 Yes Optional Optional Optional
HC5C 437.5 0.0136 1.55 17 0.174 - - - 350 609 Yes Optional Optional Optional
HC5D 475 0.0114 1.77 17 0.174 - - - 380 661 Yes Optional Optional Optional
KTA-19-G4 /
HC5D 500 0.0114 1.77 17 0.174 VTA-28-G 6 (In-Line) / 12 VEE 600/614 400 696 Yes Optional Optional Optional
HC5E 520 0.086 1.96 17 0.174 - - - 416 723 Yes Optional Optional Optional
36
HC5E 600 0.086 1.96 17 0.174 VTA-28-G3 12 VEE 710 480 835 Yes Optional Optional Optional
VTA-28-G5/
HC5F 625 0.074 2.16 17 0.174 KT-2300-G
12 VEE 750/750 500 870 Yes Optional Optional Optional
2.467
HC6W 750 0.0065 1.78 17 0.158 KTA-2300-G 12 VEE 890 600 1043 Yes Optional Optional Optional
HC6Y 800 0.00384 2.23 17 0.158 - - - 640 1113 Yes Optional Optional Optional
240 W, 230 V AC 1 ph
60
HC6Y 900 0.00384 2.23 17 0.158 - - - 720 1252 Yes Optional Optional Optional
KTA-38-G5 /
HC6Y 1000 0.00384 2.23 17 0.158 KTA-3067-G 12 VEE /16 VEE 1180/1180 800 1391 Yes Optional Optional Optional
HCK6Z 1250 0.0032 2.38 17 0.158 KTA-50-G3 16 VEE 1470 1000 1739 Yes Yes Yes Yes
HC7F 1500 0.0024 1.45 17 0.096 K1500E-G 16 VEE 1685 1200 2087 Yes Yes Yes Yes
60
HC7H 2000 0.0018 1.75 17 0.096 QSK-60-G4 16 VEE 2319 1600 2782 Yes Yes Yes Yes
Note :
1. Frame Size : Frame Size is Centre Height . Centre Height of machine is distance between the bottom of feet of machine & Centre of Shaft of Machine
2. Core Length : "A,B,C……………Z" are Core lengths
Page 8-09
3. Winding Resistance Values may Slightly vary with Change in Temperature. It should be within +/- 10% of value given.
4. AVR : Optional AVR can be Selected as per Voltage Regulation & Protection Required. For More Details Please Refer Manufacturer Manual.
Page 9-1
Section - 9 Information Parts Page 9-0
Contents Page
STANDARD APPLICATIONS
Engine Gasket Sets / Repair Kits
ALL STD. APPLICATIONS

GENSET APPLICATION
Indigenous upper Engine Gasket Set ……………………………...9-1
GASKET CYL. HEAD

Indigenous lower Engine Gasket Set ………………………………9-2
Imported upper Engine Gasket Set...………………………………9-3
Imported Lower Engine Gasket Set ………………………………..9-4
COMMENTS
P.T.Pump Gasket Set ……………………………………………….9-5
Water Pumps Repair Kits…………………………………………….9-5
Air Compressor Repair Kits………………………………………….9-5
TCL
Turbocharger Repair Kits ……………………………………………9-6
Conversion Kits Parts Nos. of
Radiator to Heat Exchanger………………………………………....9-8
Heat Exchanger to Radiator…......................................................9-8
Turbochargers …......................................................................... 9-9
High Altitude Compensation Kits .…………………………………9-12
Pipe Couplings……………………………………………………….9-12
ECP-G retrofit Kits ………………….....................………………..9-13
Short Block Assembly of Various Models …………………………….9-15
ENGINE GASKET SETS

Oversize Main Bearings ………………………………………………..9-16
Conrod Bearings…………………………………………………….9-17
Thrust Bearings …….………………………………………………9-18
PART N0.
BM54940
BM50745
Break Up of filter Element & Seal Ring …………….....……………..9-18
3240239
4072231
4072233
4072226
4072225
3880383
4058790
3936562
Part No. Structure Old and New ………………………………………9-19
B-check Kits Model Wise ….……………….....……………………….9-20
Air System
Hose Elbows Dia wise Part Nos.…………………………………..9-21
Plain Air Hump Hoses………………………………………………9-21
Air Cleaner Assemblies and Elements And Kits……...…………9-22
( INDIGENOUS )
Switch Overspeed …………..………………………………………….9-31
Tachometer…………..…..........……………………………………….9-32
Cooling System
Flex Master Coupling Part Nos. & Sizes ………………………….9-33
Cooling Water Plain Hoses Dia. & Length wise Part Nos.………9-34
CAC, Pre Mix Part Nos.…………………………………………….9-35
Clamp T-Bolt Dia. Wise part Nos.………………………………….9-35
UPPER ENGINE GASKET SETS

Miscellaneous
N/NT/NTC/NTA-495
Replacement Parts ECPG………………………………………….9-36
ENGINE SERIES
V/VT/VTA-1710
Part Nos. Information ECP …………………………………………9-37
N/NT/NTA-743
Section - 9 Information Parts
NTA-855-FFC
KT-KTA-2300
Part Nos. of Belts for Various Applications ……………………….9-38
Cummins Branded A.V. Mounts (GREB) ……...…………………9-40
KTA-3067
KTA-1150
KT-1150
PCC retrofitting kits……...…….................................……………9-44
NTA14
6B5.9
Cummins Part Numbers for Newage Alternator……......…….…9-47
PULSE Generators Starting Part Nos.& Guidelines …….......…9-52
Sr.No.
Note : Those parts not appearing compared to earlier version of Spec.
10.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Diary are superseded/supplied on lower level, or top level or
obsoleted or multi replaced.
Page 9-2
Page 9-3
NON SUPERCHARGER ( OBSOLETE)

For WET type Fly.Hsg. Application
For WET type Fly.Hsg. Application
Engine Overhaul Gasket Set.

STANDARD APPLICATION
WET/DRY EXH.MFD.
NTC-400 & BELOW
STANDARD FFC
COMMENTS
COMMENTS
COMMENTS
STANDARD
STANDARD
STANDARD
STANDARD
GENSET
GENSET
TCL
ENGINE GASKET SETS
ENGINE GASKET SETS

PART N0.
PART N0.
PART N0.
BM62427
BM62431
AR95138
4072229
4072277
3240084
3247965
3880384
3936563
4089368
4024918
4024946
4024946
3802076
3800727
3800728
3800730
3800731
3803697
3804843
4089371
3804896
4089649
4025271
OVERHAUL GASKET SET ( UPPER + LOWER GASKET SET )
LOWER ENGINE GASKET SETS (INDIGENOUS)
UPPER ENGINE GASKET SET (Imported)
SMALL CAM 672 & 743

N/NT/NTC/NTA-495
ENGINE SERIES
ENGINE SERIES
SMALL CAM 855

ENGINE SERIES
KT/KTA/KTTA-38
BIG CAM III,II,I

N/NT/NTA-743
N/NT/NTA-855
NTA-855-FFC
KTA/KTTA-19
KTA/KTTA-50
V/VT/VTA28
6CT/CTA8.3
VT (A)-1710
KT (A)-1150
KT (A)-1150
88 NT(BC)
VT-1710
LT/LTA
KT 19
4B3.9
6B5.9
6B5.9
N14
N14
Sr.No.
Sr.No.
SR
10
12
13
14
15
11
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
Section - 9 Information Parts Page 9-6 Section - 9 Information Parts Page 9-4
TURBOCHARGER REPAIR KITS ENGINE GASKET SETS
ITEM NO ITEM DESCRIPTION ENGINE MODEL REMARK
LOWER ENGINE GASKET SETS (IMPORTED)
3545834 KIT,TURBO BEARING REPAIR NT/NH,GNH743,P45
SR ENGINE SERIES PART N0. COMMENTS
3545399 KIT,H1C/H2A TURBO REPAIR 4B3.9,6B5.9, NT(A)495 TURBO MODEL H1C/H2A (CURRENT FOR SERVICE)
3545345 KIT,TURBO REPAIR KTA-2300,KTA-38 TURBO MODEL HX60 (CURRENT FOR SERVICE) 1 BIG CAM II,I 3801468 NTC-400 & BELOW
2 SMALL CAM 855 3014459 FFC & PISTON COOLING
3545479 KIT,OVERHAUL KTTA-50-C,K-2000-E TURBO MODEL HT100 (CURRENT FOR SERVICE) 3 SMALL CAM 855 3801463 NON FFC-NON PISTON COOLING
3545575 KIT,TURBO GASKETS 4B3.9,6B5.9,6C8.3 TURBO MODEL H1C,H1E,HX35 (CURRENT FOR SERVICE) 4 SMALL CAM 855 3801464 NON FFC-PISTON COOLED
3545577 KIT,TURBOCHARGER GASKETS NT/NH,V30 HC5A,HX80 (CURRENT FOR SERVICE) 5 SMALL CAM 672 & 743 3801466 NON FFC-NON SUPCHRG
6 SMALL CAM 672 & 743 3801467 NON FFC-SUPERCHARGED ( OBSOLETE )
3545627 KIT,REPAIR HX50 VTA-28 TURBO MODEL HX50 (CURRENT FOR SERVICE) 7 NHRS/NRTO 3802075 STANDARD APPLICATIONS ( OBSOLETE )
3545647 KIT,HC5A TURBO REPAIR K19,K38,K50 TURBO MODEL HC5A,HX80 (CURRENT FOR SERVICE) 8 V/VT/VTA28 3017564 STANDARD APPLICATIONS
4027309 KIT,H1C/H2A TURBO REPAIR L10,4B3.9,6B5.9,6C8.3 OBSOLETE,SUP/BY 4027309 9 KT19 4089390 STANDARD APPLICATIONS
10 KTA/KTTA19 4089391 STANDARD APPLICATIONS
3545661 KIT,4LG TURBO REPAIR NT/NTA-743,NT-855,VTA-28 TURBO MODELS 4LGK,HC3 (CURRENT FOR SERVICE) 11 KT/KTA/KTTA38 3804301 STANDARD APPLICATIONS
3545669 KIT,TURBO REPAIR HT3B,HT60 NT/NH TURBO MODELHT3B (CURRENT FOR SERVICE) 12 KTA/KTTA50 3804300 STANDARD APPLICATIONS
3545399 KIT,H1C/H2A TURBO REPAIR 4B3.9,6B5.9 TURBO MODEL H2A (CURRENT FOR SERVICE) 13 LT/LTA10 3803404 STANDARD APPLICATIONS
14 N14 4025069 STANDARD APPLICATIONS
3545679 KIT,HT4B TURBO REPAIR VTA28,NTA-855 TURBO MODEL HT4B (CURRENT FOR SERVICE) 15 4B3.9 3802375 STANDARD APPLICATIONS
16 6B5.9 3802376 STANDARD APPLICATIONS
17 6CT/CTA8.3 3800558 STANDARD APPLICATIONS
18 N14 PLUS 4025068 STANDARD APPLICATIONS
19 L 10 4025155 STANDARD APPLICATIONS
Section - 9 Information Parts Page 9-7 Section -9 Information Parts Page 9-5
PT PUMP GASKET SET
ITEM NO ITEM DESCRIPTION ENGINE MODEL REMARK
3545840 KIT,TURBO REPAIR NTC-495 (FOR TURBO P/N 3227391) TURBO MODEL TO4B (NON CUMMINS PART.) FOR ALL TYPE OF PT PUMP BM68356 INDIGENOUS GASKET SET
3575169 KIT,HX40 TURBO REPAIR 6BT/BTA5.9,6CT/A8.3 TURBO MODELS HX40W,HX35 (CURRENT FOR
SERVICE) WATER PUMP REPAIR KITS
3575210 KIT,4LG TURBO REPAIR VTA-1710,KTA-1150,GTA-1150/2300 TURBO MODEL 4LGK (CURRENT FOR SERVICE) SR .ENGINE MODEL REPAIR KIT P/N SUITABLE FOR WATER PUMPS
1 NH /NT BM91981 3880258 & BM50446--BOTH OBSOLETE SUPERCEDED BY
3575230 KIT,TURBO REPAIR N14/NTA14,NTA-855 TURBO MODEL HT60 (CURRENT FOR SERVICE) 3166497, AR95835 OBSOLETE SUPERCEDED BY 168255
3575236 KIT,TURBO REPAIR QTA-19-C,Q-19-M TURBO MODEL HX82 (CURRENT FOR SERVICE) 2 NH /NT 4084185 3166497, 3168255
3801096 KIT,TURBO REPAIR/ NT-855-L TURBO MODELS T50,ST50,VT50,T46 & T46B (CURRENT 3 NH /NT 3239763 AR 4283, AR 4284,
TURBO SEAL FOR SERVICE) 4 NT (A) 855 FFC 3239764 AR45347
3801523 KIT,HT3B BEARING/SEAL NT/NH,91N14 TURBO MODELS HT3B,BHT3B (CURRENT FOR 5 1 MW 3803284 3634033
SERVICE)
4027309 KIT,TURBO REPAIR 4B3.9,6B5.9,6C8.3 OBSOLETE (SUP/BY 4027309 ) SEA WATER PUMP REPAIR KITS
3803042 KIT,TURBO REPAIR NT/NH,V555 TURBO MODELS T50,ST50,VT50,T46 & T46B (CURRENT SR ENGINE MODEL REPAIR KIT P/N SUITABLE FOR WATER PUMPS
FOR SERVICE)
1 NH 495 3881151 3225879 (MINOR)
3803201 KIT,HT4C BEARING SEAL NT/NH,V28,V903 TURBO MODELSHT4B,BHT4C REPLACES 3801638/
NH 495 3881150 (MAJOR)
3803268 / 3803322 (CURRENT FOR SERVICE)
2 V 12 3881633 SHORT VOYAGE SPARES ( MINOR) 3881010, 3881011, 3877979
3803257 KIT,TURBO REPAIR K19,K38,K50 TURBO MODELS HC5A,HC5B & HX80 (CURRENT FOR
V 12 3881634 LONG VOYAGE, SPARES (MAJOR)
SERVICE)
3 NT 495 MG 3413337 SHORT VOYAGE, SPARES (MINOR) 3413072
4027074 KIT,TURBO REPAIR QSK-45 TURBO MODEL HX82 (CURRENT FOR SERVICE)
NT 495 MG 3413336 LONG VOYAGE, SPARES (MAJOR)
4027309 KIT,TURBO REPAIR 4B3.9,6B5.9,NT/NTA/NTC-495 TURBO MODELS H2A,H1C,H1E (CURRENT FOR
SERVICE)
AIR COMPRESSOR REPAIR KITS
SR ENGINE MODEL REPAIR KIT P/N AIR COMPRESSOR P/N.
1 NH / NT (SINGLE CYL.) AR 4154 AR 7944,AR 8312, 3246699(SUPERCEDED BY AR 7944)
2 K6 /KV (TWIN CYL.) 3880524 3239940, 3241154
3 C ENGINE 3803767 3558051
Section – 9 Information Parts Page 9-10
CONVERSION KITS - TURBOCHARGERS
* 495 SERIES
N - 855
N – 743
NTA 743
NT - 743
NTA-495
NTA-855
MODEL / CON VERSION OF KIT PART NO. REMARKS
KTA-3067 G
KTA-2300 G
VTA-1710-G
KT(A)-1150.G
KT/KTA- 1150
APPLICATION TURBOCHARGER N/NT/NTC-495
ENGINE MODEL
ENGINE MODEL
VT/VTA – 1710 G
VTA 1710-G3, G5
NT 743 M GARRETT TO HOLSET 3241932 Less Turbo for Radiator / HE Cooled
VTA- 1710-G3/ G5
KTA-2300 / 3067 G
NT/NTC/NTA-495-G
4 LGK Engine. Use Turbo. 3502490 - 4 LGK
NTA 855 C HM R35 ST50 TO HOLSET 3240293 * With Turbo. Use Turbo.
-
DUMPER * 4LGK 3502490-4 LGK
###
N/A
NTA 855 G FFC SCHWEITZER P/N 3229094 3241208 With Turbo. for Radiator / HE Cooled
3239961
3230457
3241466
3239457
3679730
TO HOLSET 4 LGK Engine. Use 4 LGK
3240788
3247555
3880142
3879625
3246405
3246399
3246317
3246318
NTA 855 C HOLSET 4LGK TO WATER 3880876 With Turbocharger P/N

ALL RIGS / AIR COOLED BRG. HSG. 4 LGK AR 3880820
COMPRESSOR TURBO.
W/P-AR3246489
WITH PLAIN HOSES

KTA 1150 G HOLSET HC5A OR 3880195 With Turbo.
WITH PLAIN HOSES
(1500 RPM) GARRETT T-18-A TO for radiator / HE Cooled Engine. Use
b) (ST 50 Turbo & Std Exht. Manifold)

HOLSET 4 LGK Turbo 3522295
3679566
3679936
a) (Holset Turbo & pulse tuned Exht. Mfd)
3241721*
KT 1150 G HOLSET HC5A OR 3880194 With Turbo
3660142 N
(1500 RPM) GARETT-18A TO for radiator / HE cooled engine
WITH PIPE
CONVERSION KITS - HEAT EXCHANGER TO RADIATOR
CONVERSION KITS - RADIATOR TO HEAT EXCHANGER
COUPLING
3679714
3990531
3879633
* This kit includes Intercooler Element, its Hsg. & mounting parts & is to be used when the basic engine is NT-855.
WITH PIPE
COUPLING
Page 9-8
Crankshaft i.e. reduced bolt circle diameter (PCD) on the crank nose.
* This kit includes parts which attach to crankshaft suitable for new
Section – 9 Information Parts Page 9-11 Section – 9 Information Parts Page 9-9
CONVERSION KITS - TURBOCHARGERS CONVERSION KITS - TURBOCHARGERS
* 495 SERIES * 495 SERIES
MODEL / CON VERSION OF KIT PART NO. REMARKS MODEL / CON VERSION OF KIT PART NO. REMARKS
APPLICATION TURBOCHARGER APPLICATION TURBOCHARGER
KT 1150 G HOLSET HC5A OR 3880195 With Turbo
NT 495 G T35 TO HOLSET H2A 3239065 Less Turbocharger for
(1500 RPM) GARETT-18A TO for radiator / HE cooled Engine, use
NT 495 G GARRETT TO HOLSET H2A 3239561 Less Turbocharger for Radiator Cooled Engine
KT 1150 C HC5A TO 4 LGK 3880194 With Turbo
HM 72-71 for radiator / HE cooled Engine, use NT 495 G GARRETT TO HOLSET H2A 3239564 With Turbocharger (3529298-00) for Heat Exg.
Turbo 3522296 Cooled Engine
NT / NTC 495 C HOLSET H2A TO WATER COOLED 3880489* With Turbocharger P/N 3533964 (Old Turbo
ALL RIGS / AIR BRG. HSG. H1E TURB. P/N 3529296 H2A)
COMPRESSOR HOLSET H2A TO WATER COOLED 3880490* With Turbocharger P/N 3533964 (Old Turbo
NT 743 G T50 TO HOLSET 4 LGK 3240293 Less Turbo. for Radiator / HE Cooled
Engine. Use Turbo. 3502490 - 4 LGK
NT 743 C T50 TO HOLSET 4 LGK 3240901 Less Turbo.

