X1.3 Engine

Engine Service Manual
X1.3 Engine
English − Original Instructions 9−2011 A030D088 (Issue 4)

Service Manual Publication A030D088
Model: X 1.3 Issue 4 - 9 - 2011
“Intentionally Left Blank”
Page 2 2011Copyright Cummins Power Generation

Publication A030D088 Service Manual
Issue 4 - 9 - 2011 Model:X 1.3
FOREWORD
This manual is designed to be of assistance to all Personnel concerned with the maintenance and
overhaul of the X 1.3 Series Engine.
It presents a complete and detailed Description of the Engine, together with precise instruction on
servicing and overhaul procedure and dimensions which should be closely followed when overhauling
any part of the Engine to the Manufacturers standards.
Effective maintenance can only be carried out if the personnel concerned are fully conversant with the
various components of the Engine.
Before maintenance operations are commenced, this manual should be carefully studied, and it should at
all times be kept where it will be needed in the workshop.
Thoroughly read the Workshop Manual before operating the generator set.
Safe operation and top performance can be obtained only when equipment is operated and maintained
property.
This manual is for guidance and assistance with recommendations for correct and safe procedures.
Cummins Power Generation Limited cannot accept any liability whatsoever for problems arising as a
result of following recommendations in this manual.
The information contained within the manual is based on information available at the time of going to print.
In line with Cummins Power Generation Limited policy of continuous development and improvement,
information may change at any time without notice. The Installers should therefore ensure that before
commencing any work, they have the latest information available.
Consult your Authorised Distributor for further information or assistance if required. It is essential that the
utmost care is taken with the application, installation and operation of any diesel engine due to their
potentially dangerous nature. Careful reference should also be made to other Cummins Power
Generation Limited literature, in particular the Health and Safety Manual 0908-0110.
Should you require further assistance contact:
Cummin India Limited

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

Fax: +91 2066028090
E-mail: cpgiservicesupport@cummins.com
Web Site: www.cumminspower.com
2011Copyright Cummins Power Generation Page 3

Model: X 1.3 Issue 4 - 9 - 2011
Table of Contents
SECTION Description Page
A GENERAL INFORMATION ....................................................................... ...... 6
B ENGINE VIEW ENGINE NIMBER LOCATION.................................................. 7

ENGINE NIMBER LOCATION........................................................................... 9
C TECHICAL DATA............................................................................................... 10
MANUFACTURING DATA AND DIMENSIONS................................................. 11
THREADS AND TORQUE SPECIFICATION ................................................... 14
D OPERATION AND MAINTENANCE......................................................... ....... 18
E FUEL SYSTEM............................................................. ................................... 22
F COOLING SYSTEM -WATER PUMP.......................................................... ..... 43
G FRONT OIL SEAL ............................................................................................ 44

H FLY WHEEL AND REAR END OIL SEAL ....................................................... . 48
I BALANCER UNIT AND OIL PUMP................................................................... 51
J CYLINDER HEAD.................................................... ........................................ 54
K TIMING CASE AND GEAR DRIVE............................................................... ... 63
L PISTONS AND CONNECTING RODS............................................................. 67
M CRANKSHAFT ASSEMBLY AND MAIN BERINGS.......................................... 71
N CYLINDER BLOCK AND LINERS ................................................................... 74
O LUBRICATING SYSTEM....................................................................... .......... 76
APPROVED LUBRICATING OILS................................................................... 77
P ELECTRICAL EQUIPMENT .......................................................................... 79
Q TROUBLE SHOOTING...................................................................................... 80
R SERVICE TOOLS................................................... ......................................... 89

Issue 4 - 9 - 2011 Model:X 1.3
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Model: X 1.3 Issue 4 - 9 - 2011
Section A
GENERAL INFORMATION
SAFETY TOOLS AND MEASURING EQUIPMENT

The safety measures that always should be Be sure that all necessary tools and
performed in order to avoid risks that is always equipments are available before starting work.
present. Use special tools where they are specified.
All servicing normally be carried out with the engine Never drop the tools
stationary. Use correct tools as specified.
Do not approach the running engine with loose cloth REMOVAL OF PARTS:
or long hair.
First find the cause of the problem and then
Be careful of hot surfaces.
determine whether removal or disassembly is
Do not open the radiator filler cap when the engine required before starting the job.
is hot.
INSPECTION OF PARTS:
Avoid skin contact with oil, fuel or chemicals that
can cause burn. Long term contact with oil can lead Each part when removed should be carefully
to the skin problem. inspected for malfunction, deformation, damage and
other problems.
Run the engine only in a well-ventilated area.
All disassembled parts required for reassembling
Note : One receipt of engine by truck,
should be carefully stored.
ensure unloading of the engine by
skiled personnel. The Personnel have Ensure to separate and correctly identify the parts
to use necessary personal protective to be replaced from those that will be used again.
equipment to avoid accidents. Engines
are to be un loaded using the lifting CLEANING OF PARTS FOR REUSE:
hooks fitted on the engines. During the
engine installation ensure proper All parts to be used again should be carefully and
fitment of Anti Vibration Mounting Pad. thoroughly cleaned by an appropriate method.
When lifting the engine use the lifting eyes that are PARTS
fitted to the engine.
When replacing parts, use genuine parts.
Never work alone when removing heavy parts.
When cleaning the engine with high-pressure water, Oil seals, Gaskets, O-rings, Lock washers, split
never direct the jet at seals, rubber hoses or pins and plastic nuts should always be replaced
electrical components. with new ones.
Always prevent diesel or oil from contacting rubber
Standard values such as torque and adjustments
parts or tubing must be strictly observed in the reassembly of all
WARNING : Guarding should not be removed parts.
when the engine is is running condition.
FITMENT
CAUTION: Warns of a risk of injury, serious
damage to the product or serious malfunctions Use correct tools, gauges and testers for correct
could occur if the instruction is not followed. fitment of the parts to standard value.
Important: Is used to draw attention to things that ELECTRICAL SYSTEM

could cause damage to or malfunction of the
Be sure to disconnect the battery cables from the
product.
negative terminal of the battery
Note : It is used to draw attention to important
Never pull on the wires when disconnecting
important information to facilitate procedure
connectors.
or handling.

Issue 4 - 9 - 2011 Model:X 1.3
Section B
ENGINE VIEW
FUEL INJECTION PUMP SIDE

Model: X 1.3 Issue 4 - 9 - 2011
ENGINE VIEW
CAM SHAFT SIDE

Issue 4 - 9 - 2011 Model:X 1.3
Engine Identification Plate
Each engine is provided with a Data Plate as shown

below. This provides information unique to the engine.
The engine data plate shows specific information about
your engine.
The Engine Serial Number (ESN) (1) and Control Parts
List (CPL) provide information for ordering parts and
service needs.
Note: The engine data plate must not be changed unless approved by
Cummins Engine Company Inc.

Model: X 1.3 Issue 4 - 9 - 2011
Section C
TECHNICAL DATA
Engine Type : 2 Cylinder. 4 Stroke. Inline Type. Water Cooled
Aspiration : Naturally Aspirated
Combustion : Direct Injection
Bore (Nominal dia.) : 3.740 inch (95.0 mm)
Stroke : 3.58 inch (91 mm)
Cubic Capacity : 78.7 cu.inch (1.29 Lts.)
Compression ratio : 18.1 : 1
Rotation : Anti-clock wise from the flywheel end
Firing order : 1, 2
Valve Tip Clearance : 0.010 inch (0.25 mm) for inlet value and 0.012 inch
(0.30 mm) for exhaust value)
Atomiser setting pressure : 250 bar (5 Spray Nozzle)
Inlet valve opens : 12° B.T.D.C.*
Exhaust valve closes : 12° A.T.D.C.**
Total inlet open period : 232°
Total exhaust open period : 236°

Fuel Injection Pump : Cambox type fuel injection pump, mechanical
governor/Electronic governor.
Injection timing : 10° B.T.D.C

When No.1 piston at TDC compression stroke.
Fuel feed pump : Plunger type pump located on cam tunnel.
Driven by engine camshaft
Application : Genset
Engine Model Lube Oil Filter Coolant Element Air Fuel Filter
Capacity Part No Capacity Cleaner Element
(Ltr ) (Ltr) Part No Part No
X1.3G2 4.5 0122-0961 4.65 0140-4088 0149-2952
DE-RATING FOR ALTITUDE :

Where engines are called upon to operate in very high atmospheres occasioned by altitude. such engines
should be derated.
APPROXIMATE ENGINE WEIGHTS :
Basic weight (with starter motor & flywheel) : Approximate 148 kg
ENGINE DIMENSION :
Height : 635 Length : 565 Width : 470
* B.T.D.C. – Before Top Dead Center ** A.T.D.C. – After Top Dead Center

Issue 4 - 9 - 2011 Model:X 1.3
MANUFACTURING DATA AND DIMENSIONS
The following data of clearances and tolerances are given as a guide for personnel engaged in major overhauls
and the figures are those used in the factory for production purposes.
Cylinder Block
Height of cylinder block (Top to bottom faces) … 12.498 / 12.501 inch (317.45 / 317.55 mm)
Parent bore dia. for Cylinder Liner … 3.740 / 3.741 inch (95.00 / 95.02 mm)
Main bearing parent bore … 2.440 / 2.442 inch (62.00 / 62.03 mm)
No. 1 Bore for Camshaft … 1.930 / 1.931 inch (49.025 / 49.050 mm)
Balancer Shaft Bore Dia 1 and 2 ... 1.023 / 1.024 inch (26.00 / 26.02 mm)
Pistons :
Type … Pistons are of special light aluminium alloy with a re-
entrant bowl in the crown. Offset of combustion bowl in
piston crown should be to the FI Pump side while
assembling piston in engine. An arrow mark is stamped
on piston top surface for identification. Arrow should face
front of Engine.
Piston Height in relation to cyl. block top face… 0.0138 inch (0.35 mm) / 0.0019” (0.050 mm) Above block
surface
Bore Dia. for Gudgeon Pin … 1.1025 / 1.1027 inch (28.005 / 28.01) mm
Top ring Groove Width … 0.102 / 0.103 inch (2.59 / 2.61 mm)
2nd ring Groove Width … 0.1 / 0.100 inch (2.54 / 2.56 mm)
3rd ring Groove Width … 0.119 / 0.120 inch (3.03 / 3.05 mm)
Piston Rings
Top Compression … Chromium inlaid. Half Keystone
(Symetric barrel on periphery)
2nd Compression … Cast Iron. Taper land
3rd Oil Control … Conformable oil control ring
Piston Ring Width

Top and 2nd ring width ... 0.097 / 0.098 inch (2.47 / 2.49 mm)
3rd ring width … 0.117 / 0.118 inch (2.97 / 2.99 mm)
Ring clearance in Piston Groove :

Top ring clearance in Groove … 0.0039 / 0.0055 inch ( 0.10 / 0.14 mm)
2nd ring clearance in Groove … 0.0019 / 0.0035 inch (0.05 / 0.09 mm)
3rd ring clearance in Groove … 0.0015 / 0.0031 inch (0.04 / 0.08 mm)
Ring Gaps
Ring Gap – Top … 0.012 / 0.020 inch (0.30 / 0.50 mm)
Ring Gap – 2nd … 0.025 / 0.037 inch (0.65 / 0.95 mm)
Ring Gap – 3rd … 0.010 / 0.018 inch (0.25 / 0.45 mm)

Model: X 1.3 Issue 4 - 9 - 2011
NOTE :
The ring gaps given above are for when checking in the unworn portion of the cylinder bore.
When checking ring gaps in a worn bore. 0.003’’ (0.076 mm) should be added to these ring gaps for
every 0.011 inch (0.03 mm) increase in bore diameter
Gudgeon Pin
Type … Fully Floating
Outside dia. of gudgeon pin … 1.102 / 1.1025 inch (27.995 / 28.00 mm)
Fit in piston boss … Transition
Clearance fit in Small end Bush … 0.0011 / 0.0019 inch (0.03 / 0.05 mm)
Small End Bush
Type … ci Steel Backed. Lead Bronze Lined
Outside Dia … 1.220 inch (31.00 mm)
Length … 1.378 inch (35.00 mm)
Inside Dia after reaming … 1.151 / 1.155 inch (29.35 /29.35 mm)
Connecting Rod
Type … “I ” Section
Big end Parent Bore Dia … 2.008 / 2.0086 inch (51.006 / 51.019 mm)
Small end Parent Bore Dia … 1.220 / 1.221 inch (31.00 / 31.25 mm)
Big end Width … 1.244 / 1.248 inch (31.60 / 31.70 mm)
Big end side clearance on Crankpin … 0.012 / 0.020 inch (0.3 / 0.5 mm)
Length between bore centers … 5.825 / 5.827 inch (147.975 / 148.025 mm)
NOTE : The numbered side of connecting rod and cap should be on the fuel injection pump side.
Connecting Rod Bearings
Type … Pre-finished. Steel Backed low carbon steel
AluminiumTin/Silicon
Inside Dia. (Big end bearing) … 1.949 / 1.950 inch (49.53 / 49.52 mm)
Bearing Running Clearance … 0.0015 / 0.003 inch (0.04 / 0.079 mm)
Recommended sizes in service … 0.010" (0.25 mm); 0.020" (0.51 mm); 0.030" (0.76 mm)
Crankshaft
Material ... Chromium molybdenum alloy steel forging. Statically
balanced. Main journals and crank pins are induction
hardened.
Main Journal Dia. (Std.) … 2.282 / 2.283 inch (57.98 / 58.00 mm)
Crank pin Dia. (Std.) … 1.889 / 1.890 inch (47.98 / 48.00 mm)
Main Journal length - Nos.1 … 1.311 / 1.326 inch (33.30 / 33.70 mm)
Main Journal Length – No.2 … 1.338 / 1.341 inch (34.01 / 34.08 mm)
Main Journal Length – No.3 … 1.330 / 1.346 inch (33.80 / 34.20 mm)
Crankpin length … 1.260 / 1.264 inch (32.00 / 32.10 mm)
Main Journal fillet radii Nos. 1 … 0.098 / 0.118 inch (2.50 / 3.00 mm)
Main Journal fillet radious No. 2 and 3 … 0.098 / 0.118 inch (2.50 / 3.00 mm)
Crankpin fillet radii … 0.098 / 0.118 inch (2.50 / 3.00 mm)
Surface finish (all Pins and Journals) … 0.4 microns (Maximum)
Crankshaft end Float … 0.003 / 0.006 inch (0.07 / 0.15 mm)
Crankshaft rear end Seal … Lip Type
Regrind Under sizes. Main Journal
and Crank Pins … 0.010" (0.25 mm) ;0.020" (0.51 mm) ;0.030" (0.76 mm)

