sa16r2018 ‘V2 REBUILD GUIDELINES <¢ | Service Bulletin Service Bulletin Number: 3666454-01 Released Date: 01-jan-2002 V28 REBUILD GUIDELINES V28 REBUILD GUIDELINES Purpose Table of Contents Section | - Failure Analysis of Camshaft, Tappets, and Other Components Page 1 Section Il - Component Inspection for Re-Use and Root Causes Investigation Page 6 Section Ill - Rebuild Facility Requirements Page 8 Section IV - Engine Assembly and Latest Updates Page 9 Group 1 - Cylinder Block Page 9 Group 2 - Cylinder Head Page 9 Group 3 - Rocker Levers Page 10 Group 4 - Cam Followers and Tappets Page 11 Group 6 = Injectors and Fuel Lines Page 14 Group 7 « Lubricating Oil System Page 15 Group 10 - Air Intake System Page 15 Section V - Customer Practices Page 18 Section VI - Recent History of the V28 Engine Relative to Camshafts Page 19 Introduction This bulletin provides the distributor and end customer with detailed guidelines for achieving the best possible camshaft life on rebuilt V28 engines This bulletin will aid the distributor in the rebuilding process and will outline specific actions the customer can take to obtain maximum camshaft life. Although the focus is on camshaft life, these practices will also benefit the general life of V28 rebuilds. Since technicians typically work at the customer's location, it is critical that they be familiar with the V28 rebuild guidelines outlined in this bulletin. Furthermore, it is imperative that technicians assist with failure analysis in the shop and in the field during disassembly and troubleshooting phases Notes about this bulletin: 1, The Shop Manual V28 Engines, Bulletin 3666014 is referenced throughout this bulletin. A copy of the shop manual needs to be on hand to support this bulletin hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 118sa16r2018 ‘V2 REBUILD GUIDELINES 2. Procedures and specifications are often not, spelled out completely in this bulletin. For complete procedures, consult the Shop Manual V28 Engines, Bulletin 3666014. Section | - Failure Analysis of Camshaft, Tappets, and Other Components Since there are many factors that can contribute to lobe deterioration, it is critical that a thorough failure analysis be performed. Inspection of unfailed parts can also lead to the root cause of the failed components Note : Before the engine is disassembled, the checks must be performed on the Pre-Disassembly Checklist for the V28 (see page 3) and the results recorded 1, Overhead settings on the unfailed cylinders for indications of why the others have failed. Worn overheads or incorrect overhead sets can lead to premature lobe wear. All values must be recorded for future reference. 2. Static injection timing on both banks. In the case of camshaft failures, check the timing on two unfailed cylinders per bank (preferably, one per head). If the camshafts have not failed, check the timing on one cylinder per bank, All values must be recorded for future reference. 3, Fuel pump calibration. Remove the fuel pump and check on a calibration stand to see if the following parameters meet specification. All values must be recorded for future reference. Rated rail pressure Torque peak rail pressure Governor breakpoint 40-psi checkpoint, 4, Check for aftercooler core leaks that would lead to coolant in the oil. Check for lubrication issues (i.e., bearing wear) 5, Identify and mark the injectors as they are removed from the engine to aid in further investigation (e., Number 1 left bank). 6, Review the engine failure history for previous camshaft failures and note which cylinders were involved. The customer records must also be reviewed for overhead set intervals and other maintenance practices. Pre-Disassembly Checklist for the V28 Engine Serial Number: CPL: Hours: Record lobe failures (i.e., 1LB exhaust, 2RB injector, and so forth): Was there evidence of aftercooler leakage? Was there evidence of lubrication issues? Do the injector part numbers match CPL requirement? Tabl e1, Ove the ad Sett ings hitpsquickserve, cummins. comigsS/pubsys2/xmi/enfoulein/3666454.him! 2126sa16r2018 ‘V2 REBUILD GUIDELINES 4R | 2R | 3R | 4R | SR | OR | tL | 2 | se | 4e | SL | 6L Inta ke Exh aust Timi ng Inje ctor Flo w Dat a Inje ctor Da ma gel Con ditio Fuel Pump Calibration Data: Does the fuel pump data tag match the engine CPL? Rated Rail Pressure: Torque Peak Rail Pressure: Governor Breakpoi 40-psi Checkpoint: As the engine is disassembled, thoroughly inspect the used camshafts and tappet rollers and record locations (right bank, left bank, cylinder number, intake, exhaust, injector lobes). Check the camshaft lobes and tappets for any signs of scratching, pitting, wearing, or edge-loading + For a single lobe failure (valve or injector): Repeated failures on one cylinder can indicate an isolated problem with that power cylinder that is manifesting itself as a camshaft failure. 1. If the failure occurred on an injector lobe, check the injector from that cylinder on a calibration test stand (i.e., Number 1 left bank as noted above) to determine whether the flow rate is higher than specification. High injector flow rate increases hertz stress on the injector lobe, which can lead to premature lobe failure. 