O & M Manual Gas & Dual Fuel

Operation and Maintenance Manual
Gas and Dual Fuel Engines
BULLETIN NO. 3243676-04

24 Hour Emergency Service
In the very unlikely event of you are not receiving the normal
prompt attention from our field force, following are the residence
telephone numbers of our officers for assistance.
While asking for assistance please

provide the following information.
1. Your Name & Phone or Fax

Number.
2. Engine Serial Number.
3. Name of the Customer.
4. Engine Location.
5. General Description of
Assistance required.
P.J.M. Khan ........................................... (020) 5434472 9822045502

R. S. Pasrija ........................................... (020) 5437679 9822061204
Cummins India Limited

Registered Office : Kothrud,-- Pune 411 038 (India)
Telex No. : 0145-7244/0145-7541 KCL IN Visit us at : www.cumminsindia.com
Phones : 5380240, 5385435, 5381105 Fax : (020) 5387125
Cummins Diesel Sales and Service (India) Ltd.
35A/1/2, Erandawana, Pune 411 038 (India)
Telex No. : 0145-7254/0145-7307 CDSS IN E-mail : Powermaster-India@Cummins.com
Phones : 5330066, 5331703, 5331234, 5330166, 5330356
Fax : (91) 020-5339490 Free-Toll No. : 1-600-332000
A.V. Nerlikar ................ (020) 5383633 9822390265 BANGALORE: S.K. Sehgal .. (080) 3073008 9845150107 LUCKNOW : Sharma A.K.(0522) 2331307 9839073433
B. Shyam Seshadri ..... (020) 6681933 9822036513 CHENNAI : R.P. Das .......... (044) 24401073 9841073543 MUMBAI : Bathe S. G. (022) 24973483 9820136143
M.S. Athalye ................ (020) 4352424 9822070542
DELHI : T.S. Rithal ............. (011) 28636950 9810399301 RAIPUR : Kaul Rewati (0771) 2427148 9826152102
Sampat Harpale ........... (020) 4001820 9822036370
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S. S. Kulkarni .............. (020) 5656939 9822036323
D. Tandon ..................... (020) 5880188 9822041149 JAIPUR : Pawar M. G. ..... (0141) 2225863 9829057417 Vadodara : S. D. Karnik(0265) 2314844 9824096860
V. Nageshwaran ........... (020) 5897321 9822002930 KOLKATA : Bhowmick K. K.(033) 24220273 9833051281
Forewor
Forew d
ord
This Manual is applicable to all Natural Gas Engines currently
being produced by Cummins India Limited, Pune 411 038 (INDIA).
It contains instructions for operators that will enable them to get
the best service from their engines. Before operating the engine
become familiar with the procedures described.
The maintenance section is for the men who are responsible for
the upkeep and availability of engine on the job. The maintenance
program is simple, realistic, easy to control and profitable one to
practice.
Repair operations should be performed by specially trained

personnel who are available at Cummins Distributor and all Dealer
locations.
Natural gas is the cleanest fossil fuel. To harness its enormous

potential, Cummins has been developing gas engine technology
for longer than three decades. Cummins India Limited has been
manufacturing and marketing Gas engines for the last 25 years.
Today, more than 4000 Gas engines built by Cummins India are
operating all over the world.
Cummins Natural Gas Engines are the first choice of ONGC, Oil
India Limited, NDDB and major Tea Gardens across the country.
Cummins gas engines have unique features. They can operate
on a variety of gaseous fuels like Natural gas, Bio Gas, Sewage
gas, LPG, etc.
Also their state-of-art technology provides high engine

performance, fuel economy, low emission and greater load
bearing capacity.

Registered Office : Kothrud, Pune 411 038 (India)
2
10 Maintenance Steps
for Cummins Engines
1 Keep dirt out of the engine
2 Maintain a lubricating film

on all bearing surfaces
3 Regulate the engine’s fuel
4 Control operating temperatures
5 Guard against corrosion
6 Let the engine breathe
7 Prevent overspeeding
8 Know your engine’s condition
9 Correct troubles while they are

simple
10 Schedule and control

your maintenance
Table of Contents
able
SECTION 1 OPERATING PRINCIPLES ............................................................................ 13
SECTON 2 ENGINE OPERATIONS ................................................................................. 53
SECTION 3 INSTALLATION AND SCHEDULE MAINTENANCE ........................................ 67
SECTION 4 SPECIFICATIONS AND TORQUE ................................................................. 89
SECTION 5 ENGINE WIRING DIAGRAMS ....................................................................... 99
SECTION 6 TROUBLE SHOOTING ................................................................................ 115
SECTION 7 CUMMINS DIESEL SALES & SERVICE NETWORK .................................. 139
3
CUMMINS OWNER ASSISTANCE CUMMINS ENGINE
SERVICE TRAINING COURSES
Cummins India Limited backs its engines with expert
service and complete parts support. We built a service
network of Cummins dealers, the largest in INDIA devoted Services Training Courses are available for
exclusively to diesel engines. We trained our people to customer’s technical personnel involved in Cummins
provide the Cummins owner with sound advice, expert Engine Maintenance, Operation and Repair. These
service and professional treatment at all Cummins locations. courses are conducted on a scheduled basis in Pune
Service Training Schools, by
Any problem that you have in connection with the sale,
operation or service of your engine can be handled at the
nearest Cummins location. Occasionally, you may feel a Cummins Diesel Sales and
problem has not been handled to your satisfaction. At Service (India) Ltd
those times, we urge you to pursue the problem until you 35-a/1/2, Erandawana, Pune 411 038.
are satisfied.
Not all problems are of engineering nature, several arise Customers, desirous of availing the training facilities
from communication gaps or sheer misunderstanding; either may contact the Training Manager
or both the parties may be involved in the procedures to
see a simple way out. The field person may also be Cummins Diesel Sales and
immobilized if he faces a real policy decision.
Service (India) Ltd
In all such events, we sincerely request you to take your 35-a/1/2, Erandawana, Pune 411 038.
problem to the higher levels till you are fully satisfied.
The service training courses offered are :
We suggest the following points of contact :
1. If problem originates with a salesperson or service 1. Engine Familiarization and Maintenance Course
technician, talk to the sales or service manager.
2. Engine Rebuild Course
2. If problem originates with a sales or service manager,
talk to the owner of the service location who is the 3. Cummins PT Fuel System Course
dealer.
3. If problem originates with a dealer, please call the 4. Correspondence Course Part I & II.
nearest Cummins Diesel Sales & Service, Regional
Office. Most problems are solved at or below the The service Training School also makes available
regional office level. Their phone numbers and Service Training Publications pertaining to Cummins
addresses are listed. However, before you can,
Engine Maintenance, Operation Repair. The list is
please write down the following information and have
it ready. available with,
A. Name and location of the Cummins dealer. Training Manager,

B. Type and make of equipment.
C. Engine model and serial number. Cummins Diesel Sales and
D. Total miles/kms. or hours of operation. Service (India) Ltd
E. Nature of problem. 35-a/1/2, Erandawana, Pune 411 038.
F. Summary of the current problem arranged in the
order of occurrence.
If you still have problems please write to :

Manager Product Quality Committee & Field Service
Engineering

Registered Office : Kothrud Pune 411 038 (India)
We do request that above steps be followed in order. Most

of the actual work on an engine can be performed at the
original location, so please give them a chance to satisfy
you first.
4
Engine Specifications
a) Engine Models and Specifications (G-Drive Applications)
b) Engine Models and Specifications (Industrial Applications)
c) Advantages of Gas Engines
d) General Operating Instructions
e) Difference between Gas and Diesel Engine
f) Derating guidelines with reference to gas composition (Natural gas engines)
g) Derating Procedure
h) 10 Maintenance Steps for Cummins Engines
5
Cummins Gas Engines Service Manual
a) Engine Specifications
i) Engine Models and Specifications (G-Drive Application)
Engine Bore Stroke Displacement Compression BHP rating

Model mm mm litre ratio at 1500 rpm
(Prime Power)
G-495-G 130 152 8.1 12:1 92

10:1 86
8.5:1 81
G-743-G 130 152 12.2 12:1 137

10:1 129
8.5:1 121
G-855-G 140 152 14 12:1 167

10:1 157
8.5:1 147
G-1710-G 140 152 28 12:1 333

10:1 313
8.5:1 293
GTA-855-G 140 152 14 10:1 242

8.5:1 227
GTA-1150-G 159 159 18.9 8.5:1 333

7.5:1 313
GTA-1710-G 140 152 28 10:1 480

8.5:1 451
GTA-2300-G 159 159 37.8 8.5:1 600

7.5:1 570
GTA-3067-G 159 159 50.3 8.5:1 800

7.5:1 750
6
ii) Engine Models and Specifications (Industrial Application)
Engine Bore Stroke Displacement Compression BHP rating

Model mm mm litre ratio at 1800 RPM
G-743-P 130 152 12.2 12:1 165

10:1 155
8.5:1 145
G-855-P 140 152 14 12:1 200

10:1 188
8.5:1 170
G-1710-P 140 152 28 12:1 400

10:1 376
8.5:1 352
7
b) Advantages of Gas Engines

1. The basic design of a gas engine is derived from a diesel engine. Since the peak cylinder
pressure of a diesel engine is higher than that of a gas engine, the load bearing parts and
basic design of the power assembly and gear train being that of the diesel is much more robust
and durable leading to longer engine life.
2. Gas is abundantly available and also cheap as compared to diesel.
3. Gas induction through carburetor, requires low pressure.
4. It requires no additional battery for ignition with altronic magtronic ignition system.
5. No lube oil dilution due to fuel and lower lub oil contamination due to cleaner combustion.
6. Combustion is paniculate free and more complete.
7. Exhaust is smoke free, hence helps for environment protection.
8. Reduced maintenance cost. Reduced contamination of lube oil results in longer change periods
of lube oil and filters.
9. The running cost of gas engines is low due to low cost of fuel and lub oil.
10. Both naturally aspirated and turbocharged and after cooled models are available.
11. Special ignition system assures high voltage at spark plugs even at low engine speeds. Shielded
ignition system is available for operating in hazardous areas.
12. Nationwide service network and easy spares availability.
c) GENERAL OPERATING PRINCIPLES
Gas engine works on the Otto cycle and is a spark ignited engine.
During the intake stroke, the piston travels downward permitting air and fuel mixture from the carburetor
to enter the combustion chamber through the intake valves.
At the end of the intake stroke, the intake valves close and the piston starts upwards on the
compression stroke. The exhaust valves remain closed. Near the end of the compression stroke the
fuel is ignited by the spark plug. The compression ratios are tailored to suit each engine to its fuel
characteristics.
During the power stroke with both the intake and exhaust valves closed, the burning of fuel causes
increase in pressure above the piston which pushes the piston downward and adds impetus to the
crankshaft rotation.
During the exhaust stroke the intake valves are closed, the exhaust valves are open, and the piston is
on the upstroke. Burned gases are forced out of the combustion chamber through the open exhaust
valves.
8
d) Difference Between Gas and Diesel Engine
GAS ENGINE DIESEL ENGINE
1. Gas engine works on Otto cycle. Diesel engine works on diesel cycle.
2. Spark plug is used to ignite the fuel. It is a compression ignition engine.
3. Gas engine has pistons with lower Higher compression ratio pistons are used.
compression ratio as compared to diesel
engines.
4. Altronic / Magtronic Ignition System is used

to generate the high voltage required to
create a spark as per required interval.
5. Bowl shaped pistons are used. Crown shaped pistons are used
6. Cylinder head houses the spark plug and Cylinder head houses the injector.
the spark plug adapter.
7. Valve guide seals are used to prevent oil Valve guide seals are not used
from getting sucked through the valve
guides.
8. Valve rotators are used to reduce valve Valve rotators are used on few engines.
beat-in.
9. Injector rocker lever and cam follower lever Injector rocker lever and cam follower lever are
are not required. necessary.
10. Valve seat angle for gas engines is 15 deg. Valve seat angle for diesel engine is 30 deg.
11. Rocker cover is modified for ignition

transformer mounting.
9
e) Derating guidelines with reference to gas composition

(Natural gas engines)
Compression Max. permissible combustibles Derating guidelines
Ratio other than Methane and Ethane
Naturally aspirated gas engines

12:1 Propane up to 2% } No derating
Butane up to 0.2% }
Pentane +} up to 0.1% }
Hexane }
10:1 Propane up to10% Propane > 5%, 0.5% per 1% Propane

Butane up to 5% Butane > 2%, 0.5% per 1% Butane
Pentane up to 1% Pentane > 0.1%, 4% per 1% Pentane
Hexane up to 1% Hexane > 0.1%, 4% per 1% Hexane
8.5:1 Propane up to 100%

Iso Butane up to 80% i Butane > 50%, 0.5% per 1% lbutane
N Butane up to 30% N Butane > 15%, 1% per 1% Nbutane
Turbocharged Aftercooled gas engines

10:1 Propane up to 2% }
Butane up to 0.2% } No derating
Pentane up to 0.1% }
Hexane up to 0.1% }
8.5:1 Propane upto10% Propane > 5%, 0.5% per 1% Propane

Butane up to 5% Butane > 2%, 0.5% per 1 % Butane
Notes:
• Gas Pressure near engine skid - 15 to 20 psig
• Low compression ratio should be selected, when any one of composite gas exceeds its permissible
limit, in case of gas engine.
• Calculate derating due to individual composite. Sum up to find out net derating, Deduct net derating from
power corresponding to selected compression ratio to find out brake horse power of a gas engine.
• Rating and diesel substitution depend on gas composition in case of dual fuel engine.
• Gas should be perfectly dry, clean and free from liquid hydrocarbons, foreign particles, dust etc.
• Sulphur content in the gas should not exceed 0.1%
• Derating on account of site conditions is applicable.
• Please contact Cummins Marketing Department for more details.
f) Derating Procedure
To compensate for intake air temperatures above 85oF and altitude above 500 feet the naturally aspirated
gas engine must be derated as follows :
1% per each 10oF above 100oF (2% per 11oC above 38oC) plus 3% for each 1000 ft.[304.800 m] altitude above
500 feet altitude.
10
g) 10 Maintenance Steps for Cummins Engines
1. Keep dirt out of the engine.
2. Maintain a lubricating film on all bearing surfaces.
3. Regulate the engine’s fuel.
4. Control operating temperature.
5. Guard against corrosion.
6. Let the engine breathe.
7. Prevent over-speeding.
8. Know your engine’s condition.
9. Correct problems while they are simple.
10. Schedule & control your engine maintenance.
11
NOTES
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12
Operating Principles 1-1
Section-1
OPERATING PRINCIPLES
Section Contents
1) Cummins Gas Engines Operating Principles ........................................................................ 15
2) Engine System Operating Principles
a) Fuel System ................................................................................................................ 18

Gas Pipe Line details .......................................................................................... 19
Carburettor .......................................................................................................... 20
Gas Pipe Line Component Details ....................................................................... 22
b) Ignition System ............................................................................................................ 23

i. Distributor Type High Tension Ignition System ..................................................... 24
Contact Braker Adjustment ......................................................................... 25
Battery Maintenance ................................................................................... 30
ii. Altronic III Ignition System ................................................................................... 32
Description ................................................................................................. 32
Circuit Diagram ........................................................................................... 36
How to Check the Engine Timing ................................................................ 37
Installation Instructions ............................................................................... 38
iii. Magtronic Ignition System ................................................................................... 39
General Operating Principles ...................................................................... 39
c) Lubricating System ...................................................................................................... 40

Description .......................................................................................................... 40
B-Check Requirement ......................................................................................... 41
Change Super Lub Oil By-Pass Filter Element .................................................... 42
Clean/Change Crankcase Breather ...................................................................... 42
d) Cooling System ........................................................................................................... 44

Description .......................................................................................................... 44
Modular Heat Exchangers ................................................................................... 44
e) Air Induction System .................................................................................................... 46

Description .......................................................................................................... 46
Clean or Replace Air Cleaner Elements ............................................................... 46
Air Cleaner Service Tips ...................................................................................... 47
Exhaust Back Pressure ...................................................................................... 49
Exhaust Flexible Bellows .................................................................................... 50
13
1-2 Cummins Gas Engines Service Manual
NOTES
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14
Section-1 The most satisfactor

satisfactory y ser vice can be
service
expected fr om
from a Cummins Gas Engine when
the operation pr ocedures
procedures are based upon a
Operating clear under standing

understanding
principles. Eac h par
Each part t
of
of
the
the
engine
engine
w orking
working
affects
affects
the operation of e ver
very
ever y other w
working par
orking partt
Principles and of the engine as a whole
whole..
Cummins Gas Engines described in this
man ual are ffour
manual our-str
our-stroke-c
-stroke-cyc
oke-cyc le engines that
ycle
burn a spark-ignited, contr olled mixture of
controlled
natural gas and air. Horse-power ratings and
other engine specifications are tabulated on
Page No. 6 & 7.
Cummins Gas Engines
1) Operating Principles & Systems Information