Issue 4 - 9 - 2011 Model:X 1.3
NOTE:
When regrinding the crank pin length should not exceed 1.5748 inch (40.00 mm) and the
rear main journal length should not exceed 1.8610 inch (47.27 mm) and Nos.2 and 4 main Journals
width should not exceed 1.2275 inch (31.1785 mm) maximum. The maximum permissible
undersize is 0.02 9 9 inch (0.76 mm)
Crankshaft Thrust Washers
Type … Steel Back - Low carbon steel - 1.8 mm incl. Aluminium
Tin (or) Copper Lead
Position in engine … Cylinder Block Centre Main Bearing Housing
Thickness-Standard Size … 0.105 / 0.107 inch (2.67 / 2.72 mm)
Thickness-Oversize … 0.1283 / 0.1303 inch (3.26 / 3.31 mm)
NOTE : While locating the Thrust Washers ensure that the plain surface Steel back is towards the
block and the rear main bearing cap.
Main Bearings
Type … Pre-finished. Steel Back low carbon steel. AluminiumTin/
Silicon or Copper Lead
Inside Dia. (fitted) … 2.362 / 2.363 inch (60.02 / 60.03 mm)
Running clearance … 0.0015 / 0.003 inch (0.04 / 0.079 mm)
Recommended size in service … 0.010" (0.25 mm) ;0.020" (0.51 mm) ;0.030" (0.76 mm)
Camshaft
Type … Chilled cast iron
No. 1 Journal Dia. … 1.927 / 1.928 inch (48.95 / 48.975 mm)
No. 2 Journal Dia. … 1.927 / 1.928 inch (48.95 / 48.975 mm)
No. 3 Journal Dia … 1.927 / 1.928 inch (48.95 / 48.975 mm)
Running Clearance – All Camshaft Journals … 0.002 / 0.004 inch (0.05 / 0.10 mm)
Oil way for cam shaft lubrication … From main oil gallary to centre cam journal
Cam Lift - Inlet … 0.393 inch (10 mm)
- Exhaust … 0.393 inch (10 mm)
Camshaft end float … 0.004 / 0.014 inch (0.10 / 0.35 mm)
Cylinder Head
Cylinder head total height … 4.410 inch (112 mm)
Leak Test … 4 Bar for 1 minute
Valve seat angle … Inlet 45° / Exhaust 45°
Permissible cylinder head bow
Transverse and Longitudinal … 0.001 / 0.002 inch (0.03 / 0.05 mm)
Valve Layout ... E, I, E, I
NOTE : Valve stem seal (with Sintered metal insert) is fitted in both inlet and exhaust valves.
Model: X 1.3 Issue 4 - 9 - 2011
Inlet and Exhaust Valves

Valve Stem Dia (Inlet) … 0.273 / 0.274 inch (6.95 / 6.97 mm)
Valve Stem Dia. (Exhaust) … 0.272 / 0.273 inch (6.93 / 6.95 mm)
Clearance fit of valve in guide (Inlet) … 0.0004 / 0.0015 inch (0.01 / 0.04 mm)
Valve face Angle (Inlet) … 45°
Valve face Angle (Exhaust) … 45°
Valve depth below cylinder head face … 0.015 inch (0.4mm)
Valve head Dia. Inlet … 1.590 / 1.598 inch (40.40 / 40.60 mm)
Valve head Dia. Exhaust … 1.492 / 1.500 inch (37.90 / 38.10 mm)
Valve Spring
Free length … 1.968 inch (50 mm)
Fitted length … 1.102 inch (28 mm)
Load at fitted length … 250 N (25 kg)
Tappet
Outside Dia. of Shank … 1.061 / 1.063 inch (26.96 / 27.00 mm)
Rocker Shaft
Outside Diameter … 0.629 / 0.630 inch (15.976 / 15.984 mm)
Rocker Lever
Bush Bore Diameter … 0.787 / 0.788 inch (20.00 / 20.02 mm)
Running clearance of Bush on Shaft … 0.011 / 0.002 inch (0.022 / 0.048 mm)
Timing Gears
Crankshaft gear … 20 Teeth
Idler gear … 25 Teeth
Camshaft gear … 40 Teeth
Fuel Pump gear … 40 Teeth
Balancershaft gear … 20 Teeth
Camshaft Gear
Gear Bore Diameter … 0.944 / 0.945 inch (24.00 / 24.013 mm)
Clearance fit of Gear on Spigot … 0.000 / 0.0019 inch (0.00 / 0.05 mm)
Idler Gear and Hub
Bore Dia of gear … 1.025 / 1.026 inch (26.040 / 26.061 mm)
Diameter of hub … 0.984 / 1.024 inch (25.00 / 26.00 mm)
Clearance of gear on hub … 0.002 / 0.003 inch (0.040 / 0.082 mm)
Gear Hub Width … 0.659 / 0.661 inch (16.75 / 16.80 mm)
Bearing length of hub … 1.6019 / 1.5940 inch (40.69 / 40.49 mm)
Gear end-float … 0.002 / 0.006 inch (0.060 / 0.140 mm)
NOTE : The bore and faces of bushes should be finished to the specified dimensions by
machining after pressing the bushes in the gear bore.
Issue 4 - 9 - 2011 Model:X 1.3
Crankshaft Gear
Diameter of Bore … 1.4996 / 1.5011 inch (38.090 / 38.13 mm)

Spigot Dia of crankshaft … 1.5005 / 1.5000 inch (38.113 / 38.10 mm)
Transition fit of Gear on Crankshaft … 0.011 / 0.0015 inch (0.03 / 0.04 mm)
Fuel Pump Gear

Diameter of Bore … 20 mm with taper bore
Pump adaptor Dia. … 1.8897 / 1.8887 inch (48.000 / 47.975 mm)
Clearance fit of gear on spigot … 0.0039 / 0.0022 inch (0.100 / 0.056 mm)
Timing Gear Backlash
All Gears … 0.002 / 0.005 inch (0.06 / 0.14 mm) (min.)
Lubricating Oil Pump
Oil Pump type … Lobe type
Number of inner rotor lobes … 9
Number of outer rotor lobes … 10
Balancer Shaft end float ... 0.003 / 0.006 inch (0.075 / 0.150 mm)
Lubricating Oil Pump Clearances

Inner Lobe to Outer Lobe … 0.0005 / 0.0025 inch (0.01 / 0.06 mm)
Inner Lobe end clearance … 0.0015 / 0.003 inch (0.04 / 0.08 mm)
Outer Lobe end clearance … 0.0005 / 0.0025 inch (0.01 / 0.06 mm)
Outer Lobe to Pump Body … 0.011 / 0.013 inch (0.28 / 0.33 mm)
Lubricating Oil Pressure at maximum engine
speed and normal working temperature … 3.5 kgf
Lubricating Oil Relief Valve

Type … Spring Loaded Plunger
1
Pressure Setting … 3.569 kgf / cm
Lubricating Oil Filter
Type … Spin on
Element … Replaceable Paper / Canister
By-pass Valve Setting … 12.94 / 17.06 psi (0.91 / 1.20 kg/ cm²)
Sump Capacity … 4.391 lts. Sump capacity vary according to application
Cooling System
Type … Water cooled
Coolant capacity–Engine only … 4 lts. (approximate)
Thermostat
Type … Wax
Opening temperature … 73° ± 2°C
Fully open … 83° ± 2°C
Water Pump
Type … Centrifugal
Pulley bore dia … 0.944 inch (24 mm)
Interference fit of pulley on shaft … 0.005 inch (0.121 mm)
Clearance between impeller blades and body ... 0.008 / 0.020 inch (0.2 / 0.5 mm)
Distance between impeller rear face to body … 3.929 inch (99.80 mm)

Model: X 1.3 Issue 4 - 9 - 2011
Fuel System
Fuel oil specification … Fuel Oil conform IS : 1460 / 2000 grade special
or Grade ‘A’
Fuel Filter Type … BOSCH single spin on with hand primer
Fuel Feed Pump … Plunger type flange mounted on cylinder block, driven
by cam shaft ecentric
Fuel Injection Pump

Make … BOSCH PF 30
Type … Individual
Mounting … Flange mounting on cam box
Drive … Gear
Pump Rotation … Anticlock wise (when viewed from fly wheel end)
Governor … Mechanical external
Starter Motor
Make … LUCAS TVS
Type … Gear Starter
No. of teeth on pinion … 10
Rotation … Clockwise when viewed from fly wheel end
No. of teeth on flywheel … 164
Note : The above electrical data is general and can vary with individual application

Issue 4 - 9 - 2011 Model:X 1.3
RECOMMENDED TIGHTENING TORQUES

Nm lbf.ft Thread Size Spaner Type
size (mm)
Cylinder head setscrew 165 122 (M14 x 1.5) 19 Ring/Socket
Connecting rod bearing cap nuts 65 48 (M10 x 1.0) 14 Ring/Socket
Main bearing cap bolts 170 125 (M14 x 1.5) 19 Ring/Socket

Balancershaft bearing cap bolts 33 24 (M 8 x 1.25) 12 Ring/Double
Idler gear hub bolt 105 78 (M14 x 1.5) 19 Ring/Socket
Camshaft gear retaining bolt 110 81 (M12 x 1.75) 17 Ring/Socket

Balancershaft gear retaining bolt 105 78 (M12 x 1.75) 17 Ring/Socket
F.I. pump gear retaining nut 105 78 (M14 x 1.5) 19 Ring/Socket
Camshaft thrust washer retaining bolt 12 9 (M 6 x 1.0) 10 Ring/Double

Camshaft rear end cover plate retaining bolt 33 24 (M 8 x 1.25) 12 Ring/Double
Flywheel mounting bolts 110 81 (M12 x 1.75) 17 Ring/Socket
Crankshaft pulley retaining setscrews 110 81 (M12 x 1.75) 17 Ring/Socket

Front cover retaining bolt 33 24 (M 8 x 1.25) 12 Ring/Double
F.I.P gear inspection cover retaining bolt 7 5 (M 6 x 1.0) 10 Ring/Double
Oil filler / Timing pointer retaining bolt 7 5 (M 6 x 1.0) 10 Ring/Double

High pressure fuel pipe nuts 25 19 (M 12 x 1.5) 17 Ring/Socket
Atomiser securing nuts 55 40 (M 24 x 1.5) 24 Ring/Socket
Low pressure fuel pipe banjo bolts 20 15 (M14 x 1.5) 19 Ring/Socket
FIP Cambox mounting bolts 40 30 (M 8 x 1.25) 12 Ring/Double
Fuel Injection Pump mounting bolts 40 30 (M 8 x 1.25) 12 Ring/Double
FIP inlet banjo bolt 20 15 (M12 x 1.5) 17 Ring/Socket
Fuel lift pump mounting nuts 12 9 (M 6 x 1.0) 10 Ring/Double
Rocker assembly mounting nut 40 30 (M10 x 1.5) 14 Ring/Socket
Cylinder head cover domed nu t 55 40 (M 8 x 1.25) 12 Ring/Double
Water pump mounting bolts 15 11 (M 6 x 1.0) 10 Ring/Double
Water outlet connection retaining bolt 60 44 (M10 x 1.5) 15 Ring/Socket
Intake manifold bolt 33 24 (M 8 x 1.25) 12 Ring/Double
Exhaust manifold nut 40 30 (M 8 x 1.25) 12 Ring/Double
Rear end oil seal housing mtg bolts 40 30 (M 8 x 1.25) 12 Ring/Double
Sump mounting bolts 35 26 (M 8 x 1.25) 12 Ring/Double
Oil suction pipe retaining bolt 7 5 (M6 x 1) 10 Ring/Double

Model: X 1.3 Issue 4 - 9 - 2011
Section D
OPERATION AND MAINTENANCE
PREPARATION FOR STARTING
Check the coolant level with radiator.
Check the oil level in engine sump.
Check the fuel oil level in the tank
Check the battery is fully charged and that all

electrical connections are properly made and all
circuits in order.
STARTING THE ENGINE

POST-DELIVERY CHECKOVER
If the engine is warm, turn starter switch in a
clockwise direction to the “Heat and Start” position After a customer has taken delivery of his genset
engine, it is advisable, a general check-over of the
As soon as the engine starts, release the switch to engine be carried out after the first 25 hours in
the “ON” position. service.
TO STOP THE ENGINE It is also recommended that the following procedure
be adopted where an engine has been laid up for a
1. Rotate the stop knob and hold until the Engine considerable period before it is again put into
ceases to rotate. service.
2. After releasing the stop control knob, ensure 1. Drain lubricating oil sump and re-fill up to the
that it returns back to the run position. full mark on the dipstick with new clean oil
3. When using the shutt-off device ensure the (Do not overfill).
device fully rotates the stop control knob and 2. Renew the lubricating oil filter (canister).
return back to its position.
3. Check external nuts for tightness.
Note: Always ensure that the starter pinion has
4. Check/ adjust valve tip clearances to to inlet
stopped revolving before re-engaging the starter,
and exhaust valve in cold. 0.010 inch
otherwise the ring or pinion may get damaged.
(0.25 mm) for inlet and 0.012 inch (0.30 mm)
RUNNING-IN PROCEDURE for exhaust value.
It is not necessary to gradually run-in a new engine 5. Check fuel pipes from tank to fuel injection
and any prolonged light load running during the early pump for leaks.
life of the engine and in fact prove harmful to the 6. Check for lubricating oil leaks and rectify if
bedding in of piston rings and liners. necessary.
Full load can be applied on a new engine as soon 7. Check hose clips for tightness.
as the engine is used, provided that the engine
8. Check cooling system for leaks and inspect
coolant is first allowed to reach a temperature of at
radiator water level.
least 167 O F (75 O C).
9. Check fan belt for tension.
10. Carry out test to check general performance
of engine.
11. Check engine mounting bolts for tightness.
12. Check the electrical equipment such as rate
of charge, effectiveness of connections and
circuits, etc.
Thereafter maintenance periods should be in
accordance with the instructions given.
(Ref. Section E).