R-25 TEREX With turbo AR 3240902 With Turbo. AR 3240902
HM DUMPER (Turbo – 3521595)
6.
5.
4.
3.
2.
1.
15 Rapid Restart Shut down coil 3017993 3017993 3017993 3017993 3017993 3017993 1
16 Air Cleaner Bracket 3392575 1
TURBO
17 Allen Head Cap Screw S-189-C S-189-C S-189-C S-189-C S-189-C S-189-C 4 TURBO.
18 Allen Head Cap Screw S-184-C S-184-C S-184-C S-184-C S-184-C S-184-C 2
19 Spring Washer 181466 181466 181466 181466 181466 181466 6
KT1150 C
HOLSET TURBO
KT 2300 C
VT 1710 C
NTA 855 C
NTA 855-C
20 Plain Washer 70704 70704 70704 70704 70704 70704 4
KTA 1150 C
FOR N-495 CPT-365
FOR N-495 D-50-A-12
21 Plain Washer 67684 67684 67684 67684 67684 67684 2

COMPRESSOR WITH
FOR N-743 D-8O-A-12
DOZER WITH HOLSET
DOZER WITH HOLSET
22 O Ring 154088 154088 154088 154088 154088 154088 1

23 O Ring 154087 154087 154087 154087 154087 154087 1
HM
R35
24 1/8 NPTF plug with head 70295 70295 70295 70295 70295 70295 2
D 355
D 155
BEML
BEML
BEML
BEML
BEML
LW 50
LW 35
HD 785
25 10 Micron Fuel Filter 4084133 4084133 4084133 4084133 4084133 4084133 2
26 Accessory Drive 3005131 3880468 3880468 3880468 3880155 3245239 1
27 Low Coolant Water Level (LCWL) Switch 4072714 4072714 1
For N14 DG Set Only

HIGH ALTITUDE COMPENSATlON KITS
CONVERSION KITS - PIPE COUPLINGS

3239329
3239329
Adapter for Air intake temperature sensor 4053490

3239755
3881602
3880050
3880214
3880051
3879742
3879743
ECP/ECPG -Remote Monitoring Kit

(With Software on CD) Diesitel 4072075
Page 9-12
Section - 9 Information Parts Page 9-15 Section - 9 Information Parts Page 9-13
SHORT BLOCK ASSEMBLY OF VARIOUS MODELS *
ECP-G Retrofitting Kit for Various Engine Models
PART NO. MODEL REMARKS Sr. ENGINE MODELS NT495 NTA495 743 855 K6 V28 Qty.
4105144 NT-495 (SO. No. E84823201) P/N 3881121 No. Description P.No. P.No. P.No. P.No. P.No. P.No.
NTC-495 Long nose crankshaft, AR96687
1 ECP-G Assembly 4083935 4083935 4083935 4083935 4083935 4083935 1
Cyl. Block, 200710 Piston and AR3013282 Con. Rod.
2 Fuel tube 4085722 4085722 4085724 4085720 4084238 Hose 1
4105237 NTA-495 AR3247490 Crank, AR95562 Piston, BM 66968GC Cover, AR3015523 CR
3 Mounting bracket 4085734 4085734 4085734 4085734 4084240 4084240/ 1
4105148 NT-180 ND LOCO AR1945 Crankshaft, 200710 Piston
Genset AR3013282 Conrod, BM66968 GC 4085717
4105142 N-743 Genset/D80 Dozer of BEML 4 Engine Harness 4911692 4911693 4911694 4911695 4911696 4911697 1
4105143 NT-743/NTA-743 C Also for R25 HM Dumper 5 Vibration Isolator 3229922 3229922 3229922 3229922 3229922 3229922 4
3879939 NT-855-C-355 (FFC) Can use for UH-181 Hyd. Excavator, Ex400 and PC300 Engines. 6 Coolant temperature sensor 3865346 3865346 3865346 3865346 3865346 3865346 1
3239195 NTA-855 Non FFC I LW 35 7 Lube oil pressure sensor 3408560 3408560 3408560 3408560 3408560 3408560 1
AR 3241910 KT-1150 C/G (D-155) Also for 20-71 HM Front End Loader 8 Adapter for Coolant temperature sensor 4053490 4053490 4053490 4053490 4053490 4053490 1
AR 3241911 KTA-1150 G/C (D-355) also for PC-650 Application 9 Adapter for lub oil pressure sensore 3814448 3814448 3814448 3814448 3814448 3814448 1
3881506 VTA-1710-Loco
10 Magnetic pick up 3875360 3875360 3875360 3875360 3875360 3875360 1
* Please refer EBR of engine and the break-up of Short Block Kit to decide the suitability of particular part number.
11 Fuel Actuator 3330601 3330601 3330601 3330601 3330601 3330601 1
12 Fuel actuator housing (For PTG / PTR pump) AX1002978 AX1002978 AX1002978 AX1002978 AX1002978 AX1002978 1
13 ECPG O & M Manual 3243803-00 3243803-00 3243803-00 3243803-00 3243803-00 3243803-00 1
14 OEM harness 4054744 4054744 4054744 4054744 4054744 4054744 1
4
3
2
1
No.
K6
MAIN BEARINGS
V1710
NH/NT
MODEL STANDARD 0.010” 0.020” 0.030” 0.040” THRUST RING
Engine
B Series
KV 12/16
C Series
495 3240000 3240001 3240002 3240003 3240004 3067568
L10 Series
3238204
3238203
3879488
3236205
743 & 855 3239990 3239991 3239992 3239993 3239994 3067568
Sr. Part Number

Std.
1150 AR12270 AR12271 AR12272 AR12273 205112
205112
4025120
3802519
4073137
3000139
3067568
173326
Section-9 Information Parts
V1710/28 AR4220 AR4221 AR4222 AR4223 4073137
0173368
3166554
0173368
3167229
3873576
3166556
Part No.
0151881
(Set Main Bearing)
Part Number
2300 AR12250 AR12251 AR12252 3000139
1
1
1
1
1
1
1
1
Break-up at ‘AR’
Qty.
KTA3067/50G 3018210 3018211 3018212 3018213 3000139
3945922
3001708
4104649
3001196
3074361
SUPERSEDENCE
st
0.010”O/S
4B 3802010 3802011 3802012 3802013 3802014 *
OVERSIZE THRUST RINGS
FILTER ELEMENT AND SEAL RING.
Seal Ring
Seal Ring
Seal Ring
Seal Ring
(lntroduced from June 1 , 1997)
BREAK-UP AT ‘AR’ PART NUMBERS I.E.

(AR and B Check Kit Part Numbers)
6B 4080707 4080708 3802072 3802073 3802074 *
Element SLOBP
Description
180282
C Series 3945917 3945918 3945919 3945920 *
3001709
3001197
3074362
0.020”O/S
Element LO Filter Std.

A) ‘AR’ Part Numbers i.e. Filter Element and Seal Ring.
Element Fuel Filter Std

Element LO Filter Small
L10 4025120 4025126
Page 9-18
*B & C Series engine MB Set Thrust Main Brg as a part of MB shell.
Page 9-19 Section - 9 Information Parts Page 9-17

Section-9 Information Parts PART NUMBER STRUCTURE OLD & NEW CON ROD BEARINGS
OLD P/N Structure New P/N Structure
Digit-> 1 2 3 4 5 6 7 8 9 10 11 12 CD 1 2 3 4 5 6 7 8 9 10 11 12 MODEL STANDARD 0.010” 0.020” 0.030” 0.040”
1 0 0 0 2 9 6 5 K 0 2 9 6 5
2 0 5 0 4 3 8 5 K 2 5 0 4 3 8 5 495/743/855 203670 203671 203672 203673 203674
3 3 2 2 5 7 2 5 K 9 3 2 2 5 7 2 5 855 203660 203661 203662 203663 203664
4 A R 0 0 0 7 0 5 8 0 0 K 4 A R 7 0 5 8
5 A R 0 0 1 2 0 9 8 0 0 K 1 A R 1 2 0 9 8 855 / N14 214950 214951 214952 214953 214954
6 A R 3 2 4 1 8 5 5 0 0 K 1 3 2 4 1 8 5 5 V1710 /28 200600 200601 200602 200603 200604
7 A R 3 8 8 0 1 5 7 0 0 K 3 3 8 8 0 1 5 7
8 B M 0 0 0 3 4 1 0 0 0 K 1 B M 3 4 1 0 1150 205840 205841 205842 205843 N/A
9 B M 0 0 9 5 1 6 1 0 0 K 0 B M 9 5 1 6 1
2300 3047390 3047391 3047392 3047393 3047394
10 3 5 2 9 2 9 6 0 0 K 4 3 5 2 9 2 9 6
11 4 0 5 5 2 8 1 0 0 K 4 4 0 5 5 2 8 1 KTA 3067/50G 3047390 3047391 3047392 3047393 3047394
12 S T 0 0 0 0 6 8 5 C K 2 S T 6 8 5 C
B Series 4080702 4080703 4080704 4080705 4080706
13 S T 0 0 0 1 2 8 1 K 3 S T 1 2 8 1
14 S T 0 0 0 1 1 7 7 1 K 4 S T 1 1 7 7 1 C Series 3950661 3901431 3901432 3901433
15 S 0 0 0 0 6 0 4 K 2 S 6 0 4
16 S 0 0 0 0 1 9 5 A K 1 S 1 9 5 A L10 3016760 3016761 3016762
17 A S 0 8 0 7 8 0 0 S S K 5 A K 8 0 7 8 S S
18 A S 1 6 0 2 0 0 0 S S K 9 A K 1 6 0 2 0 S S
19 A S 1 6 0 0 9 4 6 M C K 0 A K 1 6 0 0 9 4 6 M C
20 A S 0 6 0 7 9 4 0 M S K 1 A K 6 0 7 9 4 0 M S
21 A S 1 6 0 1 4 0 6 M O K 2 A K 1 6 0 1 4 6 M O
AIR CLEANER ASSEMBLY, ELEMENTS AND KITS
SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING
NO. ASSLY INNER OUTER OD
Old Current Old Current Old Current
B CHECK KIT
P.No. P.No. P.No. P.No. P.No. P.No.
B CHECK KIT K-6
1 -- 4020943 -- 4020552 -- 4020551 GTA-1710-G,KTA-19-G4,KTA-2300-G,KTA-38 G2 18 INCH
B CHECK KIT N-495-G

B CHECK KIT N-743-G
B CHECK KIT N-495-G
2 3872650 4055571 3230273 4055575 3237949 4055576 N-495-C/M, NT-495-F/M/MG/P,NTA-495-C/F/G/P,
KIT, B CHECK S SERIES

KIT B CHECK KTTA-1150
B CHECK KIT NT/NTA743
B CHECK KIT NT(A)495-G
B CHECK KIT NT(A)495-G
N- 743-C/L/M, NT-743-M/MG 12 INCH
Part Desc.
Section – 9 Information Parts
BCHECKKIT-KTA 50G3 RAD

3 3872651 4055571 3230273 4055575 3237949 4055576 NT-495-MG,NT-495-M,NT-495-P( IND.PUMP),NT-
B CHECK KIT INHIBITOR 495
B CHECK KIT - NTA855-LW35

B CHECK KIT N-743G/N855-G
B CHECK KIT NT(A)743/855-G

B CHECK KIT- V/VT/VTA/1710
B CHECK KIT- KT/KTA 2300-G

B CHECK KIT- KT/KTA 2300-G
495-F(FIRE PUMP),NTA-495-C (RICE MILL),NTA-
B CHECK KIT VT1710 RADIATOR

495-G, NTA-495-P(IND.PUMP),N-743-L( DE-200
LOCO,WHD-220 LOCO,SAN LOCO, ORTON
CRANE, AMERICAN BRAITHWAIT CRANE),
N-743-C (4 HA-4 COMPRESSOR,TIL RT-760 &
B CHECK KITS WITH CAC
745 MOBILE CRANE),N-743-M 12 INCH

4 3872652 4055572 3230338 4055579 3237951 4055580 6CTA-8.3-C/G2,NT-495-C/L, NTA-495-C/F/F1,
N8-G1/G2, N-743-C/T-C/T-M, NT-743-C/F/F1/G/G1
/L/MG/P/T-F, NTA-855-L(BC)/MG(BCIII), KT-1150-C,
P/N
3238515
3238529
3238526
3238524
3238530
3238531
3238527
3238525
3238517
3238516
3238528
3238523
3238521
3238520
3238515
3238487
3238518
3238514
GTA-1150-G, GTA-2300G 14 INCH
AX1002399
5 3872653 4055281 3226019 4055279 3237953 4055280 NT-743-C, NT-855-L(BC)/L4(BC), VTA-28-L,
VTA-1710-L, KT-19-R, KT-1150-L, KTA-1150-C/L 16 INCH
Page 9-20
6 -- 3872654 -- Single -- 3237954 3237954 or 3875611. NTA-855-C(BC), KTA-1150-L 17.5 INCH

Element

9
8
7
6
5
4
3
2
1
22
21
19
18
17
16
15
14
13
12
11
10
20
#

Record
SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING

7
6
5
4
3
2
1
10
8
9
11

Record #
Old Current Old Current Old Current

P.No. P.No. P.No. P.No. P.No. P.No.
Hose, Plain
Hose, Plain
Hose, Plain
Hose, Hump
Hose, Hump
Hose, Hump
Description
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
7 -- 3872655 -- 504209 -- 3237956 3238152 N-495-C (BEML D50 Dozer) 9.5 INCH
3030514
3030513
3235134
3030514
3030513
3030770
3030778
3030515
3030769
3030772
PRT.NO.
4056439
8 -- 3872656 -- 504209 -- 3237956 3238152 N-495-C (BEML D50 Dozer) 9.5 INCH
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump

Hose, Flexible Hump
Hose, Flexible Hump
9 -- 3872657 -- 504602 -- 3237958 3238153 N-743-C BG-605-M-GRADER, D-80-A12 DOZER),

NT-495-C(BL-1420-F.E.LOADER,BD-14-2 DOZER) 11.8 INCH
10 -- 3872658 -- 3236027 -- 3237960 3238154 KT-1150-C (D-155-A1 DOZER,D-155-C-1

KOMATSU PIPE LAYER) 14 INCH
103807
PRT.NO.
3235726
3030770
3872497
3232257
3227853
4056442
4055400
3904060
3014244
3030782
3030778
3030774
4056443
3230439
3030787
4056441
3030772
3904059
4056440
11 -- 3872659 -- 3236027 -- 3237960 3238154 KTA-1150-C (D-355 DOZER) 14 INCH

3.5”
7”
7”
6”
5.5”
3.5”
5.5”
5”
7”
6”
4”
DIA “IN”
12 -- 3872660 -- 3233498 -- 3237962 3238155 KTA-1150-L (ZDM/NDM-5 LOCO) 16 INCH

8”
6”
7”
4”
7”
7”
5”
3”
4”
7”
4”
5”
5.5”
5.5”
5.5”
5.5”
5.5”
5.5”
5.5”
5.5”
3.5”
13 -- 3872661 -- 3233498 -- 3237962 3238155 NT-743-C1 (1025 DUMPER,HM1025(E)DUMPER);

2.75”
PLAIN AIR HUMP HOSES
AIR SYSTEM, HOSE, ELBOWS
DIA
NTA-743-C (HM R28 DUMPER,HM 1025 (A)

DUMPER); KTA-1150-C (M-900 DRILLING RIG)
KIT A/CL LW-35. 16 INCH
8”
3”
5”
7”
4”
3”
5”
5.5”
3.5”
5.5”
5.5”
5.5”
DIA
3.5”
5.5”
3.5”
5.88”
5.5”
5.5”
2.75”
5.88”
7.38”
6.875”
“IN” “OUT”
14 -- 3872662 -- 3233498 -- 3237962 3238155 NT-855-C(BCIII) ( 300CK HYD EXCAVATOR )

3.5”
5.5”
5.5”
5.5”
3.5”
3.5”
5.5”
4”
5.5”
5.5”
4”
DIA “OUT”
NTA-855-L3(BC) (GE LOCO); NT-855-C(BC)

Page 9-21
300 CK.; NTA-855-L (BC)(GE LOCO) 16 INCH

8
4
5
4
5
6
4
4
6
6
4
4
5
5
7
5
6
6
5
6
3.5
2.75
Length
15 -- 3872663 -- 3233498 -- 3237962 3238155 KTA-1150-SL (WDS-4 SHUNTING LOCOMOTIVE) 16 INCH