2, Inspect the tappet roller pin bore for wear in the vertical direction on the oil supply side. Wear on the oil supply side of the bore allows the tappet roller to run at an angle and can lead to edge loading on the camshaft lobe. hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 3128‘avsr2018 \Vo8 REBUILD GUIDELINES + For multiple lobes failed on the same camshaft (valve and/or injectors): The fuel pump calibration and governor setting must be verified to check for overfueling and overspeeding. The injector calibration must also be tested to verify proper flow rate, Check to see whether the wear was initiated on the front or rear edge of the roller contact area. If there is a cylinder block tappet bore alignment issue, the lobes on one camshaft can break down on the front edge while the break down can occur on the rear edge of the other camshaft. See Figure 1, Cam Follower Lobe Position Right Bank Tappet Roller ‘Cam Lobe _/- Surface Edge —] Loading Tappet Roller = Se : |] Edge LL toading ~~ i Cam Lobe: i Surface Figure 1, Cam Follower Lobe Position * Although the tappets must be inspected to help determine the root cause of the camshaft failure, it is recommended that new or ReCon® tappets be used at rebuild. Cummins does not recommend rebuilding tappets in the field. However, if circumstances dictate that the tappets be rebuilt, liquid nitrogen must be used to freeze the tappet pin prior to installation, Care must be taken to make certain each pin remains in the liquid nitrogen until just before (within 30 seconds) of installation. This action is required to prevent damage to the pin during installation in the tappet pin bores. if material is removed from the pin during installation, an early tappet or camshaft failure is more likely. The tappets must be inspected according to the Shop Manual V28 Engines, Bulletin 3666014. The most critical measurements are the roller-to-pin clearance and pin-to-body wear. hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 4126‘avsr2018 \Vo8 REBUILD GUIDELINES Section |l - Component Inspection for Reuse and Root Causes Investigation 1. Cylinder Block Inspection a. Measure the tappet bores (valve and injectors) 1/2 inch from the top of the bore and 1/2 inch from the bottom of the bore as indicated in Figure 2, Cylinder Block Injector Tappet Bore and Figure 3, Cylinder Block Valve Tappet Bore. If the tappet bores are oversize, the block must be replaced. Figure 3, Cylinder Block Valve Tappet Bore ‘a, Tappet bore alignment must be verified as discussed in Section 1. If multiple lobes failed, look for a pattern in the edge-loading. The edge-loading can be on the same edge of each lobe of the camshaft. Regarding the engine, one camshaft can fail on the front edge of the lobes, and the other camshaft can fail on the rear edge of the lobes (see Figure 1, Cam Follower Lobe Position). There is no field service tool that can accurately measure this misalignment. hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 526‘avsr2018 \Vo8 REBUILD GUIDELINES However, the following technique can be used in the field: If the camshafts have multiple lobe failures and the block needs to be verified, put a very thin coat of blueing ink on the new or ReCon® tappet rollers and insert them into the bores with the new camshafts already in place. Too much blueing gives a false indication. Apply pressure to the tappets and bar the engine over. The blueing indicates the tappet roller-to- camshaft lobe contact, The contact must be in the center of the lobe and roller. If the tappet bore is misaligned, the blueing is only located on the edge of the lobe. b. Inspect and measure the camshaft bushings according to the Shop Manual V28 Engines, Bulletin 3666014, and verify proper oil hole alignment. Camshaft Bushing I.D. mm in 53,962 MIN 2.1245 54.089 MAX 2.1295 2, Camshaft Inspection (if reused): Consult the Shop Manual V28 Engines, Bulletin 3666014 , for relevant specifications and procedures. a. Inspect the journal tolerances against specification Camshaft Bushing Journal O.D. mm in 53.85 MIN 2.120 53.92 MAX 2.123 a, Inspect the thrust washer thickness. A severely worn thrust bearing leads to excessive end play. Thrust Bearing Thickness mm in 2.29 MIN 0.090 2.49 MAX 0.098 a. Inspect the camshaft gear for excessive wear. b, Measure the clearance between the camshaft gear and the shoulder of the camshaft Maximum clearance must not exceed 0.13 mm [0,005 in}. 3, Fuel Pump Calibration: Consult the Shop Manual V28 Engines, Bulletin 3666014, and the Fuel Pump PT (Type R) Rebuild and Calibration Instructions, Bulletin 3379133, Verify that the CPL on the fuel pump matches the engine CPL. If it does not, the pump wil have to be recalibrated and sealed to prevent tampering. Before reusing the fuel pump, it needs to be calibrated to make sure it meets the specifications. Zero excess is permitted as overfueling increases the hertz stresses on the injector lobes. The fuel pump must be checked for the following: a. Rated rail pressure b. Torque peak rail pressure Iipsquckeervecummins.comsdipubsys2hxmlenfouletn-666454 him a2‘avsr2018 \Vo8 REBUILD GUIDELINES ¢. Governor breakpoint d. 40-psi checkpoint. Note : If there is evidence of overfueling, both camshafts must be replaced, regardless of hours on the camshafts or their condition. Overfueling can cause damage that is not immediately obvious in a inspection. 