Issue 4 - 9 - 2011 Model:X 1.3
PRESERVATION OF LAID-UP ENGINES

FROST PRECAUTIONS
It is recommended that the following procedure Precautions against damage by frost should be
be adopted and applied immediately the unit is taken if the engine is to be left exposed to inclement
withdrawn from service: weather either by adequately draining the water
1. Thoroughly clean all external parts of the system or where this is not convenient an anti-freeze
engine. of reputable make and incorporating a suitable
corrosion inhibitor may be used.
2. Run the engine until well-warmed. Stop the
engine and drain lubricating oil from sump.
When draining the cooling system ensure that the
Remove the oil filter.
engine is in level.
3. Drain coolant from radiator and engine cylinder
block. Operators are advised to take precautions when
operating in temperatures below freezing point:
4. Replace the oil filter, fill sump to correct level
with clean, new lubricating oil or with a suitable 1. Before starting the engine, turn the fan and
preservative fluid. water pump by hand. If freezing has taken
place, this should free any ice formation.
5. Remove atomisers and spray into cylinder
bores 100 ml of lubricating oil divided between 2. If it is impossible to turn the pump by hand,
the cylinders. the radiator and engine should be filled with
6. Turn engine slowly over compression and warm water.
replace atomisers. After an anti-freeze solution has been used, the
7. Remove air cleaner intake pipe and Remove cooling system should be thoroughly flushed in
exhaust pipe and seal opening in manifolds. accordance with the manufacturer’s instructions
before refilling with normal coolant.
8. Disconnect battery and store in fully charged
condition. Before storing the battery, terminals
should be treated to prevent corrosion.
The fuel system to be drained or charged with a

suitable preservative designed for the prevailing
climatic conditions or alternatively, it may be left
primed with normal fuel oil.
If the engine is laid for several months then the fuel

oil contained in the remainder of the fuel system
should also be dispelled and the fuel filter renewed,
following which the system may then be recharged
with fresh clean fuel oil.
Before starting, the engine should be cranked over

by the starter motor with the stop control in the ’off’
position until oil pressure is recorded or the oil
warning light is extinguished. Do not rapidly
accelerate the engine after initial start; allow it to
run at slow speed for approximately two minutes to
ensure good oil circulation before accelerating to
higher speeds.
Note: Where a preservative is used in the lubricating

oil sump, this should be drained off and replaced
by normal lubricant prior to restarting the engine at
the end of the storage period.
Model: X 1.3 Issue 4 - 9 - 2011
MAINTENANCE SCHEDULE & MANDATORY CHECKS FOR X1.3 ENGINE

SYSTEM A – Check B – Check C – Check D - Check
GROUP Daily Every 475 – 500 Hrs Every 1450 – 1500 Hrs Every 4800- 5000 Hrs
OR 6 months, which is OR 12 months, which OR 24 months, which is
earlier is earlier earlier
LUBRICATION ▪ Check Lube oil level & ▪ Repeat A Check ▪ Repeat B Check. ▪ Repeat C Check
SYSTEM top-up Lube oil upto ‘H’ ▪ Change Lubrication Oil * Check visually for ▪ Measure Blow Bye .
mark on Dipstick * Use only CH4-15W40 metal particles in ( Max. -- inches of H2O
* Use only CH4-15W40 Lube Oil used Lube Oil Water column with
Lube oil ▪ Change Spin-on Lube -------- inches Dia
Oil Filter. Orifice )
▪ Change Lubrication oil
In Cambox ( FIP ).
COOLING * Check for leaks. Rectify ▪ Repeat A Check ▪ Repeat B Check. ▪ Repeat C Check
SYSTEM leak if found any. ▪ Check Fan Drive ▪ Check condition of ▪ Change Belt, Fan Drive
* Check Coolant level in arrangement. Hoses & clamps. ▪ Change Coolant &
Radiator (Caution : Do *Check Belt for Replace if necessary. fill Radiator with
not remove Cap when looseness. Tighten if * Check sealings around Premix coolant only
hot ) required Radiator
* Check Coolant level in ▪ If required,clean dust
Tank, coolant.. If on Core of Radiator by
required, fill Premix very very low pressure
Coolant only in the Tank, of Air. ( 0.2 Kg / cm 2 )
coolant up to H mark. * Check Cap,radiator for
. seal. Change the Cap
if required.
FUEL SYSTEM * Check for fuel leaks. ▪ Repeat A Check ▪ Repeat B Check. ▪ Repeat C Check
* Rectify leak if any. In ▪ Change Spin-on Fuel ▪ Check all joints in Fuel ▪ Change Fuel Hoses if
case of leak at Banjo, Filter Lines & tighten. Required
change the Copper * Clean Fuel tank inlet * Calibrate Nozzles &
Washer strainer Cambox ( FIP ) at
▪ Drain Sediments from BOSCH service
Fuel Water Separator centre.
AIR ▪ Check Indicator Service ▪ Repeat A Check ▪ Repeat B Check ▪ Repeat C Check
SYSTEM for Air Restriction ▪ Clean Element, Air * Change the Element, * Measure exhaust Back
( Red Band indication ). Cleaner, if required Air Filter pressure. Should not
* Clean Element, Air * Check Hose & Clamps. exceed 3” of Hg. Take
Cleaner in reverse * Check indicator corrective action as
direction of Air flow, Service, for its proper required.
using dry air with max function.
0.5 kg / cm2 pressure
▪ Check sealing &
condition of Air Cleaner

Issue 4 - 9 - 2011 Model:X 1.3
Note: All daily maintenance checks can be carried out by the operator whereas weekly (and above) are to be
done
by a Specialist only.
* Belt tension to be checked by ”skilled” service engineer only..

Model: X 1.3 Issue 4 - 9 - 2011
Section E
FUEL SYSTEM • Do not disturb the assembly – Throttle lever
CAM BOX TYPE FUEL INJECTION setting screw and supplementary idling device.
PUMP (FIP) • Do not disturb DV holder while loosening cap
TO CHECK & RESET FIP TIMING nuts. Ensure DV holder is firmly held while
Procedure : removing cap nuts of HP pipe.
• Measure the height of the Pump seating surface Note : FIP is to be tested at Bosch FIP test rig.
from the Tappet face by keeping the tappet at Follow the FIP test value for fuel delivery as
BDC. Use the BDC checking gauge for the per chart given by SIMPSON.
purpose. Spill Timing Setting
• Select the Shim according to match the height • Use the Spill timing setting equipment and obtain
of Pump face from the tappet face as the value 10° ± 1° BTDC while setting the
60 ± 0.05 mm. Standard shims of thickness cambox on the engine.
0.5/0.3/0.2 & 0.1 mm are available for the
purpose • Please ensure the pressure on the timing setting
equipment is 25 bar (Range 20 – 25 bar), while
• Ensure the Shim thickness should not exceed setting the spill.
1 mm.
• While making the spill check, fuel droplet rate
• Fix the Pump on Pump seating face alongwith should be 10 drops per minute.
the selected shim, keeping the pump pin
between control lever fork slots and tighten the Note : Please do not remove the delivery
bolts. Keep the Fuel shut-off lever in the “Off” valve from FIP While setting the Spill cut off.
position (for ease of assembly).
Fig. F1(a)
Fig. F1
1. Hex Flange Bolt
2. FIP (PF Pump MICO PT No. E 041 159 100)
3. Roller Tappet (MICO PT. No. 3 418 700 010)
4. Pump Shim
Issue 4 - 9 - 2011 Model:X 1.3
Model:
TO REMOVE THE FIP CAM BOX
1. Disconnect the battery terminals.
2. Disconnect the throttle linkages.
3. Remove flexible hose.
4. Turn the engine and bring No. 1 cylinder piston

to T.D.C. on compression stroke, marking on
the crankshaft pulley to be aligned with
pointer. Check that the No. 1 cylinder push
rods are free to rotate.
5. Disconnect the flexible hose from air cleaner Fig. F1

to induction manifold pipe.
6. Remove the high pressure pipes and blank

off all ports against the ingress of dirt. (Fig.
F1)
7. Keep a tray below FIP and remove the flexible

fuel pipe from FIP.
Fig. F2
8. Loosen and remove the screws (Fig. F3)

securing inspection cover on to the timing
case cover. Remove the Inspection cover.
Fig. F3
9. Hold the flywheel with suitable wrench,

Loosen and remove the nut (Fig. F4) and
washer securing the gear to the FIP camshaft.
CAUTION: Great care must be exercised in

removing nut and washer, if dropped into the
timing case the timing case cover has to be
removed for recovering.
Fig. F4
Model: X 1.3 Issue 4 - 9 - 2011
SUB ASSEMBLY - F.I.P. CAMBOX
4
1
5
6
1 0306-5454 CAM-DRIVE (ASSLY)

2 0541-1750 GASKET KIT(CAM BOX)
3 0149-2956 SUB ASSLY SIDE COVER CAM BOX
4 0149-2957 JOINT CAM BOX MOUNTING
5 0150-3011 ELECTRONIC GOVERNOR
6 0306-5449 ASSLY LINKE GOVERNOR
7 0123-2450 GASKET OIL FILL
8 0130-8528 TUBE FILL

Issue 4 - 9 - 2011 Model:X 1.3
11. Loosen and remove the four screws (Fig. F7)

and washers securing the flange of the FIP
to the timing case.
12. Using the universal puller/ suitable bolts

remove the FIP gear as shown (Fig. F8).
13. Loosen and remove the FIP Cam box rear

support mounting screw (Fig. F9).
14. Remove the Fuel Injection Pump Cam box.
CAUTION : After the removal of FIP Gear,

Fig. F7
don’t rotate the crankshaft.
TO FIT THE FUEL INJECTION PUMP WITH CAM

BOX
1. Ensure No.1 cylinder piston is in TDC at the
end of Compression stroke.
2. Turn / Ensure the FIP Camshaft key is in 10

O’ clock position.
3. Insert the FIP Cam box into the timing case.
CAUTION: While installing the FIP Cam box,

Fig. F8
the key should be properly engaged otherwise
it may fall inside the timing case!!
4. Screw the four screws (Fig. F8) with washers

and tighten the screws to torque 30 lbf.ft
(40 Nm).
5. Install the FIP gear, ensuring the FIP gear

key way is inline with the shaft key and timing
marks are alinged.
6. Position the washer and screw the nut on the

FIP drive gear and tighten to the torque of Fig. F9
105 Nm (75 lbf ft)
7. Fit the FIP Cam box rear support mounting

screw (Fig. F9).
8. Refit the inspection cover.
9. Refit the tappet cover and breather hose.
10. Connect the air intake pipes.
11. Bleed the fuel system and start the engine

and check the engine performance.
Fig. F10

Model: X 1.3 Issue 4 - 9 - 2011
INJECTOR ASSEMBLY
a
To Remove
1. Loosen the cap nuts and remove the high

pressure pipes. (If required identify the
respective pipes)
2. Disconnect the flexible fuel return pipe (a)

from leak off pipe (Fig. F11).
3. Loosen the banjo bolts (Fig. F12) securing

leak off pipe to the injector. Remove the
banjo bolt and leak off pipe.
Fig. F11
4. Loosen the nut securing the injector on the
cylinder head and remove the injector and
washer (Use 24 mm tubular spanner). (Fig.
F13)
WARNING:- Cover the fuel pump delivery

ports and injector ports against the ingress of
dirt with suitable protective caps.
WARNING:- Adequate tightness to be verified

on all fuel banjos from feed pump to fuel filter
inlet, outlet and it cambox.
Adequate tightness to be verified on feed pump Fig. F12
fuel inlet banjo to avoid fuel starvation.
To Fit
1. Align the injector dowel pin (a) with cylinder

head hole slot and insert the injector on to
the cylinder head hole with securing nut, new
seal washer in position. (Fig. F14)
2. Screw the injector securing nut and tighten

to torque: 55 Nm (40 lbs.ft)
3. Fit the leak off pipe with new washers to

injector. Tighten the banjo bolts.
Fig. F13
4. Fit the high pressure pipes.
5. Connect the flexible fuel return pipe to leak

off pipe.
6. Bleed air from high pressure pipes.
7. Start the engine and check for fuel leakages,

and performance.
Fig. F14

Issue 4 - 9 - 2011 Model:X 1.3
FUEL LIFT PUMP (Feed Pump)
To Remove
1. Close the fuel tank cock. If, fuel tank is above

engine level.
2. Disconnect the fuel pipes from the fuel lift

pump (Fig. F15).
3. Loosen the 3 mounting screws (Fig. F16) and

remove the fuel lift pump.
Fig. F15
To Fit
1. Ensure that the camshaft lobe (Fig. F17) is

in the minimum lift position.
2. Clean the matting surfaces of the lift pump

and cylinder block. Fit the lift pump with new
joint.
3. Screw the setscrews and tighten them

gradually and evenly to 9 lbf.ft (12 Nm).
4. Connect the fuel pipes and bleed air from fuel

system before starting the engine.
Fig. F16
Fig. F17

Model: X 1.3 Issue 4 - 9 - 2011
DISMANTLING OF ‘E’ CAMBOX
1. Remove oil filler tube from cam box.
2. Remove overflow pipe from cam box
3. Drain the oil from cam box.
4. Disconnect the governor linkage from .

governor plate.