Dimension in Inches
16 -- 3872664 -- 3233498 -- 3237962 3238155 16 INCH

SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING Section – 9 Information Parts Page 9-24
Old Current Old Current Old Current SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING
P.No. P.No. P.No. P.No. P.No. P.No. NO. ASSLY INNER OUTER OD
28 -- 3875256 -- 3233498 -- 3237962 3238155 N-14-C ( R-32/EH-600 DUMPER,EX-700 Old Current Old Current Old Current
EXCAVATOR); NTA-14-C (R32 DUMPER,EH-600 P.No. P.No. P.No. P.No. P.No. P.No.
DUMPER(WDB), EX-600 HYD EXCAVATOR),
NT-855-(BC)(EX-400 HYD EXCAVATOR,TELCON 17 -- 3872665 -- Single -- 3237963 KTA-1150-C (MAZ-537 TANK CARRIER) 14 INCH
EX-600 HYD EXCAVATOR C-650 BHR(600/150), Element
3HA4 RECIPROCATING COMPR., VTA-1710-L 18 -- 3872666 -- Single -- 3237963 NT-743-C (P&H 655 M ALC CRANE, TC CRANE)
(FROM SHOULDER BALLAST CLEANER), KT-1150-C Element G-855-P(COD PUMP),G-855-C (BC)
( 60 TON COAL HAULER, HM 2071 FE LOADER ) 17.5 INCH (RECIPROCATING COMPRESSOR), G-1710-G 14 INCH
29 3877554 3875256 -- 3233498 -- 3237962 3238155 N-743-T-C ( H 40 HYD EXCAVATOR), VTA-28-C 19 -- 3872667 -- Single -- 3237963 NT-743-C (TELCON TFC-280 CRANE, HIL 101-M
( LW-50 DUMPER ) 16 INCH Element SHOVEL, 101-M MAGNETIC CRANE, P&H 955 M
30 -- -- -- Single -- 3875611 KTA-3067-M (MARINE PROPULSION) 17.5 INCH ALC CRANE) 14 INCH
Element 20 -- 3872668 -- 3237742 -- 3872336 3238156 NTA-855-R(BC) (DETC UNDER SLUNG) NTA-855-
31 -- 3878893 -- 3233498 -- 3237962 3238155 LW-35 15.5 INCH R1 (DIESEL HYD MULTIPLE UNIT,ACCIDENT
RELIEF TOOL VAN), KT-2300-C ( BEML HD-785-
32 3166627 OBSOLETE -- 3875393 -- 3875391 3238057 Belaz Dumper & old 1 MW.
DUMPER, TEREX 33-11C DUMPER ); KTA-1150-C
33 3878979 -- 3879154 -- 3879155 KTTA19C ( 1400/400 SCREW COMPRESSOR ) 406.5 MM ( FRAME 6 G.T.STARTING ); VTA-28-C ( CAT 773-B
34 -- 3879160 -- 3879074 -- 3879075 KTA-1150-C( BEML BH-40 DUMPER), VTA-28-C 50T DUMP TRUCK ), NTA-855-L6 (MG-DEMU),
(H-135 HYD EXCAVATOR), NTA-855-C(BC) NT-855-R(BC)(4 WHEELER OHE CAR,MG RAIL
(ATLAS COPCO XRH-1100 SCREW BUS OUIS EQUIPMENT) 15 INCH
COMPRESSOR) 15.5 INCH 21 3812770 4055573 3812540 4055583 3812607 4055584 NT-495-C (RICE MILL), NTC-495-G/DG, G-495-P
(CRUDE OIL PUMP ), G-495-G,G-743-G,
G-855-G(BC) 10 INCH
AIR CLEANER ASSEMBLY, ELEMENTS AND KITS AIR CLEANER ASSEMBLY, ELEMENTS AND KITS
SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING
NO. ASSLY INNER OUTER OD NO. ASSLY INNER OUTER OD
Old Current Old Current Old Current Old Current Old Current Old Current
P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No.
35 -- 3877403 -- 3233498 -- 3237962 3238155 NTA-855-G2(BC),G4(BC),G5(BC),G6(BC),L(BC) 22 -- 501111 -- Single -- 3235934 FOR KOMATSU APPLICATION IN PLACE OF
(08-32 DUOMATIC TAMPING MACHINE,UNIMAT Element P/N.139136.THE ASSEMBLY CONSISTS OF SHELL
TT MACHINE),KT-1150-G 15.5 INCH ASSEMBLY P/N. 150756.
36 -- 3879084 -- 3233498 -- 3233962 3238155 VTA-28-C (LW- 50 DUMPER), NT-743-T-C
23 -- 504606 -- 504106 -- 504107 3238158 KIT ALTITUDE COMPENSATION 12.5 INCH
( H-40 HYDRAULIC EXCAVATOR)
37 3392007 -- 3236027 -- 3237960 3238154 NTA-743-C DC230 24 -- 503005 -- 503009 -- 503010 3238159 FOR ATLAS COPCO COMPRESSOR APPLICATION
AND IS TO BE MOUNTED ON THE CANOPY OF
38 3392384 3392384 -- 3875393 -- 3875391 3238057 KTA-19-G3/4/9, KTA-38-C( BH-120 DUMPER, THIS APPLICATION.FIRST USED ON S.O.3011.
UNIT RIG 120 T DUMPER).KTA-38-G5, KTA-50- THIS IS 9.7/16 INCH DIA. AIR CLEANER HAVING
G3/G8, KTA-3067-C ( 170 T DUMPER) 495 MM TOTAL LENGTH INCLUSIVE OF CONNECTION AIR
39 -- -- -- 3875560 -- 3875559 N-8-G1/2, 6-CTA8.3 ( 650/200 SCREW COMPR., CLEANER P/N.502354.
TIL TMS 750 CRANE), N-743-T-C (L&T 170 CK),
NT-743-C ( L&T 180 CK HYD EXCAVATOR ),G/G1, 25 -- 3001893 -- 3012212 -- 3012213 KTA-19-P (TAMPING M/C) 406.4 MM
NT-743-G, VTA-1710-C ( REVATHI WATER WELL
DRILL RIG ) 356 MM 26 -- 3018038 -- 504209 -- 3237956 3238152 Nissan 4BT3.9
40 4055621 -- 3879155 -- 3879154 KTTA 19C(210M), KTA-1150-C/L, NTA-855-C (BC),
27 -- 3877423 -- 3233498 -- 3237962 3238155
NTA-14-C
41 -- 3875557 -- 3875560 -- 3875559 NT-743-C (EX 300 HYD EXCAVATOR), NT-743-P
(BALLAST REGULATOR), NTA-855-C(BC)(SOIL
STABILIZER) 356 MM
AIR CLEANER ASSEMBLY, ELEMENTS AND KITS AIR CLEANER ASSEMBLY, ELEMENTS AND KITS
SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING
NO. ASSLY INNER OUTER OD NO. ASSLY INNER OUTER OD
Old Current Old Current Old Current Old Current Old Current Old Current
P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No. P.No.
61 -- 3814991 3814696 3814695 4BT3.9-IR-IPF551/ RTR220, 4BT3.9C-IR- 42 -- 3392613 -- 3875393 -- 3875391 3238057 Belaz Dumper, KTA-19-C (HIL H-95 HYD
DD90/SD110/AL10010.(FLEETGUARD P/N.8250018) EXCAVATOR) 406.5 MM
62 -- 3815371 3814313 3814312 6CTTA-8.3-G1,G2. 6CT-8.3-G2 (140 TO 220 KVA 43 -- 3166836 -- 3233498 -- 3237962 3238155 360 MM
RANGE) 44 -- 3166838 -- 3233498 -- 3237962 3238155 NTA-855-C(BC) ( KG KHOSLA,ELGI,KPC
63 -- 3924893 4BT-3.9,4BT-3.9-D(M),6BT-5.9-M COMPRESSORS, KG KHOSLA WATER WELL
64 -- 4056194 KTA-50-G3,G8-1,G(AC SCR RIG), KTA-3067-P RIG,IR 600/100 ROTA COAL BH RIG,OM 424
(INDUSTRIAL PUMP), QSK-60-G3-G4. TRANSPORT CRAWLER, WATER WELL PACK)
(FLEETGUARD P/N.1050670) 466MM 45 -- 3166840 -- 3233498 -- 3237962 3238155 360 MM
65 -- 4056462 4071693 DXP-15/25/20,S-3.8-G/G3/G7(FLEETGUARD 46 -- 3166842 -- 3233498 -- 3237962 3238155 NT-855-C/ (BC) ( H-55 N HYD EXCAVATOR),
P/N.1050640) 158.5MM NTA-743-C(H-55 N HYDEXCAVATOR)
66 -- 44169 NH-743 47 -- 3877401 -- 3875493 -- -- NT-743-G,NTA-495-G 300 MM
67 -- 4055621 4055592 KTTA-19-C (210M), NTA-14-C (Blast Hole Rig), 48 -- 3000958 -- 3013211 -- 3013210 VTA-28-G5, KTA-33-L1(LOCOMOTIVE) 16 INCH
KTA-1150-C (RH30 D O&K Shovel, 900/350 Comp, 49 -- 4020977 -- -- -- 3875391/93 -- KTA-50-L SO38133
IR 555, 1000/750 Comp), NTA-855-C (1150 Screw
Comp) 50 -- 4021127 -- 3875393 -- -- KTA-50-L (1400 HP DEMU LOCO,DE LOCO),
KIT AIR INTAKE SYSTEM P/N.4105743
68 -- -- 4055592 KTA-19-C (H95 HYD EXCAVATOR) 51 -- 3814178 -- 3814313 -- 3814312 6BTA-5.9C EX-200-V, TELCON-MG.AL10004
Section – 9 Information Parts SWITCH, OVERSPEED Page 9-31 Section – 9 Information Parts Page 9-29
NOTE :- THIS OVERSPEED STOP SWITCH SHOULD BE MOUNTED VERTICALLY WITH ITS SWITCH TERMINALS ON THE TOP SIDE AND AIR CLEANER ASSEMBLY, ELEMENTS AND KITS
CABLE END AT THE BOTTOM SIDE. SR. AIR CLEANER ELEMENT ELEMENT KIT P/N WHERE-USE HOUSING
S.No. Part No. Ratio O.S.Stop Trip Engine Tripping ENGINE MODEL
(Supplier's Setting RPM Range Old Current Old Current Old Current
Information) (Supplier's P.No. P.No. P.No. P.No. P.No. P.No.
Information)
1 500287 2 To 1 1250 To 1290 2100 2500 / 2580 NT-495-F/L,NTA-495-F,NTA-743-F,NTA-855-L,VTA-28- 52 -- 3814985 -- 3814133 -- 3814132 6BT-5.9 (IR) SD 150
L,VTA-1710-L,KT-1150-F/L,KTA-19-R/M,KTA-1150-C/F/L 53 -- 106956 N-495
2 500288 2 To 1 1075 To 1115 1800 2150 / 2230 NT-495-F/MG,NTA-495-F,NT-855-F/P/R,NTA-855- 54 -- 3050498 Disposable Air Housing. Farr P/N. FARR 71338006.
L/MG/R,VTA-1710-L,KTA-50-L,KTA-3067-L Fleetguard P/N AH1135M. Whereuse in VTA-30-G,
3 500289 2 To 1 900 To 940 1500 1800 / 1880 NT-495-P/F1,G-495-P/G,NTA-495-F,NT-743-P/F1,NTA-743- KTTA-50-G2
F,G-855-P,GTA-855-G(BC),G-743-G,VTA-1710-F,G-1710-
G,KTA-19-G4,KTA-1150-G/F,KTA-50-G3,KTA-2300- 55 -- 3276760 4BT/4BTA-3.9-G/C
F/MG,GTA-3067-G 56 -- 3315741 VTA-28-D(M.O) M/G (FLEETGUARD P/N. AH-1100)
4 505069 1 To 1 1640 To 1680 1500 1640 / 1680 GTA-1150-G,GTA-2300-G 57 -- 3414702 4020552 4020551 NTA-855-C BC (BH 35-2), KTA-38-C (BH 85-1),
5 3231354 2 To 1 850 To 870 1500 1700 / 1740 NTA-495-MG,NT-743-MG,NTA-855-MG,VTA-1710-MG,KT- NTA-855-C (LW 35), R 35, 1035, K6/VK12 (SURFACE
1150-F MINER), KTA-38C (CAT 777C), KTA-38-C (BH 100)
6 3231688 2 To 1 1130 To 1150 1950 2260 / 2300 NT-495-C/L,NT-855-R,NTA-855-R
7 3233985 2 To 1 1025 To 1045 1800 2050 / 2090 NT-495-C,G-855-C 57 -- 3814027 3814133 3814132 6BT-5.9-G
8 3235575 2 To 1 1060 To 1080 1800 2120 / 2160 NT-495-M,N-743-M,N-743-T-M,NTA-855-M,VTA-1710-M,KTA- 68 -- 3814552 3814313 3814312 6BT(EX-200-1), 6BTA(EX-210-V HYDRAULIC
19-M,KTA-1150-M,KTA-2300-M,KTA-3067-M EXCAVATOR)
9 3878441 2 To 1 580 To 620 1000 1160 / 1240 59 -- 3814683 3814696 3814695 6BTA5.9-G1,6BT5.9-M
60 -- 3814966 3815069 3815068 6BT5.9-M
TACHOMETER
Sr. Part No. Description Display Used For Used With Used with Operating REMARKS
9539
67185
61961
63495
61554
61814
66167
60985
64978
63223
67369
64030
No. Type Probe(Pickup Voltage
9539 A
110980
102522
107195
215950
200517
144047
144044
144038
144034
143992
149274
107063
104296
102234
64998 J
67185 F
63241 F
67369 A
67185 A
67185 B
70458 A
63495 A
63411 A
64998 E
67369 C
67185 H
63241 N
64998 D
64998 H
Part No.
64998 G
63241 M
3026395
3200316
3024128
63495 B
144052 K
136840 E
Magnetic)
1 501151 HOURMETER MECHANICAL
2 501434 HOURMETER MECHANICAL
3 3166518 TACHOMETER LCD 138 Teeth Gear SAE # 2 Ring Gear 3231404, 24 DIGITAL
3237092
4 3166710 TACHOMETER LCD 142 Teeth Gear SAE # 0 Ring Gear 3232740 24 DIGITAL

5 3230595 TACHOMETER LCD 60 Teeth Gear Twin Disc Torq-Conv. 24 DIGITAL
6 3231007 TACHOMETER MECHANICAL
ID
2.75
2.50
5.00
3.00
2.50
2.50
2.38
0.62
3.50
3.50
3.00
3.00
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
2.25
2 . 00
1 . 50
1 . 25
2 . 25
2 . 25
2 . 00
2 . 00
2 . 00
2 . 25
2 . 25
2 . 25
1 . 75
1 . 50
1 . 50
1 . 50
1 . 00
1 . 00
1 . 25
2 . 25
1 . 75
1 . 50
1 . 00
1 . 25
DIMENSION ARE IN INCHES

3237092
3237092
4.50
4.00
2.75
7.00
3.00
4.00
2.62
5.00
3.50
3.50
4.25
2.25
3.12
3.00
6.00
5.50
4.00
4.00
3.50
6.50
5.00
2.50
3.00
3.50
3.00
2.00
3.00
2.50
3.00
2.88
2.50
2.00
4.00
8.00
5 .00
40.00
50.00
14.25
30.00
22.00
52.00
11.00
18.00
24 .00
36.00
32.00
26.00
12 .00
58 .00
14 .00
12 4054060 HOURMETER & LCD 118 Teeth Gear DIGITAL
Length
COOLING SYSTEM WATER PLAIN HOSES COOLING
TACHOMETER
Page 9-34
Section – 9 Information Parts OVERALL DIMENSIONS OF FLEXMASTER COUPLINGS (COOLANT) Page 9-33
ASSEMBLY NO. A DIA. PIPE SIZE B DIA. C DIM. D DIM. SLEEVE COUPLING
QTY.1
RUBBER RING
3872278 25.40 (1.00 INCH) 47.0 79.5 64.00 QTY.2
RING RETAINING
SCREW
QTY.2
Part
Part
3872252 31.75 (1.25 INCH) 55.0 97.0 70.75 C QTY. 4
CLAMP
QTY.4
3872284 38.10 (1.50 INCH) 60.0 104.0 75.90
Number
Number
3167224
3167222
3167218
3167217
3167216
3167215
3167214
3167221
1/15" MINIMUM
3872258 103.60 (2.25 INCH) 86.0 128.0 57.15
A DIA
3872294 104.00 (2.50 INCH) 91.3 130.0 63.50

3872268 125.00 (3.00 INCH) 123.1 174.5 76.20 PLAIN WASHER
B DIA QTY. 4
138.1 D
3872299 170.00 (3.50 INCH) 189.0 88.90 NUT LOCK WASHER
QTY. 4 QTY. 3
AX 1001098
AX 1001097
3872304 103.00 (5.00 INCH) 170.0 225.0 127.00
100835
152026
149437
140333
140332
140331
140315
140314
140313
140312
140311
135621
135144
131891
125742
125741
125740
125739
Table 2 INSERTION DEPTHS, TORQUE VALUES & PART NUMBERS
Description
PRT.NO
Pipe “D” “D” RING

ASSEMBLY *TORQUE SLEEVE RUBBER PLAIN LOCK
OD Min. Max. CLAMP RETAINING SCREW NUT
Premixed Coolant
Premixed Coolant
Premixed Coolant
PART NO. inch-lbs COUPLING RING WASHER WASHER
Inch inch inch SCREW
RESTORE PLUS
1 00 3872278 0.72 1.21 20-24 3872279 3872280. 3872281 3872282 3872283 70704 S-600 3235449
6
4
Description
8.5
6.5
7.5
3.5
5.5
4.5
1.25 3872252 1.16 1.40 24-36 3872253 3873254 3872255 3872256 3872283 70704 S-600 3235449
3.75
CLAMP ‘T’ BOLT
7.625
6.125
3.125
3.675
3.875
3.125
5.125
4.625
4.125
1.50 3872284 1.18 1.45 24-36 3872285 3872286 3872287 3872288 3872257 S-626 S-605 S-221
PREMIXED COOLANT
Coolant Additive Concentrate

Inches
FOR AIR HUMP HOSE
2.25 3872258 1.17 1.83 45-50 3872259 3872260 3872261 3872262 3672257 S-626 S-605 S-221
Inner Dia. In
1 Gallon (4 litres)
2.50 3872294 1.17 1.83 45-50 3872295 3872296 3872297 3872298 3872257 S-626 S-605 S-221
3.00 3872268 1.67 2.30 180-200 3872269 3872270 3872271 3872272 3872273 S-602 S-604 S-223
COOLANT ADDITIVE CONCENTRATE
55 Gallons (208 litres)

3.50 3872299 1.67 2.48 180-200 3872300 3872301 3872302 3872303 3872253 S-602 S-604 S-223
5.00 3872304 1.75 2.07 180-200 3872305 3872306 3872307 3872308 3872253 S-602 S-604 S-223
* Torque to Inch-Lbs. As shown in the Table or to a minimum of 1/16” clearance between Clamp lugs, (Refer Figure 3) whichever o ccurs first.
Qty.
Qty.
HOW TO ORDER
5 lt.
2 lt.
1 lt.
0.5 lt.
10 lt.
205 lt.
10 lt.
5 lt.
To obtain complete assembly of pipe coupling, order should be placed on Assembly Part No. given in Table 2.
Page 9-35
Generally with proper installation/maintenance, the only replacement components that may be needed is, the Rubber ring which may be ordered on the
respective Rubber ring part ‘number given in Table above.
LIST OF REPLACEMENT PARTS - ECPG PART NUMBER INFORMATION
ECP Engine Model

Sr. Part name Part
No. Number For engines with 142 teeth on 3414797 KV, KTA 50, 1710, 1150
flywheel ring gear
1 ECP-G Assembly 4083935 For engines with 118 teeth on 4053453 495, 743, 855,
2 Enclosure, Front 4084218 flywheel ring gear
3 Enclosure, Rear 4084219
ECP Engine Wiring Harness
4 Seal, ring 4083975
5 I/O board 4084217 1MW 4054729
6 CPU board 4084216 KV16 4054727

7 FRC cable, 26 pin 4084223 KV12 4053890
8 FRC cable, 14 pin 4084222
V28 4053889
9 Datalink cable 4084227
10 Gasket for Connector “A” (19 pin connector) 4084283 K6 4053888
11 Gasket for Connector “B” (10 pin connector) 4084242 N4.8G 4053456
12 Gasket for Connector “C” (7 pin connector) 4084282
855 4052728
13 Gasket for datalink connector 4084224
14 Heat sink 4084285 743 4053886
15 Key switch 504975 495 4053887
16 Parameter selection push button 4071721
OEM Connector 4054744
17 Toggle switch (for Idle/Rated mode selection) 500278
18 Vibration Isolator 3229922 Coolant Water Temperature 3865346
Sensor
19 Mounting bracket 4084240
Sensors Connector Water Temperature 3823256
1 Coolant temperature sensor 3865346 Sensor
2 Air Intake temperature sensor 3865345 Lub Oil Pressure Sensor 3392445
3 Lube oil pressure sensor 3408560
Magnetic Pick Up 3875360
4 Coolant level sensor 3331472
5 Adapter for Coolant temperature sensor 4053490 Intake Manifold Temp. 3865345
Sensor (AUX)
6 Adapter for Air intake temperature sensor 4053490
7 Magnetic pick up 3875360 Low Coolant Water Level 3331472
Actuator and Actuator housing (LCWL) Switch
1 Fuel Actuator 3330601 Low Lub Oil Pressure Switch 3056344
2 Fuel actuator housing 4071944
Adapter for Coolant Water 4053490
3 Fuel tube 4084238
Temp. Sensor
4 ECPG 0 & M Manual 3243803
Harness Adapter for Intake Manifold 4053490
Temp. Sensor
Engine harness
1 K6 engine 4911696 Harness Wiring for (LCWL) Switch 3331473
Mtg. Panel Controller 4053147
4 OEM harness 4054744 Bracket Instrument Panel 4054134
5 Coolant level sensor extension harness 3331473
Page 9-39
Page 9-38
QTY
QTY
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
-
1
1
1
1
1
-
-
-
-
-
ALTR.P.NO
ALTR.P.NO
3040349
3040448
3040448
3040349
3040349
3040349
3040349
3040349
3040349
178509
178567
178567
178567
178567
178567
178456
178567
178570
178567
178685
178456
178456
178587
178509
178685
VARIOUS BELT P.N. FOR CONSTRUCTION APPLICATIONS - CONTD…..
-
-
-
-
-
-
-
-
QTY
QTY
1
1
1
1
1
1
1
2
VARIOUS BELT P.N. FOR CONSTRUCTION APPLICATIONS
-
-
-
-
-
-
-
-
-
-
1
1
1
1
-
-
-
-
-
-
-
WTR.PUMP
WTR.PUMP
3040384
200328
200328
200328
200328
200328
200328
200328
200328
178496
200328
200328
200328
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
QTY
QTY
2
2
2
2
2
4
4
2
2
3
3
1
2
-
-
2
2
3
-
-
-
1
-
-
-
-
-
-
*** Indigenous Not Available

(Imported in Use)
FAN BELT
FAN BELT
3058383
3040384
3058383
3938693
3236740
3229931
178668
178597
191491
178597
178611
191491
178611
S-2362
S-2362
178553
178611
178579
S-2362
502325
178579
-
-
-
-
-
-
-
-
-
-
-
(Indigenously Available)
Wrapped ‘V’ Belt
( Imported Only)
** Poly ‘V’ Belt
G 501163B/C
G 501163B/C
REF. S.B.M
G 5011 78A
G 64011350
REF. S.B.M
D 651103 H
G 501153 A
G 601160 B
G 411125C
G 501153A
G 451107A
G 506136A
D 621108B
G 6411350
D 451103C
G 9111070
G 6011580
G 5061146
G 8311100
D 6011430
G 6411320
G 1011890
G 4511110
G 421116A
G 4111290
G 1062410
G 9111070
D 601116 J
D 2811606
G 3011840
G 3011840
D 2811060
D 4111120
G 8311100
G 1062410

APPLICATION
APPLICATION
D 82/40/30 B
HM101/93M
TATA 1055
TATA 955
Tata 1055
33-11-C
H 40/36
UH-181
HD-785
PC-650
PC-300
PC-220
33-11-D
300-CK
H 40/36
PC-220
G-30-D
LW-35
LW-35
LW-50
D-120
D-155
LW-35
D-355
LW-25
LW-50
D-120
H-55
R-35
R-25
D-80
D-50
D-50
H-55
DO’S & DONT’S

CUMMINS BRANDED AV MOUNTS
Do’s
For a good isolation efficiency insist on approx. 10mm deflection.
How to fix this problem ? For roof top installation, deflection should be 11-13mm.
You have an advantage with Cummins GERB spring-mount that it No need to boil Cummins GERB Springmounts.
No particular direction of installation – any way you wish.
does not need fixing with bolts.
Lift the machine locally and use shims under the mounts to level the Dont’s
machine, else slide the mounts to an area that is compressed more. Do not install more number of mounts for more isolation.
Measure the height once again and carry on the process till you are Optimise engine weight w.r.t. loading capacity of each mount.
Genset is bound to move over any flexible support system as it
satisfied.
crosses resonance – technically it is not a problem as the entire
Take care that the gap between two mounts does not exceed over machine moves as one body & there is no relative movement.
1250mm, preferably 1000mm as the frame in such cases are Never use double isolation, i.e one under the DG set and one under
normally weak and more flexible. the girder.
There is minimal chance that spring – mount heights are different,
INSTALLATION OF DG OVER
because of varied property of the mounts. Cummins GERB mounts GERB springmounts type KS
are designed in a manner that will not break or loose its property The mounts are supplied with adhesive pads placed on top and
unless it is working in an overloaded condition or is mishandled. bottom.
These pads are not sticky initially and start working once loaded.
Clean the contact surfaces before placing the spring – mounts.
Position the mounts according to the layout calculated COG of
machine (for retrofit / field replacement, replacement is one to one on
existing mounting location).
Place the equipment evenly on springmounts.
Though not essential, optionally bolt the base frame to the spring
mounts.
Using mounting bolts is optional and are provided in the package.
In case the DG is to be unloaded first and springmounts to be

fixed later
Unload the DG on wooden blocks that are 120mm high. Make sure
the wooden blocks are not kept at the pr oposed location of the
springmounts.
Insert the mounts at specified locations.
If possible lift the DG with a crane or 4 – 6 jacks. Remove the wooden
packings. Synchronise all the jacks in a way that all m ounts get
loaded simultaneously.
Post Installation Checks