4, Injector Calibration/Assembly a. Verify that the injector part numbers match up with the engine CPL. b. Verify Injector flow rates. c. Verify injector cup part numbers are correct. The number of spray holes and the size of the spray holes can drastically affect the injection characteristics, as well as stress on the camshaft lobe. 5, Valve Collet, Retainer, and Stem Inspection: Excessive wear on the valve collets, retainers, and stems typically indicates the engine has been subjected to overspeed conditions. With excessive overspeed, a "no-follow” condition can occur where the camshaft tappet roller momentarily "floats" away from the camshaft When the roller contacts the lobe again, skidding occurs, which leads to premature breakdown. Check for valve indentations on the piston crown, bent valves, and bent pushtubes. Engine overspeed can be caused by any of the following conditions: a. Downhill, loaded operation using too low of a gear or transmission shift points set too high b. Governor set too high c. Incorrect pump calibration. Section Ill - Rebuild Facility Requirements 1, Cleanliness: Internal components of the V28 engine, particularly the camshafts and tappets, can be very sensitive to built-in dirt. To make certain that the amount of built-in dirt is minimized during rebuild, it is recommended that the shop meet the following guidelines: a. The assembly area needs to be separated from steam rooms, forklift traffic, wash bays, machining areas (j.e., grinders), and outside air. Ideally, the assembly area is located in an enclosed area with a controlled environment. b. Capacity to thoroughly clean engine blocks and components c. The engine and all cleaned components must be covered to prevent dirt from collecting in the assembly when no work is being done. d. The wash tanks and hot tanks used to clean the components must be properly maintained, The effectiveness of the wash tanks are affected by chemical concentration, solution temperature, cleanliness level of the solution, and residence time of the parts in the tank. The component cleaning process must be well documented to maintain consistency. e. Oil drilings in the cylinder block must be cleaned using steel brushes on rods that are long enough to extend completely through the longest drilling. Often, compressed air or high pressure water alone does not remove all the dirt that can cause damage 2, Engine Run-in Period with Engine Dynamometer: Consult Shop Manual V28 Engines, Bulletin 3666014. The procedure outlined in the shop manual detects assembly errors and identifies final adjustments needed for correct engine performance hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 7126‘avsr2018 \Vo8 REBUILD GUIDELINES The lubrication system must be primed before starting the engine. Once the engine has been run in, the overhead settings must be verified If the engine is stored (short or long term), the procedure outlined in the Shop Manual V28 Engines, Bulletin 3666014, must be followed. Before starting an engine that has been in storage, the following steps must be taken © Fill the oil pan sump, oil filters, and fuel filters. © Fill the coolant system if necessary. © Prime the lubricating system Section |V - Engine Assembly and Latest Updates Note : During rebuild, it is recommended that the engine be updated to the most recent CPL. See Group 4, Cam Followers and Tappets in this section for the latest CPL changes, The following information gives all of the latest updates to the V28 engines (arranged in order of component group) and must be used for any repair work that is undertaken. This information can also be used as a reference to supply customers with latest information. Group 1 - Cylinder Block 1. Block Cleanliness Before assembly begins, the cleanliness of the block must be checked (specifically oil holes and rifles that feed the camshaft bushings). It is strongly recommended that all cup plugs and pipe plugs be removed during the cleaning process. Group 2 - Cylinder Head Premium Cylinder Heads Cummins recommends the use of premium cylinder heads to replace the standard cylinder heads. Standard cylinder heads can be reworked to convert them to premium cylinder heads. See Cylinder Heads (prior to 1994) Upfit procedure on page 10. Premium cylinder heads utilize tribaloy intake valves and inserts. Valve rotators are also used on the intake valves in premium cylinder heads which means that the intake valve springs are a different height than the standard cylinder heads. The purpose of these changes is to reduce valve beat in and overhead wear on high duty cycle, constant speed engines. This product was introduced January 1995, on ESN first 25207547 Chrome Plated Exhaust Valves Anew exhaust valve with a chrome plated stem has been released for V28 engines. This new valve provides increased durability through reduced valve stem and valve guide wear. The old exhaust valve is Part Number 145701 and the new exhaust valve is Part Number 3803524 The non-generator drive engines with chrome plated exhaust vaives was effective November 1994 with ESN first 25193909 The generator drive engines with chrome plated exhaust valves was effective February 1995 