Operating Principles and the order in which they occur are Intake
Stroke, Compression Stroke, Power Stroke and
The most satisfactory service can be expected
Exhaust Stroke.
from a Cummins Spark Ignited Gas Engines when
the operation procedures are based upon a clear Intake Stroke
understanding of the engine working principals.
Each part of the engine affects the operation of During the intake stroke, the piston travels
every other working part and of the engine as a downward permitting air and fuel mixture from
whole. the carburetor to enter the combustion chamber
through the open intake valve(s).
The Natural Gas Engine
Compression Stroke
The Natural Gas Engines described in this manual
are four-stroke-cycle engines that burn a spark- The compression stroke starts at the end of the
ignited, controlled mixture of natural gas and air. intake stroke. The intake valve(s) close and the
The recommended fuel gas should be dry piston starts upward on the compression stroke.
pipeline quality natural gas. The exhaust valves remain closed.
Caution: Different fuel gases may require a By the end of the compression stroke, the air
change in hardware and plumbing of the fuel and fuel mixture in the combustion chamber has
system to the engine as well as physical changes been forced by the piston to occupy space
in hardware on and in the engine. significantly smaller than the volume occupied
at the beginning of the stroke. This change in
The Natural Gas Engine Cycle space is known as the compression ratio.
It is easier to understand the function of the
engine parts if it is known what happens in Power Stroke
the combustion chamber during each of the Near the end of the compression stroke, the fuel
four piston strokes of the cycle. The four strokes is ignited by the spark plug. During the power
stroke with both the intake and exhaust valve(s)
15
closed, the burning fuel causes an increase in Burned gases are forced out of the combustion
pressure above the piston. The increased chamber through the open exhaust valve port(s)
pressure pushes the piston downward and adds by the upward travel of the piston.
impetus to the crankshaft rotation.
Just slightly before the end of the exhaust stroke
and at the very beginning of the intake stroke,
Exhaust Stroke
the intake valve(s) open and a few degrees later
the exhaust valve(s) will close. This is known
During the exhaust stroke, the intake valve(s)
as valve overlap and is required to remove the
are closed, the exhaust valve(s) are open and
last of the remaining exhaust gases during that
the piston is on its upstroke.
cycle.
Fig. 1-1 The Natural Gas Engine Cycle
16
2) Engine System Operating Principles
The details of each engine system is explained in this section.
a) Fuel System
b) Ignition System
c) Lubricating System
d) Cooling System
e) Air Induction System
17
a) Fuel System
i) Fuel System
Fuel must be clean, free of acids, sulphur
compounds, water, pipe scale and other foreign
material which could cause corrosion of cylinder
liners, bearings, and internal engine parts. Dry
processed natural gases for pipeline transmission
usually have the liquids removed and contain
primarily methane and a small percent of ethane
gases.
Located between the gas supply line and the
engine intake manifold are the following units
which make up the fuel system : Fig. 1-2 Gas Filters
1. Manual shut-off valve
rotated clockwise to increase the pressure and
2. Filter
anti-clockwise to decrease the pressure so as
3. Electrical shut-off valve
to adjust the outlet pressure to 0.5 Kg/cm2 (7 psi).
4. 1st stage regulator
Proper care should be taken during installation
5. 2nd stage regulator of this regulator by ensuring the IN/OUT
6. Carburator markings.
Main Line Valve (Manual shut-off valve)
This is a manual valve provided in the main gas
line and is used in case of any emergency or if
any unit in the fuel flow is removed or to be
attempted for any failure.
Gas Filter
This filter isprovided ot remove all foreign
materials, prior to gas entering the system.
Gas Shut Off Valve

This valve is electrically operated by 24 volts D.C. Fig. 1-3 Gas Regulators
supply from the battery in series with the engine
safety system. Second Stage Pressure Regulator
The second stage regulator is bigger in size as
This assured positive Gas shut-off in case of
compared to the main line regulator and is blue
engine safety switches (e.g. HWT, LLOP, O/S). in colour. This regulator should be mounted near
the engine carburetor. It should be supported
First Stage Regulator firmly and flexible conection should be provided
This regulator is smaller in size and is red in in between the regulator and the carburetor.
colour. This main line regulator is mounted in Provide necessary conection on the piping for
the gas line near the engine. While setting the pressure measurement after and before the
outlet pressure, the brass spindle should be regulators.
18
FLEXBLE PIPE JOINT
MAX 8 INCH WC GAS SHUT-OFF VALVE (MANUAL)
OR 200 MM WC
7 PSIG 20 PSIG
Operating Principles
GAS REGULATOR ASSLY.GAS FILTER
CARBURETOR (I STAGE)
MOUNTED ON
GAS ENGINE.
Fig. 1-4 Typical Gas Pipe Line
1-7
19
Unscrew the top cover for setting the outlet diaphragm, through the passages. Due to the
pressure. The outlet pressure can be adjusted vacuum created above the diaphragm, the
by means of a 14 mm allen key. The gas pressure atmospheric air pressure lifts the diaphragm,
just before the carburetor should be set as diaphragm plate and the metering valve off the
follows : gas inlet port against the tension of the metering
spring. This permits a charge of gas and air to
When the engine is stopped, the gas pressure mix and enter the intake manifold. The volume of
should be set to 200 mm of water column. When air depends upon the amount of lift of the
the engine is running at rated load and speed, diaphragm plate. The volume of gas is controlled
the gas pressure should be set to 75 mm of water by the valve lift, valve profile and the gas port
column. internal diameter. The final quantity of the mixture
is controlled by the throttle valve.
ii) Carburetor
At full load and full speed conditions, the throttle
Carburation means mixing of air and gas in valve is fully open, therefore maximum suction is
definite proportion. This is the unit where the final created above the diaphragm. Hence the valve,
volume of gas and air is mixed and supplied to diaphragm plate and the diaphragm is fully pushed
the combustion chamber. IMPCO carburetors are up against the spring tension, allowing maximum
used on all Cummins natural gas engines. The quantity of gas and air mixture to enter the
type of carburetor used depends on the engine combustion chamber. The position of the throttle
Cubic Inch Displacement (C.I.D.), engine R.P.M., is controlled through the hydraulic governor, which
volume of air in Cubic Feet( C.F.T.) required by senses engine load through change in engine
the engine , and-composition of the fuel. On RPM. The idle screw is required to be adjusted
Cummins engines the carburetor is installed on when engine RPM is as low as 600 RPM. For
the suction side. The carburetor is made up of cummins genset engines, the low idle speed is
two parts a) Mixer Unit b) Throttle Unit. In case 1080 - 1120 RPM.
of naturally aspirated engines these two units
are installed on the intake manifold. For The-power mixture adjustment valve is to be
turbocharged-aftercooled engines, the mixer is adjusted only during initial installation. This
installed between the air cleaner and adjustment is effective only when the gas metering
turbocharger, where as the throttle unit is installed valve is withdrawn from the jet. This adjustment
in the turbocharger compressor outlet. is effective only when engine approaches full load
condition and can be set on loaded engine, at or
The principle of operation of all carburetors is the close to its rated R.P.M.
same. For explanation sake let us consider
IMPCO 225 series on a naturally aspirated Mixtures between idle and full load conditions
engine. are controlled by the gas metering valve shape.
The gas metering valve is designed to produce
When the engine is in the stopped state the gas
lean mixtures at light loads and increasingly rich
metering valve and the diaphragm plate is
mixtures at heavier loads and higher engine
completely seated in the gas inlet port, hence
speeds. The shape of gas metering valve is
there will be no gas or air supply to the intake
designed for optimum mixture for the mid size
manifold. This is achieved by the tension of the
engine between the largest and smallest cubic
metering spring on the valve.
inch displacement upon which the carburetor will
When the engine is cranked, there is a partial be installed. For engines of larger CID’s, there
vacuum created inside the combustion chamber. will be carburetor’s consisting of two or three
This vacuum is transmitted right above the diaphragm and gas jets.
20
The air-gas flow through the carburetor is assembly a distance directly proportional to the
controlled by an air-gas valve. The air-gas valve volume of air passing through the carburetor thus
meters both air and gas in proper proportions at making the assembly an Air Measuring Device.
any throttle setting. It also seals off gas flow The Gas Metering Valve, mounted within the
when the engine is shut down and provides assembly, meters the fuel introduced through
automatic choke action for starting. The working the jet into the air stream. The natural gas
parts consist of an Air Measuring Valve mounted pressure to the carburetor inlet should not exceed
on a fibre-glass diaphragm. Mounted within the (3 inches H2O 77 mm WC) IMPCO - carburetor
cup of Air Measuring Valve is a gas Metering schematic.
Valve. A metering spring is mounted above the
valve assembly which is normally held in a A pressure reduction valve or Thermac is used
closed position. As air is drawn through the to fine tune and adjust gas pressure reaching
carburetor into the engine, the metering spring the carburetor. With this valve it is possible to
causes a pressure drop below the Air Measuring maintain inches of H2O pressure to the carburetor.
Valve. This pressure drop is transferred to the
top of the diaphragm through four small holes in Caution : Do not mount gas shut-off valve
the bottom of the Air Measuring Valve. The between pressure reduction valve and
lowered pressure above the diaphragm to lift the carburetor.
Fig. 1-5 Carburetor Function
21
Table 1-1 Gas Pipe Line Component Details
ENGINE G495 / GTA 855 GTA 1150 G1710 GTA 1710 GTA 2300 /
MODELS G743 / GTA 3067
G855
GAS Line Component Name
Gas Shut off valve 3872383 3875553 3873933 3873933 3875553 3875553
(MANUAL) (25 mm) (50 mm) (1 ½ BSP) (1 ½ BSP) (50 mm) (50 mm)
Range of pressure gauge 1 to 3 1 to 3 1 to 3 1 to 3 1 to 3 1 to 3

for inlet line Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2
Assly Gas Filter 3392533 3392533 3392533 3392533 3392533 3392533
Gas shut off valve 3872384 3875535 3872384 3872384 3875535 3875535
(ELECTRICAL)
1st stage regulator 3875040 3875040 3875041 3875041 3875041 3875042

(1 BSP) (1 BSP) (1 ½ BSP) (1 ½ BSP) (1 ½ BSP) (2 BSP)
Gas Flow m3/h 1 st 60-80 60-80 100-120 100-120 100-120 200-220

stage regulator
Range of pressure 0 to 1 Kg/cm2 0 to 1 Kg/cm2 0 to 1 Kg/cm2 0 to 1 Kg/cm2 0 to 1 Kg/cm2 0 to 1 Kg/cm2

gauge 1st stage
2 nd stage Regulator 3875043 3875043 3875044 3875043 3875044 3875044

(1 ½ BSP) (1 ½ BSP) (1 ½ BSP) (1 ½ BSP) (1 ½ BSP) (1 ½ BSP)
Qty 1 Qty 1 Qty 1 Qty 2 Qty 1 Qty 2
Gas Flow / regulator 60-80 60-80 100-120 60-80 100-120 100-120

m3/hr
Range of pressure gauge 0 to 400 0 to 400 0 to 400 0 to 400 0 to 400 0 to 400

2 nd stage (mill bar) (mill bar) (mill bar) (mill bar) (mill bar) (mill bar)
1st Stage Regulator 3875040 3875040 3875041 3875041 3875041 3875042
Repair kit P/No. Vanaz AX1002316 AX1002316 AX1002317 AX1002317 AX1002318 AX1002318
2 nd Stage Regulator 3875043 3875043 3875044 3875043 3875044 3875044
Repair kit P/No. Vanaz AX1002319 AX1002319 AX1002319 AX1002319 AX1002320 AX1002320
22
b) Ignition System
CIL Natural Gas engines are equipped with one of the following Ignition Systems.
Description Engine Models
i. Distributor type HT (High Tension) This is available only on G-495,

Ignition System G-743, G-855 series engines as
optional system.
ii. Altronic III Ignition System Available for all Gas Engines.
iii. Magtronic Ignition System It was previously used on Natural Gas

engines.
This has been discontinued on

production Gas Engines.
23
i. General Description of Distributor System on

4 Cyl. & 6 Cyl. Engines
General Description : (i) Centrifugal Timing Control :

The coil lgnition equipment comprises a Mounted on the distributor driving shaft,
high tension ignition coil and a combined dis- immediately beneath the contact breaker, is a
tributor contact breaker and automatic tuning centrifugally-operated timing the control mecha-
control assembly driven at half engine speed nism. It consists of a pair of weights which, un-
via the cam shaft for four stroke engine. der the action of centrifugal force, swing out-
wards against contoured cam surfaces. These
The current flowing through the primary weights are linked through pivot to the can foot,
winding is periodically interrupted by a cam op- so that as the speed of rotation increases the
erated contact breaker, driven from the engine cam foot is advanced against the tension of two
and the subsequent collapse of the magnetic control springs. The contact breaker cam, and
field induces a high voltage in the secondary therefore the instant of sparking, is thus also
winding of the coil. At the same time a rotor advanced to suit engine conditions at the greater
arm in the distributor connects the secondary speed.
winding of the coil with one of the number of
metal electrodes in the moulded cover from (ii) Routine Maintenance :
which cables lead to the sparking plugs in the In general, lubrication, cleaning and con-
engine cylinder. Thus the high tension is dis- tact breaker adjustment constitute normal main-
tributed to the different cylinder at the exact tenance procedure.
movement to produce combustion of the mix-
ture.
The mixture are oil-impregnated before
initial fitment and lubricated automatically in ser-
vice by engine oil mist.
Fig. 1-6 Distributor System for 6 cylinder engine.
24
(iii) Contact Breaker Adjustment : (c) Contact breaker spring tension, measured
at contacts : 500 - 670 gm. (18-24 oz.)
Check the contact breaker setting. Turn the en-
The speed and advance in degrees refer to
gine until the contacts show the maximum open-
those of the distributor shaft-and hence when
ing that is when the operating heel is on the high-
taking measurements off the flywheel the above
est point on the cam. The gap between the con-
values must be doubled.
tacts should measure 0.35 mm. (.014") (0.016").
If the measurement is incorrect, keep the en-
Ser vicing
Servicing
gine in the position giving maximum opening,
slacken the screw securing the fixed contact Before starting to test, make sure that the bat-
plate and adjust its position to give the required tery is not fully discharged as this will often pro-
gap. Tighten the screw. Recheck the setting for duce the same symptoms as a fault in the igni-
other positions of the engine giving maximum tion circuit.
opening.
Testing in position to locate cause of un-
Design Data : even firing
(a) 6 - Cylinder units - Run the engine at a fairly idling speed. If Pos-
Firing angles : 0º, 60º, 120º, 180º, 240º, sible, short circuit each plug in turn with the
300º, ± 1º blade of an insulated screwdriver or a hammer
Closed period : 35º ± 3º head placed across the terminal to contact the
Open period : 25º ± 3º cylinder head. Short circuiting the plug in the
defective cylinder will cause no noticeable
(b) Contact breaker gap : 0.35 - 0.41 mm
(0.014" -.016") change in the firing.
Fig. 1-7 Contact Breaker Details
25
Note : On the others, however, there will be a or +ve terminal in case of positive earth
pronounced increase in roughness when the systems) to SW (or +ve terminal in case of
other plugs are disconnected. Having thus negative earth systems) and terminal of the coil.
located the defective cylinder, stop the engine If a reading of battery voltage is now shown it
and remove the cable from the sparking plug indicates that ignition feed wire to SW terminal
terminal. Restart the engine and hold the cable is satisfactory. In this case disconnect the cable
end about (6 mm.) from the cylinder head. If from the coil 'CB' terminal and reconnect the
sparking is strong and regular the fault lies with voltmeter lead from 'SW' to 'CB'. No reading
the sparking plug, and it should be removed, now will indicate a faulty coil while reading of
cleaned and adjusted, or a replacement fitted. battery voltage means that the contact breaker
If however, there is no spark, or only weak insulation or capacitor is faulty.
irregular sparking, examine the cable from the
2) Voltmeter Reading with Contacts
plug to the distributor cover.
Closed
Renew the cable if the insulation is cracked or
perished. Clean and examine the distributor If a reading of battery is obtained, transfer the
moulded cover for free movement of the carbon voltmeter lead from the coil 'CB' terminal to the
brush. If a replacement brush is necessary, it is distributor L.T. terminal. If this results in the
important that the correct type is used. If tracking reading dropping to zero then the coil-to-
has occurred, indicated by a thin black line distributor cable is fault, while a continued
between two or more electrodes or between one reading of battery voltage means that the
of the electrodes and the body, a replacement contacts are not 'making'. If, however, the
distributor cover must be fitted. voltmeter still shows a low reading when so
connected this indicates high resistance
Testing in position to locate cause of between the contact breaker mating surfaces.
ignition failure Clean or replace the contacts.
Spring back the clip and remove the moulded 3) High Tension Circuit
Circuit
cover. Lift off the rotor. Without disturbing the
wiring, connect a 0-20V voltmeter between the If the low tension circuit is in order, remove the
C.B. terminal (or -ve terminal in case of negative high tension cable from the centre terminal of
earth systems or +ve terminal in case of the the distributor cover. Switch on the ignition, the
+ve earth systems) of the coil and a good contacts being closed. Flick open the contacts
earthing point. The engine will normally have while the high tension lead from the coil is held
stopped with contacts closed - if so, separate about (6mm) from the cylinder block. If the
the contacts with a piece of clean card. Switch ignition equipment is in good order, a strong
on the ignition when a reading of battery voltage spark will be obtained. If no spark occurs, a
should be shown on voltmeter. If no reading is faults in the circuit of the secondary winding of
given proceed as in (1). Remove the card from the coil is indicated and the coil must be
between the contacts when the voltmeter replaced.
reading should drop to zero. If the battery voltage If sparking occurs in the above test, but apparent
reading persists, or the reading drops but not ignition failure persists, test the rotor arm by
to zero volts, proceed as in (2). substitution.
1) Low Tension Cir
Low cuit F
Circuit ault Location
Fault
The high tension cables must be carefully
Transfer the voltmeter lead from the 'CB' (or - examined, and replaced if the rubber insulation
ve terminal in case of negative earth systems is cracked or perished.
26
Dismantling the Distributor