Check all the mount heights including the top and bottom adhesive
pads. The installed final height of any spring – mount should not be
less than shown in the following table. Practically the height difference
of +/-2 mm should be acceptable which will be compensated by the
spring flexibility while in operation.
In case there is a variation in mount heights – it should be in uniform
manner from one end to another. However if the mount height is
found to be zig-zag, the most probable reason is major foundation
unevenness or base frame bending.
Section-9 Information Parts Page 9-42 Section – 9 Information Parts Page 9-43
CUMMINS BRANDED AV MOUNTS (ISOLATOR VIBRATION)
a) Selection - kva rating wise for Cummins Engines
PCC retrofitting for use in field
Engine kva Type Qty.per Part Nos.
Model of AVM Engine Old New
S3.8G2 30 KS-48 4 3238478 AX1001324 SR DESCRIPTION PART SUITABLE FOR DG
S3.8G3 35 KS-48 4 3238478 AX1001324 NO NO. CUMMINS ENGINE RATING
S3.8G4 40 KS-48 4 3238478 AX1001324 MODELS - KVA
S3.8G5 45 kS-48 4 3238478 AX1001324
S3.8G6 50 KS-48 6 3238478 AX1001324 1 POWER 4084008 NTA855 G4 / NTA 855 G5 / 225, 250,
S3.8G7 62.5 KS-48 6 3238478 AX1001324 COMMAND NT 855 G6 / NTA 855 G2 / 285, 320,
6BT5.9G1 75-82.5 KS-81 6 3238479 AX1001325 CONTROLLER KTA 1150 G / KTA 19 G3 / 380, 450,
NT495G 100 KS-81 6 3238479 AX1001325 UNIT KTA 19 G4 / VTA 28 G5 / 500, 625,
6BTA5.9G1 120 KS-81 6 3238479 AX1001325 KTA 38 G ( KTA 2300 G2 ) 750, 1000,
NTC495G 125 KS-81 6 3238479 AX1001325
/ KTA 38 G5 ( KTA 3067 G ) 1250,
NTA495G 140 KS-81 6 3238479 AX1001325
N8-G1 160 KS-81 8 3238479 AX1001325
/ KTA 50 G3 / KTA 50 G8 1500
N8-G2 180 KS-81 8 3238479 AX1001325
NTA743G 200 KS-81 8 3238479 AX1001325 2 ENGINE 4104781 NTA855 G4 / NTA 855 G5 / 225, 250,
NTA855G1 225 KS-82 8 3238480 AX1001326 HARNESS SET NT 855 G6 / NTA 855 G2 285, 320
NTA855G 250 KS-82 8 3238480 AX1001326
NTA855G2 285 KS-82 8 3238480 AX1001326 3 ENGINE 4084015 KTA 1150 G / KTA 19 G3 / 380, 450,
NTA855G2BC 320 KS-82 8 3238480 AX1001326 HARNESS SET KTA 19 G4 500
N14G1 320 KS-82 8 3238480 AX1001326
KTA1150G 380 KS-82 8 3238480 AX1001326 4 ENGINE 4084014 VTA 28 G5 625
KTA19G3 450 KS-84 10 3238481 AX1001327 HARNESS SET
KTA19G4 500 KS-84 10 3238481 AX1001327
VTA28G3 600 KS-84 10 3238481 AX1001327 5 ENGINE 4084013 KTA 38 G ( KTA 2300 G2 ) 750,
VTA28G5 625 KS-fs 1300 10 3238482 AX1001328
HARNESS SET / KTA 38 G5 ( KTA 3067 G ) 1000
KTA2300G 750 KS-fs 1300 12 3238482 AX1001328
KTA38G5 1000 KS-fs 1300 12 3238482 AX1001328
KTA50G3 1250 KS-fs 1300 14 3238482 AX1001328 6 ENGINE 4084012 KTA 50 G3 / KTA 50 G8 1250,
KTA50G8 1425-1500 KS-fs 1300 16 3238482 AX1001328 HARNESS SET 1500
QSK45G4 1450 KS-fs 1300 16 3238482 AX1001328
QSK45G6 1550 KS-fs 1300 16 3238482 AX1001328 7 PT CT MODULE 4084022 NTA855 G4 / NTA 855 G5 / 225, 250,
QSK60G3 1875 KS-fs 1300 20 3238482 AX1001328 NT 855 G6 / NTA 855 G2 / 285, 320,
QSK60G4 2000 KS-fs 1300 20 3238482 AX1001328 KTA 1150 G / KTA 19 G3 / 380, 450,
KTA 19 G4 / VTA 28 G5 / 500, 625,
b) Selection - As per weight in tons for non-Cummins engines KTA 38 G ( KTA 2300 G2 ) / 750,1000,
Approx. Weight Speed AVM QTY. per Part Nos. KTA 38 G5 ( KTA 3067 G ) / 1250,1500
(in tons) Model Engine Old New KTA 50 G3 / KTA 50 G8
0.7 – 1.10 1500 KS-48 4 3238478 AX1001324
Up to 1.60 1500 KS-48 6 3238478 AX1001324 8 GOVERNOR 4084020 NTA855 G4 / NTA 855 G5 / 225, 250,
Up to 2.10 1500 KS-81 6 3238479 AX1001325
MODULE NT 855 G6 / NTA 855 G2 / 285, 320,
Up to 3.00 1500 KS-82 6 3238480 AX1001326
Up to 4.00 1500 KS-84 8 3238481 AX1001327
KTA 1150 G / KTA 19 G3 / 380, 450,
Up to 5.50 1500 KS-84 8 3238481 AX1001327 KTA 19 G4 / VTA 28 G5 / 500, 625,
Up to 7.00 1500 KSfs-1300 8 3238482 AX1001328 KTA 38 G ( KTA 2300 G2 ) / 750,1000,
Up to 8.25 1500 KSfs-1300 10 3238482 AX1001328 KTA 38 G5 ( KTA 3067 G ) / 1250,1500
Up to 10.40 1500 KSfs-1300 12 3238482 AX1001328 KTA 50 G3 / KTA 50 G8
Up to 12.50 1500 KSfs-1300 14 3238482 AX1001328
Up to 14.00 1500 KSfs-1300 16 3238482 AX1001328 9 AVR MODULE 4084021 NTA855 G4 / NTA 855 G5 / 225, 250,
Up to 16.00 1500 KSfs-1300 18 3238482 AX1001328 NT 855 G6 / NTA 855 G2 / 285, 320,
Up to 17.50 1500 KSfs-1300 20 3238482 AX1001328 KTA 1150 G / KTA 19 G3 / 380, 450,
Technical Details KTA 19 G4 / VTA 28 G5 / 500, 625,
Maximum Dimension Height (mm) Weight KTA 38 G ( KTA 2300 G2 ) / 750, 1000,
Model
Load* F(Kg) A=B (mm) Original ** Minimum (Kg) KTA 38 G5 ( KTA 3067 G ) / 1250,1500
KS-48 322 110 73 60 2.0 KTA 50 G3 / KTA 50 G8
KS-81 540 120 114 92 3.0
KS-82 600 120 113 94 3.1
KS-84 815 120 113 97 3.2
KSfs 1300 999 120 97 86 3.3
* Normal loading 80% of maximum load.
height is lower than original height
PCC retrofitting kits for field use

SR DESCRIPTION PART SUITABLE FOR DG
NO NO. CUMMINS ENGINE RATING SR DESCRIPTION PART SUITABLE FOR DG
MODELS - KVA NO NO. CUMMINS ENGINE RATING
MODELS - KVA
10 BUS PT MODULE 4084009 NTA855 G4 / NTA 855 G5 / 225, 250,
NT 855 G6 / NTA 855 G2 / 285, 320, 27 CURRENT 4084245 KTA 50 G3 1250
KTA 1150 G / KTA 19 G3 / 380, 450, TRANSFORMER
KTA 19 G4 / VTA 28 G5 / 500, 625,
KTA 38 G ( KTA 2300 G2 ) / 750, 1000, 28 CURRENT 4084989 KTA 50 G8 1500
KTA 38 G5 ( KTA 3067 G ) / 1250,1500 TRANSFORMER
KTA 50 G3 / KTA 50 G8
29 CT PT HARNESS 4084230 NTA855 G4 / NTA 855 G5 / 225, 250,
11 KIT SENDER 4104782 NTA855 G4 / NTA 855 G5 / 225, 250, NT 855 G6 / NTA 855 G2 / 285, 320,
NT 855 G6 / NTA 855 G2 285, 320 KTA 1150 G / KTA 19 G3 / 380, 450,
12 KIT SENDER 4084019 KTA 1150 G / KTA 19 G3 / 380, 450, KTA 19 G4 / VTA 28 G5 / 500, 625,
KTA 19 G4 500 KTA 38 G ( KTA 2300 G2 ) / 750, 1000,
KTA 38 G5 ( KTA 3067 G ) / 1250,1500
13 KIT SENDER 4084018 VTA 28 G5 625 KTA 50 G3 / KTA 50 G8
14 KIT SENDER 4084017 KTA 38 G ( KTA 2300 G2 ) / 750, 1000
KTA 38 G5 ( KTA 3067 G ) 30 MOUNTING 4084028 NTA855 G4 / NTA 855 G5 / 225, 250,
ENGINE CONTROL NT 855 G6 / NTA 855 G2 / 285, 320,
15 KIT SENDER 4084016 KTA 50 G3 / KTA 50 G8 1250,1500 MODULE KTA 1150 G / KTA 19 G3 / 380, 450,
16 MAGNETIC NTA855 G4 / NTA 855 G5 / 225, 250, KTA 19 G4 / VTA 28 G5 / 500, 625,
PICK UP 4085824 NT 855 G6 / NTA 855 G2 / 285, 320, KTA 38 G ( KTA 2300 G2 ) / 750,1000,
KTA 1150 G / KTA 19 G3 / 380, 450, KTA 38 G5 ( KTA 3067 G ) / 1250,1500
KTA 19 G4 / VTA 28 G5 / 500, 625, KTA 50 G3 / KTA 50 G8
KTA 38 G ( KTA 2300 G2 ) / 750, 1000,
KTA 38 G5 ( KTA 3067 G ) / 1250,1500 31 HOUSING ETR 4913018 NTA855 G4 / NTA 855 G5 / 225, 250,
KTA 50 G3 / KTA 50 G8 CONTROL NT 855 G6 / NTA 855 G2 / 285, 320,
MODULE KTA 1150 G / KTA 19 G3 / 380, 450,
17 CURRENT 4104391 NTA 855 G4 225 (Remote Mounting KTA 19 G4 / VTA 28 G5 / 500, 625,
TRANSFORMER Panel) KTA 38 G ( KTA 2300 G2 ) / 750, 1000,
18 CURRENT 4104390 NT 855 G5 250 KTA 38 G5 ( KTA 3067 G ) / 1250,1500
TRANSFORMER KTA 50 G3 / KTA 50 G8
19 CURRENT 4104389 NT 855 G6 285 32 COOLANT LEVEL 4084762 NTA855 G4 / NTA 855 G5 / 225, 250,
TRANSFORMER SWITCH NT 855 G6 / NTA 855 G2 / 285, 320,
20 CURRENT 4104376 NTA 855 G2 320 KTA 1150 G / KTA 19 G3 / 380, 450,
TRANSFORMER KTA 19 G4 / VTA 28 G5 / 500, 625,
KTA 38 G ( KTA 2300 G2 ) / 750, 1000,
21 CURRENT 4104377 KTA 1150 G 380 KTA 38 G5 ( KTA 3067 G ) / 1250,1500
TRANSFORMER KTA 50 G3 / KTA 50 G8
22 CURRENT 4104388 KTA 19 G3 450
TRANSFORMER 33 RAPID RESTORE 3017993 NTA855 G4 / NTA 855 G5 / 225, 250,
COIL / SD COIL NT 855 G6 / NTA 855 G2 / 285, 320,
23 CURRENT 4104378 KTA 19 G4 500 KTA 1150 G / KTA 19 G3 / 380, 450,
TRANSFORMER KTA 19 G4 / VTA 28 G5 / 500, 625,
24 CURRENT 4104379 VTA 28 G5 625 KTA 38 G ( KTA 2300 G2 ) / 750,1000,
TRANSFORMER KTA 38 G5 ( KTA 3067 G ) / 1250,1500
KTA 50 G3 / KTA 50 G8
25 CURRENT 4084244 KTA 38 G ( KTA 2300 G2 ) 750
TRANSFORMER
26 CURRENT 4084175 KTA 38 G5 ( KTA 3067 G ) 1000
TRANSFORMER
Cummins Part Numbers for Alternator Parts

SR Part No Descreption frame size
SR DESCRIPTION PART SUITABLE FOR DG
No.
NO NO. CUMMINS ENGINE RATING
MODELS - KVA 1 AX1005133 ALTERNATOR 15 KVA -SINGLE BRG BCI1644D1
2 AX1005134 ALTERNATOR 25 KVA -SINGLE BRG BCI1844F1
34 PCC MANUAL 3243804 NTA855 G4 / NTA 855 G5 / 225, 250,
NT 855 G6 / NTA 855 G2 / 285, 320, 3 AX1006101 ALTERNATOR 30 KVA -DOUBLE BRG BCI 184G2
KTA 1150 G / KTA 19 G3 / 380, 450, 4 AX1006098 ALTERNATOR 30 KVA -SINGLE BRG BCI 184G1
KTA 19 G4 / VTA 28 G5 / 500, 625,
KTA 38 G ( KTA 2300 G2 ) / 750, 1000, 5 AX1006099 ALTERNATOR 35 KVA -SINGLE BRG BCI 184H1
KTA 38 G5 ( KTA 3067 G ) / 1250,1500 6 AX1006102 ALTERNATOR 35 KVA -DOUBLE BRG BCI 184H2
KTA 50 G3 / KTA 50 G8
7 AX1006100 ALTERNATOR 40 KVA -SINGLE BRG BCI 184J1
35 GCM KIT AX NTA855 G4 / NTA 855 G5 / 225, 250, 8 AX1006103 ALTERNATOR 40 KVA -DOUBLE BRG BCI 184J2
1005506 NT 855 G6 / NTA 855 G2 / 285, 320,
KTA 1150 G / KTA 19 G3 / 380, 450, 9 AX1001412 ALTERNATOR 45 KVA -SINGLE BRG UC2244D1
KTA 19 G4 / VTA 28 G5 / 500, 625, 10 AX1006077 ALTERNATOR 45 KVA -DOUBLE BRG UC2244D2
KTA 38 G ( KTA 2300 G2 ) / 750, 1000,
KTA 38 G5 ( KTA 3067 G ) / 1250,1500 11 AX1006078 ALTERNATOR 50 KVA -DOUBLE BRG UC2244D2
KTA 50 G3 / KTA 50 G8 12 AX1001413 ALTERNATOR 50 KVA -SINGLE BRG UC2244D1
36 PCW Software Kit AX NTA855 G4 / NTA 855 G5 / 225, 250, 13 AX1001416 ALTERNATOR 62.5 KVA -DOUBLE BRG UC2244F2
1005505 NT 855 G6 / NTA 855 G2 / 285, 320, 14 AX1005135 ALTERNATOR 62.5 KVA -SINGLE BRG UC2244E1
KTA 1150 G / KTA 19 G3 / 380, 450,
KTA 19 G4 / VTA 28 G5 / 500, 625, 15 AX1001418 ALTERNATOR 75 KVA -SINGLE BRG UC2244G1
KTA 38 G ( KTA 2300 G2 ) / 750, 1000, 16 AX1006079 ALTERNATOR 75 KVA -DOUBLE BRG UC2244G2
KTA 38 G5 ( KTA 3067 G ) / 1250,1500
KTA 50 G3 / KTA 50 G8 17 AX1001419 ALTERNATOR 82.5 KVA -DOUBLE BRG UC2244G2
37 SLTA - 10 / FT - 10 AX ALL All 18 AX1005136 ALTERNATOR 82.5 KVA -SINGLE BRG UC2244G1
ADAPTOR 1005503 19 AX1001420 ALTERNATOR 100 KVA -SINGLE BRG UC2744C1
38 POWER SUPPLY, AX ALL All 20 AX1006080 ALTERNATOR 100 KVA -DOUBLE BRG UC2744C2
SLTA ADAPTOR 1005504
21 AX1005479 ALTERNATOR 100 KVA -DOUBLE BRG -
39 PC Cable 3162850 ALL All MARINE UCM2734E2
40 PMG KIT W/O AVR AX 400-1250 KVA 400-1250 22 AX1001421 ALTERNATOR 110 KVA -SINGLE BRG UC2744D1
FOR FOR HC5 / 1001064 KVA
HC6 ALTERNATOR 23 AX1006081 ALTERNATOR 110 KVA -DOUBLE BRG UC2744D2
(400 KVA TO 24 AX1001422 ALTERNATOR 125 KVA -DOUBLE BRG UC2744E2
1250 KVA)
25 AX1005137 ALTERNATOR 125 KVA -SINGLE BRG UC2744E1
41 PMG KIT W/O AVR AX 210-380 KVA 210-380 26 AX1001423 ALTERNATOR 140 KVA -SINGLE BRG UC2744E1
FOR FOR HC4 1001063 KVA
ALTERNATOR 27 AX1006082 ALTERNATOR 140 KVA -DOUBLE BRG UC2744E2
(210 KVA TO 28 AX1001424 ALTERNATOR 160 KVA -SINGLE BRG UC2744F1
380 KVA)
29 AX1006083 ALTERNATOR 160 KVA -DOUBLE BRG UC2744F2
42 PMG KIT W/O AVR AX 30-200 KVA 30-200 30 AX1006084 ALTERNATOR 180 KVA -DOUBLE BRG UC2744H2
FOR FOR UC22 / 1001065 KVA
UC27 ALTER- 31 AX1001426 ALTERNATOR 180 KVA -SINGLE BRG UC2744H1
NATOR (30 KVA 32 AX1001427 ALTERNATOR 200 KVA -DOUBLE BRG UC2744H2
TO 200 KVA )
33 AX1005138 ALTERNATOR 200 KVA -SINGLE BRG UC2744H1