with ESN first 25205528. Table 2, Premium Cylinder Head Components Part Number Part Name Quantity hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 8126sa16r2018 ‘V2 REBUILD GUIDELINES Table 2, Premium Cylinder Head Components Part Number Part Name Quantity 3088264 Premium dry application head 1 3088267 Premium wet application head 1 3084186 Tribaloy intake valve (chrome stem) 6 3084185 Tribaloy intake insert 6 219091 Rotocoil (intake) 6 219092 Spring (intake) 6 3803524 Exhaust valve (chrome stem) 6 127930 Exhaust insert 6 211999 Exhaust spring 6 Premium cylinder heads are mandatory for power units and marine engines, but are optional for construction and generator drive engines. ICylinder Heads (prior to 1994) Upfit Instructions Cylinder heads produced prior to 1994 must be machined to provide clearance for the installation of rotators under the intake valve spring. A clearance cut, centered on the existing valve guide bore (A), of 38.10 mm 0.025 mm [1.500 + 0.010 in] diameter, must be machined to the existing valve aes spring seat surface (B). Overhead Settings 1, Set the overheads according to the Shop Manual V28 Engines, Bulletin 3666014. 2. Examine the height of the adjusting screws above the locknuts. Variation in the height of the adjusting screws (extra threads showing) can indicate an incorrectly seated socket or other defect. Group 3 -Rocker Levers Injector Timing The injector timing must be verified to match the CPL codes. Consult Shop Manual V28 Engines, Bulletin 3666014, for the procedures. Note : Engines stamped with CPL 1595 and 0.052 timing require an offset pointer, see to the Shop Manual V28 Engines, Bulletin 3666014. Note : The timing pointer on the V28 engine has been revised. See the new timing pointer section below for the revisions. New Timing Pointer The timing pointer on the V28 engine has been revised to improve the accuracy of the exhaust valve lash settings on engines with revised exhaust valve lobe profiles. The new camshaft lobe profile was designed to avoid a no-follow condition between camshaft lobes and rollers. No- hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 9i26sa16r2018 ‘V2 REBUILD GUIDELINES follow conditions can lead to camshaft roller skidding and subsequent camshaft lobe damage The setting point has been advanced 22.2 mm [0.88 in]. This can be done by turning the existing pointer over or installing a new pointer, Part Number 3095002. Engines manufactured after May 1995 have been equipped with the new pointer on ESN first 25207706. Note : This overhead setting location can be used on all V28 engines. 03500001 Figure 4, Old Pointer hitpsquickserve, cummins. comigsS/pubsys2/xmi/enfoulein/3666454.him! 70126sa16r2018 ‘V2 REBUILD GUIDELINES Figure 5, New Pointer Note : New pointers have a raised lip to prevent mis-assembly. Table 3, Revised Exhaust Lobe Camshaft Part Numbers 1D 21 Camshaft Part Number CPL Number 3801020 1597 3801021 1697 0679, 0680, 0759, 1689, 1690, 1692, 1693, 3801307 2950, 1195, 1651, 1176, and 21024 0679, 0680, 0759, 1689, 1690, 1692, 1693, 3801308 2950, 1195, 1651, 1176, and 21024 3803587 1691 and 1595 3803588 1691 and 1595 Group 4 - Cam Followers and Tappets Note : This group introduces + New camshaft for VTA28 engines rated at 635 bhp at 2100 rpm + New fuel pump codes used with new camshaft + Rumbled camshaft + Camshafts with revised exhaust lobes Camshafts Extreme caution must be taken not to damage the camshaft or bushings while inserting the camshaft into the block. Lubricate each camshaft lobe and all of the camshaft bushings with 15W-40 engine oil. Verify the camshaft bushing oil hole alignment is correct. This allows the hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 11108sa16r2018 ‘V2 REBUILD GUIDELINES maximum amount of oil flow to the camshaft bushing, New Camshafts Two new camshafts, Part Numbers 3078018 and 3078019, have been released to reduce soot formation in engines built to CPL 680 rated at 635 bhp at 2100 rpm. The new camshafts have the injector lobe timing advanced approximately 3-camshaft degrees from the previously used camshafts, Part Numbers 3070838 and 3070837. New CPL 1595 has been released to include these new camshafts. See Table 4, Control Parts List for CPL 1595. Note : New engines built to CPL 680 rated at 635 bhp at 2100 rpm are no longer available. Camshafts, Part Numbers 3070837 and 3070838, remain for other CPLs and for CPL 680 engines that are not rated at 635 bhp at 2100 rpm. AXCAUTION A Do not use the new camshaft, Part Numbers 3078018 and 3078019, in engines originally built to CPL 680 that have a nominal horsepower rating other than 635 bhp at 2100 rpm. Using the new camshafts with a fuel pump code other than the one listed in Table 5 results in excessive cylinder pressure and decreased durability. Do not use the new camshafts unless the fuel pump calibration is changed to the appropriate code in Table 5 or the cylinder pressure can be excessive and engine durability can decrease, Table 4, Control Parts List for CPL 1595 Injector Camshaft Piston Turbocharger | Engine Models 3054255- 3078018 RB VTA28-C (635) 156BK 3080819 LB 3040097 3523590 VTA28-L3 (635) Cylinder Head | Timing Exhaust Aftercooler are es 133573, U (0.0525) Dry 3411460, ASA Notice that the injector