Distributor mechanism it is important that it is carried
out in the order described below otherwise
When dismantling, carefully note the positions
damage to the springs may result.
in which the various components are fitted in
order to ensure their correct replacement on
Carefully lift off the springs, withdraw the screw
reassembly. The tongue of the driving dog is
inside the cam and take off the cam and cam
offset; note the relation between it and the rotor
foot, noting the position of the cam slot. The
electrode and maintain this relation when
weights can be lifted off. Note that a distance
reassembling the distributor. The amount of
collar is fitted on a shaft beneath the action plate.
dismantling necessary will obviously depend on
the repair required. Spring back the securing
Bearing Replacement
clips and remove the moulded cover. Lift the
rotor arm off the spindle. With 25D units, Prepare the new bush for fitting by allowing it to
disconnect the vacuum unit link to the contact stand completely immersed in medium viscosity
breaker moving plate. Remove the two screws engines oil for at least 24 hours. In case of
at the contact breaker baseplate. The contact extreme urgency, this period of soaking may be
breaker assembly and external terminal can now shortened by heating the oil to 100ºC for 2 hours,
be lifted off (see (i) below). Where applicable then allowing the oil to cool before removing the
remove the circlip on the end of the micrometer bush.
timing screw, and turn the micrometer nut until
The following procedure should be closely
the screw and the vacuum unit assembly are
followed when fitting a replacement bearing
freed. Take care not to lose the ratched and coil
bush.
type spring located under the micrometer nut.
The complete shaft assembly, with centrifugal i) Using a shouldered mandrel of appropriate
timing control and cam foot can bow be removed diameter, press out the worn bush from
from the distributor body (see (ii) below) on the body end.
knocking out the dog securing pin.
ii) Insert the replacement bush from the drive
i) Contact Breaker : To dismantle the end, which the smaller bush diameter as
assembly fur ther, remove the nut, the leading part. The bush will be a push
insulating piece and connections from the fit until the larger diameter, comes into
pillar on which the contact breaker spring contact with the shank. With the mandrel
in anchored. Lift off the contact breaker in position, the bush should then be
lever and the insulating washers beneath pushed fully in with a steady pressure. The
it. bush should be a tight fit, flush with the
shank at the drive end with a slight
Remove the screw securing the fixed
protrusion at the top end.
contact place together with the spring and
plain steel washers, and take off the plate. iii) The original bush may have a drilled
Withdraw the single screw securing the through one side. If so, using the hole in
capacitor. On model 25D dismantle the the shank as a guide drill the replacement
contact breaker base assembly by turning bush in save manner.
the base plate clockwise and pulling to
iv) Insert the shaft and action plate assembly,
release it from the contact breaker moving
with clean engine oil applied to the shaft.
plate.
Make sure that there is no dirt around the
ii) Shaft and Action Plate : When hole in the shaft through which the driving
dismantling the centrifugal timing control dog pinion securing pin is inserted. If the
27
shaft is tight in the bearing when fitted, tap v) Refit the capacitor. Place the fixed contact
lightly at the drive end and withdraw the plate in position and secure lightly with the
shaft. Again insert the shaft and repeat the securing screw. One plain and one spring
operation as long as any tightness exists. washer must be fitted under the securing
It is important that the shaft is free to rotate screw.
without binding.
vi) Place the insulating washers etc. on the
v) Clamp the body and run the shaft in a test contact breaker pivot post and on the pillar
rig or lathe for about 15 minutes, re- on which the end of the contact breaker
lubricate the shaft with clean engine oil and spring locates. Refit the contact breaker
reassemble the distributor. lever and spring.
Note : Under any cir

any cumstances should the
circumstances vii) Slide the terminal block into its slot.
bush not be o ver
over-bored b
ver-bored y reaming or an
by y
any
other means.
Reassemb
Reassemblly
The following instructions assume that complete
dismantling has been undertaken.
i) Place the distance collar over the shaft,
smear the shaft with Ragosine Moly-
bdenised non-creep oil or clean engine oil,
and fit it into its bearing.
ii) When the unit is so fitted refit the vacuum
unit into its housing and replace the spring,
milled adjusted nut and securing circlip.
iii) Reassemble the centrifugal timing control
weights, cam and cam foot to the shaft.
Fit the cam securing screw, then engage
the springs with the cam foot pillars.
(See that the springs are not stretched or
damaged)
iv) Before reassembling the contact breaker
base assembly, lightly smear the base
plate with Ragosite Molybdenised non-
creep oil or Mobil grease No. 2. Where
applicable, fit the contact breaker moving
plate to the contact breaker and secure
using a reversal of the dismantling
procedure. Refit the contact breaker base
into the distributor body and engage the
link from the vacuum unit. Insert the two
base plate securing screws, one of which
also secures one end of the contact Fig. 1-8 Distributor model 25D 6
breaker earthing cable (Model 25D)
28
viii) Thread the low tension connector and capacitor eyelets on to the insulating piece, and place
these on to the pillar which secures the end of the contact breaker spring. Refit the washer and
securing nut.
ix) Set the contact gap to 0.014" - 0.016" (0.35 - 0.41 mm) and tighten the fixed contact plate
securing screw.
x) Refit the rotor arm, locating the moulded projection in the rotor arm with the key way in the
shaft and pushing fully home. Refit the moulded cover.
Replacement of Contacts
If the contacts are so badly worn that replacement is necessary, they must renewed as a pair
and not individually. The contact gap must be set to 0.014 - 0.19" (0.35 - 0.48 mm) : after the first 500
miles' running with the new contacts fitted, the setting should be checked and this gap set to 0.014"
- 0.016" (0.35 - 0.41 mm). This procedure allows for initial "bedding" of the heel.
Distributor Securing Plates

Distributor
Maximum Saf
Maximum e Tightening Tor
Safe ques
orques
Excessive clamping of the distributor securing plate may result in the shaft to bearing runnings
clearances being reduced, with the consequent risk of shaft seizure. Accordingly, the following
maximum safe tightening torques are specified for the two alternative securing plate assemblies
commonly met with in services.
Securing Plate Assemb
Assemblly Max. Safe Tor
Safe que
orque
i) Trapped bolt types, i.e. rotating nut : 30 lb-in. (0.36 kg. m.)
ii) Trapped nut type, i.e. rotating bolt : 50 lb-in (0.576 kg. m)
Fault Diagnosis in the Ignition System

Diagnosis
Before starting the test, check the battery is not discharged as this will produce the same
symptoms as a fault in the ignition circuit.
In the case of a fault in the ignition system, the engine may not run regularly and may be hard
to start and the location of the fault should be carried out in a step by step manner.
Broadly the ignition system can be broken into two circuits as shown in the block diagram. The
individual components that make the circuit are also shown.
Ignition System
Secondar
Secondaryy Circuit
Circuit Primar
Primaryy Circuit
Circuit
Spark Plug Contact Breaker Assy.
HT Cable Condenser
Ignition coil Ignition Coil
Secondary winding Primary Winding
Ignition Switch
29
Turn the engine. A good bright spark should be Battery Maintenance

obtained. If not proceed to check other
components of the system. Care must be exercised for proper upkeep of the
battery, in order to get good life out of it. The
HT Cable following points should be remembered for
efficient maintenance of the battery.
Disconnect the spark Plug. Hold the cable so
that the lead is about 3 mm the metal body of 1. Secure the battery firmly in its carrier.
the equipment. Switch the ignition 'On'. Turn the
engine. A good spark, if now obtained, indicates 2. Keep vent plugs tight.
a defective plug which should either be cleaned
and reset or replaced. No spark or a weak spark 3. Keep terminals free from corrosion with
would indicate poor insulation of the HT cable or Vaseline. Do not use Grease.
defective secondary wiring of the coil. If
replacement of HT cable does not improve the 4. Keep the battery top, clean and dry.
quality of spark, then the primary circuit should
be checked as indicated in figure 8. 5. Maintain level of acid to the bottom of filling
hole be adding periodically distilled water.
If after all these tests, no defect is indicated in Never use acid to top up the battery.
the primary circuit, it suggests that the secondary
winding of the coil is defective, and the coil should 6. Measure the specific gravity of the acid in
be replaced. In case the coil is replaced, while each cell at regular intervals with a
connecting it in the circuit, correct polarity of the hydrometer. The specific gravity readings,
connection must be ensured. The LT terminals along with the state of charge of the battery,
of the coil are marked '+' and '-'. The terminal are indicated in the table below :
having polarity marking that correspondents with
the battery earth polarity should always be Specific Gravity at State of Charge
connected to the contact breaker. For Example, 0 0
27 C [80 F]
in case of a position earth system, as is adopted
in the motor cycle, the '+' terminal of the coil 1.260 -1.280 100 %
should be connected to the contact breaker. It
must also be ensured that the coil top is kept 1.230 -1.250 75 %
clean and dry. 1.200 -1.220 50 %
1.170 -1.190 25%
When the contacts are replaced, they must be
renewed as a pair and not individually. The 1.110 -1.130 Discharged.
contact gap must be set to 0.014" - 0.019" (0.35-
0.48 mm) : after the first 500 miles running with The readings should be consistent for all the
the new contacts fitted, the setting should be cells.
checked and the gap set to 0.014" - 0.016" (0.35-
0.41mm). This procedure allows for initial 'Bedding
- in' of the heel.
30
In case the battery is fully discharged, remove it from the equipment and put it on an external charger,
at the normal recharge rate of 1 Amp.
Fig. 1-9 Ignition System, Primary Circuit - Fault Diagnosis
31
ii. Altronic III Ignition System
IMPORTANT SAFETY NO
IMPORT TICE
NOTICE
Proper installation, maintenance
Proper maintenance,, repair and operation of this equipment is essential.
The recommended practices contained herein should be ffollo ollowed without de
ollowed viation.
deviation.
An impr operl
improperl
operlyy installed or operating ignition system could cause per sonal injur
personal injuryy to
operators or other nearb
operators nearbyy personnel.
personnel.
Description The alternator (A) provides the power to charge

energy storage capacitor (B). A separate pick-
Altronic III is an alternator powered, electronic
up coil (C) and SCR (D) are used for each of
ignition system. All electronic parts are mounted
the system’s outputs which correspond usually
to the back cover which disconnects as a
to each engine cylinder. A rotating timer arm
module from the alternator section.
(E) driven through speed reducing gears passes
over the pick-up coils to trigger on the SCR
switches in sequence. This releases the
capacitor’s stored energy to the Ignition coils
which step up the voltage to fire the spark plugs.
Fig. 1-10
Fig. 1-11 Cross Sectional View - Altronic III Unit

A - Alternator D - SCR electronic switch
B - Energy storage capacitor E - Timer arm
C - Pick-up coil F - Distribution gears
32
Fig. 1-12 Exploded view of Altronic Ignition System
33
2.0 PARTS IDENTIFICATION AND SPECIFICATION

2.1 PARTS LIST - ALTRONIC III - Reference the exploided view
Ref. Description Ref. Description
No. No.
1 Coupling - BLACK 23 Driven gear 4:1

Coupling - YELLOW Driven gear 1.5:1
1a Spring pin 2-1/8” lg. Driven gear 2:1
2 Flex coupling w/pin Driven gear 3:1
2a Spring pin 1-1/8” lg. Driven gear 2.5:1
3 Flange ass’y. (-A) Driven gar 1:1
Flange ass’y. (-G) 24 Timer arm
Flange ass’y. (-D) 25 Bearing-shaft
Flange ass’y. (-AO) 26 Screw 8-32
Flange ass’y. (-GO) 27 Timing label - shaft
Flange ass’y. (-J) 28 Magnet-plate ass’y.
3a Oil seal 29 Gasket
3b Gasket - mounting 30 Spacer
4 Gasket 31 Pick-up coil - BLACK
5 Front housing (flange) Pick-up coil - WHITE
Front housing (-EL) Pick-up coil - WHITE 16-cyl.
Front housing (-BEL) 32 Lockwasher #8
5a Shield 33 Nut 8-32
5b Screw 5/16-18 34 Screw 10-24
5c Lockwasher 5/16 35 Timing label - cover
5d Washer 5/16 36 Cover plate
5e Washer 37 Screw 6-32
6 Bearing 38 Core ass’y. - pick-up
7 Shaft-rotor ass’y. 39 Receptacle
Shaft-rotor ass’y. “X” unit 40 Screw 1/4-20
8 Spacer - bearing 41 Washer
9 Cover - bearing 42 Washer
10 Stator 43 Screw 8-32
11 Screw 1/4-20 47 Lockwasher #10
12 Screw 8-32 48 Screw 10-24
13 Intermediate housing 50 Brace
13a Ventillator, press fit 51 Circuit board ass’y.
14 Nameplate 51a Zener diode
15 Drive pin 51b Nut 10-32, zener diode
16 Drive gear 4:1 51c Connector
Drive gear 1.5:1 51d Socket
Drive gear 2:1 54 Connector ass’y. 3-leads
Drive gear 3:1 Connector ass’y. 6-leads
Drive gear 2.5:1 55 Gasket
Drive gear 1:1 56 Screw 4-40
17 Wire clamp 57 Lockwasher #4
18 Washer #8 58 Cover casting 8-12 cyl.
19 Wire guide 16-cyl. Cover casting 2-6 cyl.
Wire guide 2-12 cyl. Cover casting 8-12 cyl.
20 Screw 8-32 Cover casting 2-6 cyl.
21 Screw 6-32 Cover casting 16 cyl.
22 Lockwahser #6 Cover casting 16 cyl.
* Parts for units with electronic timing option.
NOTE : Reference numbers with a letter suffix are part of the assembly of the same number without the
suffix. Example : (1a) is part of (1).
Tabler 1-2
34
2.2 Part No. Description
A = Vertical flange, 1 slot

BEL = Adjustable base
D = Flange, 3” pilot
EL = Base mount
G = Horizontal flange, 2 slots
GL = Horiz. flange, flex coupling
GN = Horiz. flange, gear-flex coupling
GV = Vertical flange, 2 slots
J = Round flange, 3 slots
H = High output unit

S = Extra high output unit
T = Electronic timing
0 = 371 006
1 = 371 601
2 = 371 600 (16-cyl.), 371 601 (6, 8-cyl.)
3 = 371 602
5 = 371 604
6 = 371 604
7 = 371 602
9 = 371 604
1 = 1:1
2 = 2:1
3 = 3:1
4 = 4:1
5 = 2.5:1
6 = 1.5:1
A = Even Firing Pattern

Other Letters = Odd Firing Pattern
2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16
35
2.3 ALTRONIC III - CIRCUIT DIAGRAM
A. The diagram below shows the Altronic III circuit for one cylinder. Each component in the
Timing-Distribution section (to the right of the dashed line) is present in a quantity equal to
the number of cylinders being served; each engine cylinder requires a pick-up coil assembly,
capacitor C3 and power SCR2.
B. The operation Is as follows: The AC voltage generated by the alternator is converted to DC by

the full wave rectifier (FWR) and stored In the energy storage capacitor (C1). The DC voltage
level is regulated by a zener diode regulation circuit Z1. Capacitor C2 is charged through
resistor Rl to provide the energy to trigger power SCR2. This occurs when the rotating
distributor arm passes a pick-up coil (P) triggering on SCR1 and connecting capacitor C2
through resistor R3 to the gate of SCR2. SCR2 then turns on discharging capacitor C1 into
the primary of the Ignition coil which steps up the voltage to fire the spark plug. Components
D3, Q1 and Q2 insure that SCR2 turns off Immediately after each discharge. Capacitors C2,
C3 and C4 act as filters to prevent crossfiring between cylinders.
Fig. 1-13
C. Components :
C1 Capacitor, energy storage Q1 Transistor, isolator
C2 Capacitor, trigger circuit Q2 Transistor
C3 Capacitor, filter R1 Resistor, trigger circuit
C4 Capacitor, SCR gate R4 Resistor, SCR gate
D1 Diode, Trigger circuit SCR1,P,R2,R3 Pick-up coil assemlby
D2 Diode, dual SCR2 SCR, power
D3 Diode, recirculating Z1 Zener diode regulation circuit
FWR Full wave rectifier Z2 Zender diode, 33V.
36
HOW TO CHECK THE ENGINE TIMING ? 3. Mark a line at the desired degree BTDC of
no. 1 cylinder (on accessory drive pulley) by
The following procedure should be followed for means of a chalk (say 25 deg bTDC).
checking engine timing.
4. Start the engineand observe timing with the
The timing light works on a very high voltage timing light directed towards the timing mark
supply. on the accessory drive pulley at the timing
pointer.
1. Connect one extra ignition transformer in
parallel with the No. 1 cylinder ignition Rotating the magtronic towards the engine
transformer. advances the engine timing and vice-a-
versa. The magtronic unit capscrews should
2. Connect the timing light between the high be loosened slightly.
voltage terminal of external ignition
transformer and the spark plug (which is 5. Final ignition timing is to be adjusted with
externally mounted). the engine at rated speed and load. After
the final adjustments tighten the capscrews.
SECONDARY
TIMING LIGHT
ACC DRIVE H.T.COIL