No. SR Part No Descreption frame size
No.
34 AX1005370 ALTERNATOR 200 kVA WITH PMG
EXCITOR -DOUBLE BRG HC634C2 67 AX1005143 ALTERNATOR 1000 KVA -DOUBLE BRG HC634Y2
35 AX1001429 ALTERNATOR 225 KVA -SINGLE BRG HC444C1 68 AX1005378 ALTERNATOR 1000 KVA WITH RTD/BTD
AND SPACE HEATER -DOUBLE BRG H64Y2/-C
36 AX1006085 ALTERNATOR 225 KVA -DOUBLE BRG HC444C2
69 AX1006097 ALTERNATOR 1250 KVA -DOUBLE BRG HCK634Z2
37 AX1006086 ALTERNATOR 250 KVA -DOUBLE BRG HC444C2
70 AX1002979 ALTERNATOR 1250 KVA -SINGLE BRG HCK634Z1
38 AX1001430 ALTERNATOR 250 KVA -SINGLE BRG HC444C1
71 AX1002589 ASSEMBLY, COUPLING FLEX PLATE
39 AX1001431 ALTERNATOR 275 KVA -SINGLE BRG HC444D1
72 AX1002589 UC 22 SAE 10 COUPLING ASSLY
40 AX1006087 ALTERNATOR 275 KVA -DOUBLE BRG HC444D2 (30-82.5 KVA)
41 AX1006088 ALTERNATOR 285 KVA -DOUBLE BRG HC444E2 73 AX1002590 ASSEMBLY, COUPLING FLEX PLATE
42 AX1001432 ALTERNATOR 285 KVA -SINGLE BRG HC444E1 74 AX1002590 UC 22 SAE 11.5 COUPLING ASSLY
43 AX1001433 ALTERNATOR 300 KVA -SINGLE BRG HC444E1 (30-82.5 KVA)
44 AX1006089 ALTERNATOR 300 KVA -DOUBLE BRG HC444E2 74 AX1002591 ASSEMBLY, COUPLING FLEX PLATE
45 AX1006090 ALTERNATOR 320 KVA -DOUBLE BRG HC444E2
75 AX1002591 UC 27 SAE 11.5 COUPLING ASSLY
46 AX1001434 ALTERNATOR 320 KVA -SINGLE BRG HC444E1 (100 KVA -200 KVA)
47 AX1005139 ALTERNATOR 380 KVA -SINGLE BRG HC444F1 76 AX1002636 ASSEMBLY,COUPLING
48 AX1005140 ALTERNATOR 380 KVA -DOUBLE BRG HC444F2 77 AX1002636 UC 27 SAE 14 COUPLING ASSLY
49 AX1001437 ALTERNATOR 400 KVA -SINGLE BRG HC544C1 (100 KVA – 200 KVA).
50 AX1006091 ALTERNATOR 400 KVA -DOUBLE BRG HC544C2 78 AX1002637 ASSEMBLY, COUPLING
51 AX1006092 ALTERNATOR 437.5 KVA -DOUBLE BRG HC544C2 79 AX1002637 HC4 SAE 11.5 COUPLING ASSLY
(250 KVA – 380 KVA).
52 AX1001439 ALTERNATOR 437.5 KVA -SINGLE BRG HC544C1
80 AX1002638 ASSEMBLY, COUPLING
53 AX1001440 ALTERNATOR 450 KVA -SINGLE BRG HC544C1
81 AX1002638 HC4 SAE 14 COUPLING ASSLY
54 AX1006093 ALTERNATOR 450 KVA -DOUBLE BRG HC544C2 (250 KVA – 380 KVA).
55 AX1006094 ALTERNATOR 550 KVA -DOUBLE BRG HC544E2 82 AX1002639 ASSEMBLY, COUPLING
56 AX1001442 ALTERNATOR 500 KVA -SINGLE BRG HC544D1 83 AX1002639 HC5 SAE 14 COUPLING ASSLY
57 AX1005695 ALTERNATOR 500 KVA -DOUBLE BRG HC544D2 (437.5 KVA – 650 KVA).
58 AX1001444 ALTERNATOR 550 KVA -SINGLE BRG HC544E1 84 AX1002640 ASSEMBLY, COUPLING
59 AX1001445 ALTERNATOR 600 KVA -SINGLE BRG HC544E1 85 AX1002640 HC5 SAE 18 COUPLING ASSLY
(437.5 KVA – 650 KVA).
60 AX1006095 ALTERNATOR 600 KVA -DOUBLE BRG HC544E2
86 AX1002641 ASSEMBLY, COUPLING
61 AX1001446 ALTERNATOR 625 KVA -SINGLE BRG HC544F1
62 AX1005141 ALTERNATOR 625 KVA -DOUBLE BRG HC544F2 (750 KVA – 1250 KVA).
63 AX1001448 ALTERNATOR 750 KVA -SINGLE BRG HC634W1 88 AX1002642 ASSEMBLY, COUPLING
64 AX1006096 ALTERNATOR 750 KVA -DOUBLE BRG HC634W2 89 AX1002642 HC6 SAE 18 COUPLING ASSLY
65 AX1005586 ALTERNATOR 750 KVA - RTD BTD (750 KVA – 1250 KVA).
CONTROLS HC634W 90 AX1001025 DIODE FORWARD-SET OF 3 HC4/5
66 AX1005142 ALTERNATOR 1000 KVA -SINGLE BRG HC634Y1 91 AX1001013 DIODE FORWARD-SET OF 3 UC22/

SR Part No Descreption frame size No.
No.
92 AX1002153 DIODE FORWARD-SET OF3 HC6 (100 KVA – 200 KVA).
93 AX1001026 DIODE REVERSE-SET OF 3 HC4/5 122 AX1001031 ISOLAT.TRANSFORM. HC6
94 AX1001034 DIODE REVERSE-SET OF3 HC6/7 123 AX1001017 DROOP KIT (C.T.) UC22
95 AX1001014 DIODE REVERSE-SET OF3 UC22/7 124 AX1001018 DROOP KIT (C.T.) UC27
96 AX1001021 DROOP KIT (C.T.) HC4 125 AX1001021 DROOP KIT (C.T.) HC4
99 AX1001017 DROOP KIT (C.T.) UC22 128 AX1001063 PMG KIT (LESS AVR) HC4
100 AX1001018 DROOP KIT (C.T.) UC27 129 AX1001064 PMG KIT (LESS AVR) HC5/HC6
101 AX1002637 HC4 SAE 11.5 COUPLING ASSLY 130 AX1001065 PMG KIT (LESS AVR) UC22/27
(250 KVA – 380 KVA).
(250 KVA – 380 KVA).
(437.5 KVA – 650 KVA).
(437.5 KVA – 650 KVA).
(750 KVA – 1250 KVA).
(750 KVA – 1250 KVA).
107 AX1001031 ISOLAT.TRANSFORM. 2:1 RATIO
108 AX1001053 ISOLATION TRANSFORMER 1:1
109 AX1001063 PMG KIT (LESS AVR) HC4
110 AX1001064 PMG KIT (LESS AVR) HC5/HC6
111 AX1001065 PMG KIT (LESS AVR) UC22/27
112 AX1001028 SURGE SUPPRESSOR/MOV HC4/5
113 AX1001027 SURGE SUPPRESSOR/MOV HC6/7
114 AX1001011 SURGE SUPPRESSOR/MOV UC22/27
115 AX1001022 TERMIN1 PANEL INSU.SET HC5/6
116 AX1001019 TERMINAL BLOCK HC4
117 AX1001016 TERMINAL BLOCK UC22/27
(30-82.5 KVA)
(30-82.5 KVA)
(100 KVA -200 KVA)
Cummins “PULSE” Batteries Sealed Maintenance-Free
Generator Starting System
Pulse Selection Guidelines for Cummins and Other Engines
l A packaged power supply for generator starting
Part No Generator Battery Replaces old No of
l Comprising of one or more Pure Lead-Tin Valve Regulated Lead
KVA Rating Rating batteries of type
Pulse
Acid (VRLA) Monobloc batteries and a Switch Mode Power
system
Supply (SMPS) to charge the battery
AH Plates No of reqd
Batt-
Pulse Recommendation Guide for Cummins Engines
eries
Sr. Cummins Engine Battery Cummins Qty AX1006138 15,20,25 12V 20 AH 150 21 1 1
No Engine KVA Rating Part No per
Model Rating Engine AX1006139 30,35,40,45,50, 12V 32 AH 180 25 1 1
62.5,82.5
1 X1.7G1 15 12V 20AH AX 1006138 1
2 X2.5G1 20 12V 20AH AX 1006138 1 AX1006139 100,125 12V 32 AH 180 21 1 1
3 X2.5G2 25 12V 20AH AX 1006138 1
4 S3.8G2 30 12V 32AH AX 1006139 1 AX1006140 50,62.5,70,100, 24V 20 AH 150 21 2 1
5 S3.8G3 35 12V 32AH AX 1006139 1 110,125,140
6 S3.8G4 40 12V 32AH AX 1006139 1
7 S3.8G5 45 12V 32AH AX 1006139 1 AX1006141 160, 180,200, 24V 32 AH 180 25 2 1
8 S3.8G6 50 12V 32AH AX 1006139 1 225,250,285,
9 S3.8G7 62.5 12V 32AH AX 1006139 1 320,380,437,
10 6BT/A5.9G1 75-82.5 12V 32AH AX 1006139 1 500,590
11 6BTA5.9 G1-I 100 12V 32AH AX 1006139 1
12 NT495G 100 24V 20AH AX 1006140 1 AX1006142 625,750 24V 80 AH 180 21 4 1
13 6BTA5.9 G2-I 125 24V 20AH AX 1006140 1
14 NTC495G 125 24V 20AH AX 1006140 1 AX1006143 1000,1250 24V 80 AH 180 25 4 1
15 6BTAA5.9 G1-I 140 24V 20AH AX 1006140 1
16 NTA495G 140 24V 20AH AX 1006140 1 AX1006143 >1250 24V 100 AH 180 25 4 1
17 6CT8.3-G2-I 140 24V 20AH AX 1006140 1
18 6CTA8.3-G1-I 160 24V 32AH AX 1006141 1
19 NS-G1 160 24V 32AH AX 1006141 1
20 6CTA8.3-G2-I 180 24V 32AH AX 1006141 1 Cranking Currents and Benefits
21 NS-G2 180 24V 32AH AX 1006141 1
22 6CTAA8.3.-G1-I 200 24V 32AH AX 1006141 1 Parameter Brief Description Flooded Thin Plate
23 NTA743G 200 24V 32AH AX 1006141 1 (Normal AGM (Pulse
24 NTA855G1 225 24V 32AH AX 1006141 1 Battery) Battery)
25 NTAS55G 250 24V 32AH AX 1006141 1
26 NT-855-G5-I 250 24V 32AH AX 1006141 1 Cold Cranking Amps a battery can deliver for 2.5 A / Ah 11 A / Ah
27 NTAS55G2 285 24V 32AH AX 1006141 1 amperes 30 sec at 0°F (- 18°C) to a battery
28 NTA355G2BC 320 24V 32AH AX 1006141 1 (CCA) end voltage of 1.2V per cell
29 N14G1 320 24V 32AH AX 1006141 1
Marine Amps a battery can deliver for 4.4 A / Ah 15.5 A / Ah
30 NTA-855-G2-I 320 24V 32AH AX 1006141 1
Cranking 30 sec at 32°F(0°C) to a battery
31 KTA1 150G 380 24V 32AH AX 1006141 1
Amperes end voltage of 1.2V per cell
32 NTA-14-G3 380 24V 32AH AX 1006141 1
(MCA)
33 KTA19G3 450 24V 32AH AX 1006141 1
34 KTA19G4 500 24V 32AH AX 1006141 1
Hot Cranking Amps a battery can deliver for 5.5 A / Ah 20 A / Ah
35 KTA-19-G9 500 24V 32AH AX 1006141 1
Amperes 30 sec at 80°F (26.7°C) to a
36 VTA28G3 600 24V 80AH AX 1006142 1
(HCA) battery end voltage of 1.2V per cell
37 VTA28G5 625 24V 80AH AX 1006142 1
38 KTA2300G 750 24V 80AH AX 1006142 1
39 KTA-38-G2-I 750 24V 80AH AX 1006142 1
40 KTA38G5 1000 24V 100AH AX 1006143 1
41 KTA50G3 1250 24V 100AH AX 1006143 1
42 KTA50GS 1425-1500 24V 100AH AX 1006143 1
43 QSK45G4 1450 24V 100AH AX 1006143 1
44 QSK45G6 1550 24V 100AH AX 1006143 1
Features Benefits
Maintenance Free 1. No Battery topping up or specific gravity

checks & No spillage of battery acid
2. No adjustment of charger
Ready to use 1. Compact & light weight for easy handling.

2. Pre-assembled battery & charger
3. Filled & factory charged battery
Reliability 1. High battery power capability for

guaranteed starting
2. Consistent performance throughout
battery life and absence of sudden death
3. Charger ensures that battery is always
kept fully charged
Thin Plate Technology 1. High Starting current with smaller Ah

capacity battery
Shelf life 1. Provides extended storage capability

while maintaining high state of charge for
dependable operation
Cost effective 1. Separate battery charger not needed

2. No maintenance cost
3. Low cost of ownership over its long
lifetime
4. No risk of cost due to failure to start
standby genset.
Note : Ensure to disconnect the positive terminal of engine's charging

alternator while using these batteries. Also do necessary
modifications as and when required in wiring.
Section - 10 General Information Page 10-0 Section - 10 General Information Page 10-01
Lubricating Oil Recommendations Diesel Fuel
GENERAL INFORMATION
Contents Page The lubricating oil used in Cummins diesel engines should be multi
functional and capable of performing its functions for prescribed
Lubricating Oil & Recommendations …………………………………..10-1 period
Fuel Oil & Recommended Properties ………………………………….10-4 Cummins India Limited approves the use of SAE 15W40 multigrade
lubricating oil meeting API CH4 classifications for all Cummins diesel
Engines. This recommendation is in addition to the existing
High Speed Diesel Requirements………………………………………10-5
recommendations of SAE 15W40 API CF4 lubricating oil as mentioned
in the O&M manual.
Engine Storage Procedures……………………………………………..10-6
For the following products, usage of 15W40 API CH4 oil is
Fraction, Decimal, Millimeter Conversion……………...………………10-8
mandatory.
Conversion Factors & Practices……………………………...............10-10
• C engines
Capscrew Markings & Torque Values ……………………………….10-16 • N14 engines
• NTA 855 C big cam on excavator and dumper application engines.
Drive Belt Tension …………………………………………………….10-20
For all other products please refer respective O&M manual
Pipe Plug Torque Values ………………………………………………10-21 recommendations.
Tap Drill Chart …………………………………………………………..10-22 Usage of SAE 15W40 CH4 oil is beneficial for all models considering
the several advantages such as,
• Very High Resistance to Oil thickening due to soot
• Better heat dissipation and greater resistance to oxidation
• Improved viscosity characteristics for easier cold starting.
• Outstanding soot handling capability, leading to reduced
component wear.
• Optimum lube oil consumption
• Lesser deposits on piston crown, piston land and valves.
• Better emission control.
• Better cleanliness of internal passages and components.
• Less sludge formation due to improved dispersancy.
• Increased resistance to acid formation resulting in less corrosion of
bearings and other components.
Cummins Recommended SAE Oil Viscosity Grades vs Ambient

Temperatures
o
C -40 -30 -20 -10 0 10 20 30 40 50
O
F -40 -22 -4 14 32 50 68 86 104 122
All Seasons
15W-40
Winter Conditions 10W-30
Arctic Conditions* 5W-20 & 5W-30

o
C -40 -30 -20 -10 0 10 20 30 40 50
O
F -40 -22 -4 14 32 50 68 86 104 122
Note : For temperature consistently below - 250C (-130F) refer to lub oil
manufacturer for recommendations
Oil Contamination Guidelines
Important Properties and their limits for fresh oil
Property Guidelines
0
Properties Limits Testing Methods Viscosity change @ 100 C + 1 SAE Viscosity grade or
(ASTM D-445) 4 cSt from the new oil
Viscosity 12.5 to 16.4@ 100 dec. ASTM D-445
Fuel Dilution 5 Percent
TBN 10.5 minimum ASTM D-2896 Total acid number (TAN) 2.5 number increase from the
(ASTM D-664) new oil value, maximum
Sulphated ash 1.85 mass % maximum ASTM D-874
Total base number (TBN) 2.5 minimum or, one half original
Water Should be negligible ASTM D-95 (ASTM D-2896) (New Oil) value or equal to TAN
content (2 to 3 crackles max.)
Water content ASTM (D-95) 0.2 percent maximum
Potential Contaminants
* These Limits are for reference and exact applicable values can
Silicon (Si) 15 ppm increase over new oil
be obtained from the respective oil manufacturer against
Sodium (Na) 20 ppm increase over new oil
specific brands.
Boron (B) 25 ppm increase over new oil
Oil Change Interval Potassium (K) 20 ppm increase over new oil
Soot 1.5 percent mass of used oil
Oil does not wear but gets contaminated and the additive package
maximum
gets depleted. After contamination, It can no longer perform its
functions satisfactorily. Hence, oil need to be changed BEFORE the NOTE : The contamination guidelines presented above are
guidelines only. This does not mean values that fall on the
additive package gets depleted.
acceptable side of these guidelines be interpreted as indicating the
oil is suitable for further service.
Cummins India Ltd. recommends oil to be changed at every 250/300 hrs
of engine operation or three/six months whichever is earlier. * ASTM (The American Society for Testing and Materials)
publishes these methods in their Annual Book of
Standards, Part 23. Other methods should not be used
Note : N-495 & QSK-60 with big oil sump, oil change period is without consulting Cummins Diesel Sales & Service (l) Ltd.
500 hrs or 6 months whichever is earlier.
** SAE Viscosity grades are published by the Society of
For specific engine refer respective maintenance schedule Automotive
Engineers in their annual SAE Handbook as SAE
Properties of Lubricating Oil–Valvoline Power Supreme Extra Recommended
15W 40 CF-4 High TBN or equivalent for engines running with
Practice J300d, and are shown in Table 1 of this bulletin.
LDO fuel.
*** AES (Atomic Emission Spectroscope) and AAS (Atomic
Property Value Absorption Spectroscopy) are not standard ASTM
Sp. Gravity@29 C
o
0.867 methods, however most used oil analysis laboratories are
o capable of determining additive metal concentration by one
Kinematic Viscosity @ 40 C 116.8
o
of these methods and sample results determined by the
Kinematic Viscosity @100 C 15.10 same laboratory using the same method can be safely
Viscosity Index 135 compared.
o
Flash point, COC, C 230
o Procurement :
Pour point C max -30
Sulphated ash % by Wt. 2.52 Oil should always be procured from the original manufacturer or the
authorized distributors.
TBN mg/KOH/g 20.38
o
CCS Viscosity, cP 6900@-10 C Lubricating oil to be used on the engine must meet all qualities as per
manufacturers’ specifications. Cummins recommends audit checks of
fresh engine oil to ensure the quality of oil.
Section - 10 General Information Page 10-4
Page 10-5
RECOMMENDED FUEL OIL PROPERTIES
P : 33 or P : 35
Fuel Oil
Cummins Diesel Engines have been developed to take the advantage of
high energy content and generally lower cost of No. 2 Diesel Fuels.
Appendix (P : of IS 1448)
Method of test Ref. to
Experience has shown that a Cummins Diesel Engine will also operate
P : 10
P : 15
P : 18
P : 20
P : 25
P : 30
P : 40
P:2
P:2
P:4
P:8
P:9
satisfactorily on No. 1 fuels or other fuels within the following
-
specifications.
Property Recommended
Specifications
Viscosity 1.3 to 5.8 centistokes
(ASTM D445) (1.3 to 5.8 mm per second)
REQUIREMENTS FOR HIGH SPEED DIESEL FUEL AS PER IS 1460: 1974

0 0
at 104 F (40 C)
0
Cetane Number 40 Minimum above 32 F
A
-
-
-
-
-
-
-
-
-
-
-
-
-
0
(ASTM D-613) 45 Minimum below 32 F
Sulphur Content Not to exceed 1.0 mass

(ASTM D-129 or 1552) percent.
Not worse than No.1

Active Sulphur Copper Strip Corrosion not
(ASTM D130) to exceed No. 2 rating after
0 0
three hours at 122 F (50 C)
6 C (42.8 F)
0
Requirement
2.0 to 7.5
Water and Sediment Not to exceed 0.1 volume
0.01
0.20
0.05
0.50
0.05
(ASTM D1796) percent.
1.0
1.0
42
38
90
nil
0
Carbon Residue Not to exceed 0.35 mass
(Rams bottom, percent on 10 volume
Carbon residue (Ramsbottom) percent by mass, max.

ASTM D524 or percent residium.
Copper strip corrosion for 3 hours at 212 F (100 C)

Conradson,
0
ASTM D189)
0 0
Density (ASTM D287) 42 to 30 API gravity at 60 F (0.816
Distillation percent recovery at 366 C min.

0
Kinematic viscosity CS at 38 C (100.4 F)

0
Water content, percent by volume, max.

to 0.876 g/cc at 15 C).
Total sediments, mg. per 100 ml. max.

Total sulphur, percent by mass max.
0
0 0
Cloud Point 10 F (6 C) below lowest
Sediment, percent by mass max.

Acidity, total mg. of KOH/g max.
(ASTM D97) ambient temperature at which the
0
Flash point: (a) Abel, C min..
fuel is expected to operate
Ash, percent by mass max.

Section - 10 General Information
0
Ash Not to exceed 0.02 mass
Cetane Number, min.