timing for CPL 1595 is different from that for CPL 680. The standard 0.0115-inch offset key, Part Number 3021595, installed in the retard position (offset in the direction of camshaft rotation) will normally result in the injection timing being within the specification of 0.050 to 0.055. A slip-fit camshaft gear can be used to more quickly select the proper keys. If a slip-fit camshaft gear is used, always confirm the injection timing is within specification after the standard camshaft gears have been installed. Table 5, Fuel Pump Code Supercession New Code Old Code: Torque Rise 10 percent torque rise with check valves Vvo9s \VOS6 hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 12126sa16r2018 ‘V2 REBUILD GUIDELINES Table 5, Fuel Pump Code Supercession New Code Old Code Torque Rise ose Vos4 36 percent torque rise with check valves 36 percent torque rise voor vos4 without check valves 10 percent torque rise vo98 voso without check valves Rumbled Camshafts All V28 camshafts are now rumbled to improve durability. The rumbling precess induces residual compressive stress to the camshaft surface, making it stronger. Rumbling also changes the surface texture so that the lobe surface retains more lubricating oil, even under high loads during fuel injection. Rumbled camshafts can be visually distinguished from the old lapped camshafts (Figure 6, Lapped Camshafi-Left, Rumbled Camshaft-Right). The camshaft lobes and bearing journals on rumbled camshafts have a dull gray or brownish-gray appearance. The camshaft lobes and bearing journals on lapped camshafts are bright and shiny. The appearance caused by the rumbling is not unlike that of a part that has been bead blasted. The part number has not been changed for the rumbled camshafts. Figure 6, Lapped Camshaft (Left), Rumbled Camshaft (Right) Comparison Exhaust Valve Lobe In October 1991, new camshafts with a revised exhaust lobe profile were released to improve camshaft durability. The new lobe profile provides for an improvement in the exhaust valve train no-follow speed, thus decreasing the possibility of the tappet roller skidding on the camshaft lobe. Repetitive tappet roller skidding can lead to failure of the tappet roller and/or the camshaft. The change in the exhaust valve profile does not increase engine-rated speed or overspeed hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 13126‘avsr2018 \Vo8 REBUILD GUIDELINES capabilities. Only the camshafts for right-handed rotation engines were changed. Camshafts for left-handed rotation engines have not changed. Refer to Table 6, V28 Camshaft Progression, for camshaft part number supersession and ESN first information. General The following intermixing guidance is to be used with camshafts that are within the same CPL. 1, Rumbled and non rumbled camshafts can be intermixed. 2. Camshafts with and without the revised exhaust lobe can be intermixed. 3. Camshafts with and without the revised injector lobe must not be intermixed. AXCAUTION A Do not attempt to advance the injection timing on camshafts that do not have the revised injector lobes on CPL 680 engines, or the pistons can hit the valves. Camshafts with the revised injector lobe must be installed in pairs if they are installed in an engine originally built to CPL 680. If the camshafts are installed in an engine originally built to CPL 680, change the data tag to show CPL 1595. Table 6, v28 Camsh aft Progre ssion Camsh | Servic Revise | pavige | Supers aft ekit | cine | Engine | Rumbt | a i eded | Date in Part | Part | o03y° | Rotati [ed*3 | Exhau | 10 ., | byPart | Produ Numbe | Numbe on 6 st i Numbe | ction rLobe r r Lobe r 173340 peorce Right | Left Yes No No Presen 173350 peotee Left | Left | Yes No No Presen 195500 | 3°97? | right | Right Yes | No | No | Presen 195510 peotee Left Right | Yes No No Presen 163880 pete Right | Right | No No No aurea 163930 sporee Left | Right | No No No gore 307084 | 380102 Presen | Octobe 3 3 Right | Right | Yes | Yes | No f votea 307084 | 380102 Presen | Octobe ‘ , Let | Right | Yes | Yes | No ' vorea hitpsquickserve, cummins. comigsS/pubsys2/xmilenfoulein/3666454.him! 74126sa16r2018 ‘V2 REBUILD GUIDELINES Table 6, v28 Camsh aft Progre ssion Camsh aft Part Numbe e Servic eKit Part Numbe e Engine Bank Engine Rotati on Rumbl ed*3 6 Revise Exhau st Lobe Revise d Injecto r Lobe Supers eded by Part Numbe r Date in Produ ction 302645 1 380130 7 Right Right No No No 307083 7 302654 2 380130 8 Left Right No No No 307083 8 307083 7 380130 7 Right Right Yes Yes No Presen ia Octobe r91'4 307083 8 380130 8 Left Right Yes Yes No Presen t'2 Octobe r91t4 307801 8 380358 7 Right Right Yes Yes Yes Presen t'7 May 92 "5 307801 9 380358, 8 Left Right Yes Yes Yes Presen v7 May 92 5 4 Supers eded by 307801 8 for engine s rated at 635 bhp at 2100 tpm original ly built to CPL 680 hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 16:26sa16r2018 Table 6, v28 Camsh aft Progre ssion ‘V2 REBUILD GUIDELINES Camsh aft Part Numbe e Servic eKit Part Numbe Engine Bank Engine Rotati on Rumbl ed*3 6 Revise Exhau st Lobe Revise d Injecto r Lobe Supers eded by Part Numbe Date in Produ ction 2 Supers eded by 307801 9 for engine s rated at 635 bhp at 2100 rpm original ly built to CPL 680 *3 Al product ion engine s