Issue 4 - 9 - 2011 Model:X 1.3
5. Remove the governor plate from rod end

bearing
6. Screw out the link operating rod.
7. Remove three setscrews and take out the

mounting bracket along with governor
8. If required governor can be removed from the

mounting bracket by removing four setscrews.
9. Loosen slowly & evenly, two setscrews holding

each fuel injection pump & remove them.

Model: X 1.3 Issue 4 - 9 - 2011
10. Take out fuel injection pump along with

respective shim.(If required identify the
respective pumps)
11. Remove the roller tappets from cam box.
12. Remove the side cover & inspect the parts

inside.

Issue 4 - 9 - 2011 Model:X 1.3
13. Remove six setscrews & take out the drive

end (front end ) cover with seal and bearing.
14. Pull out the cam shaft wit h bearing. Inspect

cam lobes & ball bearing fo r any wear & tear.
NOTE :
• FIP cambox with electronic governor on engines are to be filled with 200 ml
of lubricating oil CH4 15W40 seperately through oil filler provided on cam box.
• Drain plug also provided at the bottom of cambox to drain the oil.
• lubrication oil return pipe from Cam box to Sump should not be disturbed during
CAUTION :

Model: X 1.3 Issue 4 - 9 - 2011
ASSEMBLING OF ‘ E ‘ CAMBOX
1. Thoroughly clean & inspect all the components
before assembling the cam box assy. Replace
the parts like seal & bearing if found worn out.
2. Press the ball bearing on camshaft end journal.
3. Assemble the camshaft into the cambox after

slightly oiling the bearing seating journal.
4. Replace the oil seal in front cover and press

the ball bearing in its position.

Issue 4 - 9 - 2011 Model:X 1.3
5. Fix the joint with sealing compound to the

cover.
6. Assemble the front cover to the cam box after

slightly oiling the seal lip & tighten the set
screws evenly.
7. Assemble the side cover with joint to cam box

after ensuring that control rod, spring retainer
& fork control rod, stop lever are in proper
working order.
8. Drop the roller tappets in its correct position.
9. To fit fuel injection pumps & to reset the FIP

timings refer section ‘F’ under caption, check
& reset FIP timings

Model: X 1.3 Issue 4 - 9 - 2011
10. Screw in link operating rod to control rod &

assemble the rod end bearing
11. Connect the governor plate to rod end bearing

and governor.
12. Fit electronic governor & mounting bracket at

the cambox rear side using three set screws.
13. Refit oil filler tube & over flow pipe.

Issue 4 - 9 - 2011 Model:X 1.3
Calibration Procedure for E
Cambox on FIP Test Bench

1. Assemble both the FIPs in the Cambox
ensuring the BDC Dimension of 60+/–
0.05 mm. Connect the pipe required for test
bench with test injector No. 0681343009 with
opening pr: 172 to 176 bar.
2. Fill up 200 ml of CH4 15W40 grade oil in cam

box during test. Ensure Plug-Oil Drain to Part
No.: SK004433 is fitted on the cam box prior
to Oil filling.
3. Run the pump after removing Air Lock, get

the maximum delivery equal in both the pump
by setting at 30.5 ml/500 stroke in each pump.
(To achieve this place the pumps such that
they are located midway in the slots).
4. Push the linkage to max fuel position of

(Control Rod) and note the reading.
5. Place the actuator on the bracket, rotate the

actuator shaft to minimum fuel position and
pull the link to the minimum fuel position. Now
tighten the governor plate setscrew.
Note :
1. While tightening the linkage, ensure no

movement is lost due to slackness. The
linkage should be free and should move
smoothly.
2. FIP to Part No. SK003819 (BOSCH Part No.

E 041 159 100) to be used.
3. Test Fluid is as used on FIP Test Rig.
Testing Procedure of engine with

E Cambox fitted
1. Assemble the Cam Box on the engine, check
the spill specification (10 degree " 1 E).
2. Load the engine in test bed and connect L

series tool kit Wood Ward No. 8923 1061
between laptop or computer with serial port.
3. Set for 1500 RPM and 80 percent on the fuel

limiting percentage of the set delivery, then
run the engine.
4. If the load is not achieved, increase the fuel

limiting percentage in steps of % so as to
obtain the required load, fuel time and smoke.
5. Checkthe engine performance for 25%, 50%,

75%, 100% Load.
Model: X 1.3 Issue 4 - 9 - 2011
Woodward make actuator (Position controller) being fitted to Fuel Injection pump assembly of X1.3 Engines
(Genset application) to Govern the engine speed in place of the mechanical governor. The microprocessor-
based bi-directional actuator is mounted on to the bracket fitted to the cam box housing and the control rack
is connected to the actuator shaft by means of linkages. The terminals are connected to the Magnetic pick up
(Speed sensor) fitted on to the flywheel housing and powered by 12V DC supply).
A Magnetic pick up (for sensing engine speed) is fitted on to the flywheel housing and connected to 12V DC
supply through main switch. The signals induced in the Magnetic Pick up is sent to the Actuator (Position
controller) and the engine speed is monitored. If there is any change in the set engine speed due to load
fluctuations, the actuator pushes / pulls the FIP control rack to increase or decrease the fuel delivery and
maintains the engine speed.
1. Woodward Actuator (Position controller –

Integrated with PID and stepper motor).
Cummins part no 0150-3011 (Fig. F1)
Fig. F1
2. Magnetic Pick up unit fitted on to the flywheel
housing (Fig. F2).
Fig. F2
3. FIP cam housing with Actuator (Position Oil filler

Controller) connected to the operating rack
(Fig. F3)
4. Oil supply to cam box for lubrication of FI
pumps, camshaft and bearings is through
external filling of 200 ml CH4 15W40 lub oil
(Fig. F3)
A drain plug provided in cam box for oil drain.
Oil drain
Fig. F3
5. Engine with Actuator (Position

controller) fitted to the FIP assembly (Fig. F4)
The procedure for removal & re-fitment of FIP
assembly on to the engine remains same as
described in section ‘F’ of workshop manual
except for :
Un plugging / plugging the electrical socket
from the Actuator.
Fig. F4
Issue 4 - 9 - 2011 Model:X 1.3
Installation of EPG actuators is easy as they require neither mechanical drive nor hydraulic
supply.
Woodward Governor (Cummins Part No : 0150-3011).
Step 1: Fix the bracket support on the genset.
Step 2: Mount the Actuator on the bracket. Ensure that there

is no relative movement between the actuator and the
bracket.
Step 3: Engage the fuel rack with the fuel pump.

Model: X 1.3 Issue 4 - 9 - 2011
Step 4: Subsequently, connect the engine harness to the

governor.
After all the connections are complete, make the
connections for the battery.
Once powered up, the control will be at minimum position by

default.
Step 5: Align the fuel rack at its minimum position and fix the
linkage. The fuel rack pulled at the extreme right can be verified as
its minimum position.
Step 6: Turn the power off and check if the assembly is free.

Issue 4 - 9 - 2011 Model:X 1.3
Woodward Governor: is an Electrically Powered Governor (EPG).

An EPG is a three component system requiring a magnetic pickup, speed control and actuator.
Calibration Process of the governor:

The PC based tool required for Woodward controller calibration is ‘L-Series service tool’.
This tool is available for free download on the Woodward site.
It is available on the software shelf for Cummins Group users.
The setup details for connecting the controller to the tool can be shown as follows:
The controller is connected to the serial com port of the computer with the help of the Governor
Calibration kit and a straight through cable. It is a straight wire communication cable with a 9-pin
type connector on one end and a socket type connector on the other end.
Part Description Part No

Woodward actuator 0150-3011
Governor Calibration Kit 0338-4987 (CPG Fridley)

Model: X 1.3 Issue 4 - 9 - 2011
Click on the ‘L-Series service tool’ icon to start it.
On start-up, the first screen on the service tool is as shown below:

Issue 4 - 9 - 2011 Model:X 1.3
The calibration process involves two steps:
1. To load the configuration file on the control:

The configuration file contains a copy of all the parameter values, history and faults.
In order to open the configuration file for a particular genset;
• Go to File/Open Configuration File.
• The selected file will be opened.
The configuration file editor looks like as shown below:
• The default gain setting values are as shown above.

• In order to load the file on the control, go to File/Load to control.
• The selected file will be loaded on to the control.
2. The second step in the calibration process is to do the Governor Position

Calibration.
• Once powered-up the control will be at minimum position by default.
• Align the fuel rack at its minimum position and fix the linkage on control shaft.
• Turn the power off and check if the assembly is free.

Model: X 1.3 Issue 4 - 9 - 2011
Auto Position Calibration: The automatic calibration mode is selected to set the minimum
position and fail direction and to calibrate the valve to the user physical stops.
After the settings are performed the control moves from one stop position to another to
get the physical minimum and maximum positions.
With the controller powered up and connected to the service tool, the position calibration
can be done as follows:
• Select the Tools/Position Calibration/Automatic menu.
• A warning will be displayed to ensure the engine stop state as shown below:
A screen indicating the auto calibration, as shown below will appear:
• Recycle the power once the process is complete.

Issue 4 - 9 - 2011 Model:X 1.3
Section F
COOLING SYSTEM – WATER PUMP

TO REMOVE AND REFIT FAN - (SEC - G1 - 34)
1. Loosen and remove the set screws (Fig. G1-

1
34) securing the fan and remove the fan.
2. Clean the fan thoroughly. Renew, if defective.
3. Fit the fan. Tighten the set screws to 9 lbf.ft

(12 Nm). Ensuring the side marked as engine
side face the water pully ensure the side
marked as engine side faces the water pump
pully. Fig. G1
NOTE : While fitting the fan. If wrongly

fitted engine will get overheated.
TO REMOVE WATER PUMP - (SEC - G2 - 34)
1. Drain the coolant by removing drain plug from

engine and radiator.
2. Remove Fan.
3. Slacken fan belt tensioner adjusting screw

and remove fan belt.
4. Loosen the hose clips and disconnect water

pump inlet and by-pass hoses (Fig. G2).
Fig. G2
5. Loosen the water pump mounting setscrews
(Fig. G3) and remove the water pump
alongwith setscrew.
Inspection
Check the water pump for any damage or wear.
Check the bearing rotation for sluggish and

noisy movement.
Check the seal for wear / damage.
Replace the water pump kit or water pump

assembly as necessary.
NOTE : If seal is damaged coolant will Fig. G3

leak through the tell - tale hole.
NOTE: The water pump shaft and bearings
are integral as one component and cannot
be dismantled.
To Dismantle Water Pump
1. Remove the water pump pulley using a

suitable puller (5).
2. Press the water pump shaft complete with

bearings and impeller with suitable drift. Press
the shaft from the impeller side.
3. Remove the unitised seal from the shaft.
Fig. G4

Model: X 1.3 Issue 4 - 9 - 2011
Section G
FRONT OIL SEAL & SUMP
CRANKSHAFT PULLEY
To remove - (SEC - H1 - 35)
1. Remove the fan belt.
2. Lock the flywheel so as to avoid the engine

rotation. Fig. H1
3. Loosen and remove the bolt mounting the

pulley on the crankshaft. (Fig. H1)
4. Pull the pulley out of crankshaft, if required

use suitable puller as shown. (Fig. H2)
5. Clean the components and check for damage.

Renew damaged components.
To Refit - (SEC - H2-35)
1. Lubricate the timing case cover oil seal lip

with clean engine oil.
Fig. H2
2. Lubricate the crankshaft pulley mounting bolt
threads. Rear Front
3. Position the pulley on the crankshaft with key

way aligned.
NOTE : The pulley should be positioned

with the centre projection facing timing
case cover side.
4. Screw the bolt along with washer and tighten

gradually to torque 81 lbf.ft ( 110 Nm).
5. Fit the fan belt and adjust the tension.

(Fig. H4) Fig. H3
OIL FILLER AND BREATHER ASSEMBLY
To Remove - (SEC - H3-35)
1. Remove the dip stick.
2. Loosen and remove the oil filler securing bolt.
3. Remove the breather assembly.
Fig. H4
Issue 4 - 9 - 2011 Model:X 1.3
FRONT COVER ASSEMBLY
Fig. H5
1. Front Cover FIP
2. O - Ring (FIP Front Cover)
3. Bracket Timing Pointer
4. Assembly - Front Cover (with Oil Pump)
5. Oil Seal Front Cover
6. Suction Pipe Assebly
7. Assembly oil filter with breather.

Model: X 1.3 Issue 4 - 9 - 2011
To Renew the Crankshaft Front Oil Seal -

(SEC - H4-35)
1. Remove the crankshaft pulley. (Refer Sec.

H1-35)
2. Carefully pull out the oil seal from the timing

case cover using a suitable drift.
3. Clean the timing case cover seal area.
4. Position the new seal in the timing case cover

with the lip of the seal towards the inside of
the timing case cover. Fig. H6
5. Press the new seal in position using a
(SER 012/013) special tool to ensure the seal
is square in the bore of the cover. (Fig. H6)
6. Remove the special tool. (Fig. H7)
7. Fit the crankshaft pulley. (Refer - SEC -

H2 - 35)
SUMP
To Remove - (SEC - H5 - 37)
1. Operate the engine until it is warm. Fig. H7
2. Remove the dipstick a (Fig. H8).

3. Loosen and remove the sump drain plug a
(Fig. H8) and “O” ring
4. Drain the oil completely.
5. Loosen and remove the setscrews (Fig. H9)
which fasten the sump to the cylinder block
rear oil seal housing and front cover.
6. Remove the sump and the joints.
7. Clean the sump and drain plug.
8. Clean the mating face of the sump and of the
Fig. H8
cylinder block.
To Fit - (SEC - H6 - 37)
1. Position the sump together with a new joint

and ensure the correct location with a
setscrews on each side.
2. Fit the remainder of the setscrews and tighten
them to torque 33 Nm (24 lbf ft) .
3. Fit the drain plug together with a new “O” ring
and tighten the plug to 35 Nm (26 lbf ft).
4. Fit the dipstick.
5. Fill the sump to the “MAX” level on the dipstick Fig. H9
with approved lubricating oil.