(ASTM D482) percent (0.05 mass percent with
Acidity, Inorganic
Characteristics
Pour point, max.

lubricating oil blending).
Distillation The distillation curve must

(ASTM D86) be smooth and continuous.
Acid Number Not to exceed 0.1 mg KOH

(ASTM D664) per 100 ml.
No.
Sr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
ENGINE STORAGE Preparing a preserved (treated) engine for putting in service.
On any engine not in service, whether installed in equipment or
waiting to be installed, the unpainted machined surfaces are subject When an engine is removed from storage and put into service the
operation listed below process should be performed.
to rust and corrosion. Often an engine is not prepared for storage
(Temporary/Long time storage) with all types of rust-proofing (i) Clean off all accumulated dirt from exterior of engine.
measures taken, however, every engine going out of the factory is
always processed with rust preventive oil for shipment purpose. (ii) Remove all protective caps, tape and wrappings from
connections such as Breathers, Fuel in and out, connection,
The rate of corrosion varies with climatic conditions. Variances in
Water in and out connections etc.
climatic conditions make it impossible to state the length of time an
engine can be stored without rust and corrosion damage. Following (iii) Use suitable solvent, cleaner or degreaser to remove rust
procedure covers the basic method of preparing the engine for preventive compound from unpainted external surfaces of the
Temporary/Long storage. engine.
Procedure (iv) Refill oil pan with fresh lubricating oil. Replace the fuel, lub oil
The engine system wise details of the process are described filters and lub oil bypass filters, only in case wherein engine is
below. stored beyond six months from the date of shipment.
Cooling System Passage :
Sr. No. Description Remarks (v) Check and correct the engine belt tensioning.
a Prepare engine for Ensis, Fabricate and install a plate to (vi) In case of any doubts, contact CSS & S/ Dealer.
Long Storage Process close the water pump inlet
connection.
B. Inspection
b Fill the cooling system Leave the drain cocks open
with Ensis oil RUSTILO until all air is completely vented
DW901, (Castrol India out. Progressively close the 1. When an engine has been stored for six months or less, it is
make) up to thermostat cocks until the ensis oil flows necessary to make only a routine initial inspection. This
outlet connection, using from the thermostat housing. inspection includes adjustment of injectors, valves and belts
external priming pump and checking cylinder head capscrews, oil filter and
trolley. connections, air filter, screens and straps.
C Keep the Ensis oil in the Remove the fabricated plate at 2. Pressurize the lubricating system about 1 kg/cm including the
2
engine for 5 minutes and water pump inlet and close the turbocharger or supercharger prior to starting the engine.
then drain it completely, opening by plastic cap. (Collect
from engine. the drained oil in clean 3. Flush entire fuel system with clean fuel until all preservative oil
container for reuse.) is removed. This can be done by running the engine on NO
LOAD IDLE for five minutes with clean high speed diesel oil.
Lubricating Oil Passage :
4. When recommissioning a stored engine, care should be taken
Sr. No. Description Remarks to see that any foreign matter which may collect on screens and
a Prepare engine for Lube Use lube oil priming pump for strainers during initial operation is removed before considering
oil priming. priming. the engine properly prepared for future service.
b Prime the engine with Use engine Lube oil trolley for Engine is ready to start for regular operations.
engine lube oil 15W40 priming. Circulate the Lube oil
(CF-4 category). till the lube pressure gauge
shows 1kg/cm sq. pressure. It
will take max. five min. to reach
this lube oil pressure. Bar the
engine during the process
C Drain the Lube oil from
the oil pan.
If the engines are going to be stored for more than 6 months, repeat
the engine preservative treatment as mentioned above after every six
months.
Section - 10 General Information WEIGHT AND MEASURES - CONVERSION FACTORS Page 10-10 Section - 10 General Information Page 10-8
FRACTION, DECIMAL, MILLIMETER, CONVERSION
From U. S. From Metric
U. S. Customary Metric Customary To U. S.
Quantity Fraction Inch mm Fraction Inch mm
To Metric Customary
Unit Name Abbr. Unit Name Abbr. Multiply By Multiply By 1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
2 2
Area sq. inch in sq. millimeters mm 645.16 0.001550
3/64 0.0469 1.191 35/64 0.5469 13.891
sq. centimeters 2 0.155
cm 6.452 1/16 0.0625 1.588 9/16 0.5625 14.288
2
ft 2
sq. foot sq. meter m 0.0929 10.764 5/64 0.0781 1.984 37/64 0.5781 14.684
lb/hp-hr 3/32 0.0938 2.381 19/32 0.5938 15.081
Fuel pounds per grams per kilowatt g/kW-hr 608.277 0.001645
7/64 0.1094 2.778 39/64 0.6094 15.478
Consumption horsepower hour hour
1/8 0.1250 3.175 5/8 0.6250 15.875
2.352
Fuel miles per gallon mpg kilometers per liter km/I 0.4251 9/64 0.1406 3.572 41/64 0.6406 16.272
Performance gallons per mile gpm I/km 2.352 0.4251 5/32 0.1563 3.969 21/32 0.6563 16.669
liters per kilometer
11/64 0.1719 4.366 43/64 0.6719 17.066
Force pounds force lbf Newton N 4.4482 0.224809 3/16 0.1875 4.763 11/16 0.6875 17.463
Length inch in millimeters mm 25.40 0.039370 13/64 0.2031 5.159 45/64 0.7031 17.850
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
FRACTION, DECIMAL, MILLIMETER CONVERSIONS – CONTD…
From U. S. From Metric
U. S. Customary Metric Customary To U. S. Fraction inch mm Fraction inch mm
Quantity
To Metric Customary
17/64 0.2656 6.747 49/64 0.7656 19.447
Unit Name Abbr. Unit Name Abbr. Multiply By Multiply By
9/32 0.2813 7.144 25/32 0.7813 19.844
Length foot ft millimeters mm 304.801 0.00328
19/64 0.2969 7.541 51/64 0.7969 20.241
Power horsepower hp Kilowatt kW 0.746 1.341 5/16 0.3125 7.938 13/16 0.8125 20.638
Pressure pounds force per psi Kilopascal kPa 6.8948 0.145037 21/64 0.3281 8.334 53/64 0.8281 21.034
sq.inch 11/32 0.3438 8.731 27/32 0.8438 21.431
inches of mercury in Hg kilopascal kPa 3.3769 23/64 0.3594 9.128 55/64 0.8594 21.828
0.29613
in 3/8 0.3750 9.525 7/8 0.8750 22.225
inches of water 2 H O Kilopascal kPa 0.2488 4.019299
25/64 0.3906 9.922 57/64 0.8906 22.622
inches of mercury in Hg millimeters of mercury mm Hg 25.40 0.039370 13/32 0.4063 10.319 29/32 0.9063 23.019
inches of water in H2O millimeters of water mm H 20 25.40 0.039370 27/64 0.4219 10.716 59/64 0.9219 23.416
bars bars kilopascal kPa 100.001 0.00999 7/16 0.4375 11.113 15/16 0.9375 23.813
bars bars millimeters of mercury mm Hg 750.06 0.001333 29/64 0.4531 11.509 61/64 0.9531 24.209
0 0 0 0 15/32 0.4688 11.906 31/32 0.9688 24.606
Temperature fahrenheit F centigrade C ( F-32) / 1.8 (1.8 x C) + 32
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor : 1 inch = 25.4 mm

Page 10-12
CONVERSION PRACTICES
Length
From Metric
Multiply By
Customary
0.264179
0.219976
2.204623
61.02545
0.737562
Multiply lengths in inches by 25.4 and carry to one less decimal place.
0.000948
8.850756
To U. S.
0.06102
0.6214
1.341
3414
Example : 1.565 inches (39.75 mm)
1.5650 inches (39.751 mm)
Note that zeros in the ten-thousands place are significant and define
the accuracy of measurement. They cannot be dropped. Dropping a
decimal place affects the accuracy of the metric equivalent.
Fractions and whole numbers written without a decimal point should be

Multiply By
Customary
From U. S.
To Metric
carried to two decimal places in the conversion unless a strong reason
0.000293
0.01639
1.35582
3.7853
16.387
0.4536
1054.5
1.6093
4.546
0.746
0.113
exists to do otherwise.
Example : 2-5/16 in. (58.74 mm]
Certain items which are standard and have no direct metric equivalent
are not converted to metric. These include capscrew sizes, drill bits
etc.
Abbr.
kW-hr
Mass
kW-hr
N-m
3
N-m
kph
cm
kg
I
J
Multiply pounds mass by 0.454 and carry to one extra decimal place.
Example : 27 lbs.[12.3kg]
Force
Multiply pounds force by 4.448 and round to the same decimal place.
Metric
Example :12.5 lbs.[65.6 N]

cubic centimeter
kilometers/hour
Newton-meter
Newton-meter
Spring force is an exception to our standard practice. While the correct

kilowatt-hour
kilowatt-hour
Unit Name
metric unit is the newton, most foreign scales are in kilograms force.
kilograms
Therefore we will list both units, newton in brackets and kilograms in

joules
parenthesis.
liter
liter
liter
Example : 12.5 lbs. [65.6 N] (5.68 kg)
Torque
In the customary system we use inch pound for small torque values
and foot pounds for larger values. Both are converted to the newton
metre in the metric system. W hen converting foot pounds, multiply by
Abbr.
hp-hr
BTU
BTU
mph
in-lb
1.356 and round to the nearest whole number. When working with inch
ft-lb
gal.
gal.
U. S. Customary
lb
in
in
pounds, multiply by 0.113 and round to the nearest tenth.

Example : 20 ft. lb. [27 N.m]
20 in. lb. [2.3 N.m]
Pound force per inch
Pound force per foot
British Thermal Unit

British Thermal Unit
horsepower hours
Section - 10 General Information
Pressure
pounds (avoir.)
gallon (lmp*)
gallon (U.S.)
Pressure is given pascals(Pa). Since one pound per square inch

Unit Name
miles/hour
cubic inch
cubic inch
equals 6.894 pascals, we will always use the kilo prefix, o r

kilopascals(kPa). To determine pressure in kPa, multiply psi by 6.894
and round to the nearest whole number.
Example : 50 psi[345 kPa]
Weight (mass)
Pressure given as inches of mercury or water will convert to millimetres

displacement
Quantity
mercury or water. See the section on length for conversion practices.

Volume:
Velocity
Torque
Volume and Displacement

liquid
Work
Engine displacement is given in litres to the nearest tenth. Multiply

cubic inches by 0.01639.
Example: 555 cu. in. [9.11 Liter]
Section - 10 General Information Page 10-14 Section - 10 General Information Page10-15
Gallons convert to litres by multiplying by 3.785 and rounding to the

same decimal place. To determine fuel consumption
Example :16 gal.[60 I] Example -
Small volumes (less than one litre) may be given in milliliters (ml) which
KTA-3067-G -The fuel consumption at full load is 150 gms/bhp/hr
are equal to the old designation, cubic centimetres. Multiply cubic
inches by 16.39 and round to the nearest whole number. Specific Gravity of diesel is 0.84
Example: 21 cu. in. [344 ml) 150 x 1180 = 177 = 210. Lit/Hr.
Pressure Conversion
1000 x .84 .84
lnches of Water (H2O) = P.S.I. X 27.7
Inches of Water (H2O) = Hg X 13.6 To evaluate units generated per litre of diesel
lnches of Mercury (Hg) = P.S.I. X 2.07 Full load of engine is 800 kW, i.e. generated units is 800 units as
lnches of Mercury (Hg) = H2O / 13.6
1kWh = 1 Unit
To Determine Torque (Load)
Load(Nm) = H.P X 7123.77. or B.H.P X 7123.77 that is 800 Units/210 Ltrs = 3.8 Units/Ltr of diesel
R.P.M. R.P.M.
NEWTON-METER TO FOOT-POUND CONVERSION CHART
To Determine Power
N.m ft-lb N.m ft-lb
Load (Nm) X R.P.M. Load (Nm) X R.P.M. 1 8.850756 in-lb 105 77
Horse Power = kW = 5 44 in-lb 110 81
7123.77 9549.3
6 53 in-lb 115 85
To Determine Fuel Rate in Lbs. Per Hour 7 62 in-lb 120 89
Lbs. Fuel X 60 8 71 in-lb 125 92
Fuel Rate = 9 80 in-lb 130 96
Time in minutes 10 89 in-lb 135 100
1 0.737562 ft-lb 140 103
To Determine Cubic inch Displacement 12 9 145 107
2
Piston Displacement = (.7854) X (Bore) X (Stroke) X (No. of Cylinders) 14 10 150 111
15 11 155 114
To Determine Axle Ratio
16 12 160 118
60 X R.P.M.
18 13 165 122
Axle Ratio = with 1 to 1 Transmission Ratio
Rev./Mile X M.P.H. 20 15 170 125
25 18 175 129
To Determine Piston Speed 30 22 180 133
Stroke (in.) X R.P.M. 35 26 185 136
Piston speed (Feet per minute) = 40 30 190 140
6 45 33 195 144
To Determine Brake Specific Fuel Consumption 50 37 200 148
55 41 205 151
Fuel Rate
60 44 210 155
BSFC = 65 48 215 159
Brake Horsepower
70 52 220 162
To Determine Torque Wrench Values with Adapter 75 55 225 165
TW X (L + A) 80 59 230 170
85 63 235 173
TA =
90 66 240 177
L
95 70 245 180
Explanation of Terms:
100 74 250 184
TA = Amount of torque applied at the end of the adapter.
NOTE : To convert from Newton-Meters to Kilogram-Meters divide
TW = Torque Wrench reading.
Newton-Meters by 9.803.
L = Length of wrench.
A = Length of adapter.
*CAPSCREW MARKINGS AND TORQUE VALUES
Capscrew Body Size Cast Iron Aluminium Cast Iron Aluminium
N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb CAUTION
When replacing capscrew, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong
7/16-14 60 45 45 35 90 65 45 35 capscrews can result in engine damage.
-20 65 50 55 40 95 70 55 40
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U. S. Customary
1/2 -13 95 70 75 55 130 95 75 55 capscrews are identified by radial lines stamped on the head of the capscrew.
-20 100 75 80 60 150 110 80 60 The following examples indicate how capscrews are identified
9/16-12 135 100 110 80 190 140 110 80
Metric - M8-1.25 x 25 U. S. Customary [5/16 x 18 x 1 - 1/2]
-18 150 110 115 85 210 155 115 85 M8 1.25 X 25 5/16 18 1-1/2
Major thread diameter in millimeters Major thread diameter in inches
5/8 -11 180 135 150 110 255 190 150 110
-18 210 155 160 120 290 215 160 120 Distance between threads in millimeters Number of threads per inch
3/4 -10 325 240 255 190 460 340 255 190
Length in millimeters Length in inches
-16 365 270 285 210 515 380 285 210
7/8 -9 490 360 380 280 745 550 380 280 NOTE:
-14 530 390 420 310 825 610 420 310 1. Always use the torques values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
1 -8 720 530 570 420 1100 820 570 420
3. The torque values in the table are based on the use of lubricated threads.
-14 800 590 650 480 1200 890 650 480 4. When the ft-lb values less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque wrench.
Example: 6 ft-lb equals 72 in-lb
CAPSCREW MARKINGS AND TORQUE VALUES – METRIC – CONTD….. CAPSCREW MARKINGS AND TORQUE VALUES – CONTD….
Capscrew steel Capscrew Markings and Values - U.S. Customary

8.8 10.9 12.9 SAE Grade Number
Capscrew Head Markings Capscrew Head Markings
These are all SAE Grade 5 (3) line
8.8 10.9 12.9
Body Size Torque Torque Torque 6

Diam. Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
Capscrew Torque - Grade 5 Capscrew Capscrew Torque Grade 8 Capscrew
mm N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb
6 9 5 7 4 12 9 7 4 14 9 7 4
Capscrew Body Size Cast Iron Aluminium Cast Iron Aluminium
7 14 9 11 7 18 14 11 7 23 18 11 7
N.M ft-lb N.m ft-lb N.m ft-lb N.m ft-lb
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25 1/4 - 20 9 7 8 6 15 11 8 6
12 80 60 55 40 105 75 55 40 125 95 55 40 - 28 12 9 9 7 18 13 9 7
14 125 90 90 65 165 122 90 65 195 145 90 65 5/8 - 18 20 15 16 12 30 22 16
16 180 130 140 100 240 175 140 100 290 210 140 100 12
18 230 170 180 135 320 240 180 135 400 290 180 135 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
TAP-DRILL CHART - U. S. CUSTOMARY AND METRIC DRIVE BELT TENSION
NOTE ON SELECTING TAP-DRILL SIZES : The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60% and 75% of full SAE melt Size Belt Tension Gauge Part No. Belt Tension new Belt Tension Range Used *
thread depth. Generally, it is recommended that drill sizes be selected in the 60% ra nge as these sizes will provide about 90% of the potential holding Click-type Burroughs N lbf N lbf
power. Drill sizes in the 75% range are recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel. 0.380 in 3822524 620 140 270 to 490 60 to 110
Tap Size Drill Tap Size Drill Tap Size Drill Tap Size Drill 0.440 in 3822524 620 140 270 to 490 60 to 110
60% 75% Size 60% 75% Size 60% 75% Size 60% 75% Size 1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
48 4.40mm 7.50mm 13.25mm 11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
1.95mm 12-24 16 19/64 5/8-11 17/32 3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
5/64 4.50mm 7.60mm M15x1.5 13.50mm
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
3-48 47 15 N M15x1.5 13.75mm
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
2.00mm M5.5x.9 4.60mm 7.70mm 5/8-11 35/64 6 rib 3822524 ST-1293 710 160 290 to 580 65 to 130
M2.5x.45 2.05mm 12-24 12-28 14 M9x1.25 7.75mm M16x2 14.00mm 8 rib 3822525 ST-1293 1110 200 360 to 710 80 to 160
46 13 7.80mm 14.25mm 10 rib 3822525 3823138 1330 250 440 to 890 100 to 200
3-48 3056 45 4.70mm 7.90mm 5/8-18 9/16 12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
M16x2 M16x1.5 14.50mm 12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
2.10mm M5.5x9 4.75mm 3/8-16 5/16
M2.5x .45 M2.6x.45 2.15mm 12-28 3/16 M9x1.25 M9x1 8.00mm 5/6-18 37/64 NOTE : This chart does not apply to automatic belt tensioners.
3-56 4-36 44 12 0 14.75mm * A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is Iess than the minimum value, tighten the belt to the maximum used belt value.
2.20mm 4.80mm 8.10mm M16x1.5 15.00mm
M2.6x.45 2.25mm 11 M9x1 8.20mm 19.32
Tap Size Drill Tap Size Drill Tap Size Drill Tap Size Drill PIPE PLUG TORQUE VALUES
60% 75% Size 60% 75% Size 60% 75% Size 60% 75% Size
Size Torque Torque
4-36 4-40 43 4.90mm P 15.25mm Thread Actual Thread O. D. In Aluminium Components In Cast Iron or
2.30mm 10 8.25mm 39/64 Steel Components
2. 35mm 9 8.30mm M17x1.5 15.50mm in in N.m ft-lb ft-lb N.m
4-40 4-48 42 M6x1 5.00mm 3/8-16 1/8-27NPT 21/64 M17x1.5 M18x2.5 15.75mm 1/16 0.32 5 45 in-lb 15 10
3/32 8 8.40mm 5/8
1/8 0.41 15 10 20 15
M3x.6 2.40mm 5.10mm 3/8-24 Q M18x2.5 M18x2 16.00mm
4-48 41 1/4-20 7 M10x1.5 8.50mm M18x2 16.25mm 1/4 0.54 20 15 25 20
2.45mm 13/64 8.60mm 3/4-10 41/64 3/8 0.68 25 20 35 25
40 6 R M18x1.5 16.50mm
M6x1 1/2 0.85 35 25 55 40
M3x.6 M3x.5 2.50mm 5.20mm 3/8-24 8.70mm 3/4-10 M19x2.5 21/32
39 5 1/8-27NPT 11/32 M18x1.5 16.75mm 3/4 1.05 45 35 75 55
5-40 38 M6x.75 5.25mm M10x1.25 8.75mm M19x2.5 17.00mm 1 1.32 60 45 95 70
M3x.5 2.60mm 5.30mm M10x1.5 8.80mm 43/64
1/4-20 1-1/4 1.66 75 55 115 85
5-40 5-44 37 4 S 17.25mm
M6x.75 1-1/2 1.90 85 65 135 100
2.70mm 5.40mm 8.90mm 3/4-16 3/4-16 11/16mm
1/4-28
5-44 6-32 36 3 M10x1.25 M10x1 9.00mm M20x2.5 17.50mm
2.75mm 5.50mm T 17.75mm
76
/ 4 7/32 9.10mm 45/64
35 5.60mm 23/64 M20x2.5 M20x2 18.00mm
1/4 –28
2. 80mm 2 M10x1 9.20mm M20x2 18.25mm
34 5.70mm 9.30mm 23/32
6-32 6-40 33 5.75mm 7-16-14 U M20x1.5 18.50mm
Tap Size Drill Tap Size Drill Tap Size Drill Tap Size Drill
M3.5x6 2.90mm 1 9.40mm 47/64
32 5.80mm M11x1.5 9.50mm M20x1.5 18.75mm
3. 00mm 5.90mm 3/8 19.00mm
M3.5x6 31 A V 3/4
3-4C 3.10mm 15/64 9.60mm 19.25mm
1/8 M7x1 6.00mm 9.70mm 7/8-9 49/64
3. 20mm B 9.75mm M22x2.5 19.50mm
M4x.75 3.25mm 6.10mm M11X1.5 9.80mm 7/8-9 25-32
30 C 7/16-14 W 19.75mm
M4x.7 3.30mm M7x1 6.20mm 9.90mm M22x2.5 M22x2 20.00mm
M4x.75 3.40 D --20 25/64 7/8-14 51/64
M4x.7 8-32 29 M7x.75 6.25mm 10.00 M22x2 20.25mm
3.50mm 6.30mm 7/16-20 X M22x1.5 20.50mm
8-36 28 E M12x1.75 10.20mm 7/8-14 13/18
8.32 9/64 1/4 Y 20.75mm
3.60mm M7x.75 6.40mm 13/32 M22x1.5 M24x3 21.00mm
8.36 27 6.50mm Z 53/64
3.70mm 5 /16-18 F M12x1.75 M12x1.5 10.50mm 21/25mm
26 6.60mm 1/2-13 27/64 27/32
M4.5x75 3.75mm G M12x1.5 M12x1.25 10.75mm M24x2 21.50mm
10-24 25 6.70mm M12x1.25 11.00mm 21.75mm
3. 80mm 17/64 1/2 –13 7/16 55/84
Tap Size Drill Tap Size Drill Tap Size Drill Tap Size Drill
24 M0x1.25 6.75mm 1/4-18NPT M24x2 22.00mm
M4.5x75 3.90mm 5/16-18 H 11.25mm 1”x-8 7/8
23 6.80mm 11.50mm M24x2 22.25mm
5/32 6.90mm 29/84 M24x1.5 22.50mm
10-24 22 5.16-24 I 11.75mm 1”-8 57/64
M5x1 4.00mm M8x1.25 M8x1 7.00mm 11.50mm M24x1.5 22.75mm
10-32 21 J 1/2-20 29/84 M25x2 23.00mm
20 7.10mm 9/16-12 15/32 1”-12 29/32
M5x.9 4.10mm 5/16-24 K M14x2 12.00mm M25x2 23.25mm
M5x1 M5x.8 4.20mm 9/32 12.25mm 1”x12 1”-14 59/64
10-32 19 M8x1 7.20mm 9/16-12 31/64 M25x1.5 23.50mm
M5x.9 4.25mm 7.25mm M14x2 M14x1.5 12.50mm M20x1.5 23.75mm
M5x.8 4.30mm 7.30mm 9/16-18 1/2 1”-14 15/16
18 L M14x1.5 M14x1.25 12.75mm
11/64 7.40mm M14x1.25 13.00mm
17 M 9/16-18 33/64
Section -11 Trouble Shooting Page 11-0 Section -11 Trouble Shooting Page 11-01
Five Steps of Problem Solving Methodology