CYL.NO.1
IGN TRANSFORMER
PRIMARY
SPARK PLUG
FROM ALTRONIC/MAGTRONIC
Fig. 1-14 Connections for Checking Engine Ignition Timing
37
Installation Instructions - Altronic III Ignition checked using a timing light with the engine at
system operating speed.
The following parts are required for each

installation :
1. Altronic III Unit

2. Wiring Harness
3. Ignition Coils - one per spark plug.
Engine :
CW ROTATION CCW ROTATION
Set engine so that No. 1 Cylinder is at the ignition
Fig. 1-15
firing point.
Engine :
Rotation :
Rotate engine, so that, No. 1 cylinder is at firing
Determine the rotation of the Altronic III unit point (both the valves Intake & Exhaust are
(looking at the drive end of the Altronic unit) for closed).
the engine being equipped.
Caution : For GV-1710-G/GTA-1710-G engine
Mounting the Unit : take No. 1 RB.
For GTA-2300-G/GTA-3067-G engine take No. 1
Locate the timing mark of the housing for the
LB.
proper rotation (see below). Rotate the drive
coupling until the red mark on the shaft lines up
Rotation :
with the proper mark on the housing. Mount unit
to engine keeping the two red lines together as For all inline Gas Engine : Clockwise (CW)
close as possible. Final timing should be
GV-1710/ Anticlockwise (CCW)
GTA-1710-G
GTA-2300 Clockwise (CW)
GTA-3067
38
iii. Magtronic Ignition System
The ignition system of gas engine consists of Ignition Transformer

the following parts : The ignition transformer is a pulse type
transformer, which receives pulse of 150 volts
1. The Ignition Generator. (Magtronic Unit)
D.C and the output of which is 25 KV.
2. The Wiring Harness.
3. The Ignition Transformer. Ignition Transformer (Internal)
Part No - 166836
4. The Spark Plug.
5. The Ignition Kill system (Engine shut off) Ignition Transformer (External)
Part No - 3873589
General Operating Principle - Magtronic
Ignition System Spark Plug
The spark plug is the unit which creates a spark
Mag-tronic ignition system is a self contained,
self powered, low tension, low fire hazard, in the combustion chamber, which ignites the
electronic system specially designed to meet charge of air and gas. The very high voltage
the ignition demand and reliability requirements induced in the spark plug causes the ignisation
of small to medium size, high speed, spark of the molecules of gas and air in between the
ignited engines. It is a breakerless ignition electrodes, which in turn burns the rest of the
system which is capable of producing a low charge.
voltage which is about 150 volts. This voltage is
fed through the wiring harness. This low voltage Ignition Kill System
is then fed to the ignition transformer, where the
voltage is stepped up to 21 Kilovolts. The In the case of Single capacitor power module,
transformers are mounted directly above and in the ‘P’ terminal from the Magtronic is connected
contact with the spark plugs in wells in the to the single pole switch. During engine operation
cylinder head, thus eliminating all high voltage the switch must be in ‘OFF’ mode. To shut down
wiring. The spark created in the spark plug ignites the engine, switch ‘ON’ the switch to earth the
the fuel. terminal ‘P’. At this point the entire capacitor of
the power module gets earthed and it gets
Wiring Harness discharged. Therefore there is no supply to the
transformer and the engine shuts off.
The important considerations for wiring harness
is as follows: In the case of dual capacitor power modules the
‘P’ and ‘N’ terminals cannot be directly connected
1. The ends must be fastened perfectly, to for earthing the system for shut off. Each
avoid any type of sparking. terminal must be independently earthed, or the
2. The ‘P’ or ‘P’ & ‘N’ junctions must be terminals must be passed through a diode
connected properly. isolator network like (SSA 203). This unit then
3. The wire harness must be shielded and provides one output lead which can be taken to
properly earthed to avoid induced effect of ground through a regular single pole switch or
one wire on the next. safety control.
39
c) Lubricating System
Cummins Gas Engines are pressure lubricated. upper rocker housings, and various drillings
The pressure is supplied by a gear-type throughout the block, crankshaft, connecting
lubricating oil pump. rods and rocker levers complete the oil
circulating system.
A pressure regulator is mounted in the
lubricating oil pump to control lubricating oil 3. Lubricating oil pressure is controlled by a
pressure. regulator located in the lubricating oil pump.
A by-pass valve is provided in the full-flow oil 4. By-pass filter when used, should be
filter as insurance against interruption of oil flow connected into the lubricating oil circuit
by a dirty or clogged element. between the oil pump and the full-flow filter.
This will increase the service life of the full-
1. Oil is drawn into the pump through an flow filter by removing part of the filtering
external oil line connected to the oil pan load from the full-flow filter. The return line
sump. A screen in the sump filters the oil. should discharge below the oil level in the
oil pan to prevent aeration.
2. Oil pipes-or a combination of pipes and
passages-carry oil from the camshaft to
40
d) The Cooling System
CIL natural gas engines are water cooled, and Details of modular Heat Exchanger :
uses wet liners. The flow of coolant, the cooling
The unit consists of two heat exchangers (one
efficiency, maintenance and trouble shooting is
for jacket water & one for aftercooler ), common
similar to engines operating in the diesel mode.
expansion tank, internal piping, gauges, structure
etc. The heat exchangers are covered by panels
For aftercooled gas engines a 2 loop cooling
from three sides for better aesthetic. This is with
system is provided. The first loop is for engine
two pump two loop cooling system. Please refer
jacket and the other is for after cooler. A seperate
to attached photographs of modular heat
external pump is provided to circulate cold water
exchanger.
in to the after cooler, and it’s seperate heat
exchanger., as the intake manifold air temperature
Features / Advantages :
1. Stainless steel tubes - Tubes are corrugated
(patented) for better heat transfer & reduced
scaling.
2. Aesthetic - Better look than present set
up.
3. Optimized heat exchangers providing lower
intake manifold temperature & coolant
temperatures.
4. Simple connections - only one raw water
connection (present set up requires two).
Raw water inlet to be supplied to aftercooler
Heat Exchanger (top connection) & outlet
is from engine Heat Exchanger. Make up
& vent connections already incorporated.
5. Gauges for monitoring - The Heat
Exchanger is provided with following
Fig. 1-16 gauges.
is vary critical in case of gas engines. This is a) Raw water temperature - inlet & outlet,
required to cool the air and gas mixture going in Raw water pressures
to the cumbustion chamber. Cooling of the air b) Aftercooler - inlet & outlet
and gas mixture prevents engine backfiring.
c) JWC - inlet & outlet (Jacket Water
MODULAR HEAT EXCHANGERS Cooling).
CIL has introduced Modular Heat Exchangers 6. High service life - Less cleaning required -
on GTA 3067, GTA 2300 AND GTA 1150 Due to 18-mm ID tubes & less scale
engines. formation due to corrugated tubes.
41
7. Single coolant filling point - Common 10. Butterfly valve for controlling raw water flow
expansion tank as against two in for optimizing temperature / fuel
conventional design. consumption for various ambient.
8. Ladder for easy filling of coolant. 11. The mating flanges & gasket (additional)
for raw water inlet & outlet piping are
9. Better heat transfer due to turbulence
included in the heat exchanger.
created by corrugated tubes.
Major parts on Modular Heat Exchanger part no. 4055447
Expansion Tank
ß
ß Sight Glass
ß Monitoring Panel
ß Butterfly Valve for Raw Water Control
ß Raw water inlet
ß Raw water outlet
Fig. 1-17 Modular Heat Exchanger
42
e) The Air Induction System
The required function of an air system is to supply 2. Outer element should be removed for the
clean dry air to the engine without excessive cleaning only when red band appears on
restriction and at a temperature at which engine the vacuum indicator. It is observed that
will operate efficiently. elements are cleaned frequently to keep
the system clean. But this practice leads
The overall system design should provide to damage to the paper element as well as
minimum intake restrictions to maintain adequate problems associated with handling and too
air flow to the engine for good combustion. In frequent opening and closing the air intake
order to provide satisfactory engine performance, system.
intake air should always be routed through an air
cleaner. Suggested procedure to clean the outer
element
The cleaner may be mounted on engine or
equipment and may be either paper element or Always use clean, dry air on a dry filter
composite type depending directly into carburetor element. The air pressure should not exceed
where it mixes with a metered amount of fuel 60 PSI. Direct the compressed air through the
and is dispersed into intake manifold(s) and on filter element from the clean side i.e. inside to
into cylinders. outside, running the nozzle up and down the
filter element.
A dry type element will keep dirt and dust out of
Don’t bring the nozzle in contact with the paper
an engine almost 100% if it is sealed properly in of filter element, as damage is likely to occur.
its housing and has not been ruptured due to
back fire or mishandling. Do not direct the air jet from outside to inside.
This will make the dirt to penetrate the paper,
The maximum air intake restriction for allowing the dirt to go into the clean side,
gas engine is 15” of H2O. damaging the engine. Penetration of dirt will
make tiny holes, reducing the efficiency.
Clean or Replace Air Cleaner Elements Handle the element carefully. Do not strike the
element against hard surface to loosen the
Many air filter manufacturers discourage the accumulated contaminants.
practice of cleaning air cleaner elements. The
paper of filter element gets weakened as a Cleaning will reduce the dust holding capacity
result of cleaning and can lead to rupture / of the filter element. Replace the outer element
microscopic damages. Also inspection of the after 4/5 cleanings or as soon as the red band
appears even after cleaning.
filter element after cleaning is difficult.
Hence, it is suggested to replace the filter Inspection of the element after cleaning.
element for longer engine life before first (Ref. Fig 1-18)
overhaul. However, if you decide to clean your If small holes or parts are found on element
filter element following are the suggestions- when it is checked with an electric bulb after
cleaning and drying, replace the element.
1. Clean only outer element. Never remove
inner element for cleaning. Inner element Do not use element whose folds or gasket or
should be removed only for the replacement. seal is damaged.
43
Caution : Holes, loose end seals, dented the eye. You can’t see the
sealing surfaces and other forms of damage dirt that’s embedded deep
render cleaner in-operative and require within the filter paper. Your
immediate element replacement. best bet for lowest filter
maintenance costs and
best engine performance is
to follow a restriction
gauge. It’s a smart, low-
cost investment.
Never lea
Never ve an air c
leave leaner open long
cleaner er than
longer
necessary.
Your open air cleaner is a
direct entry to the engine!
Keep it protected during Filter
Fig. 1-18 Element checking with electric changes. If the housing is not
bulb going to be reassembled
immediately, cover the
AIR CLEANER SERVICE TIPS opening. The only way to be
sure nothing got in, is to make
Don’t remove element for inspection. sure nothing can get in!
Such a check will always do
more harm than good. Don’t ignore a worn or dama
worn ged gasket in
damag
Ridges of dirt on the gasket the housing.
sealing surface can drop on
If your air cleaner has a
the clean filter side when the
cover gasket, replace it
gasket is released. Stick
with a new one. Always
with the regular maintenance
check to be sure that no
schedule, or, if you service
piece of the old gasket
by restriction, believe the
remains in the housing and that the gasket is
gauge or restriction indicator. Get a new indicator
not worn. If your filter model calls for a new gasket
if you don’t trust your current one.
with each use, never reuse the old one.
Never rap a filter to clean it.
Don’t use a damaged or bunched filter.
Rapping hard enough to knock off
dust damages the filter and Never install a dented or punctured
destroys your engine protection. filter because it cannot protect
Deeply embedded dirt is never properly against contamination. A
released by tapping. It is always dent can make a firm seal impossible
safer to keep operating until you can or can indicate damaged media. A
change to a fresh Filter. filter with bunched pleats saps
engine power and fuel dollars.
Never judge the filter’s life by looking at it......
Measure the airflow restriction. Never use a warped cover on a housing.
A dirty-looking filter may still have plenty of life Replace it with a new cover as soon as possible.
left, while carbon contamination is not visible to A warped or damaged cover cannot make a
44
proper seal. Also that all hardened dirt ridges are completely
check to ensure that removed, both on the bottom and top of the
there is no damage to air cleaner.
the air cleaner housing
that could cause a 4. Check for uneven dirt patterns
leak.
Your old filter has
Never substitute an incorrect element model valuable clues to dust
number. leakage or gasket
sealing problems. A
Filters may look almost pattern on the element
identical, but even a fraction of clean side is a sign
an inch difference in size can that the old filter
prevent a good seal or affect element was not firmly
cfm delivery. It’s always better sealed or that a dust
to use the dirty filter until you leak exists. Identify the cause of that leak
can get the correct one. and rectify it before installing a new filter.
7-STEP FILTER ELEMENT REPLACEMENT 5. Press your fresh gasket to see that it
your
1. Remove the old element springs back
back
gently ‘Baby’ that dirty filter,
until you get ii clear of the Make sure your new filter
housing. Accidentally is made with a highly
bumping it while still inside compressible gasket that
means dropped dirt and dust
springs back (promptly)
that will contaminate the
when finger pressure is
clean side of your filter
housing, before the new filter released. A high quality
element has a chance to do its job. gasket is one of the most
important parts of the filter.
2. Always clean the inside of the
housing carefully Dirt left in 6. Make sure the gash seats evenl
evenly
venly
the air cleaner housing spells
death for your engine. Use a
If you don’t feel the
clean, damp cloth to wipe
every surface clean. Check it gasket seating evenly for
visually to make sure it’s clean a perfect seal, you don’t
before putting in a new filter. have protection. Re-
check to see if the
3. Always clean the gasket sealing surface in the
sealing surfaces of the housing is clean, and
housing
ensure that the filter is
An improper gasket seal is the correct model. It may
one of the most common be too short for the
causes of engine
housing.
contamination. Make sure
45
7. Ensure air-tight fit on all connections and Exhaust Back Pressure

ducts
High exhaust back pressure can be caused by
foreign objects or excessive bends in the
Check that all exhaust piping. The use of piping smaller than
clamps and the exhaust outlet of the turbocharger can also
flange joint are cause high back pressure. If the exhaust back
tight, as well as pressure exceeds 2 inch (50 mm) of mercury,
the air cleaner you will have poor performance and early engine
mounting bolts. failure. To check exhaust back pressure :
Seal any leaks
irnmediately — 1. The point of measurement must be as
close as possible to the turbocharger outlet
leaks mean dirt is directly entering your
flange. The area to be measured must be
engine
where there is uniform flow such as a
straight section of pipe. Make sure the area
Proper air cleaner servicing results in maximum to be measured is at least one pipe
engine protection against the ravages of dust. diameter from any changes in the flow
Proper servicing can also save you time and direction. If it is impossible to locate a point
money by maximizing filter life and air cleaning of measurement in a straight section, you
efficiency. can measure on the side of a bend. Make
Sure the flow is uniform and equivalent to
Two of the most common prob
problems are:
oblems the flow in the centerline. Do not measure
A) Over Servicing. New filters increase in dust on the inside or outside radius of a her
The flow is not uniform at these points.
cleaning efficiency as dust builds up on the
Fig. 1-2.
media. Don’t be fooled by filter appearance!
The filter should look dirty. By using proper
filter measurement tools, you will use the
full life of the filter at maximum efficiency.
B) Improper Servicing. Your engine is vulnerable
to abrasive dust contaminants during the
servicing process. The most common cause
of engine damage is careless servicing
procedures.
By following the steps listed above, you can

avoid unnecessary risk to the engine.
To change element:
Fig. 1-19 Checking the exhaust backpressure
1. Loosen clamp assembly which holds cup
assembly to body air cleaner. 2. At the point selected, weld a 1/8 inch [3.2
mm] pipe coupling to the exhaust tubing.
2. Remove cup assembly. Drill through the tubing with a 1/8 inch drill.
3. Loosen wing nut of outer element and Remove all the burrs on the inside of the
remove it. pipe and mount a 90° fitting to the coupling.
Use 3ft. [0.9 m] of 1/8 inch [3.2 mm] 1.D.
4. Loosen wing nut of inner element and copper tubing (to resist the heat) plus 10 ft.
remove it. [3 m] of 3/16 inch [4.8 mm] 1.D. soft rubber
46
hose to manometer. The manometer can be Exhaust Flexible bellows :