Issue 4 - 9 - 2011 Model:X 1.3
To Remove Timing Case Cover - (SEC - H7 - 38)
1. Drain the lubricating oil from the sump.
2. Remove the fan, fan belt and belt tensioner

pully. (Fig. H10)
3. Remove the crankshaft pulley.

(SEC - G1-34)
4. Remove the oil filler with breather assembly

and sump. (Fig. H11)
5. Loosen the screws fixing timing case cover Fig. H10

to case and remove the timing case cover.
(Fig. H12)
NOTE: The oil pump is mounted inside the

timing case, care must be taken while
removing / refitting the timing case.
INSPECTION
1. Check the front case for cracks and damages,

replace if necessary.
2. Replace the oil seal if found worn out or

damaged / lips worn. Fig. H11
To Replace the Timing Case Cover -

(SEC H8-37)
1. Clean the joining faces.
2. Position the new joint on to the timing case

and apply sealant.
3. Replace the cover taking care not to damage

the front crankshaft oil seal. Ensure the proper
alignment of oil pump drive lug with the flat
milled on crankshaft.
Fig. H12
4. Centralise the cover around the crankshaft
by using the centralizing tool.
5. Fit the timing case cover fixing screws.
6. Refit the crankshaft pulley. (SEC - H2 - 35)
7. Refit the sump and oil filler pipe. (SEC -

H6 - 37)
8. Replace the tensioner, pulley, fan belt and

adjust fan belt tension.
9. Refit the oil filler with breather assembly.
10. Refill the lubricating oil.

Fig. H13

Model: X 1.3 Issue 4 - 9 - 2011
Section H
FLY WHEEL AND REAR END OIL SEAL
FLY WHEEL
To Remove (SEC - I 1 - 39)

1. Remove the startor motor assembly.
2. Disconnect the generator from the engine
3, Remove the fly wheel cover.
4. Rotate the crankshaft and bring pulley TDC
mark inline with the pointer.
5. Loosen the setscrews (Fig. I 1 - 41) uniformly.
6. Remove the setscrews. Fig. I1
7. Gently tap the flywheel with mallet hammer
and remove the flywheel carefully
To Fit Flywheel and Check Alignment
(SEC - I 2 - 39)
1. Inspect flywheel ring gear for wear / damages.
Replace, if necessary.
2. Ensure the flywheel and crankshaft flange is
clean and free from burrs.
3. Position the flywheel on the crankshaft.
Ensure the projection ( ) in flywheel at the
bottom and crankshaft pulley mark inline with Fig. I2
the pointer as shown.
NOTE: The flywheel can be fitted with the
crankshaft in only one position.
4. Screw in the setscrews ( ) complete into the
flywheel holes and tighten setscrews evenly
to torque 81 lbf.ft (110 Nm).
5. Secure the base of the dial gauge to the
flywheel housing and set the needle of the
gauge on the flywheel periphery.
6. Turn the crankshaft and check the dial guage,
the flywheel should run truly within 0.30 mm
(0.012”) - (total indicator reading). Fig. I3
Note : Ensure alignments end torque of related

fasteners while connecting alternator to the
engine flywheel housing.

Issue 4 - 9 - 2011 Model:X 1.3
FLY WHEEL AND REAR END OIL SEAL
Fig. I 4
1. Dowel - Rear Housing 6. Ring Gear

2. Joint - Rear End Oil Seal Housing 7. Hex Flange Bolt - Flywheel Mounting
3. Rear End Oil Seal Housing 8. Stay Bracket - Breather Hose
4. Oil Seal - Rear Housing 9. Hex Bolt
5. Flywheel 10.Bottom Cover - Flywheel
11.Hex. Flange Bolt - Rear Housing

Model: X 1.3 Issue 4 - 9 - 2011
FLY WHEEL RING GEAR

To Renew the Flywheel Ring Gear (SEC - I 3 - 41)
1. Remove the flywheel.

2. Check the position of the chamfer on the teeth.
3. Break and remove the ring gear (Fig.I 4) using
chisel and hammer. Ensure no damages to
the flywheel.
WARNING! Wear eye protection while
removing flywheel ring gear from flywheel.
4. Heat the new ring gear and fit onto the
flywheel. Ensure that the chamfer of the teeth
of the gear is towards rear end.
Fig. I4
5. Refit the flywheel and check flywheel runout
/ alignment. (SEC - I 2- 41)
REAR END OIL SEAL - LIP TYPE

To Remove Rear End Oil Seal (SEC - I 4 - 41)
1. Remove the fly wheel. (Refer SEC - I 2- 39)
2. Loosen and remove all the fixing bolts
(Fig. I 5) of the rear end oil seal housing
(Fig. I 5) as per sequence shown.
3. Remove the housing (Fig. I 6) along with seal.
To Renew oil seal (SEC - I 5 - 41)

1. Fit the new oil seal into the housing.
NOTE: Seal surface with the part number Fig. I5
identification should be positioned towards
the operator.
2. Clean the faces of the cylinder block and oil
seal housing, and the outside diameter of the
crankshaft flange.
3. Check that the seal and the outside diameter
of the crankshaft flange are not damaged.
4. Coat the joint with jointing compound and
position the joint over the dowels in the
cylinder block.
NOTE : Two dowels are fitted in the
cylinder block.
5. Lubricate the crankshaft flange, the seal and
the seal guide with clean engine oil to prevent Fig. I6
damage that may be caused by initial dry
running.
6. Locate the seal guide special tool on the
crankshaft flange
7. Position the seal and housing on the seal
guide and gently press the seal and its
housing into position on the flange, locating
the housing on its dowels
8. Withdraw the guide and secure the housing
with setscrews and washers.
9. Tighten the setscrews as per sequence using
a torque wrench. Torque: 40 Nm (30 lbs.ft)
10. Refit the flywheel. (Refer SEC - I 2- 39) Fig. I7

Issue 4 - 9 - 2011 Model:X 1.3
Section I – BALANCER UNIT AND OIL PUMP

BALANCER SHAFT
Fig. J1
1. Dowel - Balancer Shaft Bearing Cap 5. Balancer shaft

2. Bearing Upper Balancer Shaft 6. Bearing Lower Balancer Shaft
3. Rear Bush - Balancer Shaft 7. Bearing Cap - Balancer Shaft
4. Woodruff Key - Balancer Shaft 8. Bolt - Balancer Shaft

Model: X 1.3 Issue 4 - 9 - 2011
BALANCER SHAFT
To remove (SEC – J1 - 43)

1. Drain the lubricating oil from the sump and
remove the sump. (Refer Sec. – H5 - 39)
2. Remove the timing case cover. Sec. – H8-41
3. Remove the flywheel. A
4. Remove the blanking screw from balancer
shaft rear bush.
5. Fit a suitable bolt into the bush and screwin
the bolt . Driveout the bush.
6. Loosen and remove the bolts (Fig. J4) fixing Fig. J2
the balancershaft to crank case.
7. Remove the bearing cap along with the lower
bearing.
8. Tilt and remove the balancer shaft unit (Fig.
J5) carefully.
9. Remove the upper bearing.
10. Clean and check the balancershaft for any
damage or journal wear.
To fit (SEC – J2 - 43)
1. Ensure that the contact faces of the cylinder
block and of the balancershaft bearing cap Fig. J3
are clean and the dowel are fitted correctly to
the balancer shaft bearing cap.
2. Fit the balancershaft upper bearing, apply oil
and place the balancershaft in position as
shown.
3. Fit lower halves of balancershaft bearing to
bearing cap.
4. Fit and tighten the balancershaft securing bolt
to torque 33 Nm (24 lbf ft) (8 off Fig. J1)
Note: The cap bolts should be tightend
evenly to the specified torque.
5. Fit the balancershaft rear end bush, ensure
the oil hole is aligned. (3 off Fig. J2) Fig. J4
6. Ensure that the balancershaft turns freely.
7. Check the end float fo the balancershaft.
End float : 0.075 / 0.150 mm (0.003 / 0.006’’)
8. Fit the balancershaft gear and tighten the bolt
to torque 110 Nm
9. Fit the timing gears ( if removed), ensure the
timing marks are aligned properly.
10. Check the backlash between the gears.
0.002/ 0.006 mm (0.0023/ 0.0055")
11. Rotate the crankshaft through two turns to
ensure that it is free to rotate.
12. Fit the other parts in the reverse order. Fig. J5

Issue 4 - 9 - 2011 Model:X 1.3
OIL STRAINER AND SUCTION PIPE
The oil strainer is an integral part of the suction

pipe. No regular services are necessary but wash
the strainer when it is removed.
The suction pipe is normally a short pipe which is
fastened to the timing case cover.
OIL PUMP
Note: The oil pump is an integral part of the

timing case cover, Commonly it cannot be
serviced. How ever the pump rotors can be
checked for its serviceability.
To Remove , Inspect and Refit

Fig. J6
1. Remove sump.
2. Remove the strainer pipe (Fig. J6).
3. Remove the timing case cover.
4. Using a suitable wrench, unscrew the three

screws from oil pump end plate (Fig. J7).
5. Remove the end plate.
Note: The oil relief valve (Fig. J7) is located in

the body of the timing case cover. It is an
adj ustable plunger type valve but unless
special test equipment is available, no attempt
should be made to dismantle. Fig. J7
Fig. J8

Model: X 1.3 Issue 4 - 9 - 2011
Section J
CYLINDER HEAD
5a
Fig. K1
1. Water Outlet Connection 8. Valve - Spring

2. Thermostat Assembly 9. Valve Steam Seal
3. Sensor 10. Pipe Bypass Connection
4. Sensor 11. Spring Seat Bottom
5. Cylinder Head Bolt 12. Lock Nut
5a. Core Plug 13. Tappet - Adjusting Screw
6. Cotter Lalve Spring 14. Dowel - Rocker Bracelet
7. Cap - Valve Spring 15. Cylinder Head
Issue 4 - 9 - 2011 Model:X 1.3
INDUCTION MANIFOLD
To Disconnect the Air Cleaner
1. Loosen the inlet flexible pipe securing clips

from air cleaner to induction manifold pipe(1)
and remove the inlet flexible pipe.
2. Remove the inlet pipe secred to induction
manifold. (2 off Fig. K4)
NOTE: The induction manifold is the
integral part of the cylinder head.
To Connect the Air Cleaner
1. Clean the induction manifold and inlet passage

in the cylinder head.
Fig. K2
2. Ensure the mounting surfaces are clean.
3. Fit the induction manifold pipe with new
gasket and tighten the mounting bolts.
4. Refit air cleaner pipes in reverse order.
EXHAUST MANIFOLD
To Remove
1. Loosen and remove exhaust pipe fixing

screws to exhaust manifold (Fig. K3).
2. Disconnect the exhaust pipe connection from
exhaust manifold. Fig. K3
3. Loosen and remove the exhaust manifold
securing bolts and remove the manifold with
gasket.
To Fit
1. Clean the Exhaust manifold and exhaust

passage in the cylinder head.
2. Ensure the mounting surfaces are clean.
3. Fit the exhaust manifold with new gasket and
tighten the mounting bolts.
4. Refit the exhaust pipe connection.
Fig. K4
1. Gasket inlet Manifold
2. Intake Manifold
3. Hex. Flange Bolt
4. Flange Nut - Exhaust Manifold
5. Stud Exhaust Manifold
6. Exhaust Manifold
7. Gasket Exhaust Manifold
Model: X 1.3 Issue 4 - 9 - 2011
ROCKER ASSEMBLY
Fig. K5
1. Washer Cylinder Cover 6. Rocker Lever

2. Hex. Flange Nut 7. Rocker Arm Bush
3. Stud Rocker Bracket 8. Rocker Shaft
4. Sleeve Rocker Cover 9. Washer Rocker Arm
5. Rocker Bracket 10.Circlip

Issue 4 - 9 - 2011 Model:X 1.3
ROCKER ASSEMBLY
To Remove Shaft Rocker Assembly (SEC K1-48)
1. Remove the rocker cover (Fig. K6).
2. Loosen evenly and gradually the screws

securing rocker shaft brackets to cylinder
head. (Fig. K7)
3. Remove the screws and washers and lift off

the rocker assembly.
To Dismantle and Assemble Rocker Shaft

Assembly (SEC K2 - 48) Fig. K6
1. Remove the circlip and dismantle the rocker

shaft assembly. (10 off K1)
NOTE: When dismantling rocker shaft

assembly make careful note of the order
of assembly.
2. Clean and inspect all the components for wear

and any other damages. If required renew the
components
3. Lubricate the components and re-assemble
in the correct order. Ensure that the oil holes
in the rocker shaft and in the rocker lever are Fig. K7
not restricted.
4. Fit the rocker shaft into the bracket by aligning
its grove and oil holes. (Fig. K8)
5. Fit the oil hole dowel pin into the bracket and
ensure oil passage is not blocked.
6. Fit the rocker, washer and circlip. Ensure the
free movement of rockers in its position.
To Fit – Rocker shaft Assembly (SEC K2 - 48
1. Check that the push rods fit correctly in the

sockets of the tappets.
Fig. K8
2. Fit the rocker shaft assembly; ensure the
ends of the adjustment screws fit correctly
in the socket of the push rods.
3. Tighten evenly and gradually the screws of

the rocker shaft brackets.
4. Tighten the nuts to torque 30 lbf.ft (40 Nm).
5. Set the valve tip clearance.
6. Start and run the engine, check the

performance.
7. Fit the rocker cover.

Fig. K9

Model: X 1.3 Issue 4 - 9 - 2011
To Remove Timing Case Cover - (SEC - H7 - 38)
1. Drain the lubricating oil from the sump.
2. Remove the fan, fan belt and belt tensioner

pully. (Fig. H10)
3. Remove the crankshaft pulley.