Contents Page STEP 1 - Listen to the complaint & Gather the Data :
Problem solving methodology …………………………………........11-01
Study the problem thoroughly and ask the following questions.
Engine Cranks But Does Not Start................................................11-01 1. What were the signs preceding the trouble?
Engine Not Taking Rated Load ....................................................11-03 2. What previous repairs and maintenance has been
carried out ?
Engine Overheating .....................................................................11-07 3. Has similar trouble occurred before?
Trouble Shooting of Engine..........................................................11-10 4. If the engine still runs, is it safe to continue running it to
make further checks ?
PT (Type G) Fuel System Troubleshooting..................................11-15
Electronic Control Panel + Governor Fault Code Information...... 11-16 STEP 2 - List out the probable causes and evaluate which may
eliminate in to problem :
Fault Code Diagnostics ECM, ECPG etc......................................11-19
STEP 3 - Carry out the logical repairs :
STEP 4 Find and correct Basic Trouble :
STEP 5 - Fail-safing :
Engine Cranks But Does Not Start

Crank the engine and confirm the
complaint. If the engine fails to
start the problem may be due to
•Engine cranking speed is less •Low fuel level / no fuel in tank.

•Low battery voltage/
discharged battery.
•Loose battery terminal
connections.
•capacity oflength/inadequate
Excessive
battery cable.
•Defective starter/
magnetic switch.
•Out of 2 starters, 1 No starter
failed in KV12, KV16 & 1 MW.
•(e.g. defective
Excessive parasitic load
unloader valve
in compressor application,
alternator shaft bearing
seized in genset)
• Contaminated/bad
of fuel.
quality •Check the fuel for water
contamination and
adulteration.
• Engine
low.
low idle RPM set too •Set the low idle speed as per
engine application.
• Magnetic Pick Up unit.
Weak / no signal from •flywheel ringgapgear
Excessive between
and MPU.
•Defective MPU. Loose/open/
short circuit wiring from CPU.
•Air in fuel system. •Low

tube)
fuel level. (Below suction •Improper injection timing. •Too much advanced/
retarded injection timing.
•for loosehoses
Check and end fitting
fitment, crank,
mutilated/cut 'O' rings gaskets
etc. •Weak compression •Excessive valve leakage.
• Crank fuel filter mounting •Worn out piston rings/

cylindrical liners.
head/water separator bowl.
• Defective non return valve •Sticky piston rings.
(NRV) in suction line. BEFORE ATTEMPTING ENGINE REPAIRS, CHECK THE
• Puncture in fuel supply drop
tube in fuel tank.
APPLICATION SIDE FOR ENGINE OVERLOADING AS
DETAILED BELOW.
Engine overloaded •For Genset application, check kW output
as per engine rating and confirm.
•Restricted air intake/exhaust. •Chocked air cleaner.
•discharge
For Compressor application - Check air
•Pre-cleaner
depressed.
hood damaged/ pressure settings/RPM,
unloader valve setting, Air Oil Separator
•Blocked exhaust piping. condition.
• For Earth moving applications - Check
fuel pump pressure / excessive gradient/
•Restricted fuel supply •Stuck closed fuel suction excessive load factor.
Insufficient fuel supply valve if provided.
•Chocked • Check Retarder Brake Operation.
applicable.
strainer as
• Check for Vehicle Parasitic loads are
excessive i.e. vehicle brakes for
•Collapsedfuel
Chocked filter. dragging, transmission malfunctioning,
•blocked dropsuction hose or
tube.
cooling fan operation cycle time, or
(Drive Train is not matched with engine
•Fuel supply and drain tubing (New / Repower Applications only)
in 855 series interchanged
at Cylinder head fuel inlet.
• Check for Torque Converter
malfunctioning. Measure Stall Speed. If
•Excessively worn gear pump.
Broken gear pump shaft.
Stall speed is less than specified, engine
is faulty. If it is more than specified,
•filter/wrongly fitted.screen
Choked magnetic Transmission is defective.
•Defective • Check for brake binding.
•Defective
solenoid valve.
safety control/
• Check for Hydraulic Oil Pressure
settings.
loose-open electrical wiring.
•Seizure of governor plunger
• For Marine engines check for propeller
damage, Sea Growth on propeller,
in PT pump. foreign object such as fishing net stuck
•on shaft. coupling slipping
PT pump to propeller.
•Pressure regulator plunger

seized in PTR pump.
Engine Not Taking Rated Load (Black Smoke From Exhaust)
•position. in closed
Actuator stuck Choked Air Cleaner Ø Check whether Vaccum Indicator is
Element or Air Inlet showing Red indication. Clean Air
•Governor controller defective. Hood/Pre-cleaner. Cleaner Element. If Vaccum indicator
still shows Red Indication, check Air
Inlet Hood Screen for restriction or
•Improper valve setting. Excessive valve clearances. insufficient Air Inlate Passage caused by
dislocation of Hood (Old Design
Hoods.) For Air cleaners with Cyclonic
•Dribbling/Malfunction of •Choked fuel inlet screen. Tubes, check the tubes for cleanliness.
injectors. •Cracked injector cup/or
choked injector cup holes/
enlarged cup holes. Air Intake Piping Ø Check the Air Intake Piping & hoses for
•Seized injector barrel &
plunger.
obstructed/Damaged obstruction caused by damage or foreign
material such as cloth rag left inside
during maintenance/repairs.
Fuel Inlet Ø Check Fuel Supply Valve at Fuel Tank

High Intake Air Ø Check for proper ventilation. Restriction. for full opening.
Temperature. Ø Check for Air Temperature Drop across Ø Check Fuel Suction Line Strainer.
Aftercooler. After cooler choked Ø Check Fuel Lines & hoses for restriction.
internally will not cool the air to desired Ø Check Fuel Line Non-return Valves for
temperature. choking/correct orientation.
Dirty / Improper Ø Check Fuel visualy for dirt &
Grade Fuel. adulteration. If suspected collect sample
Turbocharger not Ø Inspect the Turbocharger Air discharge
for analysis.
delivering desired piping for compressed air leaks and
boost pressure. arrest leaks. Choked Magnetic Ø Check & clean / replace the Magnetic
Ø Inspect the turbocharger for free rotation. Filter Screen of Filter Screen.
Ø Inspect the Turbo Compressor Wheel and PT pump. Ø Check & clean / replace the Injector Fuel
Turbine Wheel for dirt/carbon Connection screens.
accumulation or damage. Choked Injector Fuel Ø Check which cylinders are misfiring by
Ø Measure the Turbo Boost Pressure. Connection screens touching the Exhaust ports immediately
in case of PT after starting cold engine. Remove the
Flanger Injectors. Injectors of Cylinders which are
Choked Aftercooler Ø Restriction will be created to air flow if Choked Fuel Inlet suspected to be misfiring and clean the
fins. the Aftercooler is choked externally. Screens on screens. Check Injector cup holes
Clean the Aftercooler and measure Turbo Cylindrical Injectors. for choking.
boost pressure before and after the
Aftercooler.
Ø Check After Cooler Housing Air Inlet Improper Valve & Ø Check and adjust Valves & Injectors.
Fins for damage causing restriction to air Injector Adjustment.
flow.
Low Fuel Manifold Ø Measure the Fuel Manifold Rail Pressure.

Exhaust Back- Ø Excessive Exhaust Back Pressure will Pressure If found out of specification, recalibrate
pressure more than affect engine Fresh Air Aspiration and the Fuel Pump.
specified. easy combustion smoke clearing. Check
Exhaust Back Pressure and take
corrective action as appropriate. AFC Plumbing Ø Check & rectify.
Leak/Blocked.
Leaky Cylinder Head Ø Repair the Cylinder Heads.
Valves.
ENGINE NOT ENGINE NOT EMITTING BLACK High Pressure Fuel Ø Check & adjust Fuel Shut Off Lever.
TAKING LOAD SMOKE. System -
Engine Shut Off Ø Check Fuel Return Valve on Fuel pump
Lever partially Body for dirt or malfunctioning.
Improper Throttle Ø Check and adjust throttle travel. For engaged.
adjustment. Engines with Speed Governors activating Fuel Return Overflow
the throttle, check the throttle linkage Valve Malfunctioning.
adjustments and governor droop setting.
AFC Air signal line Ø Check AFC Signal Line, Wastegate
Check whether EFC Controller 'Actuator crack, blocked. plumbing & Cylinder.
OK" LED is glowing Red indicating high Wastegate Cylinder
current drawn for fuel starvation. Diaphragm/sensing
Choked Fuel Filter Ø Check Fuel Filter Restriction. Replace line damage.
Fuel Filter if found choked. Ø Check Lift Pump Delivery volume at the
Ø Clean the Fuel Tank if Fuel Filters are Lift Pump time of cranking. The values are listed in
found dirty. Malfunctioning. Troubleshooting & repair Manuals.
Nozzles Ø Check for double sealing washer fitment

malfunctioning. to Injector erroneously.
Check and Repair the nozzles.
Engine Overheating (High Coolant Temperature.)
Ø Check and clean the Actuator Screens.
Quantum Engines :
Chocked fuel
Defective Gauge/
Malfunction/Gauge
•Replace the gauge and check.
Metering & Timing Capillary touching
Actuator Screens the exhaust
manifold.
Incorrect ECM Ø Check and download correct calibration

Calibration data to ECM Low Coolant level in Check coolant level.
Radiator/H.E.top tank •
Coolant level should be up to bottom of
fill neck.
High ambient Ø Check ambient temperature near engine
temperature/ which should not exceed LAT. Check for visible Results in coolant loss.
improper ventilation. (Limiting Ambient Temperature) external leaks from
gaskets, O rings,
• Inspect and arrest leaks.
seals, hoses.
GENERAL REASONS Missing top tank
pressure cap.
Very high lub oil Ø Corret the oil level.
level.
Choked/excessive
length of coolant
•Restriction in the coolant line hoses can
result in improper filing of cooling system
High Fuel Inlet Ø Clean the Fuel Cooler vent line hoses. and false indication of coolant level.
temperature(Engines
having Return line
Make up line hose/
pipe choked.
•Clean or replace vent line hoses.
Fuel Coolers)
Engine operating Ø Derate the engines as per recommendations

Loose fan belt/water
pump belt/slippery
•Check belt tension by thumb pressure.
Deflection should be approx. width of
above recommended in engine data sheet. belts due to spillage belt.
altitude. of oil or grease. •Adjust belt tension Or replace belts if
found worn excessively. Clean fan belts/
pullies.
High Blow By Ø Check and correct the Blow by problem.
Radiator shround
missing/no sealing
•Results in by-passing fan air flow and
reduces cooling system efficiency.
Injection Timing Ø Check & correct Injection Timing.
Incorrect
Damage to Check conditions of Camshaft & tappets.

Insufficient opening/
obstruction in front
•Re-circulation
core.
of hot air over the radiator
Camshaft or Tappets
of radiator
Less/No raw water

flow through heat
•Check raw water level in the cooling
tower pond.
exchanger. Check operation of raw water pump.
Excessive raw water Check raw water pump suction strainer if
inlet temperature. choked.
Check cooling tower water sprinklers for
choking / fins clogging / operation of
cooling tower fan etc.
Radiator core choked Clean radiator fins.

externally with oil,dust
debris, insects etc
•Use 60 psi air pressure to blow the dirt
from the fins. Blow the air in the opposite
direction of fan air flow.
Clogged radiator oil •Clean the ROC assembly. Clogged oil
Thermostat/s not
opening at its
•Check thermostat operation and replace
if not functioning properly.
cooler (ROC)
assembly (Comp
cooler leads to high compressor oil
temperature raising the coolant
specified temperature •temperature
(Should operate within specified limits of
and open fully).
Application) temperature.
High transmission •Dissipates excess heat to engine coolant

Check the coolant
capacity of radiator
•Ifthan
radiator capacity is less than specified,
replace the radiator with correct part
oil temperature. raising coolant temperature.
as specified by number.
manufacturer.
High torque convertor
oil temperature
•Dissipates excess heat to engine
coolant raising coolant temperature.
Water pump impeller

pitted/impeller loose
•Results in reduction in coolant flow.
Check and replace pump if necessary.
Fan fitted in reverse •Confirm sucker / blower type fan as per
direction. engine application.
on shaft.
Water pump drive •Results water pump not rotating and no

Damaged Fan blade
profile/angle/dents
•Results
confirm.
in less air flow. Check and
coupling broken circulation of coolant. Replace drive
(K series) coupling.
Excessive Fan tip to •Reduce fan efficiency.
Choked engine oil •Choked lub oil cooler can cause less
shroud clearance •Adjust fan position in the shroud.
cooler (N & V Series) coolant flow.
• Clean or replace LOC element. Incorrect Fan
position in the
Results in reduced effective fan air flow. Fan
should be outside the shroud by 3/4" of
shroud and distance blade width in case of sucker type fan and
Radiator/H.E. tubes
choked internally /
•Check the temperature difference across
radiator/coolant inlet and outlet across
from radiator core. 3/4" inside the shroud in case of blower
type fan.
Excessive plugging H.E.
of tubes (i.e. more •Difference should be 7-10 deg C.
than 20%) •Clean heat exchanger/radiator tubes
internally.
High ambient
temperature
•Check ambient temperature near engine
which should not be LAT.
improper ventilation (Limiting Ambient Temperature)
Engine overloaded •Check KW output as per engine rating

and confirm.
•discharge pressure
For Compressor application-Check air
settings/RPM.
•For Earth moving applications - Check
fuel pump pressure/excessive gradient/
excessive load factor.
High engine oil •Check oil temperature.

temperature •Ifengine
oil temperature is more it leads to
overheating.
Page 11-10
Excessive Crankcase Pressure

Page 11-11
Excessive Noise Excessive Crankcase Pressure

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Excessive Engine Vibration Excessive Noise

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Gear Train Whine Excessive Engine Vibration

Mechanical Knocks Gear Train Whine
Fuel Knocks (Combustion Noise)
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Mechanical Knocks
Worn Valves and Guides Fuel Knocks (Combustion Noise)
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Wear of Bearings and Journals

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Worn Valves and Guides

Piston Liner and Ring Wear Wear of Bearings and Journals
Oil Temperature Too High Piston Liner and Ring Wear
Coolant Temperature too High Oil Temperature Too High
Coolant Temperature too Low Coolant Temperature too High
Low Oil Pressure Coolant Temperature too Low
Dilution
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Low Oil Pressure

Crankcase Sludge
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Dilution
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Excessive Oil Consumption Crankcase Sl udge

Surging at Governed RPM Excessive Oil Consumption
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Engine Dies
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Surging at Governed RPM

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Erratic Idle Speed Engine Dies

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Poor Deceleration
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Erratic Idle Speed

Excessive Fuel Consumption
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Poor Deceleration
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Sluggish Engine Acceleration Excessive Fuel Consumption

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Low Air Output

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Sluggish Engine Acceleration

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Cannot Reach Governed RPM

Low Air Output
Low Power or Loss of Power
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Cannot R each Governed RPM

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Excessive Acceleration Smoke

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Low Power or Loss of Power

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Excessive Smoke Under Load Excessive Acceleration Smoke

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Excessive White Smoke at Idle

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Excessive Smoke Under Load

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Excessive Black Smoke at Idle

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Engine Misses
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Hard Starting or Failure to Start
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Engine Misses
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COMPLAINTS Hard Starting or Failure to Start

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COM PLAINTS
TROUBLE SHOOTING
Thin Air in Hot Weather or High Altitude
Improper Use of Starter Aid / Air Temp.