mercury filled or water filled.
CIL has developed Exhaust Flexible Bellows for
Note : It is important that the line to the all series engines to be installed in the Exhaust
manometer be the size and length as given. This piping. This specified installation guidelines for
will minimize the variation in the reading. A G-Drive engine applications.
change in the length of the line can cause a
change in the manometer reading.
Installation Guideline Notes :
Air and Exhaust Pipe Suppor
Supportsts
• Misalignment between the exhaust flexible
The air and the exhaust connections to the & vertical exhaust pipe is not permissible
turbocharger requires support. Make sure these during installation of exhaust flexible.
connections are not bent. Too much bending
can put stress on the turbocharger housing.- • For exhaust piping suppor
supportt & maximum
maximum
There must be a flexible joint between the exhaust pipe lengths before support
turbocharger and the support. This will help in refer details in respective sketches as
movement, misalignment and thermal indicated in table.
expansion of the joint.
• Exhaust Flexible shall have its free length
1. Exhaust Piping as indicated in table when it is installed.
a. The maximum bending movement of
unsupported piping at the outlet plane • Exhaust Flexible shall not be used to
must not exceed lOft-lb [14 N-m]. compensate the misalignment between the
piping.
b. A maximum of 12 inches [30.48 mm]
of flexible connections or two ball joints • Exhaust Flexible shall not be under any
must be orovided within the first 4 feet undue piping load & it shall not be subjected
[1.22 m] of exhaust piping on to any compression / expansion / lateral
turbocharged engines. This will permit movement during installation.
thermal growth and help avoid over
stressing the turbocharger components. • Exhaust pipe shall be made from specified
diameter pipes & standar
standardd elbo ws.
elbows.
c. No more than 4 feet [1.22 m] of exhaust
(Refer BS : 970 standard for dimgntional
tubing of flexible connection without
details)
support can be attached to the
turbocharger. • Use of Thimble is must while passing the
2. Air Piping piping through concrete wall. (refer sketch
# 1 for details).
a. The maximum bending movement of the
piping at the compressor inlet place without • For V-Type engine models use exhaust
support can not exceed 5 ft-lb [7 N•m]. flexible for each bank of engine.
b. A flexible connection must be provided
between the turbocharger and the support
point of the.piping.
c. No more than 5 feet 9 inches. [1.75m] of air
intake tubing without suppor t can be
attached to the turbocharger.
Note : One foot pound equals one pound of

weight at a distance of one foot.
47
Fig. 1-20 Exhaust System Details
48
Engine Operations 2-1
Section-2
ENGINE OPERATIONS
Section Contents
a) Normal Starting Procedure .................................................................................................... 51
b) Engine Warm-Up .................................................................................................................. 53
c) Engine Shut-Down ................................................................................................................ 54
d) Oil Pan Capacities ................................................................................................................ 54
e) Commissioning / Setting of Gas Engines .............................................................................. 55
f) Field Adjustment-Carburettor ................................................................................................ 56
g) Engine Preservation Procedure ............................................................................................. 57
49
NOTES
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50
Section-2
Engine Operations
a) Starting Procedure
NORMAL STARTING PROCEDURE (ABOVE

O°C [32°F] )
Engines equipped with air starters require a
minimum of 480 kPa [70 psi] compressed air
pressure.
To prevent damage to the starter, do not
engage the starting motor more than 30
seconds. Wait two (2) minutes between each
attempt to start (electrical starting motors only).
Fig. 2-1 Caution : When using jumper cables to

start the engine, make sure to connect the
cables in parallel; positive (+) to positive (+)
and negative ( - ) to negative ( - ). When
using an external electrical source to start
the engine, turn the disconnect switch to
the OFF position. Remove the key before
attaching the jumper cables.
The accompanying illustration shows a typical

parallel battery connection. This arrangement
doubles the cranking amperage.
Fig. 2-2 This illustration shows a typical series battery

connection. This arrangement, positive to
negative, doubles the voltage.
• Engine oil pressure must be indicated

on the gauge within 15 seconds after
starting. If oil pressure is not registered
within 15 seconds, shut off the engine
immediately to avoid engine damage.
Confirm the correct oil level in the oil
pan.
Fig. 2-3
51
• Idle the engine three (3) to five (5)

minutes at engine idle speed before
operating with a load.
Fig. 2-4
• When starting a cold engine, increase

the engine speed (RPM) slowly to
provide adequate lubrication to the
bearings, and to allow the oil pressure
to stabilize.
Fig. 2-5
Do not idle the engine for excessively long

periods. Engine operation at idle / partial loads
caused oil suction across valve guides.
Fig. 2-6
This may lead to excessive oil consumption,

oil deposits on spark-plug & cylinder head
components.
Fig. 2-7
52
b) Engine Warm-Up
When the engine is started, it takes a while to of the engine have expanded evenly to the most
get the lubricating oil film re-established between favourable oil clearances. Maximum engine
shafts and bearings and between pistons and coolant temperatures should not exceed 203°F
liners. The most favourable clearances between (95°C).
moving parts are obtained only after all engine
parts reach normal operating temperature. Avoid Keep thermostats always in the engine, avoid
seizing pistons in liners and running dry shafts long periods of idling, and take necessary steps
in dry bearings by bringing the engine up to to keep water temperature up to a minimum of
operating speed gradually as it warms up. 167°F (75°C). If necessary in cold weather, use
radiator shutters or cover a part of the radiator
On some emergency equipment (such as fire to prevent overcooling.
pump engines) warm-up may not be necessary
due to equipment being housed inside a heated Oil Pressure
building. For an engine starting with a parasitic
load, such as a fire pump, coolant temperature Normal engine oil pressure at 221°F (105°C)
must be a minimum of 120°F (49°C). should be between 3 to 7 kg/cm2 at rated speed
and 1 to 2 kg/cm2 at low idle speed.
Oil Temperature
The oil temperature gauge normally should read Note : Please note that oil pressure will vary
between 167°F (75°C) and 221°F (105°C). Under with temperature.
full load conditions, an oil temperature of 240°F
(116°C) for a short period is not a cause for alarm.
Note : Individual engines may vary from
Caution: Any sudden increase in oil above normal pressures. Observe and record
temperature which is not caused by load pressure when engine is new to serve as a
increase is a warning of possible mechanical guide for indication of progressive engine
failure and should be investigated at once. condition. (High oil pressure during start-up
is not a cause for alarm.) For record purposes
these readings are more accurate and reliable
During warm-up period, apply load gradually until
when taken immediately after an oil change.
oil temperature reaches 140°F (60°C). While oil
is cold it does not do a good job of lubricating.
Continuous operating or long periods of idle with Engine Exhaust
oil temperatures below 140°F (60°C) may cause
crankcase dilution and acids in the lubricating The engine exhaust is a good indicator of engine
operation and performance. If engine smoke
oil which quickly accelerate engine wear.
through exhaust is bluish in colour, then it
indicates that the engine lube oil is burning inside
Water Temperature
the engine combustion chamber. Similarly, if the
A water temperature of 167° to 203°F (75°C to exhaust gives puffing and white smoke then it
95°C) is the best assurance that working parts indicates engine misfiring.
53
c) Engine Shut-Down d) Oil Pan Capacities
Idle Engine A Few Minutes Before Shut-Down Table 2-1 : Oil Pan Capacities
It is important to idle an engine 3 to 5 minutes Engine Lub oil
before shutting it down to allow lubricating oil C.I.D. Capacity
and water to carry heat away from the combustion High Low
chamber, bearings, shafts, etc. This is especially Litres Litres
important with turbocharged engines. (U.S. gal.) (U.S. gal.)
The turbocharger contains bearings and seals 495 17 (4.5) 13 (3.5)

that are subject to the high heat of combustion 15 (4)
exhaust gases. While the engine is running, this 743 27 (7) 19 (5)
heat is carried away by oil circulation, but if the 855 27 (7) 19 (5)
engine is stopped suddenly, the turbocharger
temperature may rise above 360°F. The results 1150 38 (10) 32 (8.5)
of extreme heat may be seized bearings or loose 1710 68 (18) 61 (16)
oil seals. 2300 114 (30) 87 (23)
3067 152 (40) 122 (32)
Do Not Idle Engine ffor
or Excessively Long
Excessively
Periods Capacities listed are for oil pan only on G-
drive applications. Total system capacities
If the engine is not being used, shut it down. vary with filter sizes and length of oil lines.
Please refer to Engine Data Sheet for Oil
Turn Switch Key to ‘Off’ Position to Shut capacities on other application.
Down the Engine
Check Hydraulic Governor
The engine can be shut-down completely by Many engines used in stationary power
turning off the switch key on installations applications are equipped with hydraulic-governs
equipped with an electric shut-down valve. which use lubricating oil as an energy medium,
same as used in engine. Oil level in governor
sump must be at H mark on dipstick.
CAUTION
Check Air Connections
Stop engine Immediately If Any Parts Fails Check air connections to compressor and air
equipment, as used, and to air cleaner
cleaners and
leaners
Practically all failures give some warning to the air crosso
crossover
ossovers to assure all are secured.
vers
operator before the parts fail and ruin the
engine. Many engines are saved because alert Check Engine Coolant Supply
operators heed warning signs (sudden drop in oil 1. Remove the radiator or heat exchanger cap
pressure, unusual noises, etc.) and immediately and check engine coolant level. Add coolant
shut down the engine. as needed.
2. Make visual check for leaks.
54
e) Commisioning / Setting of Gas Engines
1. To check ignition system and leakages (oil, 5. Check carburetor governor linkage.
water, charge etc.) if any, engines are tested
at CIL on 1/3 load and using LPG. For this 6. Check ignition timing. Timing should
ignition timing is set for 20 deg. After testing approximately 27 deg BTDC for natural gas
and before dispatch of engine timing is reset engines before initial starting.
to 27 deg. However final setting is 7. Start the engine. Set/check idle speed (1080-
required to be done in the field. 1120 RPM).
2. Ensure the correct mounting and connection 8. Check exhaust temperature.
of regulators.
9. Optimisation of engine timing is necessary
3. When the engine is stopped the gas pressure
for proper burning of fuel in the combustion
should be set to 8” of water column.
chamber.
When the engine is running at rated load
and speed the gas pressure should be set Please note that the effects of advance of
to 3” of water column. engine timing (say 27 deg BTDC → 30 BTDC)
lowers the exhaust temperature, gives better
4. The caburetor “rich” and “lean” setting screw fuel consumption but results in excessive
should be set at the center. engine knocking.
Retarded engine timing (27 deg BTDC → 25
BTDC) reduces the tendency of engine
knocking but results in higher exhaust
temperatures and increased fuel
consumption.
The timing may vary as per the composition
of natural gas (propane content etc.).
Gradually increase RPM upto rated 1500
RPM observe for any abnormal noise.
Fig. 2-8
OPERATING THE ENGINE
• Allow the engine to idle three (3) to five
(5) minutes before shutting it off after a
full load operation. This allows adequate
cool down of pistons, cylinder liners,
bearings and turbocharger components.
NOTE : Continuous operation with low

coolant temperature, below 60°C [140°F], or
high coolant temperature, above 100°C
[212°F], can damage the engine.
Fig. 2-9
55
• Monitor the oil pressure and coolant

temperature gauges frequently. Refer to f) Field Adjustment-Carburetor
Lubricating Oil system Specifications or
Cooling System Specifications, Section V,
for recommended operating pressures and Intake manifold vacuum on the natural Gas Engine
temperatures. Shut off the engine if any is one of the most important factors on gas engine
pressure or temperature does not meet the operation. This vacuum should be measured by a
specifications. suitable gauge or column containing to use a dial
type gauge. The dial type vacuum gauge is calibrated
in inches of mercury, 0 inch to 30 Inch Hg.
• If an overheating condition starts to occur,
1. Close main gas supply valve.
reduce the power output of the engine 2. Set carburetor power mixture adjustment valve
Troubleshooting, Section T, or contact a at centre between “R” (Rich) and “L” (Lean)
Cummins Authorized Repair Location. marks. Fig. 5-9.
3. Close the idle adjustment; then open two and
one-half turns. Fig. 5-10.
4. Remove pipe plug from intake manifold and
install a vacuum gauge.
5. Open the main line gas supply valve.
6. Adjust line gas pressure to the regulators.
7. Start the engine, using normal starting
procedure.
8. Start the engine, using normal starting
procedure.
9. Adjust gas pressure to carburetor to 3 inches of
water with engine running at 600 to 700 rpm.
This adjustment is very important and must be
accurately accomplished as the engine fuel
Fig. 2-10 economy and power output are directly affected
by any variation in inlet gas pressure at the
• Most failures give an early warning. Look carburetor.
and listen for changes in performance, sound 10. After engine coolant attains operating temp-
or engine appearance that can indicate erature (140° to 160°F), operate the engine at
rated rpm and system load.
service or engine repair is needed. Some a. Check the carburetor inlet gas pressure. This
changes to look for are as follows : pressure must remain between 2 to 3 inches
– Engine misfires [50 to 76 mm) of water when the engine rpm
and load varies from rated load and speed to
– Vibration no-load at idle. If gas pressure to carburetor falls
below 2 inches [50 mm] of water at full load, this
– Unusual engine noises may indicate excessive pipe length, flow
restriction between the main line pressure
– Sudden changes in engine operating regulators.
temperature or pressure b. With engine running at rated rpm and load, move
the carburetor power mixture adjustment valve
– Loss of power
slowly toward the “L” position.
– An increase in oil consumption Any and all final adjustments on the engine should
be to obtain and highest amount of manifold
– Gas, oil or coolant leaks. vacuum. Any adjustment that cause a drop or less
vacuum is an incorrect adjustment. Final
adjustments must be made with the engine
operating at its rated load and speed.
11. Shut down engine.
12. Close the main gas supply valve.
56
g) Engine Preservation Procedure
Introduction iii) Engine preservation procedure for engines

installed in equipment.
On any engine not in service, whether installed
in equipment or waiting to be installed, the Note
unpainted surfaces and various internal passages The rate of corrosion varies with climatic
are subject to rust and corrosion. condition. Variance in climatic condition makes
it very difficult to state the length of time an engine
Every engine going out of factory is processed can be stored without rust and corrosion damage.
and is suitable for storage upto six months from However the procedures outlined below are useful
the date of despatch. However sometimes for various climatic conditions except for arctic
engines are required to be stored for more than conditions and vary low temperatures. For such
six months, also on many occasions engines conditions, please refer to Cummins India
as installed in equipment are not put in service. Limited for engine storage requirements.
Hence it is necessory to process such engines
for storage. Based on above the procedure for 1) Engine preservation procedure for
preservation can be catagorised as below. engines to be stored upto six months,
from the date of engine shipment from
i) Engine preservation procedure for engines factory.
to be stored upto six months, from the date
Note
of engine shipment from factory.
Every engine going out of factory is processed
ii) Engine preservation procedure to be carried for storage upto six months. Hence no additional
out for engine storage beyond six months processing is required except proper storage, as
from date of shipment from factory. given on next page.
i) IF ENGINE HAS TO BE STORED IN THE ENGINE BOX, AS RECEIVED FROM FACTORY,
SR NO DESCRIPTION
a Store engine box along with kit boxes, in enclosed place protected from
water / rain water, dust etc.
b Tag all these boxes indicating following,
ENGINE SHIPMENT DATE :
THE ENGINE HAS BEEN TREATED FOR

PRESERVATION FOR A PERIOD OF SIX
MONTHS FROM THE ENGINE SHIPMENT
DATE MENTIONED ABOVE.
c Do not stack any material on engine box to avoid damage to engine / engine box.
57
ii) IF ENGINE HAS TO BE STORED WITH OUT ENGINE BOX, AND / OR SKID.
SR NO DESCRIPTION
a Store engine along with kit boxes, in enclosed place protected from water / rain
water, dust etc.
b Tag all these boxes indicating following,
ENGINE SHIPMENT DATE:

PRESERVATION FOR A PERIOD OF SIX
MONTHS FROM ENGINE SHIPMENT DATE
MENTIONED ABOVE.
c Ensure that all engine openings and opening on kit items such as radiators, air cleaners,
silencers etc. are covered by water proof protective caps / plastic tapes.
d Do not rotate the engine, as engine is in dry condition.
2) Engine preservation procedure to be carried out for engine storage beyond six months
from date of shipment from factory.
The engine system wise details of the process are described below.
Cooling System Passage :
SR DESCRIPTION REMARKS
NO
a Prepare engine for Ensis, Long Storage Fabricate and install a plate to close the
Process. water pump inlet connection.
b Fill the cooling system with Ensis oil Leave the drain cocks open until all air is
RUSTILO DW 901, (Castrol India make) completely vented out. Progressively close
up to thermostat outlet connection, using the cocks until the ensis oil flows from the
external priming pump trolley. thermostat housing.
c Keep the Ensis oil in the engine for Remove the fabricated plate at water pump
5 minutes and then drain it completely, inlet and close the opening by plastic cap.
from engine. ( Collect the drained oil in clean container for
reuse. )
58
ii) Lubricating Oil Passage :
SR DESCRIPTION REMARKS
NO
a Prepare engine for Lub oil priming. Use lub oil priming pump for priming.
b Prime the engine with engine lub oil Use engine Lub oil trolley for priming.
15W40. (GEO) Circulate the lub oil till the lub pressure gauge
shows 1 kg / cm sq. pressure. It will take max five
min. to reach this lub oil pressure. Bar the engine
during the process.
c Drain the Lub oil from the oil pan.
NOTE :
a) The above procedure for engine b) Loosen the belt tension on fan belt,
preservation is to be carried out / alternator belt, water pump belt and
repeated at the end of every six months other accessories driven by belt.
during the storage period. The
c) Tag the engine indicating preservation
procedure may have to be done at
process date and due date for next
OEM works or at customer's place
preservation (6 months period).
depending upon location of engine.
ENGINE PRESERVATION PROCESS