from 251859 49 12 May 92 have rumble d camsh afts “4ESN first 251822 12 hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 16126sa16r2018 Table 6, v28 Camsh aft Progre ssion ‘V2 REBUILD GUIDELINES Camsh aft Part Numbe e Servic eKit Part Numbe Engine Bank Engine Rotati on Rumbl ed*3 6 Revise Exhau st Lobe Revise d Injecto r Lobe Supers eded by Part Numbe Date in Produ ction *5 ESN first 251858 22; refer to Table 7 Engine s Chang edat Cummi ns Plants From CPL 680 to CPL 1595 hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 726sa16r2018 ‘V2 REBUILD GUIDELINES Table 6, v28 Camsh aft Progre ssion Camsh | Servic Revise | Revise | Supers aft eKit Engine | Engine | Rumbi | d 4 eded | Date in Part Part a Rotati | ed*3 | Exhau by Part | Produ Numbe | Numbe | @"* | on 6 st Inject | Numbe | ction r Lobe e e Lobe r *6 All service camsh atts have been rumble d starting 1 Novem ber 91 except 307083 7 and 307083 8 which started 15 Februa ry 92 7 only used in cPL 1595 The camshafts have been changed in some engines built prior to the ESN first 25185822 as they were processed through Cummins plants other than the original manufacturing plant. Refer to Table 7, Engines Changed at Cummins Plants From CPL 680 to CPL 1595, for the engine serial numbers of these engines. Table 7, Engines Changed at Cummins Plants From CPL 680 to CPL 1595 25173985 hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 18126sa16r2018 ‘V2 REBUILD GUIDELINES Table 7, Engines Changed at Cummins Plants From CPL 680 to CPL 1595 25176052 25176107, 25176108, and 2517609 25176605, 25180977 25182717 and 25182718 25183003 25183739 25184489, 25484491, and 25184492 25185354, 25185355, 25185356, and 25185357 25185620 25185818, 25185819, 25185820, and 25185821 The engine and fuel pump dataplates on all engines were changed, However, OEPL data will reflect CPL 680 and the original build pump codes. Note: + Cummins recommends adjusting the V28 valves and injectors at 1500-hour intervals + If the injector tappets have crowned rollers, adjust the injector to 8 Nem [70 in- ib] torque. All injector tappet rollers made after January 1985, ESN first 37109220, have crowned rollers. All engines with ESN first starting with 25 have crowned injector tappet rollers also. + Cummins recommends that injectors be removed and rebuilt or replaced at 6000-hour intervals. Tappets Tappet Installations: 1, Drilled Hole Tappets Replace non-drilled valve and injector tappets with new style tappets with drilled holes. The newer drilled oil hole tappets provide pressurized oil to the camshaft lobes and tappet rollers Puller holes have been added to aid the removal of the valve tappets. A pressurized lubricating oil hole has been added to the V28 injector and valve tappets to improve the life of the camshaft and roller. The addition of the oil supply hole does not change the engine oil pressure specifications. The tappets that are drilled and the tappets that are not drilled can be used in the same engine. Table 8, Parts Status New PartNumber | Part Name Old Part Number | O14 Stock Disposition 3019155 Valve tappet 3019155 Use 3019156 Injector tappet 3019156 Use hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 19126sa16r2018 ‘V2 REBUILD GUIDELINES ESN first is 25166293, March 21,1989. It has been determined through extensive testing that the tappet guide retaining ring, Part Number 135530, is not required to retain the tappet guide on the injector tappet, Part Number 3019156, in the V28 Series Engines. Table 9, Parts Status Part Number Part Name Part Status 3019156 Injector tappet with retaining | ring 3019186 Injector tappet without Use retaining ring The retaining ring can remain on the tappet if it is already installed ESN first is 25165697, February 11,1989. 2, Pin Material Change Significantly more wear resistance is gained with the release of a new tappet roller pin material. New material CMS 54030 (manganese phosphor bronze) will replace old material CMS 54000 (phosphor bronze). Camshaft life will also improve. The new material will be marked with an ‘M' on the pin. New injector tappet pins, Part Number 4071444, and new valve tappet pins, Part Number 4071443 began installation on 9 August 2001 (ESN first 25273489), 3, Rebuilding Tappets Cummins recommends using new or Cummins Recon™ manufactured tappets during repairs and engine overhauls. This is to make certain that a quality tappet assembly is used and protects the customer if a failure occurs, If it is deemed necessary to rebuild tappets, new tappet pins and rollers must always be used. Never re-use a tappet pin that has been removed from a tappet. Proper inspection of the tappet body is also critical New tappet pins in a worn tappet body eventually result in tappet failure. Rebuilt tappets must follow Cummins recommendation to freeze the tappet pin prior to installing it into the tappet body. The tappet pin must slide freely into the tappet body to prevent any scuffing of pin material The following items must be verified when installing tappets into the block: 1, The tappet assemblies must be pre-cleaned 2, The tappet pin oil hole alignment is correct, 3, The tappet socket oil hole is open. Push Rods Push rod installation The ball and socket wear must be checked against the specifications