Air leaks Between Cleaner and Engine
OF ENGINE - CONTD…..
Damaged /Worn AFC Plunger Seal / Barrel

TROUBLE SHOOTING
Incorrectly Assembled Governor Weights

Out of Fuel or Fuel Shut Off Closed
OF ENGINE
Excessive Injector Check Ball Leakage

Scored Gear Pump or Worn Gears
CAUSES
Dirty Turbocharger Compressor
External or Internal Fuel Leaks

Poor Quality Fuel / Grade Fuel
Broken Fuel Pump Drive Shaft
Incorrectly Assembled idle Springs
High-Speed Governor Set too Low

Cracked Injector Body or Cup
Plugged Injector Spray Holes
CAUSES
High Exhaust Back Pressure
Fuel Pump Calibration Incorrect

Throttle Linkage or Adjustment
Air Leaks in Suction Lines
Water in Fuel and / or Waxing

Restricted Fuel Lines
Damaged Injector O-Ring
AFC Calibration Incorrect

Wrong Injector Cups
Restricted Air Intake
Section -11 Trouble Shooting
Stuck Drain Valve
AFC Air Leak, Bellows

Injector Flow Incorrect
System
System
Fuel
Air
System
Fuel
Weight Assist Set Wrong
Repair
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Mechanical
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ll l l l ll l l Torque Spring Wrong
l l l l Throttle Shims Insufficient
l l l l l l Throttle Shims Excessive
l l l l Throttle Shaft Restricted
l l l l l l l l l l Throttle Linkage
l l l l Throttle Leakage Excessive
l l l l l l Spring Fatigue
l l l l l Speed Settings, Unmatched auto/MVS or VS
l l l Shut-down Valve Restriction
Injectors Need Adjustment
l l l l l l l l l l Screw Adjusted, Incorrect

CAUSES
l Reversed Rotation, Drive Failure

Worn or Scored Liners or Pistons
Geartrain Backlash/Broken Tooth
ll Pressure Valve Failure

Broken/Bent Push Rod or Cam Box
Adjustments or Incorrect Valve and Injection Timing
TROUBLE SHOOTING
l l l Injector Plunger Worn

OF ENGINE - CONTD….
Misalignment – Engine to Driven Unit

Loose Mounting Bolts/Head Capscrew
l l l l l l l l l Injector Orifice Size Wrong

l l l l l l l l l l l Incorrect Injector
l l l ll l l Injector Flow High
l l l l l l l Injector Cup Cracked, Wrong, Damaged
COMPLAINTS
l l l l l l l Injector Adjustment Loose
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l l l l l Idle Spring Wrong Hard Starting or Failure to Start

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l l l l l l l l Idle Plunger (Button) Wrong Excessive Black Smoke at Idle

ll l l l l l l l High Speed Spring Shimming Wrong Excessive White Smoke at Idle
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l l l l l l l Governor Weights Incorrect (Heavy)
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l l l l Governor Spring Shims Low Low Power or Loss of Power

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ll l l l l l l l Governor Plunger, Worn/Scored Cannot Reach Governed RPM

l l ll l l l l l l Governor Plunger, Wrong/Worn/Sticking Low Air Output
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Governor Plunger Chamfer, Inadequate
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Poor Deceleration
l l l l l Fuel Wrong Type
l l l l Fuel with Water Erratic Idle Speed
l l l l l Fuel Dirty Engine Dies
l l l l l l Filter Suction Restricted Surging at Governed RPM
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l l l l Cooling Line By-passing
Crankcase Sludge
l l l l l l Aneroid Valve Stuck Open
Dilution
l l l l l Aneroid Stuck Open
Low Oil Pressure
l l l l l l l Aneroid Not Opening
Coolant Temperature too Low
l l l l l l l l l ll Air Leaks
l l l l Air Signal Attenuator Filter Plugged Coolant Temperature too High
POSSIBLE CAUSES Oil Temperature Too High
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Piston Liner and Ring Wear

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Air Leaks
Low Power

COMPLAINTS
Rough Operation
Idle surge MVS
Wear Rate High
TROUBLE SHOOTING
Idle Speed Too High
Acceleration Slow
Deceleration Slow
Idle Undershoot MVS

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Fuel Knocks (Combustion Noise)

Governed Speed Low
Governed Speed High
FUEL SYSTEM
High Speed Surge MVS
Fuel M anifold, PSI Low
Fuel M anifold, PSI High
Smoke Black, Low Speed

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Failure To Pick -Up Fuel
Mechanical Knocks
Throttle Leakage Excessive
PT (TYPE G)
Fuel Consumption Excessive
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Carboned Valves, Injector Cups
Gear Train Whine

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Excessive Engine Vibration

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Excessive Noise
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Page 11-14
Page 11-15 Section -11 Trouble Shooting

Repair
System
System
Cooling
Practices
Lubricating
Mechanical
Maintenance
Operation and
Adjustments or
Dirty Oil Filter
Long Idle Periods

Oil Level Too High

Faulty Thermostats
Engine Overloaded
Broken Cam Lobes

Clogged Oil Drillings
Oil Needs Changing

Internal Water Leaks
Engine Exterior Dirty
Engine Due for Overhaul

Coolant Temperature Low
Faulty Cylinder Oil Control
Oil Suction Line Restriction

CAUSES
Damaged Hose/Loose Belts

Crankcase Low or Out of Oil
Gasket Blow-By or Leakage

Exterior Leaks / Air in System
Faulty Oil Pressure Regulator
Broken or Worn Piston Rings

Incorrect Bearing Clearances
CAUSES
External and Internal Oil Leaks
Valve Leakage/Adjustment Bad

Dirty Filters / Screens / Breather
Damaged Main or Rod Bearings

Insufficient Coolant / Worn Pump
TROUBLE SHOOTING
Faulty Damper / Flywheel Balance

OF ENGINE - CONTD…..
Low Coolant Capacity/Dirty Radiator
Main Bearing Bore Out of Alignment

TROUBLE SHOOTING
OF ENGINE - CONTD….
Excessive Crankshaft End Clearance

Clogged Oil Cooler or Water Passages
Wrong Grade Oil for Weather Conditions
COM PLAINTS
COMPLAINTS Hard Starting or Failure to Start
Engine Misses
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Hard Starting or Failure to Start
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Engine Misses
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Excessive Acceleration Smoke
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Excessive Acceleration Smoke Low Power or Loss of Power
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Low Power or Loss of Power Cannot R each Governed RPM
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Cannot Reach Governed RPM Low Air Output
Low Air Output Sluggish Engine Acceleration
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Sluggish Engine Acceleration
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Excessive Fuel Consumption Poor Deceleration
Poor Deceleration Erratic Idle Speed
Erratic Idle Speed Engine Dies
Engine Dies Surging at Governed RPM
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Surging at Governed RPM l
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Excessive Oil Consumption
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Excessive Oil Consumption
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Crankcase Sl udge
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Crankcase Sludge
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Dilution
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Dilution
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Low Oil Pressure
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Low Oil Pressure
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Coolant Temperature too High Coolant Temperature too High
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Oil Temperature Too High
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Oil Temperature Too High
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Fuel Knocks (Combustion Noise) Fuel Knocks (Combustion Noise)
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Mechanical Knocks M echanical Knocks
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Gear Train Whine Gear Train Whine
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Excessive Engine Vibration Excessive Engine Vibration
Excessive Noise
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Excessive Noise
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Page 11-13
Page 11-12
Electronic Control Panel + Governor (ECPG) Fault Code Information
Fault Engine Default Fault Description Effect(Only when fault is active)
Code Protection/ Fault Fault Description
Fault Engine Default Effect(Only when fault is active)
System Response
Code Protection/ Fault
Fault
System Response
1416 System Warning Engine fail to shutdown Engine failed to stop even after a stop command Fault
was issued by the system. No engine protection feature. 135 System Warning Engine Lube Oil Pressure sensor signal No engine protection for Lube Oil Pressure.
1438 System Warning Engine fail to crank No effect on engine performance. is shorted high No effect on engine performance
141 System Warning Engine Lube Oil Pressure sensor signal No engine protection for Lube Oil Pressure.
3111 System Warning Speed Bias Analog Input signal is shorted low The speed bias analog input signal feature will be disabled. is shorted low No effect on engine performance
Possible loss of engine performance. 143 Engine Warning Engine Lube Oil Pressure has dropped below Low Lube Oil Pressure warning relay driver is energized.
3112 System Warning Speed Raise Switch is shorted high The Speed Raised Switch feature will be disabled. Protection the warning threshold for Low Lube Oil Pressure No effect on engine performance.
Possible loss of engine performance. 144 System Warning Engine Coolant Temperature sensor signal No engine protection for Coolant Temperature.
3113 System Warning Speed Lower switch is shorted high The Speed Lower Switch feature will be disabled. is shorted high No effect on engine performance.
Possible loss of engine performance. 145 System Warning Engine Coolant Temperature sensor signal No engine protection for Coolant Temperature.
is shorted low No effect on engine performance.
3115 System Shutdown Speed signal was lost while engine running. Engine will shutdown.
146 Engine Warning Engine Coolant Temperature has exceed the High Coolant Temperature warning relay driver is
3116 System Warning Fuel Actuator PWM signal is close to maximum Possible loss of engine performance at higher loads. Protection warning threshold for High Coolant Temperature. energized. No effect on engine performance.
for long enough time due to possibly 151 Engine Shutdown Engine Coolant temperature has exceed the Engine will shutdown.
stuck actuator or insufficient fuel supply. Protection shutdown threshold for high Coolant Temperature
3118 System Warning Powerdown hardware within 1) No effect on engine performance. 153 System Warning Engine Intake Air Temperature sensor signal No engine protection for Intake Air Temperature.
ECPG malfunctioning. 2) ECPG will not powerdown. Potential battery drain. is Shorted high No effect on engine performance.
Section -11 Trouble Shooting Page 11-17
343
326
266
265
263
261
259
254
253
252
236
235
234
233
232
231
222
214
213
212
197
155
154
153
152
151
146
145
144
141
123
122
121
119
118
117
116
115
113
112
318
316
221
135
228
143
111
Fault Engine Default Fault Description Effect(Only when fault is active)
Code Protection/ Fault
System Response
Fault
154 System Warning Engine Intake Air Temperature Sensor signal No engine protection for intake Air Temperature.
is shorted low No effect on engine performance.
Low Oil Level

155 Engine Warning Engine Intake Air Temperature has exceed High Intake Air Temperature warning relay driver
Engine Overspeed
Protection the warning threshold for High Intake is energized. No effect on engine performance.
Generator Set ECM

Air Temperature.

234 Engine Shutdown Engine Speed Signal indicate that engine speed Engine will shutdown. Fuel Shut-Off Valve (S.D. Coil) is
Electronic Control Module

Protection is greater than Overspeed threshold. de-energized (valve closed). Overspeed shutdown
Fuel Pump Actuator Circuit

Oil Pressure Sensor Circuit
Timing Rail Actuator Circuit
Oil Pressure Sensor Circuit
Oil Level - Engine Protection

Oil Level - Engine Protection
Engine Speed Sensor Circuit
Engine Speed Sensor Circuit
relay driver is energized.
Timing Fueling Flow Mismatch
Oil Temperature Sensor Circuit

Oil Temperature Sensor Circuit
Coolant Pressure Sensor Circuit

Coolant Pressure Sensor Circuit
Oil Pressure - Engine Protection
235 Engine Shutdown Engine Coolant Level has dropped below the Engine will shutdown.
Fuel Temperature Sensor Circuit

Fuel Temperature Sensor Circuit
Fuel Pump Fueling Flow Mismatch

Fuel Shutoff Valve Solenoid Circuit
Protection shutdown threshold for Low Coolant Level.
Fuel Pump Pressure Sensor Circuit

Fuel Pump Pressure Sensor Circuit
Timing Rail Pressure Sensor Circuit
Timing Rail Pressure Sensor Circuit
Oil Temperature - Engine Protection

Coolant Temperature Sensor Circuit
Ambient Air Pressure Sensor Circuit

Ambient Air Pressure Sensor Circuit
Coolant Pressure - Engine Protection

Coolant Pressure - Engine Protection
Fuel Temperature - Engine Protection

Fuel Temperature - Engine Protection
Engine Speed/Position Sensor Circuit
359 System Warning Engine cranked but failed to start No effect on engine performance.
Intake Manifold Pressure Sensor Circuit

Intake Manifold Pressure Sensor Circuit
Coolant Temperature - Engine Protection

Coolant Temperature - Engine Protection
Engine Coolant Level - Engine Protection

Engine Coolant Level - Engine Protection
415 Engine Shutdown Engine Lube Oil Pressure has dropped below Engine will shutdown
Intake Manifold Temperature Sensor Circuit

Intake Manifold Temperature Sensor Circuit
Protection the shutdown threshold for Low Oil Pressure
Fuel Shutoff Valve Solenoid - Not Responding

Intake Manifold Temperature - Engine Protection
441 System Warning Low voltage has been detected for Engine may not crank. Possible loss of ECPG functionality.
FAULT CODE DIAGNOSTICS ECM, ECPG etc.

battery during engine crank.
1411 System Warning Speed Bias Analog Input signal is shorted high The Speed Bias Analog Input signal feature will be disabled.
Possible loss of engine performance.
Page 11-19

FAULT CODE DIAGNOSTICS ECM, ECPG etc. - CONTD..
359 Engine Will Not Start 1319 Alternator Temperature - Alternator Protection
378 Fueling Actuator #1 Circuit 1321 Common Warning Output Relay Driver Diagnostic
379 Fueling Actuator #1 Circuit 1322 Load Governed kW Setpoint-Analog Input Signal Circuit
394 Timing Actuator #1 Circuit 1323 Load Governed kW Setpoint - Analog Input Signal Circuit
395 Timing Actuator #1 Circuit 1324 Load Governed kVAR Setpoint - Analog Input Signal Circuit
396 Fueling Actuator #2 Circuit 1325 Load Governed kVAR Setpoint - Analog Input Signal Circuit
397 Fueling Actuator #2 Circuit 1326 Starter Backup Disconnect
398 Timing Actuator #2 Circuit 1327 Load Governed kW Setpoint - Analog Input Signal Circuit
399 Timing Actuator #2 Circuit 1328 Generator Set Circuit Breaker
415 Oil Pressure - Engine Protection 1329 Voltage Regulator
421 Oil Temperature - Engine Protection 1331 Voltage Regulator Driver Diagnostic
422 Coolant Level Switch Sensor Circuit 1332 Off/Manual/Auto Switch Circuit
423 Timing Rail Pressure in Range Error 1333 Off/Manual/Auto Switch Circuit
441 Unswitched Battery Supply Circuit 1334 One or More Trims Have Been Set
442 Unswitched Battery Supply Circuit 1335 One or More Trims Have Been Set
449 High Fuel Pressure 1336 Engine Shutdown
451 Fuel Rail Pressure Sensor Circuit 1337 LonWorks Wink Event Has Been Commanded
452 Fuel Rail Pressure Sensor Circuit 1341 Paralleling Controller Requested a Generator Shutdown
455 Fuel Rail Actuator 1342 Fuel System Board - Incorrect Installation
467 Timing Fueling Flow Mismatch 1343 Base Board - Incorrect Installation
468 Fueling Rail Flow Mismatch 1344 Generator Interface Board - Incorrect Installation
471 Engine Oil Level - Engine Protection 1345 Paralleling Board - Incorrect Installation
482 Low Fuel Pressure 1346 LonWorks Network Board - Incorrect Installation
488 Intake Manifold Temperature Sensor - Engine Protection 1347 Slot 5 Board - Incorrect Installation
498 Oil Level Sensor Circuit 1348 Slot 6 Board - Incorrect Installation
499 Oil Level Sensor Circuit 1349 Slot 7 Board - Incorrect Installation
514 Fuel Rail Flow Mismatch 1351 LonWorks Network Board - Missing
546 Fuel Pressure Sensor Circuit 1414 Run Relay Contact Diagnostic
547 Fuel Pressure Sensor Circuit 1415 Run Relay Driver Diagnostic Detected an Error
554 Fuel Rail Pressure Sensor Circuit 1416 Fail to Shut Down
555 Blowby Pressure - Engine Protection 1417 Controller Power Down Fault
556 Blowby Pressure - Engine Protection 1419 Fuel Rail Driver Diagnostic
611 Engine Was Shut Down Before Proper Engine Cooldown 1421 Timing Rail #1 Driver Diagnostic
688 Engine Oil Level - Engine Protection 1422 Timing Rail #2 Driver Diagnostic
689 Crankshaft Engine Position Sensor Circuit 1423 Fuel Pump Driver Diagnostic
719 Blowby Pressure Sensor Circuit 1433 Emergency Stop Button Was Pressed
729 Blowby Pressure Sensor Circuit 1434 Remote Emergency Stop Button Was Pressed
731 Engine Speed Sensor Circuit 1435 Engine is Cold - Potential Starting Problem
778 Camshaft Engine Position Sensor Circuit 1436 HPI-PT Fuel System Driver Diagnostic
1311 Customer-defined Fault Code No. 1 1438 Fail to Crank
1312 Customer-defined Fault Code No. 2 1439 Fuel Level Low in Day Tank
1313 Customer-defined network Fault Code No. 1 1441 Fuel Level Low in Main Tank
1314 Customer-defined network Fault Code No. 2 1442 Unswitched Battery Supply Circuit
1315 Customer-defined network Fault Code No. 3 1443 Unswitched Battery Supply Circuit
1316 Customer-defined network Fault Code No. 4 1444 kW Overload - Alternator Protection
1317 Customer-defined Fault Code No. 3 1445 Alternator Short Circuit - Alternator Protection
1318 Customer-defined Fault Code No. 4 1446 Generator AC Output Voltage
1447 Generator AC Output Voltage
Section -11 Trouble Shooting Page 11-22

1448 Generator AC Output Frequency
1449 Generator AC Output Frequency
1451 Generator Circuit vs Bus Voltage
1452 Generator Set Circuit Breaker - Failed to Close
1453 Generator Set Circuit Breaker - Failed to Open
1454 Generator Set Circuit Breaker - Failed Position Contact
1455 Utility Circuit Breaker Position Contact - Incorrect for
Application
1456 Generator Circuit - Cannot Synchronize
1457 Generator Set - Failed to Synchronize
1458 Generator Set - Cannot Synchronize Phase
1459 Reverse kW
1461 RevekrV
seAR
1462 High Current on Ground
1463 Generator Announces to LonWorks Network that it is Not
in Auto
1464 Generator Announces to LonWorks Network that it a
"Load Dump" has Occurred
1465 Generator Announces to LonWorks Network that it is
"Ready to Accept Load"
1466 Modem - Lost Communication
1468 LonWorks Network - Lost Communication
1469 Measure Speed vs AC Output Frequency
1471 AC Output Current - High Warning
1472 AC Output Current - High Shutdown
1473 ECM Internal Watchdog Test Failed
1474 Base Board - Extended I/O Software Mismatch
1475 Permission to Connect - Not Received
1476 Base Board - Not Responding to LonWorks Board
1477 Crank Relay Contact Diagnostic
1478 Crank Relay Driver Diagnostic Detected an Error
1481 Voltage Regulator Driver Diagnostic
1483 One or More Fault Codes Have Not Been Acknowledged
1487 Not in Auto LED Driver Diagnostic
1488 Warning LED Driver Diagnostic
1489 Shutdown LED Driver Diagnostic
1491 Ready to Load Output Relay Driver Diagnostic
1492 Load Dump Output Relay Driver Diagnostic
1493 Operator Interface Panel Power Relay Driver Diagnostic
1494 Modem Power Relay Driver Diagnostic
1495 Common Shutdown Output Relay Driver Diagnostic
1496 Auto Mode Output Relay Driver Diagnostic
1497 Manual Run/Stop LED Driver Diagnostic
1498 Exercise LED Driver Diagnostic
1499 Remote Start LED Driver Diagnostic
2111 Aftercooler Water Inlet Temperature Sensor Circuit
2112 Aftercooler Water Inlet Temperature Sensor Circuit
2113 Aftercooler Water Inlet Temperature - Engine Protection
2114 Aftercooler Water Inlet Temperature - Engine Protection
Multiple Multiple Fault Codes on the Engine Harness

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LIC Policies No. _______________________________

No part of publication may be reproduced, stored in a retrieval system,

Tel. : (020) 25436680 Call Toll Free

Our Goal : Zero Engine Down

GENERAL SAFETY INSTRUCTIONS

General Safety Instructions WARNING

Read and understand all of the safety precautions and warnings

• Always wear protective glasses and shoes when working.

• Rotating parts can cause cuts, mutilation or strangulation.

• Do not wear loose-fitting or torn clothing. Remove all jewellery

• Disconnect the battery cables first and discharge any capacitors

• Use only the proper engine barring techniques for manually

• Do not work on anything that is supported ONLY by lifting jacks

• To prevent suffocation and frostbite, wear protective clothing and

G-Drive Original Equipment Manufacturer

• To avoid personal injury, use a hoist or get assistance when

positioned correctly. Always use a spreader bar when

necessary. The lifting hooks must not be side-loaded.

Engine Position Sensor

Ignition Control Module

• Corrosion inhibitor and lubricating oil, contain alkali. Do not get

the substance in your eyes. In case of contact, immediately flood

eyes with large amounts of water for a minimum of 15 minutes.

immediately call a physician. Keep out of reach of children.

Avoid prolonged or repeated contact with skin. Do not

swallow internally. In case of contact, immediately wash skin

with soap and water.

understand how to use them before performing any service

• Always use the same fastener part number ( or equivalent) when

• Do not perform any repair when fatigued or after consuming

alcohol or drugs that can impair your functioning.

disconnect all electrical/electronic controls before welding.

Coolant Temperature Sensor

Electronic Control Module

Electronic Control Panel

Data Terminal Ready

Data Set Ready

Section -11 Trouble Shooting Page 11-22 INDEX IN-01

INDEX IN-02 INDEX IN-03

INDEX IN-04 INDEX IN-05

CUMMINS ENGINE NOMENCLATURE (N, V, K, QSK SERIES)

R = Railcar (Horizontal engine)

= Displacement in (cubic inches)

The model name provides the following data

Fuel Pump Serial Number

Fuel Pump Code Number

Fuel Pump AR/BM

C.I.D. (Liter) Breathing

5 1/8 X 6 (130 X 152)

5 1/8 X 6 (130 x 152)

using the E.S.N. (2) The Control Parts

identifies the original engine parts list

standards for engine certification. The