DATE :
PRESERVATION FOR A PERIOD OF SIX MONTHS.
DUE DATE FOR NEXT PRESERVATION PROCESS
(IF NOT INSTALLED IN THE EQUIPMENT).
DATE :
3) Engine preservation procedure for Run the engine once in every week for 5
engines installed in equipment. to 10 min. at Low Idle RPM. "B" check
to be carried out at every six months as
Many times, the engines shipped from mentioned in Section 6.
factory are installed on the equipment or
4) Preparing a preserved ( treated ) engine
Genset within six months from date of
for putting in service.
shipment from factory. However these
engines as installed in the equipment are When an engine is removed from storage
not put in the service for a long period. For and put into service the operation listed
such engines the engine coolant below should be performed.
and engine lub oil is generelly filled in
i) Clean off all accumulated dirt from exterior
the engine. Hence no special ensis
of engine
process is required, but periodic running of
engine as given below is mandatory ii) Remove all protective caps, tape and
requirement. wrappings from connections such as
59
Water in and out connections etc.

iii) Use suitable solvent, cleaner or degreaser
to remove rust preventive compound from
unpainted external surfaces of the engine
iv) Refill oil pan with fresh lubricating oil.
Replace the fuel, lub oil filters and lub oil
bypass filters, only in case wherein engine
is stored beyond six months from the date
of shipment.
v) Check and correct the engine belt
tensioning.
vi) Refer Section 1 for engine starting
instructions.
vii) In case of any doubts, contact CDS&S /
Dealer.
60
Installation and Schedule Maintenance 3-1
Section-3
INSTALLATION AND SCHEDULE MAINTENANCE
Section Contents
a) Installation Instructions ......................................................................................................... 67
b) Typical Gas Pipe Line Sketch ............................................................................................... 68
c) Schedule Maintenance ......................................................................................................... 69
d) Maintenance Schedule Chart ................................................................................................ 71
e) Maintenance Schedule Chart with Distributor Type Ignition System ...................................... 72
i) “A” Maintenance Check (Daily) ..................................................................................... 73

Check Operator’s Report, check air cleaner ................................................................. 73
Check gas pipe line ..................................................................................................... 73
Check leaks and correct lub oil system ....................................................................... 74
Check ignition system ................................................................................................. 74
ii) 500 Hours Check ......................................................................................................... 75

Check Heat Exchanger Zinc Plugs ............................................................................... 75
Change lub oil filter element ......................................................................................... 75
Check belt tension ....................................................................................................... 77
Check contact breaker setting ..................................................................................... 77
Check Air Inlet Restrictions .......................................................................................... 77
iii) B/1000 Hours Check .......................................................................................................

Change engine lub oil ......................................................................................................
Change crankcase breather ............................................................................................
Check coolant additive concentrate .................................................................................
Ignition system check .....................................................................................................
Valve adjustment .............................................................................................................
iv) “C” Maintenance Check (3000 Hours Check) ................................................................ 78

Ignition system check .................................................................................................. 78
Change engine oil ........................................................................................................ 78
Check cylinder compression ........................................................................................ 78
61
NOTES
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
........................................................................................................................................................
62
Section-3 The operator of the engine assumes the

responsibility of engine care while it is being
worked. This is an impor tant job and one that
important
will determine to a lar largge degree the e xtent of
extent
Installation and pr ofit fr
profit om the operation. There are
from
comparativel
comparatively y ffe
ew rules whic
which h the operator m ust
must
Schedule obser
observeve to g get
Cummins Gas Engine
et the best ser
Engine.. Ho
Howewe ver
vice fr
service
ver,, if an
wever
om the
from
y of these
any
rules are broken, a penalty is cer
broken, tain to ffollo
certain ollow.
ollow
Maintenance The penalty ma
because of lo
may y be in lac
lowered
lackk of w ork accomplished
work
wered engine efficienc
efficiency y or it ma
mayy
be in down time and costl
down costlyy repair bills resulting
from premature engine failure
from failure..
a) Installation Instructions
1. Remove all tape and plastic covers from fuel, 6. Inspect all wires for cut or frayed insulation;
lubricating oil and air intake connections. replace all damaged wiring.
2. Locate unit on a firm base and secure in 7. Check throttle for free travel; correct as
desired position with anchor bolts and shock necessary.
mounts. Check alignment of engine with
driven unit, shim as necessary to obtain GENERAL INFORMATION
desired alignment. Allow sufficient space to
Correct care of your engine will result in longer
provide access to all sides of unit.
life, better performance and more economical
Note : On installations with external coolant lines, operation.
such as cooling towers and heat exchangers,
• Follow the daily maintenance checks
piping should be installed with flexible
listed in Maintenance Guidelines,
connections to reduce stress on rigid piping due
Section 3.
to engine vibration.
3. Provide outside venting of exhaust gas if unit
is installed in an enclosed area: also, venting
of radiator cooling air must be provided.
4. Connect gas supply piping as suggested in
Preferred Piping Schematic Fig. 2-1.
Note : Install flexible connection between second
stage pressure regulator and carburet. Install
second stage pressure regulator valve nearer to
the carburetor gas inlet.
Caution : Do not use rubber hose for flexible
connection.
5. Inspect units for damaged or missing parts.
Check all bolts and nuts for tightness; replace
as necessary. Table 3-1
63
Maintenance Schecule ENGINE MODEL ___________ ENGINE SR NO. ____________
CUSTOMER _______________ DATE _____________________
Cummins Gas Engines Check each operation as performed
A - Daily 500 Hrs. - Check B - Check C - Check D - Check

500 Hours 1000 Hours 3000 Hours 6000 Hours
o Check Operators o Repeat ‘A’ Check o Repeat Daily Check o Repeat ‘A’, ‘B’ & 500 o Repeat ‘A, B, and C’
Report and 500 Hours Check. Hours Check Check
Air Intake System Cooling System Lubrication System Ignition System Lubrication System
o Change engine lube o Check Engine Blow-
o Check for leaks o Check Heat o Relpace Champion
oil. Use only special By
and correct it. Exchanger Zinc make Spark plug.
Gas Engine Oil SAE
Plugs
o Observe the Air Grade 15 W 40 for o Replace HT Cables Cooling System
Cleaner restriction fill and top up.
indicator
Ignition System * o Change Lub Oil filters.
with Spark Plug o Check Thermostat.
o In case of connectors.
o Clean Crankcase o Clean Radiator Core
Gas Pipe Line Distributtor system Misc. Check
Breather
check CB points and (Externally)
o Check for leaks o Lubricate water pump o Check Fan Hub.
and correct it. adjust gap, if & fan hub bearings Apply Grease to the o Clean heat
required. o Check engine blow-by.
o Check Gas Bearings exchanger core tube
Pressure at Misc. Checks Cooling System internally to remove
o Check cylinder
Carburetor inlet and o Check Coolant the scaling.
o Check and Adjust compression.**
before and after Additive Concentrate
Belt Tension o Replace water line
the pressure level and add
regulator. o Check Connection concrete if required. hoses
and Gauges o Check Auxiliary
Lubrication System Ignition System
Water Pump
o Check for leaks Intake Manifold Temp. Ignition System o Check Disc Altronic
and correct it. o Check / Clean Spark
o For turbocharged Ignition Timer
o Check Engine Oil aftercooled engines plug, and adjust spark coupling.
Level. check and ensure, plug gap if equiped with
intake manifold Champion make Misc. Check
o Check Hydraulic spark plugs.
Governor Oil Level temp. is less than
55oC (130oF) o Clean and Tighten o Clean Engine
Cooling System Electrical Connections
including ignition o Tighten Engine
o Check for leaks system. Mounting Bolts and
and correct it. o Check transformer Nuts
o Check Coolant registance
Primary - 0.2 to 0.3 Ω o Check AVM and
Level and top up
with pre-mixed Secondary - 6 to 8 kΩ mounting.
coolant, if required. o Replace MICO Spark
o Check Crankshaft
plug
Ignition System End Clearance
o Check Ignition Timing
o Check wiring and Adjust if required. o Check Damper for
connections are Misc. Checks fluid leak and
proper o Check and adjust
Wobble, and replace
valve clearances
Misc. Checks if required.
Air Intake System
o Check Governor & o Check intake Reconditioning
Carburetor linkages manifold vacuum.
are free. o Recondition cylinder
Gas Pipeline Check head if intake
o Check Pressure drop manifold vacuum is
across the Gas low.
fillter. Replace if
more than 3 PSI
while engine running.
Note : * For engines with Lucas make Distributor Type Ignition System refer to ignition system maintenance schedule on next page.
** After first 6000 hours operation, intake manifold vacuum should be checked at every 1000 hours to decide if reconditioning of
cylinder head is necessary.
Table 3-2
64
b) Typical gas pipe line sketch
FLEXBLE PIPE JOINT

OR 200 MM WC
7 PSIG 20 PSIG
Installation and Schedule Maintenance

MOUNTED ON
GAS ENGINE.
3-5
65
• Check the oil pressure indicators,

temperature indicators, warning lights
and other gauges daily to make sure
they are operational.
Gas Line Pressure
Main Line Pressure 20 Psig (1.4 kg/cm2)

After 1st stage regulator 7 Psig (0.5 kg/cm2)
After 2nd stage regulator 1) 5-6 WC bef. engine
starting.
2) 3 WC at engine Fig. 3-2
running full load.
Warning : DO NOT OPERATE A ENGINE

WHERE THERE ARE OR CAN BE
COMBUSTIBLE VAPORS. These vapors can
be sucked through the air intake system
and cause engine acceleration and over-
speeding, which can result in a fire, an
explosion and extensive property damage.
Numerous safety devices are available, such
as air intake shutoff devices, to minimize
the risk of overspeeding where an engine,
due to its application, might operate in a
combustible environment, such as due to a
fuel spill or gas leak. Remember, Cummins
has no way of knowing the use you have
for your engine. THE EQUIPMENT OWNER
AND OPERATOR ARE RESPONSIBLE FOR
SAFE OPERATION IN A HOSTILE
ENVIRONMENT. CONSULT YOUR CUMMINS
AUTHORIZED REPAIR LOCATION FOR
Fig. 3-3
FURTHER INFORMATION.
66
c) Scheduled Maintenance
Maintenance is the key to lower operating A detailed list of component checks is provided
costs. An engine - like any other engine - through several check periods; also a suggested
requires regularly scheduled maintenance schedule basis is given for hours of operation.
to keep it running efficiently. Most engines
are purchased and used for the sake of Your maintenance schedule should be estab-
revenue. Any failure or loss of efficiency lished using the check sheet as a guide; the
reduces revenue; it also requires additional result will be an excellent maintenance program
funds for repair. to fit your specific operation.
Investigate any successful operation where
engines are used and you will find a good,
regularly scheduled, maintenance program
in effect.
Note :
Preventive maintenance performed on schedule Schedule for Distributter Type Ignition
is the easiest, as well as the least expensive, Checks :
type of maintenance. It permits the maintenance
department to do work in the shop on schedule, For other checks refer to the Maintence
rather than on the job under poor working Checks.
conditions and at inconvenient hours.
Frequency hrs.
A Good Maintenance Schedule Depends
On Engine Application
IGNITION SYSTEM
Actual operating environment of the engine must
govern the establishment of the maintenance Distributor parts check and clean
schedule. Some engines operate under rather Distributor cap 250

clean conditions, some under moderately dusty Rotor arm 250
conditions and others under severiy dusty or dirty
Distributor contact breaker point gap
conditions; each type of operation must be
analyzed as the maintenance schedule is Check and correct 250
established. A look at the suggested check Centre carbon brush

sheet, on the next page, indicates some checks Check and correct 250
may have to be performed more often under heavy Wiring harness and connections
dust or other special conditions.
Check 250
Table 3-3
67
d) Maintenance Schecule - Cummins Gas Engines

Check each operation as performed

Gas Engine Oil SAE
Plugs
indicator
Breather
o Check cylinder
o Check and Adjust compression.
Water Pump
Level and top up
o Check Crankshaft
plug
Wobble, and replace
valve clearances
Air Intake System
across the Gas low.
fillter. Replace if
more than 3 PSI
Table 3-4
68
i) “A” Maintenance Checks - Daily
i) CHECK OPERATOR’S REPORT ii

ii)) CHECK AIR CLEANER
Clean Pre-Cleaner and Dust Pan
Check the operator’s daily reports; investigate
and correct reported cases of : Under extremely dirty conditions an air
precleaner may be used. Clean pre-cleaner jar
1. Low lubricating oil pressure. and dry-type air cleaner dust pans daily or
2. Low power. more often, as necessary, depending on
3. Abnormal water or oil temperature. operating conditions.
4. Unusual engine noises.
5. Excessive smoke.
Check Inlet Air Restriction
Make a Daily Report of Engine Operation to
Vacuum Indicator
the Maintenance Department
A mechanical restriction indicator is available
The engine must be maintained in top to indicate excessive air restriction through a
mechanical condition if the operator is to get dry type air cleaner. This Part No. 3392504 can
optimum satisfaction from its use. The be mounted on air cleaner outlet or connection
maintenance department needs daily running between aircleaner and carburetor. The red
reports from the operator to make necessary flag (1) in window gradually rises as cartridge
adjustments in the time allotted and to make loads with dirt. After changing or replacing
provisions for more extensive maintenance cartridge, reset indicator by pushing reset button
work as the reports indicate the necessity . (2).
Comparison and intelligent interpretation of the 1

daily report along with a practical follow-up
action will eliminate practically all failures and
emergency repairs.
Report to the Maintenance Department any of

the following conditions : 2
1. Low lubricating oil pressure.

2. Low power.
3. Abnormal water or oil temperature.
4. Unusual engine noise. Fig. 3-4. Air inlet restriction indicator
5. Excessive smoke. Air restriction for Gas engins must not exced
15 inches (508 mm) of water column.
6 Excessive use of coolant, fuel or lubricating
oil.
7. Any fuel, coolant or lubricating oil leaks.
69
iii
iii)) GAS PIPE LINE :
Check for leaks and correct it.
Refer to Section No. 1 for the Installation
Recommendations for Gas Pipe Line. A sketch
of typical gas pipe line is given on this page.
Check gas pressure at carburetor inlet and
GAS SHUT-OFF VALVE (MANUAL)
before and after the pressure regulator.