outlined in the Shop Manual V28 Engines, Bulletin 3666014. hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 20728sa16r2018 ‘V2 REBUILD GUIDELINES Group 6 - Injectors and Fuel Lines Top-Stop injectors must replace non top-stop injectors where applicable. Top-Stop injectors reduce injector lobe loading and wear on camshafts. Top-Stop injectors have the identical cup and flow specifications as the existing PTD injectors so that there is not a change in engine performance. The top-stop injectors require a different hold down clamp, Part Number 3028171 The overhead setting procedure and values do not change. Table 10, Overhead Settings Component to Set Setting Outer base circle injector set 8 Nem [70 in-tb] intake lash 0.35 mm [0.014 in] Exhaust lash 0.68 mm [0.027 in] The top-stop injector change for these engines causes the CPL to change. When top-stop injector assemblies are installed, the new CPL must be stamped on the engine dataplate and the fuel pump dataplate for future service reference. The fuel pump does not require recalibration, only the fuel pump code will change. Do not mix the injector assemblies. Cummins Inc., recommends that the injectors only be exchanged as a complete set. Table 11, Injector Conversi ons PTD Top-Stop Engine | Configura | PTD injector | TPStP | injector | Effective tion Injector Injector Model Part Part Date Number | CPL cPL Number Number vraze- | 0153091 tooo oxen 0679 3054255 | 1689 3084108 | 28 April 93, ViAzé- | 0153094 ie oxen 0680 3054255 | 1690 3084108 | 28 April 93, VTAzé- | 0153094 ie oxen 1595 3054255 | 1691 3084108 | 28 April 93, VTAzé- | D153099 os00 oxeo 0759 3054258 | 1692 3084109 | 28 April 93, VTAze-M2 | 0153045 07 June (675) uxo2 1593 3078016 | 1693 sosatio | 3) The ESN first to reflect this change is 25192043. hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 216sa16r2018 ‘V2 REBUILD GUIDELINES Group 7 - Lubricating Oil System Lubricating Oil Cooler Lubricating oil cooler elements must be pressure tested to enable detection of any leaks. Any leaks require the element be replaced with a new one. Do not attempt to make repairs to the element. Prelube Starter Option Cummins encourages customers to install this option. The option allows the lubrication system to be pressurized prior to engine start up. This allows for maximum lubrication availability to critical components at the moment the engine is started. Cummins highly recommends this option to reduce potential wear on tappet roller pins and prevent camshaft damage. See the Prelubrication Device for High Horse Power Engine Service Bulletin 3666091, for more information Group 10 - Air Intake System Flanged Aftercooler Core Anew flanged design aftercooler core design has been released for improved durability on severe applications. The new aftercooler core Part Number is 3001519. This new core is more durable and has a higher cooling efficiency which reduces combustion and exhaust gas temperatures. This in turn improves engine efficiency and durability. This change is effective for service only on industrial engines. The following procedure provides installation instructions for updating V28 industrial engines in service that experience aftercooler failures on the flange mounted aftercooler cores. lAftercooler Assembly Upgrade Consult Shop Manual V28 Engines, Bulletin 3666014, for disassembly, cleaning, and inspection procedures. AXWARNING A Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Using a 7/16 inch drill, drill the existing 8 cross bolt holes. Using a 1/4 inch pipe tap, tap the 8 cross bolt holes. Clean the housing using compressed air. ‘Apply thread locking compound to a 1/4 inch pipe plug. Install the pipe plug into the housing. hitpsfquickserve,cummins.comlgsS/pubsys2/xmifenfouletn/3666454.him! 22106‘avsr2o18 \Vo8 REBUILD GUIDELINES Tighten the pipe plug [Torque Value: 20 nem [177 in-tb ] Repeat the above procedure for the remaining cross bolt mounting holes. Assembly Place the aftercooler housing in a horizontal position with the cover plate mating surface positioned upward Install guide pins in opposing corners to assist in the assembly of parts. Apply a light film of RTV, Part Number 3823494, to the gasket and mating surface to hold the gasket in place during assembly, Place a new gasket, Part Number 3077201, on the after cooler housing. Install new o-rings on the aftercooler core inlet and outlet connections. Place the aftercooler core into the housing. Place a new gasket, Part Number 3077201, on top of the aftercooler core. Install the aftercooler cover. Remove the guide pins. Place RTV under the head of each capscrew and install the 24 capscrews into the cover. Tighten the capscrews in the sequence shown. {Torque Value: 34 nem [25 ft1b] rnntent QUT I hitpsfquickserve,cummins.comigsS/pubsys2/xmifenfouletn/3666454.him! 226sa16r2018 ‘V2 REBUILD GUIDELINES Slot the lower portion of the coolant inlet tube flange mounting holes downward 3.81 mm [0.150 in]. Install the inlet and outlet connections and tighten the capscrews. Inlet connection: Torque Value: 45 nm [35 ft-lb ] Outlet connection: [Torque Value: 28 nem [20 ft-lb] Section V - Customer Practices The end users or customers of the V28 engine can increase the life of their engines by following some simple guidelines. 