(SEC - G1-34)
4. Remove the oil filler with breather assembly

and sump. (Fig. H11)
5. Loosen the screws fixing timing case cover Fig. H10

to case and remove the timing case cover.
(Fig. H12)
NOTE: The oil pump is mounted inside the

timing case, care must be taken while
removing / refitting the timing case.
INSPECTION
1. Check the front case for cracks and damages,

2. Replace the oil seal if found worn out or

damaged / lips worn. Fig. H11
To Replace the Timing Case Cover -

(SEC H8-37)
1. Clean the joining faces.
2. Position the new joint on to the timing case

and apply sealant.
3. Replace the cover taking care not to damage

the front crankshaft oil seal. Ensure the proper
alignment of oil pump drive lug with the flat
milled on crankshaft.
Fig. H12
4. Centralise the cover around the crankshaft
by using the centralizing tool.
5. Fit the timing case cover fixing screws.
6. Refit the crankshaft pulley. (SEC - H2 - 35)
7. Refit the sump and oil filler pipe. (SEC -

H6 - 37)
8. Replace the tensioner, pulley, fan belt and

adjust fan belt tension.
9. Refit the oil filler with breather assembly.
10. Refill the lubricating oil.

Fig. H13

Issue 4 - 9 - 2011 Model:X 1.3
CYLINDER HEAD ASSEMBLY
To Renew Cylinder Head Gasket (SEC - K6 - 50)
1. Disconnect the battery terminals.

2. Drain coolant from radiator and cylinder block.
3. Detach coolant hose connections from
thermostat housing on front of cylinder
head.
4. Remove air cleaner and hose connection.
5. Disconnect the coolant hose from thermostat
housing to water pump. (Fig. K13)
6. Disconnect the exhaust pipe from the engine Fig. K13
exhaust manifold.
7. Remove the breather hose.
8. Remove the cylinder head cover.
9. Remove the high pressure pipes from the FIP
to injector assembly.
WARNING:- Cover the fuel pump delivery

ports with suitable protective caps.
10. Remove the injector assembly (Use 24 mm
tubular spanner) (SER 016) Fig. K14.
11. Remove the rocker shaft assembly. (Fig. K15)

Fig. K14
12. Remove the push rods.
13. Loosen and release the cylinder head

setscrews as per the sequence shown.
Remove the setscrews.
NOTE: Do not insert screwdriver or any

other sharp instrument between the
cylinder head and block.
14. Lift and removal the cylinder head. Place the
cylinder head on a flat surface, preferably
wood, to avoid damages.
15. Remove the cylinder head gasket.

Fig. K15
16. Ensure both gasket faces of the cylinder block
and cylinder head are cleaned properly.
17. Place the gasket on locating dowels with “top

mark” on gasket towards cylinder head. This
gasket should be fitted dry.
18. Place the cylinder head properly on locating

dowels. (Fig. K16)
Fig. K16
Model: X 1.3 Issue 4 - 9 - 2011
Cylinder Head Tightening Procedure :
19. Screw the cylinder head mounting bolts and

tighten the bolts uniformly in sequence to
165 Nm (122 lbf.ft) in first turn using torque
wrench.
20. Replace the push rods, rocker shaft

assembly, and tighten the securing nuts.
21. Fit the injector assembly and high pressure
pipes.
22. Set the valve tip clearance to (0.010 inch)
(0.25 mm) for inlet value 0.012 inch (.30 mm)
for exhaust valve.
Fig. K17
23. Fit the cylinder head cover, breather pipe
hose, air inlet connection and exhaust pipe.
Fig. K18

Issue 4 - 9 - 2011 Model:X 1.3
CYLINDER HEAD
DISMANTLING
To Remove Valves
1. Remove cylinder head.
2. Remove the valves by depressing the spring

cap and spring by means of a valve spring
compressor. (SER 001 - Special Tool)
3. Remove the two half conical cotters. Remove

the spring caps, springs and washers. Take
out the valves.
NOTE: The valves should be suitably

marked to ensure it is fitted in to
respective ports / cylinder.
4. Remove the valve stem seals with pliers.
NOTE: Do not reuse the valve stem seals.

! WARNING:
INSPECTION
1. Check the cylinder head for cracks, damage

and coolant leakage. If cracked, replace the
cylinder head.
2. Remove scale, sealing compound and carbon

deposits completely. After cleaning the oil Fig. K20
passages, blow with compressed air to clear
the passages.
3. Check the cylinder head surface for flatness
in transverse and longitudinal. If flatness
exceeds the limit in any direction, either
replace the cylinder head or machine head
surface. (Fig. K20)
Cylinder head bow limit transverse and
longitudinal: 0.03 / 0.05 mm (0.0011 / 0.0019
inch.)
Valves and Valve Seats
0
2. The valve seat angle is 45 for inlet and
exhaust valve. (Fig. K21) Fig. K21
1. Maximum height between the valve head and

the cylinder head bottom face should not
exceed .015" (0.4 mm) for both the inlet and
exhaust valve. Check by means of a suitable
gauge. (Fig. K22)
Valves Inlet and Exhaust
The inlet valve stem dia.:
6.95 / 6.97 mm (0.273 / 0.274’’)
The Exhaust valve stem dia.:
6.93 / 6.95 mm ( 0.272 / 0.273’’)
Fig. K22

Model: X 1.3 Issue 4 - 9 - 2011
CYLINDER HEAD REASSEMBLY
NOTE: Clean each part before assembly.

Apply engine oil to the sliding and rotating
parts.
1. Install the valve spring seats.
2. Insert the valve into the valve guide and fit
the valve stem seal.
3. Place the valve spring.
4. Using the valve spring compressor, compress
the spring and install the retainer cotters.
5. Place the cylinder head gasket and cylinder
head assembly.
Fig. K23
6. Replace the push rods, rocker shaft
assembly, and tighten the securing setscrews.
7. Fit the injectors and high pressure pipes.
8. Set the valve tip clearance to 0.010” (25mm)
and 0.012” (0.30 mm)
9. Fit the cylinder head cover, oil breather hose,
air inlet connection and exhaust pipe.
10. Start the engine and check for its
performance.
Fig. K24

Issue 4 - 9 - 2011 Model:X 1.3
Section K
TIMING CASE AND GEAR DRIVE
GEAR TRAIN
12
13
1. Gear - Idler 8. Gear - Crank Shaft
2. Gear - FIP 9. Gear - Cam shaft
3. Washer Machined (Camshaft - FIP Bolt) 10.Gear - Balancer Shaft
4. Nut - FIP Gear 11.Washer Machined (Camshaft / Balancer Shaft Bolt)
5. Washer Machined (Idler Gear MTG. Bolt) 12.Cam shaft F I P
6. Hex. Bolt - Gear Idler 13. Balancer shaft.
7. Hex. Bolt - Gear Camshaft / Gear Balancer Shaft

Model: X 1.3 Issue 4 - 9 - 2011
To Remove the Timing Gears (SEC – L1 - 55)
1. Remove the fan belt, Tensiner Assembly,

Crankshaft pulley and Timing case cover
2. Lock the flywheel from moving.
3. Loosen and remove the bolt securing the fuel
injection pump gear. (Fig. L2)
Loosen and remove camshaft gear securing
bolt and washers. Remove the camshaft gear.
4. Remove the F I P gear. (Fig. L2)
5. Remove the bolt securing the idler gear and
remove the idler gear (Fig. L2).
INSPECTION
Fig. L2
1. Check the timing gears for wear or damage,
To Replace the Timing Gears (SEC - L2 - 55)

1. Turn the crankshaft and bring No. 1 piston to
T.D.C. i.e. with the key-way at the front of
the crankshaft uppermost.
2. Turn the camshaft and position the key way

to the uppermost.
3. Fit the camshaft gear. Ensure the camshaft

gear alinined with the timing marks of the
balancershaft gear.
Fig. L3
4. Fit camshaft secring bolt and tighten the bolt
to torque
5. Fit the fuel injection pump gear. Fit the FIP

gear securing washer and nut. Tighten the
nut to torque 78 lbf. ft (105 Nm).
6. Position the idler gear ensuring that the timing

marks align with other timing gear marks as
shown. (Fig. L4)
7. Position the idler gear securing bolt and

tighten the bolt to torque 78 lbf.ft (105 Nm).
8. Check the backlash between the idler gears

gear and other gears is 0.002 (0.60 mm) and
0.005” (0.140 mm). Fig. L4

Issue 4 - 9 - 2011 Model:X 1.3
CAMSHAFT GEAR AND CAMSHAFT
To Remove the Camshaft Gear and Camshaft

(SEC – L3 - 56)
1. Remove the cylinder head and remove the

tappets.
2. Remove the timing case cover.
3. Release the camshaft gear securing bolt from
the camshaft and remove the camshaft gear.
Use suitable long bolts to driveout the gear.
(Fig. L5)
4. Remove camshaft thrust washer mounting
bolts and thrust washer. (Fig. L6)
Fig. L5
5. Remove the camshaft from its location in the
cylinder block taking care not to damage the
journals and cams. (Fig. L7)
INSPECTION
Check the camshaft bores:

1.930 / 1.931inch (49.025 / 49.050 mm)
Check the camshaft journal dia.:
1.927 / 1.928 inch (48.95 / 48.975 mm)
The running clearance in journals:
0.001 / 0.003 inch. (0.05 / 0.1 mm)
Cam lift : Inlet and exhaust : 0.393 inch (10 mm)
(Refer - Fig. L8) Fig. L6
To Replace the Camshaft Gear and Camshaft
(SEC – L4 - 56)
1. Fit the camshaft carefully and continually

turning the camshaft. Take care not to
damage the journals and cams.
2. Fit camshaft thrust washer.
Camshaft Thrust
The camshaft end float is taken up by camshaft
thrust washer (sintered) which is retained by two
setscrews
Camshaft End Float (Measure with dial Gauge)
0.10/ 0.35 mm (0.004/ 0.014 in.) Fig. L7
Note:
1. Ensure camshaft key and key way on the
camshaft gear align properly.
2. Replace the camshaft gear aligning timing
marks and secure the camshaft setscrew
using torquue wrench.
Camshaft gear bolt Torque81 lbs.ft ( 110 Nm)
3. Replace the tappets and fit the cylinder head.
4. Refit the push rods, rocker arm shaft assembly
and reset the valve tip clearance.
Fig. L8
5. Refit the timing case cover
Model: X 1.3 Issue 4 - 9 - 2011
TIMING
When the engine is timed at the factory, timing

marks are stamped on the gears.
To Reset Engine Timing
1. Turn and bring No. 1 piston to T.D.C. on its

compression stroke. The T.D.C that has
been obtained can be checked by
examining the valve position.
Now the No.1 cylinder valves are closed and

No.2 cylinder valves are in overlap position .
2. Fit the camshaft gear on locating key

Fig. L9
provided on camshaft.
Ensure the FIP is fitted properly in its position
3. Fit the fuel pump gear . This is provided with

key way and will only go in one position.
4. With the crankshaft gear fitted, replace the

Idler gear ensuring the timing marks coincide
as shown.
To Verify Valve Timing
1. Turn the engine until maximum lift is obtained

on No. 2 cylinder Inlet valve.
2. Set the valve tip clearance between rocker

Fig. L10
lever and No. 1 inlet valve to 0.50 mm (0.020”)
3. Now, turn the engine in the normal direction

of rotation until the No. 1 inlet valve tip
clearance reduces and push rod just tightens.
4. At this point, No. 1 piston should be at T.D.C.

This can be checked by examining the T.D.C.
mark given on the pulley is inline with pointer.
5. To set No. 1 piston to T.D.C. bring the notch

mark on the pulley in line with the pointer.
The tolerance for valve timing is plus or minus
1°.
6. When the valve timing is found to be correct,

adjust the valve tip clearance of No. 1 inlet
valve to 0.25 mm (0.010 in.)
7. The valve layout is E, I, E, I .
Inlet Valve Opens – 12° BTDC

Inlet Valve Closes – 40° ABDC
Exhaust Valve Opens – 44° BBDC
Exhaust Valve Closes – 12° ATDC
BTDC – Before Top Dead Centre
ATDC – After Top Dead Centre
ABDC – After Bottom Dead Centre
BBDC – Before Bottom Dead Centre

Issue 4 - 9 - 2011 Model:X 1.3
Section L
PISTONS AND CONNECTING RODS
PISTON
The Pistons are of special light aluminium alloy

with a re-entrant bowl in the crown. They are
secured to the connecting rods by means of fully
floating gudgeon pins which work in thin wall steel
backed bronze lined bushes fitted in the small ends
of the connecting rods. Fig. M1
Fig. M1
The connecting rod big end bearings are of
the thin wall type consisting of a thin steel shell
lined with aluminium tin.
DISASSEMBLY
To Remove Pistons and Connecting Rods

(Sec. M1 - 61)
1. Drain the coolant and engine oil.
2. Disconnect air intake manifold, Exhaust

manifold and coolant pipe connections
Fig. M2
3. Remove cylinder head assembly. (Fig. M2)
4. Remove the sump. (Fig. M3)
5. Turn the engine until the connecting rod is at

bottom centre. Remove bolts and nuts
securing the connecting rod cap.
6. Remove the connecting rod cap and both top

and bottom half bearing shells.
7. The piston and connecting rod can then be

pushed out through the top of the cylinder
block.
8. Keep all pistons, connecting rods, caps, Fig. M3

bearing shells, bolts and nuts together as
separate assemblies.
NOTE: Keep the bearing in order with their

corresponding connecting rods (according to
cylinder numbers) for proper reassembly.
Remove Gudgeon Pins (SEC – M2 - 58)

Remove the circlips from the pistons, using a
long nosed plier and push the pin from one end.
The gudgeon pins can now be pushed out and the
connecting rod can be separated from the pistons.
Fig. M4