ASSLY.GAS FILTER
Refer to Section No. 1 for the Installation

Recommendations for Gas Pipe Line.
iv
iv)) CHECK LEAKS AND CORRECT
LUBRICATING OIL SYSTEM
Check for evidence of gas leakage at regulator
and all pipe connections.
1. Apply liquid soap around regulator and gas

line connection to check for leaking gaskets.
GAS REGULATOR
Check Engine Oil Level

20 PSIG
(I STAGE)
1. Check oil level with dipstick oil gauge located

on the engine. Fig. 3-6. For accurate
readings, oil level should not be checked for
approximately 15 minutes after engine shut-
7 PSIG
down. Keep dipstick with the oil pan with

which it was originally shipped. Keep oil
level as near “H” (high) mark as possible.
MAX 8 INCH WC
OR 200 MM WC
FLEXBLE PIPE JOINT
Caution: Never operate the engine with oil

level below the “L” (low) mark or above the
“H” (high) mark.
CARBURETOR
MOUNTED ON
GAS ENGINE.
Fig. 3-6. Checking engine oil level
70
2. If necessary, add oil of the same quality coolant on a hot engine unless no pressure
and brand as already in the engine. cap is in the system, except in an emergency.
Check Hydraulic Governor Oil Level Check pressure cap at each “C” Checkto
prevent coolant loss through overflow. Investigate
1. Many engines used in stationary power any excessive loss of coolant.
applications are equipped with a hydraulic
governor. The governor uses the same Check Coolant Level
type lubricating oil for energy medium as
the engine. However, the governor oil Keep cooling system filled to operating level.
system is separate from the engine Check coolant level daily or at each fuel fill
lubricating oil system and must be obtained. point. Investigate for cause of coolant loss.
Recheck the level after engine reaches normal
2. Oil level in governor sump must be at high- operating temperature. At operating temperature
level mark on dipstick. the thermostat is open and water is free to
circulate to all parts of the system and fill all
v) COOLING SYSTEM air pockets.
Check for evidence of external coolant leakage. vi) IGNITION SYSTEM

Tighten capscrews, hose clamps, fittings and
connections, or replace gaskets or hose as Check wiring conections of wiring harnesses.
necessary to correct. Tighten the loose connections.
Fill Cooling System vii) MISCELLANEOUS CHECKS
Keep cooling system completely filled. Check Check the Governor and carburetor linkages for
coolant level daily before starting engine. free movement.
Recheck after engine cools. Do not check
71
ii) Maintenance Schecule - Cummins Gas Engines


Gas Engine Oil SAE
Plugs
indicator
Breather
o Check cylinder
Water Pump
Level and top up
o Check Crankshaft
plug
Wobble, and replace
valve clearances
Air Intake System
across the Gas low.
fillter. Replace if
more than 3 PSI
Table 3-6
72
iii) 500 Hours Maintenance Checks
Repeat ‘A’ Check 5. Remove NPTF plug on can, fill clean oil and
replace the plug.
i) COOLING SYSTEM
6. Torque the can retaining bolt to 30 to 35 ft.
Check Heat Exchanger Zinc Plugs lbs. (41 to 47 N•m).
Check zinc plugs in heat exchanger and change 7. Run the engine, check for leaks, recheck
if badly eroded. Frequency of change depends
engine oil level; add oil as necessary to
upon chemical reaction of raw water circulated
bring the oil level to “H” mark on the
through heat exchanger.
dipstick.
ii) Lubrication System
Note : Always allow oil to drain back to the oil
Change Lubricating Oil Filter Elements pan before checking the level. This may require
15 minutes.
1. Loosen centre bolt securing lub oil filter to
lubricating oil pump. On G-1150, 1710, 2300 and 3067 series engines
to change element lub oil, remove centre bolt,
takeout element and seal “O” ring and discard
them. Replace new element and “O” ring. Fill
can with oil and mount element and can back
to the position. Torque bolt to the 30 to 35 ft-
lbs.
Fig. 3-7. Changing lub pump mounted

filter element.
2. Remove filter element, cut it open and

check for metal particles, if found check for
source. Discard “O” ring and element. Insert
new filter element into the can.
Fig. 3-8. Changing L.O. element on
3. Install new rectangular seal on the pilot GTA 2300 / GTA 3067 engines.
located on the lub pump.
4. Install can and element assembly with it’s

mounting bolt and washers.
73
bring the oil level to the “H” mark on the

dipstick.
iii) IGNITION SYSTEM
In case of Lucas make distributor type Ignition

system, check the contact bracker points and
adjust gap as suggested below :
Design Data :
(a) 6 - Cylinder units -
Firing angles : 0º, 60º, 120º, 180º, 240º, 300º,
± 1º
Fig. 3-9. Changing L.O. element on Closed period : 35º ± 3º
K6 engines. Open period : 25º ± 3º
(b) Contact breaker gap : 0.35 - 0.41 mm
Change Super Lub Oil By-Pass Filter
Element (0.014" -.016")
1. Loosen four capscrews from head and (c) Contact breaker spring tension, measured
remove head super L.O. by-pass filter. at contacts : 500 - 670 gm. (18-24 oz.)
The speed and advance in degrees refer to those
of the distributor shaft-and hence when taking
measurements off the flywheel the above values
must be doubled.
iv) MISCELLANEOUS CHECKS
Check Belts
Visually check belts for looseness. If there is
evidence of belt slippage adjust as follows :
Using appropriate gauge, check and /or adjust
belts to tension as indicated in Table 3-7.
1. Eccentric Water pump adjustment.

Fig. 3-10. Super L.O. Bypass filter
a. Loosen water pump clamp ring to allow
pump body to turn.
2. Takeout element and remove ring sealing
between head and shell. b. Loosen pump body by pulling up on
belts. A sharp jerk may be required
3. Replace ring sealing and element. Fill filter
c. Insert bar in water pump body slots
with some oil and reassemble.
and rotate pump body counterclockwise
to tighten belts.
4. Run the engine, check for leaks, shut
down the engine. Add oil as necessary to
Note : Do Not adjust to final tension at this
74
time.
1. Loosen locknut securing idler pulley to
d. Snug clamp ring capscrew farthest bracket or water pump.
from belts, on exhaust side to 5 ft-lbs
(7 N•m). 2. Tighten water pump idler pulley bolt till
e. Snug two capscrews above the first sufficient tension is obtained. Retighten
one to 5 ft-lbs (7 N•m). locknut securing idler pulley to idler bracket
to 45 to 55 ft. lbs.
f. Finish tightening by tightening alternate 3. Check belt tension as per Table 3-7.
link in 5 ft-lbs (7 N- m) increments to
a final torque of 12 to 15 ft-lbs (16 to Note : Self tensioning idler if present on V-
20 N•m). 1710 belt driven water pumps requires no
adjustment or belt tension check.
g. Check belt tension.
Fan Drive Belts
Final belt tension was not obtained by
adjustment alone. The water pump body was 1. Loosen large locking nut using rachet
pulled straight by snugging the capscrews in spanner 3244252 on fan hub shaft or
the order described, thus increasing belt tension capscrews securing fan hub shaft to
to final value. mounting bracket. The fan hub will fall out
of line when this is done.
Table 3-7 : Belt Tension (Pounds) 2. Turn the adjusting screw to increase belt
tension.
3. Tighten the locknut or capscrews until the
Belt Belt * New Belt ** Belt Tension fan hub is straight. Snug the nut to
Width Gauge Tension After Run-in
Inches No. + 10 + 10 maintain hub in proper alignment with the
fan hub bracket.
Standard “V” Belt
Caution : Do not adjust to full tension with
1/2 ST-1274 140 100 the adjusting screw, this would result in
over-tightening
over-tightening.
11/16 ST-1138 140 100
3/4 ST-1138 140 100 4. Belt tension should read as indicated in
7/8" ST-1138 140 100 Table 3-7 on applicable gauge.
Poly-V
6 Rib ST-1293 150 130
5. Tighten NH/NT Engines locknut to 350 ft-
lbs using ratchet spanner 3244252. Tighten
the four 1/2 inch capscrews Fig. 4-5 on NT
855 (Water pump with idler) FFC Engines to 75 to 85 ft-lbs (101 to 115
N•m).
15/32 ST-1274 130 80
* New belts must be re-tensioned to values listed 6. Recheck belt tension.

under “New Belt Tension”.
7. Back out adjusting screw one-half turn to
** Used belts should be retensioned to values listed
under “Belt tension after run-in” prevent breakage
Generator/Alternator Belts
In-line Engine Water Pump Belts (With Idler)
75
Belt tension should be as indicated in Table 3-7 Readjusting New Belts

when measured with the applicable gauge.
All new belts will loosen after running for
Belt Installation 5 minutes and must be readjusted to “belt
tension after run-in” Ref. Table 3-7.
If belts show wear or fraying replace as follows:
At every 500 Hours
1. Always shorten distance between pulley
centers so belt can be installed without Check the contact breaker setting. Turn the
force. Never roll a belt over the pulley and engine until the contacts show the maximum
never pry it on with a tool such as a opening that is when the operating heel is on
screwdriver. Either of these methods will the highest point on the cam. The gap between
damage belts and cause early failure. the contacts should measure 0.35 mm (.014”)
(0.016”). If the measurement is incorrect, keep
2. Always replace belts in complete sets. the engine in the position giving maximum
Belts riding depth should not vary over 1/16 opening, slacken the screw securing the fixed
in ( 1.6 mm) on matched belt sets. contact plate and adjust its position to give the
required gap. Tighten the screw. Recheckthe
3. Pulley misalignment must not exceed 1/16
setting for other positions of the engine giving
in (1.6 mm) for each ft (0.3 m) of distance
maximum opening.
between pulley centers.
v) INTAKE MANIFOLD TEMPERATURE
Check the Intake Manifold Temperature on
4. Belts should not bottom on pulley grooves Turbocharged aftercooled engines. The
nor should they protrude over 3/32 in (2.4 temperature should be less than 55oC (130oF).
mm) above top edge of groove.
Adjust Throttle Linkage
5. Do not allow belts to rub any adjacent
parts. Check throttle linkage and make sure it is in good
operating condition. Check throttle travel to make
6. Adjust belts to proper tension. sure linkage operates throttle from stop to full
throttle and that degree of travel is within
specifications for application.
76
iv) Maintenance Schecule - Cummins Gas Engines


Gas Engine Oil SAE
Plugs
indicator
Breather
o Check cylinder
Water Pump
Level and top up
o Check Crankshaft
plug
Wobble, and replace
valve clearances
Air Intake System
across the Gas low.
fillter. Replace if
more than 3 PSI
Table 3-8
77
NOTES
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78
B / 1000 Hours Maintenance Checks
Repeat Daily Check and 500 Hrs. Checks. hrs/6 months (the oil change period for NT/
NTC-495-G and N-4.8-G engines is 500 hours
i) LUBRICATION SYSTEM of operation or every 6 months) prior to initiating
a Used Oil Analysis Program.
At every “B” Maintenance Check, perform all
In order to initiate a Used Oil Analysis Program
the “A” Checks in addition to the following. for a large number of engines they should be
This check should be carried out at every 500 grouped by basic model, rated horsepower and
hour of operation or at every six month. type of service. The horsepower range of a
group should not exceed 25. NH, V and K
Lubricating Oil Change Intervals models must be in separate groups. Use
common nomenclature for engines. After the
Maintaining a proper “B” maintenance check engines have been grouped, a sub-group
interval is a very important factor in preserving consisting of 10 percent of the total engines in
the integrity of an engine. Lubricating oil each group should be selected for the Used Oil
contamination is the direct result of engine analysis program. If a group consists of less
operation and load factor involved. The amount than 50 engines but more than 25 engines the
of contamination generated depends on the sub-group size should be 8 engines. The
selection of engines for each sub-group should
amount of fuel the engine consumes.
be completely random.
The total lubricating system upto capacity in
litres can be determined by adding high level of Oil samples should be taken from each of the
the lubricating oil in the oil pan and the engines in the sub-groups at every 48-operating-
hour interval. This sampling frequency may be
capacities of the full-flow and bypass filters.
varied somewhat as dictated by the operation.
Maintaining a proper “B” maintenance check The sampling frequency should not be extended
interval is a very important factor in preserving beyond 60 hours for equipment safety reason
the integrity of an engine. Lubricating oil or reduced below 40 hours because of the
contamination is the direct result of engine added analytical costs.
operation and load factor involved. The amount
of contamination generated depends on the This sampling process should continue until
amount of fuel the engine consumes. At each the results of the analysis of the samples
“B” check interval it is recommended to change indicate that any one of the condemnation
the full-flow filter and the by-pass filter. limits listed in Table 6-1 has been reached or
The total lubricating system upto capacity in exceeded until the desired oil change interval
litres can be determined by adding high level of extension is reached. This process should be
the lubricating oil in the oil pan and the continued cautiously since the engines in the
capacities of the full-flow and bypass filters. sub-groups are subject to permanent damage
because of the over-extended oil change interval.
Lubricating Oil Analysis The analytical work on the samples and the
Lubricating oil and filter change period can be examination of the analytical results should be
determined by laboratory tests of used oil. The done as quickly and carefully as possible to
analysis used are for the purpose of determining prevent serious engine damage.
the amount of contamination in the oil; not for
predicting potential engine failures. It is 1. Sample valve method
recommended that new engines be operated 2. Vacuum Pump method
through at least one oil change interval of 300 3. Oil drain method
79
Oil Sample Collection 1. Bring engine to operating temperature, shut-

off engine and remove drain plug from bottom
Three methods are commonly used to collect of oil pan and drain oil in suitable container.
oil samples for analysis. They are : 2. Install drain plug in pan and torque to 60 to
70 ft-lb [8.2980 to 9.6810 kg.m.].
1. Sample Valve Method : A valve is installed
on the dirty side of the filter. When 3. Fill crankcase to “H” (high-level) mark on
collecting a sample, the valve is wiped dipstick.
clean; and after the engine is brought up to 4. Start engine and visually check for oil leaks.
operating temperature, the valve is opened.
Stagnant oil is allowed to flow out, and a Note : It is important to visually check for oil
sample can be collected from the oil stream leaks after every oil and/or filter change.
being pumped by the engine at idle.
5. Shut down engine; allow 15 minutes for oil
2. Vacuum Pump Method : A length of to drain back into pan; recheck oil level with
tubing, measured against the dipstick, long dipstick. Add oil, as required, to bring oil
enough to reach 25.4 to 51 mm (1 to 2 level to “H” mark on dipstick.
inches) below the oil level in the sump is
attached to a hand operated vacuum pump. CLEAN/CHANGE CRANKCASE BREATHER
Immediately after stopping the engine at There are two types of breathers used on CIL
operating temperature, pump the sample engines. Element type breather on naturally
into a clean, dry bottle. Always replace
aspirated engines and baffle type breather on
the tubing after each sampling to avoid the
turbocharged engines. In element type breather
possibility of sample cross-contamination.
used on naturally aspirated engines element is
to be changed. It is not to be cleaned. On
3. Oil Drain Method : Clean the area around
turbocharged engines baffels from breather are
the drain plug to avoid foreign contamination.
to be cleaned.
Immediately after stopping the engine at
operating temperature, remove the drain
Element type Breather
plug. After approximately 8 liters (2 gallons)
of oil have streamed out, collect the sample 1. Remove the wing nut (1 Fig. 3-11), lock
from the continuous stream. washer (2) and plain washer (3).
CHANGE ENGINE OIL

Kind of oil used, efficiency of filtering system and
condition of engine must be considered in
determining when to change oil.
It is suggested that oil change periods be set up
on schedule indicated in Maintenance Schedule;
and then extended, or in unusal cases reduced,
based upon the type of oil used and other items
as described in the above paragraph.
Factors to be checked and limits for oil analysis
are listed below. Oil change at “B” Check, as
shown in Maintenance Chart, is for average
conditions. Fig. 3-11. Crankcase Breather-Element type.
80
2. Remove washer (4) and gasket (5). iii) Lubricate Water Pump and Fan Hub
Bearings
3. Lift off the cover (6) and lift out the breather
element (8). Check Engine Blow-By
4. Discard element, clean cover (6) and body. iv) COOLING SYSTEM
Inspect the body and cover for cracks, Please refer to coolant specifications
dents or breaks. for details :
5. Install a new breather element (8). Check and Coolant Replacement
6. Inspect gasket (7). Replace if necessary. Cummins engines are provided with Borate
Install the rubber gasket (7) in the Cover base coolant (Coolant Additive Concentrate -
(6); position the cover assembly to the (CAC). To ensure adequate corrosion protection
body. checking coolant at every B Check is essential.
The checking procedures are detailed below :
7. Inspect gasket (5). Replace if necessary.
Install the gasket (5), washer (4), (3), (2) CHECK COOLANT ADDITIVE CONCENTRATE
and wing nut (1). Tighten securely.
Coolant Additive Concentrate (CAC) is Borate
Baffel type Breather – Cleaning and base chemical compound. When mixed with
Inspection water in pre-determined quantity, and used as
coolant in diesel engine protects internal coolant
Procedure for removing and inspection is similar passages against corrosion, rusting and pitting.
to element type breather.
During engine operation the chemicals from CAC
After removing baffels. Clean them in suitable are depleted. Coolant Additive Concentrate is
solvent. Inspect and replace if necessary. added during ‘B’ check of engine to maintain the
concentration level and to replenish the depleted
Install baffels back to the position and assemble chemicals in following steps. (Refer Annexure
the breather assembly as described under Table for CAC requirement at ‘B’ check for Genset
element type breather. application).
a. Open radiator top tank / heat exchanger

expansion tank cap & add Coolant Additive
Concentrate.
b. If Coolant Additive Concentrate cannot be

accommodated into the cooling system,
drain appropriate amount of coolant from
the system. This drained coolant can be
used for top up if collected & stored in clean
container.
c. Do not overfill.
Please refer to Section-2 for coolant checking

details.
Fig. 3-12. Crankcase breather - Baffel type
81
IGNITION SYSTEM terminal or black wire, to high tension

connecting spring or spark plug contacting
Spark Plugs
spring should be 4,500 to 5,500 OHMS.
Note : If your engine is equipped with Resistance from both low tension terminals,
Champion Make Spark Plug then check/clean or black to white wires should be 0.2 to 0.3
Spark Plug and adjust the gap. OHMS. Any values not in above listed range
If your engine is equipped MICO Make Spark would indicate a faulty transformer.
Plug then replace with new.
5. Using a 13/16 inch deep-well rubber insert
Removal sparkplug socket, remove sparkplug from
1. Remove ignition harness wire from adapter. Lift out spark plug.
transformer terminal. Installation
2. Remove screws securing transformer cover, 1. Check spark plug gap; it should be 0.020
retainer, spring and transformer ground wire inch.
to rocker cover; lift off cover.
2. Inspect spark plug seating area of the adapter
Caution : Remove transformer assembly and clean to insure a good seating surface
cover with care as the transformer assembly for the spark plug.
is spring loaded to assure contact with spark 3. Insert spark plug in adapter and tighten to
plug. 28 to 30 ft-lb torque.
3. Lift transformer, spring, spring retainer and
cover assembly from the spark plug adapter Clean and tighten electrical connections
tube. including Ignition System
4. The ignition transformers are mounted Check transformer resistance
directly on the spark plugs and must be Primary ....................................... 0.2 to 0.3 Ω
removed for inspection. Visual inspection Secondary ..................................... 6 to 8 k Ω
should be made for cracks, broken or
otherwise damaged terminals. Electrical
Check Ignition timing and adjust if required.
continuity can be checked with an Ohm-
meter and the following values should be For details on how to adjust Ignition timing Refer
obtained; resistance from the positive Section No. 1.
82
VALVE ADJUSTMENTS Table 3-10 : Valve Set Position for