4. Oil Quality: Cummins Inc. recommends the use of 15W-40 oil. Oils with an API classification of CH-4 are preferred if they are available. Lower API classification oils (CG-4, CF-4) can be used if CH-4 is unavailable, To optimize camshaft and engine life, the customer must use the highest quality oil available in their region. For more information on oil specifications, refer to Cummins Engine Oil Recommendations, Bulletin 3810340 The use of a 15W-40 oil (API CH-4) will provide the following benefits for the engine: a. Better cold pumpabilty, which means oil is supplied to camshaft and tappets faster during cold starts, b. More stable viscosity over a wider temperature range. Stable viscosity is critical to maintain the oil film at high temperature. c. Better oxidation resistance, Exhaust gases cause oxidation, which breaks down oil The acid level in the oil (usually expressed as TAN) will increase with oxidation. Higher acid levels in the oil cause more aggressive wear toward bearing and wear surfaces, d. More stable additive package. e. Better dirt dispersing capability, which allows the oil to carry the dirt to the lubrication filters where it is removed 2, Service Intervals: Cummins Inc. recommendations for service intervals for the V28 engine are as follows: a. 250-hour oil drain and filter change intervals for API CD oils and above. b. 125-hour oil drain and filter change intervals for API CC oils. c. Must have bypass filtration. d. Do not extend service intervals by any method. hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 20726tarz018 \a8 REBUILD GUIDELINES e. Use name-brand, high-quality lubrication filters (full-low and bypass), such as Fleetguard®. 3, Maintenance: In addition to oil and filter changes, the customer must make sure the following items are part of their routine maintenance practices: a. The overheads must be adjusted at 1500-hour intervals by a qualified technician. Check the valves, injectors, and crossheads and record excessive wear. b. Clean and calibrate the fuel pump and injectors at D-check intervals. c. Utilize an oil analysis program to detect fuel, coolant, dirt, excessive metal particles, and oil deterioration 4, Operator Training: Operators must be trained to understand how their operating practices affect the engine life of the equipment. Specific areas that affects camshaft life directly are: a. Proper operating procedures. These procedures need to be in place to avoid engine overspeed where the load drives the engine, Overspeed occurs at 2400 rpm for the V28 engine b. Effects of engine overspeed i, Tappet roller reaches no-follow conditions ii, Oil flm breakdown il, Valve collet, retainer, stem wear, bent valves, and bent push tubes iv. Possible dropped valves. a, Proper warm-up and cooldown cycles. Allow the engine to idle 3 to 5 minutes after a full load operation before shutting down. This allows the engine to cool gradually and uniformly. Likewise, the engine must be allowed to warm up at idle until the coolant temperature reaches 71° C [160° F] (approximately 3 to 5 minutes). 5, Changes to fuel pump calibration Any adjustments to the fuel pump calibration or governor setting can drastically influence the life of the V28 camshafts. As mentioned earlier, overfueling increases the hertz stresses on the camshaft injector lobes, which leads to premature failure. 6, Prelube starters: Prelube starters can be used to make certain the engine has immediate oil pressure to the camshaft at start-up. Having oil at the camshaft at start-up prevents the normal wear and tear associated with “dry starts." A prelube starter needs to be considered at rebuild. The 28 Prelub™ integral starter kit is Part Number 3803791, and the remote starter kit is Part Number 3803793. Section VI - Recent History of the V28 Engine Relative to Camshafts The table below outlines the changes that have taken place to increase the durability of the V28 camshaft Table 12, Major Product Changes (timeline summary) Jan 89 First V28s produced in India. Feb 89 Oil drilling added to valve and injector tappets Nov 91 Began rumbling process for service camshaft hitpsquickserve, cummins. comigsS/pubsys2/xmi/enfoulein/3666454.him! 2526sa16r2018 ‘V2 REBUILD GUIDELINES 20 Feb 92 Pin material improved at Cummins India Ltd 27 Mar 92 Oil drilling added to ReCon® process 12 May 92 Began rumbling process for production camshafts at Cummins India Ltd. See Section IV, Engine Assembly and Latest Updates, Group 4, Cam Follower and Tappets for details of the rumbled cam introduction Jan 93 Exhaust lobe redesigned to reduce skidding at 2300 rpm Jan 93 Improvements made at Cummins India Ltd to improve tappet bore quality Jan 94 ReCon® implemented 25-ft-b torque test for top retainers Jun 94 Tappet guide plate alignment inspection implemented at ReCon® Jun 94 New tooling at Cummins India Ltd improved tappet bore capabilities Oct 94 Started drilling valve tappet bodies at ReCon® May 96 Improved assembly and measurement process implemented at ReCon® (tappets marked with an "M") 10 Oct 98 Atlas tempering furnace temperature adjusted to increase cam hardness. MCR No. 98-203 Last Modified: 12-Apr-2007 hitpsfquickserve,cummins.comlgsS/pubsys2/xmilenfouletn/3666454.him! 2628