Model: X 1.3 Issue 4 - 9 - 2011
INSPECTION
1. Check each piston for scuffing, scoring, wear

and other defects. Replace any piston that is
defective.
2. Check each piston rings for breakage,
damage and abnormal wear. Replace the
defective rings. If piston to be replaced,
replace piston with ring assembly.
3. Check that the piston pin fits in the piston pin
hole. The piston pin must be smoothly pushed
easily into the piston hole.
4. Measure the piston ring side clearance. Fig. M5
(Fig. M6).
Piston Ring Width (Standard)
Top and 2nd ring width
0.097 / 0.098 inch (2.47 / 2.49 mm)

3rd ring width
0.117 / 0.118 inch (2.97 / 2.99 mm)
Ring clearance in Piston Groove : (Std)
Top ring: 0.004 / 0.0055 inch ( 0.10 / 0.14 mm)
2nd ring: 0.002 / 0.0035 inch (0.05 / 0.09 mm)

Fig. M6
3rd ring: 0.0015 / 0.003 inch (0.04 / 0.08 mm)
Fig. M7

Issue 4 - 9 - 2011 Model:X 1.3
REASSEMBLY
Install New Small End Bushes
The small end bushes are a press fit in the

connecting rods.
Press out the old bushes using a suitable drift.
Press in the new bushes using a suitable dolly/

drift, aline by aligning and ensuring that the oil holes
in the bushes coincide with the holes in the top of
the connecting rods.
Assemble Pistons and Connecting Rods

Fig. M8
If removed pistons are to be used again
they should be re-fitted to the respective connecting
rods only.
Pistons should be fitted with the offset of

combustion bowl in the crown towards fuel injection
pump side.
Offer the connecting rod to the pistons

and insert the gudgeon pin.
Fit the circlips on both sides of the piston.
Assemble Piston Rings
When fitting new rings to removed pistons, Fig. M9

clean out the piston ring grooves. (Fig. M10)
The pistons should be carefully examined

for bruising of the ring grooves and to ensure
that the rings move freely in their grooves.
1. Apply engine oil around the piston ring

grooves.
2. Fit the helical coil spring on to the 3rd groove

of the piston.
3. Insert the latch into the coil spring aligning

both the ends.
Fig. M10
NOTE: The piston skirt should be
examined and if there is any scoring,
the piston must not be used again.
Fig. M11
Page 69
2011Copyright Cummins Power Generation
Model: X 1.3 Issue 4 - 9 - 2011
TIMING
4. Fit the outer C.I. ring over the coil spring.

Ensure coil spring gets seated properly inside
the ring groove and the coil spring latch is
on the opposite side of the ring open end
gap.
5. Using piston ring expander, install the No.2

ring (Cast Iron, Taper land with ‘Top’ marked).
6. Install the Top ring (Chromium inlaid with ‘Top’

marked).
7. Place each piston ring end gap as far apart

from neighboring gaps as possible. Ensure
that gaps are not positioned in the thrust and Fig. M12
pin direction.
8. Hold the piston rings firmly with piston ring

compressor as they are inserted into cylinder.
(Fig. M11)
9. Make sure that the arrow mark on the piston

crown is towards the front of the engine.
(Offset of combustion bowl in the crown
toward fuel injection pump side).
10. When connecting rod is installed, ensure that

the cylinder numbers put on the rod and caps
assembly match.
11. Tighten the rod cap nuts. Tightening torque

to 65 Nm (48 lbf.ft)
12. Rotate crankshaft by hand and note that all
parts move freely.
Fig. M13
13. Check the piston height in relation to the
top face (Fig. M13) of the cylinder as
described below.
When the crankpin is at top dead centre the

crown of the piston height in relation to cylinder block
top face must be with the limit. 0.05 mm (0.002’’)
below or 0.35 mm (0.014 in.) above block surface.
14. Check the big end side clearance on crankpin.

(Fig. M14)
Side clearance: 0.3 / 0.5 mm (0.012/ 0.020 in.)
Fig. M14

Issue 4 - 9 - 2011 Model:X 1.3
Section M
CRANKSHAFT ASSEMBLY AND MAIN BEARINGS
4a
Fig. N1
1. Thrust Washer - Crank Upper 5. Pulley Crankshaft
2. Main Bearing Upper 6. Washer
3. Woodruff Key - (Gear - Crankshaft / Pulley - 7. Hex. Bolt - Pulley Crank Shaft
Crankshaft)
8. Main Bearing Lower
4. Crankshaft
9. Main Bearing Cap - First & Third
4a.Crank Shaft Gear
10.Hex. Flange Bolt - Main Bearing Cap
Page 71
Model: X 1.3 Issue 4 - 9 - 2011
CRANKSHAFT ASSEMBLY
The crankshaft runs in three pre-finished re-

placeable shell bearings lined with aluminium tin.
The seal at the rear end of the crankshaft is a
Lip type seal fitted in a one-piece housing.
REMOVAL (SEC – N1 - 63)
1. Remove the fan belt, tensioner assembly and

crankshaft pulley.
2. Remove the startor motor.
3. Remove the flywheel, rear end oil seal housing
and oil seal. Fig. N2
4. Remove the cylinder head assembly.

5. Remove the sump.
6. Remove the timing case front cover.
7. Remove the connecting rod and piston
assembly.
8. Remove setscrews and remove main bearing
caps and half bearings. (Fig. N3)
NOTE: Marks provided on connecting rod
cap and main bearing caps in order,
according to the cap number.
Fig. N3
9. Lift out the crankshaft. (Fig. N4)
INSPECTION
Check the crankshaft journals and pins for damage,

uneven wear and cracks.
Check the oil holes for restriction.Inspect the

crankshaft journals and pins for taper and out-of-
round.
Crankshaft journal outer diameter: Standard
57.98 / 58.00 mm (2.282 / 2.283 in.)
Crankpin outer diameter: Standard

Fig. N4
47.98/ 48.00 mm ( 1.889 / 1.890 in.)
A. 69.832 / 69.812 mm (2.749 / 2.748”) STD Size
Main Bearing and Connecting Rod Bearing B. 57.132 / 57.109 mm (2.2493 / 2.248”) STD
Visually inspect bearing for pealing, melting, seizure Size
and improper contact, replace if defective. C. 31.06 / 30.85 mm (1.2227 / 1.2147 in)
D. 39.88 / 39.67 mm (1.570 / 1.562 in)
NOTE: It is important that the RADII on the main
E. 46.88 / 46.80 mm (1.8457 / 1.8427 in)
j ournals and crankpins are maintained. If these
are neglected, a fatigue fracture is liable to occur. F. 46.936 / 46.727 mm (1.8477 / 1.8397 in)
The main j ournal and crankpin diameters should R1. 3.56 / 3.18 mm (0.140 / 0.125 in)
be checked to ascertain the next appropriate under
size to which the crankshaft can be-reground, R2. 4.221 / 3.967 mm (0.1662 / 0.1562 in)
R3 . 5.159 / 4.763 mm(0.2031 / 0.1875 in)

Issue 4 - 9 - 2011 Model:X 1.3
Measuring Oil Clearance
Check the oil clearance by measuring the outside

diameter of the crankshaft journal as well as the
inside diameter of the bearings in position on the
cylinder block. The clearance can be obtained by
calculating the difference between the measured
diameters.
Running clearance:0.04 / 0.08 mm (0.0015/

0.0031 in.)
REASSEMBLY
1. Ensure that no blockage in oil-ways.

2. Clean block main bearing housing and place Fig. N5
half bearing in position.
3. Spray oil on the bearing and Place crankshaft
in position.
4. Lightly smear the two upper thrust washers
with lubricating oil and slide in to the recesses
provided on either side of the centre main
bearing housing, with the steel side or plain
surface of the washers towards the housing.
5. Ensure the dowels are fitted properly in the
rear main bearing cap.
6. Fit lower halves of main bearings to bearing
caps and place in position ensuring that the
thrust washers on No. 2 main bearing cap Fig. N6
are fitted correctly. (Fig. N6)
7. Lightly coat the rear main bearing cap butt
faces with Jointing Compound, only coat
outboard of the grooves machined in the cap
butt faces and ensure that the grooves are
free from jointing compound.
8. When replacing the main bearing caps, ensure
that they are fitted in their respective
positions. Each cap is also marked with a
serial number and when fitted, this number
should read in line with the serial number
stamped on the cylinder block bottom face.
10. Install and tighten the Main bearing cap bolt
Fig. N7
to the torque: 170Nm (122 lbf.ft)
NOTE: The cap bolts should be tightened
evenly 4 to 5 increments before they are
tightened to the specified torque.
11. Ensure that the crankshaft turns freely.
12. Check the end play of the crankshaft.
(Fig. N7)
End Float is 0.07/ 0.15 mm (0.003/ 0.006’’)
13. Using the special tool, install the rear end Lip
type oil seal.
14. Fit the other parts in reverce order.
Page 73
Model: X 1.3 Issue 4 - 9 - 2011
Section N
CYLINDER BLOCK AND LINERS
Fig. O1
1. Cylinder Block 8. Gasket - Cylinder Head

2. Camshaft 9. Cover Plate Rear End - Camshaft
3. Thrust Washer 10. Water Gallery Drain Plug
4. Oil Gallery - Plug 11. Allen Plug - Oil Gallery
5. Hub - Idler Gear 12. Core Plug
6. Push Rod 13. Dowel - Main Bearing
7. Valve Tappet

Issue 4 - 9 - 2011 Model:X 1.3
CYLINDER BLOCK
The cylinder block is linerless type. When the
bore is worn so as engine performance is affected
a service liner can be fitted.
For fitting service liner Refer Fig. O2.
INSPECTION
1. Check the cylinder block for cracks, scores,

rust and any other defects.
2. Measure the cylinder bore with the cylinder

gauge at the three levels at thrust side and
non- thrust side. (Fig. O3)
Fig. O2
Level 1: No 1 piston ring position at TDC
Level 2: Centre of cylinder
Level 3: Bottom of cylinder
3. If the cylinder bore show more than specified

out-of-round, taper, worn, badly scuffed or
scored, a service liner should be used.
Standard Cylinder Bore Size:
95.00/95.02 mm (3.740/ 3.741 inch)
4. Maintain the specified clearance between the

piston and cylinder bore, and ensure that all Fig. O3
pistons used are of the standard size.
5. Check the top surface of the cylinder block

for flatness. If the top surface exceeds
flatness limits, surface to minimum limit or
replace.
Flatness limit: 0.01 mm (0.0004 in.)
Fig. O4
Page 75
Model: X 1.3 Issue 4 - 9 - 2011
Section O
LUBRICATION SYSTEM

Issue 4 - 9 - 2011 Model:X 1.3
Engine Oil
WARNING: CRANKCASE PRESSURE CAN BLOW OUT HOT OIL AND CAUSE SEVERE
BURNS. DO NOT CHECK OIL WHILE THE ENGINE OIL IS OPERATING.
Caution: Do not operate the engine with the oil level below the low mark or above the high
mark. Overfilling can cause foaming or aer ation of the oil while operation below the
low mark may cause loss of oil pressure.
Caution: Prolonged and repeated skin contact with used engine oils can cause skin disorders
or other bodily injury.
Check the engine oil level during engine shutdown

periods at the intervals specified in the Maintenance
Table 1 .
Never operate the engine with the oil level below the L
(Low) mark, or above the H (High) mark. Wait at least
fifteen minutes, after shutting off the engine, before
checking the oil level. This allows time for the oil to drain
back to the oil pan.
Note: Use high-quality CH4 15W-40 multi-viscosity lubricating oil such as Cummins Premium
Blue® or its equivalent. Consult your authorised distributor for the correct lubricating
oil for your operating conditions.
Fuel System
WARNING: IGNITION OF FUEL CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH BY
FIRE OR EXPLOSION. DO NOT PERMIT ANY FLAME, CIGARETTE, OR OTHER
IGNITER NEAR THE FUEL SYSTEM, OR IN AREAS SHARING VENTILATION.
WARNING: ENGINE FUEL ACTUATORS CAN OPERATE AT VOLTAGES UP TO

140 VOLTS DC.
CAUTION: VERIFY THE TIGHTNESS OF THE FUEL BANJOS FROM FUEL PUMP TO
FUEL FILTER INLET, OUTLET AND IN CAMBOX TO AVOID FUEL
STARVATION.
ENSURE THAT THE FUEL RETURN HOSE IS CONNECTED FROM NOZZLE
OVERFLOW PIPE TO RESERVOIR
Page 77
Model: X 1.3 Issue 4 - 9 - 2011
WARNING: DO NOT MIX GASOLINE OR ALCOHOL WITH DIESEL FUEL. THIS MIXTURE
CAN CAUSE AN EXPLOSION.
Caution: Due to the precise tolerances of diesel injection systems, it is extremely important
that the fuel be kept clean and free of dirt or water. Dirt or water in the system can
cause severe damage to both the injection pump and the injection nozzles.
Use ASTM No. 2D fuel with a minimum Cetane number of 40. No. 2 diesel fuel gives the best
economy and performance under most operating conditions. Fuels with Cetane numbers higher
than 40 are often needed in high altitudes, or extremely low ambient temperatures, to prevent
misfires and excessive smoke. Contact your authorised distributor for your operating conditions.
Note: A diesel fuel to BS 2869:2006; (Fuel oils for agricultural, domestic and industrial
engine and boilers), conforming to the requirements and test methods of that
specification would be an acceptable alternative to ASTM No. 2D.
COOLANT RECOMMENDATIONS
Cummins recommends, use of Premix Coolant, for engine cooling. This is ‘Ready to Use’
type Coolant is available in 5 Litre Can. (Cummins Part Nofor Sleetguard coolant A024J834,
Valvoline Part No.: 4962836) Coolant is ‘Ethylene Glycol & water’ (Type JIS K 2234-94, Class 2)
Coolant is recommended to prevent Corrosion of Engine & Radiator. It also broadens the
Operating Temperature range by Lowering the coolant freezing point & by raising it’s boiling point.
Note : This Premix Coolant Do-Not require, any addition OR mixing of Raw Water. Coolant
is to be used, directly from Coolant Can (Ready To Use)
Coolant recovery Bottle is to be filled externally, with Coolant. Radiator is to be
filled slowly, upto bottom of Fill Neck.
Check Coolant Level Daily, before starting Engine Oil.
CAUTION: Do-not add cold coolant to hot engine. Engine castings can be damaged. Allow
engine to cool below 500 C, before adding Coolant.
Do-Not remove Cap, Radiator, from hot engine. Allow engine to cool below 50 0 C,
before adding Coolant. Failure to do so, can result in personal injury from steamy
coolant.
Do-Not use sealing additives, to stop leaks in the cooling system. This can result in
coolant system plugging & inadequate coolant flow, causing, engine to Over heat.

Issue 4 - 9 - 2011 Model:X 1.3
Section P
ELECTRICAL EQUIPMENT
STARTER MOTOR
To remove
1. Disconnect the battery.

2. Disconnect the starter motor cables.
3. Release the fasteners and remove the starter
motor and, if necessary, the distance piece
and dowls.
To fit
1. Fit the spacer plate locating dowls. Fit the

starter motor and tighten the fasteners.
2. Connect the starter motor cables. Fig. Q1
3. Connect the battery.
Page 79
Model: X 1.3 Issue 4 - 9 - 2011
Section Q
TROUBLE SHOOTING
The following table lists problems and their possible causes with recommended action.
IMPORTANT : When attending/performing a repair, the cause of the problem must also
be investigated and corrected to avoid repeat failures.
PROBLEM POSSIBLE CAUSES REMEDY
LOW CRANKING SPEED
Battery capacitylow Change or renew the battery
Bad electrical connections Check the connections or renew electricals
Faulty starter motor Overhaul starter motor
Lubricating Oil of incorrect grade Drain and refill with specified grade of oil
Low cranking speed See Problem – Low Cranking speed
Fuel tank empty Fill the tank with fuel
Incorrect type or grade of fuel Drain and refill with correct type/grade of fuel
Faulty stop control operation Check the stop control movement and setting
Blocked fuel feed/supply pipe Clean the pipe

ENGINE DOES NOT START
Faulty fuel feed/supply pump Overhaul fuel feed/supply pump
Chocked/Plugged fuel filters Renew filter elements
Air in fuel system Remove air lock/Bleed air
Faulty fuel injection pump Overhaul injection pump
Faulty injectors Overhaul injectors
Broken fuel injection pump drive Fit new drive
Incorrect fuel pump timing Check and reset
Incorrect valve timing Check and reset
Poor compression See Problem – Poor Compression
Worn cylinder bores Re-sleeve block with liner and fit new pistons
Pitted valve/s and seat/s Replace valve with new standard or oversize.
Broken, worn or sticking piston ring/s Fit new ring/s, check bore and pistons for damage

Issue 4 - 9 - 2011 Model:X 1.3
Low cranking speed See Problem – Low Cranking Speed
Faulty stop control operation Check the stop control movement and setting
Blocked fuel feed/supply pipe Clean
Blocked fuel tankvent Clean
Incorrect type or grade of fuel Drain the fuel and refill with correct grade of fuel
Exhaust pipe restriction Check and clean/remove the restrictions

DIFFICULT STARTING
Chocked/Plugged fuel filters Renew filter elements
Restriction in air cleaner or induction system Check and clean/remove the restriction
Sticking valves Replace valve with new standard or oversize.
Worn cylinder bores Re-sleeve block and fit new pistons
Pitted valves and seats Replace valve with new standard or oversize.
EXCESSIVE CRANKCASE PRESSURE
Chocked/Plugged breather pipe Clean the pipe
Cylinder head gasket leaking Check the cylinder head bolts torque or renew the
gasket
Broken, worn or sticking piston ring/s Fit new rings, check bore and pistons for damage
Worn valve stems Renew valves
Piston seized Replace with new pistons assembly and check/
Page 81
Model: X 1.3 Issue 4 - 9 - 2011
Overheating See Problem – Overheating
Incorrect valve timing Reset the timing
gasket
POOR COMPRESSION
Incorrect tappet adjustment Check and reset the adjustment
Sticking valves R eplace valve with new standard or oversize.
Pitted valves and seats Replace valve with new standard or oversize.
Broken, worn or sticking piston ring/s Fit new rings, check bore and piston for damage
Worn valve stems Renew valves
Broken valverings
sp Fit new springs
Blocked fuel feed/supply pipe Clean pipe
Faulty fuel feed/

supply pump Overhaul
fuel feed/supply pump
Chocked/Plugged fuel filters Remove filter elements

MISFIRING
Poor compression See Problem – Poor compression
gasket
Sticking valves Replace valve with new standard or oversize
Incorrect high pressure pipes Renew the pipes of correct specification
Pitted valves and seats Replace valve with new standard or oversize,

Issue 4 - 9 - 2011 Model:X 1.3
Blocked fuel feed/supply pipe Clean the pipe
Chocked/Plugged fuel filters Remove filter components
Blocked fuel tank vent Clean

LOCK/LACK OF POWER
Incorrect vale/valve timing Check and reset
Incorrect type/grade of fuel Drain the fuel and refill with correct grade of fuel
Sticking throttle or restricted movement Check, clean, lubricate and adjust settings
gasket
Pitted valves and seats Replace valve with new standard valves
Page 83
Model: X 1.3 Issue 4 - 9 - 2011
Faulty injectors Overhaul Injectors

EXCESSIVE FUEL CONSUMPTION
Poor compression See Problem – Poor compression
Incorrect type or grade of fuel Drain the fuel and refill with correct grade of fuel
gasket
Sticking valves Replace valve with new standard
Pitted valves and seats Replace valve with new standard valves.

Issue 4 - 9 - 2011 Model:X 1.3
Incorrect grade of lubricating oil Drain and refill with specified grade of oil
Overfilled air cleaner oil or use of incorrect grade Check the oil level and remove as necessary orof oil
(wet type air cleaner) refill with correct grade oil

BLUE/WHITE SMOKE
gasket
Worn valve stems and guides Renew valves and guides
Piston seized Replace piston assembly and check the bore for
damage
Worn or damaged big end bearings Renew the bearings

LOW ENGINE OIL PRESSURE
Insufficient oil in sump Top up as necessary
Plug in oil gallery Tighten plug
Faulty suction pipe Renew the pipe
Chocked/Plugged oil filter Replace with new filter
Blocked sump strainer Clean the strainer
Page 85
Model: X 1.3 Issue 4 - 9 - 2011
Incorrect type or grade of fuel Drain and refill with correct grade of fuel
ENGINE KNOCKS
Incorrect tappet adjustment Check and rest the adjustment
Sticking valves eplace

R valve with new standard or oversize.
Worn cylinder bores Re-sleeve block with liners and fit ne pistons
Overfilled cleaner or use of Incorrect grade of oil Check the level or drain out and refill with correct
(Wet type Air cleaner) grade oil
Worn or damaged big end bearings Renew the bearings
damage
Broken valve spring Replace new springs
Faulty stop control operation Check the stop control cable movement and setting
Blocked fuel feed/supply pump Clean

ERRATIC RUNNING
Chocked/Plugged fuel filters Chocked fuel filters
Air in fuel system Remove air/Bleed air lock
Poor compression Renew piston rings or re-sleeve as necessary
Blocked fuel tank vent Clean the vent

Issue 4 - 9 - 2011 Model:X 1.3

ERRATIC RUNNING
Sticking valves Replace valve with new standard valves
Incorrect high pressure pipes Renew the pipes of correct specifications
Broken, worn-out or sticking piston ring/s Fit new rings, check bore and pistons for damage
damage
Broken valve spring Replace with new springs
Sticking throttle or restricted movement Check, clean, lubricate and adjust settings.
gasket
VIBRATION
Sticking valves Replace valve with new standard valves.
Incorrect high pressure pipes Renew with pipes of correct specifications
Broken worn or sticking piston ring/s Fit new rings, check bore and pistons for damage
damage
Faulty engine mounting Check and redo the installation of engine
Incorrectly aligned flywheel housing or flywheel Check and align flywheel housing and flywheel
HIGH OIL
PRESSURE
Page 87
Model: X 1.3 Issue 4 - 9 - 2011
Coolant level too low Top up as necessary
Loose fan belt Tighten the fan belt
Faulty Temperature gauge Check and replace
Restriction in water jacket Remove the restriction by reverse flushing entire

cooling system
Chocked/Blocked radiator Clean and check for free flow
Damaged fan Fit new fan

OVERHEATING
Faulty thermostat Replace with new thermostat
Faulty water pump Overhaul or renew the water pump
Exhaust pipe restriction Remove the restriction
Faulty injector Overhaul Injector
Incorrect fuel pump timing Reset the timings
Incorrect valve timing Reset valve timings
gasket
damage
STARTS & STOPS
Chocked/Plugged fuel filter Fit new filter
Restriction in air cleaner or induction system Remove the restriction
Air in fuel system Remove the air lock/Bleed air

Issue 4 - 9 - 2011 Model:X 1.3
Section R
SERVICE TOOLS
Tool Number Description Remarks
Valve spring compressor with adaptor
SER 001
Cylinder liner remover / replacer adaptors

suitable for liners of 95,0 mm dia
SER 006
Piston ring compressor Available in

local market
SER 007
Timing cover oil seal replacer
SER 012
Timing cover centraliser
SER 013
Page 89
Cummins Power Generation Cummins Power Generation Cummins Power Generation
1400 73rd Avenue NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis Manston Park TT International Tradepark
MN 55432 Manston Singapore 608838
USA Ramsgate
Kent CT12 5BF
United Kingdom
Tel:+1 (763) 574-5000 Tel:+44 (0) 1843 255000 Tel: (65) 6417 2388
Fax:+1 (763) 574-5298 Fax:+44 (0) 1843 255902 Fax:(65) 6417 2399
e-mail: pgamail@cummins.com e-mail: cpgk.uk@cummins.com e-mail: cpg.apmktg@cummins.com
Web: www.cumminspower.com Web: www.cumminspower.com Web: www.cumminspower.com
Cummins Power Generation Cummins Power Generation

35A/1/2, Erandawana Rua Jati, 310 - Cumbica
Pune 411 038 Guarulhos –SP
India Brazil
CEP: 07180-900
Tel.: (91 020) 3024 8600 Tel.: (55 11) 2186 4195
Fax: (91 020) 6602 8090 Fax: (55 11) 2186 4729
e-mail: e-mail:
cpgiservicesupport@cummins.com falecom@cumminspower.com.br
Web: www.cumminspower.com Web: www.cumminspower.com
®
Cummins , the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
©2011 Cummins Power Generation, Inc. All rights reserved

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Engine Service Manual

English − Original Instructions 9−2011 A030D088 (Issue 4)

“Intentionally Left Blank”

Page 2 2011Copyright Cummins Power Generation

Should you require further assistance contact:

Cummin India Limited

Tel: +91 2030248600

2011Copyright Cummins Power Generation Page 3

A GENERAL INFORMATION ....................................................................... ...... 6

B ENGINE VIEW ENGINE NIMBER LOCATION.................................................. 7

D OPERATION AND MAINTENANCE......................................................... ....... 18

E FUEL SYSTEM............................................................. ................................... 22

F COOLING SYSTEM -WATER PUMP.......................................................... ..... 43

G FRONT OIL SEAL ............................................................................................ 44

O LUBRICATING SYSTEM....................................................................... .......... 76

APPROVED LUBRICATING OILS................................................................... 77

P ELECTRICAL EQUIPMENT .......................................................................... 79

R SERVICE TOOLS................................................... ......................................... 89

Page 4 2011Copyright Cummins Power Generation

“Intentionally Left Blank”

2011Copyright Cummins Power Generation Page 5

SAFETY TOOLS AND MEASURING EQUIPMENT

Important: Is used to draw attention to things that ELECTRICAL SYSTEM

Page 6 2011Copyright Cummins Power Generation

FUEL INJECTION PUMP SIDE

2011Copyright Cummins Power Generation Page 7

CAM SHAFT SIDE

Page 8 2011Copyright Cummins Power Generation

Engine Identification Plate

Each engine is provided with a Data Plate as shown

2011Copyright Cummins Power Generation Page 9

Total exhaust open period : 236°

Injection timing : 10° B.T.D.C

DE-RATING FOR ALTITUDE :

Page 10 2011Copyright Cummins Power Generation

MANUFACTURING DATA AND DIMENSIONS

Piston Ring Width

Ring clearance in Piston Groove :

2011Copyright Cummins Power Generation Page 11

Page 12 2011Copyright Cummins Power Generation

Position in engine … Cylinder Block Centre Main Bearing Housing

Thickness-Standard Size … 0.105 / 0.107 inch (2.67 / 2.72 mm)

Thickness-Oversize … 0.1283 / 0.1303 inch (3.26 / 3.31 mm)

Inside Dia. (fitted) … 2.362 / 2.363 inch (60.02 / 60.03 mm)

Running clearance … 0.0015 / 0.003 inch (0.04 / 0.079 mm)

No. 1 Journal Dia. … 1.927 / 1.928 inch (48.95 / 48.975 mm)

No. 2 Journal Dia. … 1.927 / 1.928 inch (48.95 / 48.975 mm)

No. 3 Journal Dia … 1.927 / 1.928 inch (48.95 / 48.975 mm)

Cam Lift - Inlet … 0.393 inch (10 mm)

- Exhaust … 0.393 inch (10 mm)

Camshaft end float … 0.004 / 0.014 inch (0.10 / 0.35 mm)

Leak Test … 4 Bar for 1 minute

Valve seat angle … Inlet 45° / Exhaust 45°

Permissible cylinder head bow

Transverse and Longitudinal … 0.001 / 0.002 inch (0.03 / 0.05 mm)

Valve Layout ... E, I, E, I

Inlet and Exhaust Valves

Diameter of Bore … 1.4996 / 1.5011 inch (38.090 / 38.13 mm)

Fuel Pump Gear

Lubricating Oil Pump Clearances

Lubricating Oil Relief Valve

2011Copyright Cummins Power Generation Page 15

Fuel Injection Pump

Page 16 2011Copyright Cummins Power Generation