G-743/G-855/GTA-855 Engine.
It is essential, the valves be in correct Bar in Pulley Set Cylinder
adjustment at all times for the engine to operate Direction Position Valve
properly. This helps to control engine breathing. Start A OR 1-6 VS 1
Adv. To B OR 2-5 VS 5
Final operating adjustments must be made Adv. To C OR 3-4 VS 3
Adv To A OR 1-6 VS 6
using correct values as stated. Adv. To B OR 2-5 VS 2
Adv To C OR 3-4 VS 4
Caution: Be sure the valve set markings,
Firing Order 1-5-3-6-2-4
wherever located, are in proper alignment
with the indicator mark.
Table 3-11 : VALVE CLEARANCE -
Inch (mm) for
Engine Temperature : G-743/G-855/GTA-855 Engine.
The following temperature conditions provide Intake Valves Exhaust Valves
the necessary stabilization of engine Cold Set Cold Set
components to allow for an accurate valve
adjustment. Table 3-12 : Aluminium Rocker Housing :
Cummins India Limited recommends that valve 0.015 0.026
adjustments be made when the engine is cold. (0.39) (0.66)
The engine must be at any stabilized
temperature of 140°F (60°C) or below.
Table 3-13 : Cast Iron Rocker Housing :
A resetting after the engine is warm is not
0.016 0.029
recommended
(0.41) (0.74)
Warning: Use only proper engine barring
techniques for manually rotating the engine. ADJUST VALVES (TORQUE METHOD)
The barring can be done either from GV-1710 / GTA-1710 ENGINES
accessory drive or from barring mechanism
Timing Mark Alignment
provided on flywheel housing. Do not
attempt to rotate the engine by pulling or Note : Before adjusting the valves be sure
prying on the fan. This practice may damage to determine if the rocker housings are
fan blade(s) and cause premature fan made of cast iron or aluminium and use the
failure resulting in serious personal injury appropriate setting.
or property damage. 1. Bar the engine in the direction of rotation
until a valve set mark aligns with the mark
Table 3-9 : Torque Method: G-495 engines or pointer on the gear case cover. Example :
Bar in Pulley Set Cylinder A or 1-6 “VS” on In-line Engines or 1-6R
“VS” on V-1710 Engines.
Direction Position Valve
2. Check the valve rocker levers on the two
START A OR 1-4VS 1 cylinders aligned as indicated on the pulley.
ADV. TO B OR 2-3VS 2 On one cylinder of the pair, both rocker
ADV. TO A OR 1-4VS 4
levers will be free and the valves closed;
ADV. TO B OR 2-3VS 3
this is the cylinder to be adjusted.
83
3. For the firing order see Table 3-10 for In-line pounds and a screwdriver adapter tighten
Engines and Table 3-11 and Fig.3-13 for V- the adjusting screw to the value shown in
1710 Engines. Fig. 3-16 and tighten the locknut to 40 to
45 ft-lbs (54 to 61 N•m) torque. If ST-669
Torque Wrench Adapter is used, torque to
30 to 35 ft-lbs (41 to 47 N•m).
Crosshead Adjustment
Crossheads are used to operate two valves

with one rocker lever. The crosshead adjustment
is provided to assure equal operation of each
pair of valves and prevent strain from
misalignment.
Fig. 3-13. V-1710 Piston position
1. Loosen the valve crosshead adjusting screw

Table 3-14 Engine Firing Order for G-855
locknut and back off the screw (4) Fig 3-14
Engines
one turn.
Right Hand
2. Use light finger pressure at the rocker lever
Rotation
contact surface (1) to hold the crosshead
in contact with the valve stem (2).
1-5-3-6-2-4
Table 3-15 :
Firing Order for GV-1710/GTA-1710 Engines
Right Hand -
1L-6R-2L-5R-4L-3R-6L-1R-5L-2R-3L-4R
4. Continue to bar the engine to the next “VS”

mark and adjust each cylinder in the firing
order.
Note : Only one cylinder is aligned at each

mark. Two complete revolutions of the
crankshaft are required to adjust all Fig. 3-14. Valve crosshead
cylinders.
3. Turn down the crosshead adjusting screw
Note : Number one L and one R cylinders until it touches the valve stern (3).
on V-1710 Engines are at the gear case of
the engine. 4. Using ST-669 Torque Wrench Adapter,
tighten the locknut to 22 to 26 ft-lbs (30 to
1. Loosen the adjusting screw one turn; then 35 N•m). If ST-669 is not available, hold
using a torque wrench calibrated in inch- the screws with a screwdriver and tighten
84
the locknuts to 25 to 30 ft Ibs (34 to 41 Note : Do not use the fan to rotate the
N•m). engine. Remove the shaft retainer clip. Fig.
7-9, and press the shaft inward until the
5 Check the clearance between the cross- barring gear engages the drive gear; then
head and the valve spring retainer with a advance. After the adjustments are complete,
wire gauge. There must be a minimum of retract the shaft and install the retainer clip
0.020 Inch (0.51 mm) clearance at this into the safety lock groove.
point.
Caution : The barring mechanism gear must
Valve Adjustment be completely engaged when barring the
1. Loosen the locknut and back off the engine to avoid damage to the teeth of the
adjusting screw. Insert a feeler gauge gear.
between the rocker lever and crosshead.
Turn the screw down until the lever just Adjustment Limits GTA-1150-G Valve
touches the gauge and lock the adjusting Clearances
screw in this position with the locknut.
Tighten the locknut to 40 to 45 ft-lbs (54 to Table 3-18 : Valve Clearances — Inch (mm)
61 N•m). torque. When using ST-669 torque
to 30 to 35 ft-lbs (41 to 47 N•m). Intake Exhaust
2. Discard old rocker cover gaskets and use
new gaskets. Mount rocker covers and 0.017" 0.029"
tighten capscrews to 45 N•m (35 ft-lb). (0.44 mm) (0.74 mm)
Table 3-16 : Valve Clearances — Inch (mm) Caution: Be sure the crossheads are adjusted
before setting the valves. See Crosshead
Intake Valves Exhaust Valves Adjustment following
following.
Cold Set Cold Set
Valve Adjustment
V-1710 Engines
0.014 (0.36) 0.027 (0.69) 1. Insert the correct thickness feeler gauge
between the rocker lever and the crosshead
for the valves being adjusted. See Table
Table 3-16 : Valve Set Position for for valve clearance.
GTA 1150-G Engine.
2. If adjustment is required, loosen the locknut
Bar in Pulley Valve Set Cyl.
Direction Position Closed Valve
and turn the adjusting screw down until
the rocker lever just touches the feeler
Start A 1 5 gauge; lock the adjusting screw in this
Adv. To B 5 3
Adv. To C 3 6
position with the locknut.
Adv To A 6 2
Adv. To B 2 4 3. Tighten the locknut to 40 to 45 ft-lb (54 to
Adv To C 4 1 61 N•m) torque. When using ST-669
Firing Order 1-5-3-6-2-4
Torque Wrench Adapter tighten the locknuts
to 30 to 35 ft-lb (41 to 47 N•m) torque.
It is essential that the valves be in correct 4. Repeat the adjustment procedure for each
adjustment at all times for the engine to operate cylinder. See Table 7-9 for firing order and
properly. injector and valve set positions.
85
5. Discard old rocker cover gaskets and use 5. Check the clearance (6) between the
new gaskets. Mount rocker covers and crosshead and valve spring retainer with a
tighten capscrews to 40 N•m (30 ft-lb). wire gauge. There must be a minimum of
0.025 inch (0.64 mm) clearance at this
Crosshead Adjustment point.
Crossheads are used to operate two valves

with one rocker lever. The crosshead adjustment GTA 2300 AND GTA : 3067 ENGINES
is provided to assure equal operation of each Valve Set Mark Alignment
pair of valves and prevent strain from
misalignment.
Note : If your engine has stemless

crossheads no adjustment is required.
1. Loosen the valve crosshead adjusting

screw locknut and back off the screw (4)
Fig. 3-15 one turn.
Fig. 3-16. Cylinder arrangement and firing order —

GTA 2300
Fig. 3-15. Valve Crosshead
2. Use light finger pressure at the rocker lever

contact surface (1) to hold the crosshead
in contact with the valve stem (2) The
adjusting screw should not touch the valve Fig. 3-17. Cylinder arrangement and firing order —
stem (3) at this point GTA 3067
3. Turn down the crosshead adjusting screw The crankshaft must be turned through two (2)
until it touches the valve stem (3). complete revolutions to properly set all injector
plunger travel and valves.
4. Using ST-669 Torque Wrench Adapter,
tighten the locknuts to 22 to 26 ft-lbs (30 Note : The barring mechanism may be
to 35 N-m). If ST-669 is not available, hold located on either the left bank or right bank
the screws with a screwdriver and tighten at the flywheel housing. The cover plate on
the locknuts to 25 to 30 ft-lbs (34 to 41 opening “A” or “C” directly above the
N•m). barring rnechanism must be removed when
86
viewing the timing marks at the flywheel 3. Turn down the adjusting screw until it
housing. touches the valve stem (3).
1. When viewing the engine at the vibration 4. Using 3375008 Torque Wrench Extension
damper, align the timing marks on the to hold the adjusting screw in position,
damper with the pointer on the gear case tighten the locknut to 22 to 26 ft-lb (30 to
cover. 35 N•m) torque. If the torque wrench adapter
is not used, hold the adjusting screw with
Adjustment Limits a screwdriver, tighten the locknut to 25 to
Table 3-19 : Valve Clearances — Inch (mm) 30 ft-lb (34 to 41 N•m) torque.
Intake Exhaust 5. Check the clearance (6) between the

0.017" 0.031" crosshead and the valve spring retainer
with a gauge. There must be a minimum of
(0.44 mm) (0.79 mm)
0.025 inch (0.64 mm) clearance at this
point.
Crosshead Adjustment
Valve Adjustment
Note: If your engine has stemless crossheads
no adjustment is required. 1. Insert the correct thickness feeler gauge
between the rocker lever and the crosshead
Crossheads are used to operate two valves for the valves being adjusted. See Table 7-
with one rocker lever, an adjusting screw is 12 for valve clearance.
provided to assure equal operation of each pair
of valves and prevent strain from misalignment. Note : Exhaust valves are toward the front
Crosshead adjustment changes as a result of of the engine in each cylinder head on the
valve and seat wear during engine operation. LB side and are toward the rear of the
engine in each cylinder head on the RB
1. Loosen the adjusting screw locknut, back
side.
off the screw (4) Fig. 3-18 one turn.
2. Use light finger pressure at the rocker lever 2. If adjustment is required, loosen the locknut
contact surface (1) to hold the crosshead and turn the adjusting screw down until the
in contact with the valve stem (2). The rocker lever just touches the feeler gauge;
adjusting screw should not touch the valve lock the adjusting screw in the position
stem (3) at this point. with the locknut.
3. Tighten the locknut to 40 to 45 ft-lb (54 to

61 N•m) torque. When using ST-669
Torque Wrench Adapter tighten the locknuts
to 30 to 35 ft-lb (41 to 47 N•m) torque.
Discard old rocker cover gaskets and use new

gaskets. Mount rocker covers and tighten
capscrews to 40 N•m (30 ft-lb).
Fig. 3-18. Valve Crosshead
87
v) Maintenance Schecule - Cummins Gas Engines


Gas Engine Oil SAE
Plugs
indicator
Breather
o Check cylinder
Water Pump
Level and top up
o Check Crankshaft
plug
Wobble, and replace
valve clearances
Air Intake System
across the Gas low.
fillter. Replace if
more than 3 PSI
Table 3-20
88
3-28 Cummins Gas Engines Service Manual Installation and Schedule Maintenance 3-29
‘C’ Check / 3000 Hrs. Check
Repeat ‘A’, ‘500 hrs’, and ‘B’ Check. 3. Remove air valve cover, spring and
diaphragm from carburetor.
i) IGNITION SYSTEM
4. Place carburetor butterfly in full open
Note : If your engine is equipped with position.
Champion Make Spark Plug then replace the
5. Remov all spark plugs.
Spark Plug.
6. Attach compression gauge by utilizing a
Replace HT Cables with Spark Plug 14 mm spark plug adapter, to No. 1 cylinder
Connectors. spark plug opening.
ii) MISCELLANEOUS CHECKS 7. Remove wiring harness from Mag-tronic

connector at the Mag-tronic.
Check Fan hub. Apply grease to the bearing.
8. Crank the engine with the starter motor a
Check cylinder compression minimum of 6 revolutions at which time the
compression gauge should reach maximum
Satisfactory engine operation depends upon pressure. To obtain accurate readings, each
adequate and uniform compression in all cylinder should be checked at the same
cylinders. Loss of compression results in loss cranking speed and revolutions. See
of power and non-uniform compression in Photograph.
cylinders causes unsatisfactory or rough
operation. 9. Proceed to check each cylinder as per
above.
When making a compression test it is essential
the engine be at operating temperature, the Compression pressure will vary depending on
engine lubricating oil be of the proper grade the cranking speed, altitude, air density and
and the cranking motor be operating properly. sealing ability of the engine. The maximum
The engine should be disconnected from any pressure is not as important as the pressure
driving unit by removing drive shaft, belts or dis- variation of the individual cylinders, and any
engaging the clutch if so equipped to make the one or more cylinders indicating a pressure
compression test. Proceed as follows : differential of 7% or more, would indicate
excessive compression loss in that cylinder.
1. Close manual gas valve to engine.
2. Remove air cleaner piping at crburetor.
89
vi) Maintenance Schecule - Cummins Gas Engines


Gas Engine Oil SAE
Plugs
indicator
Breather
o Check cylinder
Water Pump
Level and top up
o Check Crankshaft
plug
Wobble, and replace
valve clearances
Air Intake System
across the Gas low.
fillter. Replace if
more than 3 PSI
Table 3-21
90
D / 6000 Hours Maintenance Checks
Repeat ‘A’, ‘B’, and ‘C’ Checks.

LUBRICATION SYSTEM
Check Engine Blow-By
COOLING SYSTEM
Check Thermostat.
Clean Radiator Core (Externally)
Replace water line hoses
IGNITION SYSTEM
Check Disc Altronic Ignition Timer
coupling.
MISC. CHECK
Clean Engine
Tighten Engine Mounting Bolts and Nuts
Check AVM and mounting.
Check Crankshaft End Clearance
Check Damper for fluid leak and Wobble,
and replace if required.
RECONDITIONING
Recondition cylinder head if intake manifold
vacuum is low.
91
NOTES
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92
Specifications and Torque 4-1
Section-4
SPECIFICATIONS AND TORQUE
Section Contents
The Function of Lubricting Oil ........................................................................................................ 93
Oil Specifications for Gas Engines ................................................................................................ 94
Grease Specifications ................................................................................................................... 94
Coolant Specifications ................................................................................................................... 95
Capscrew Markings and Torque Values (Metric) ............................................................................ 99
Capscrew Markings and Torque Values ....................................................................................... 100
93
NOTES
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94
Section-4 Providing and maintaining an adequate

Pro
suppl
supply y of clean, high quality fuel, lubricating
oil, grease and coolant in an engine is one
Specifications wa
way
perf
y of insuring long lif
ormance
performance
ormance. .
e and satisfactor
life satisfactory y
and Torque
Lubricant and Coolant
The Functions of Lubricating Oil Dirt entering the engine through the
combustion air, fuel, while adding or changing
The Lubricating oil used in a Cummins engine lubricting oil.
must be multifunctional. It must perform the
primary functions of : The oil must have an additive package to combat
these contaminants. The package generally
Lubrication by providing afilm between the consists of:
moving parts to reduce wear and friction.
Detergents/Dispersants which keep insoluble
Cooling by serving as a heat transfer media to matter in suspension until they are filtered from
carry heat away from critical areas. the oil or are removed with the oil change.
Sealing by filling in the uneven surfaces in the This prevents sludge and carbon deposits from
cylinder wall, valve stems and turbocharger forming in the engine.
oil seals. Cleaning by holding contaminants Inhibitors to maintain the stability of the oil,
in suspension to prevent a build up of deposits prevent acids from attacking metal surfaces
on the engine surfaces. and prevent rust during the periods the engine
In addition, it must also provide : is not operating.
Dampening and cushioning of components that Other Additives that enable the oil to lubricate
operate under high stress, such as gears and highly loaded areas, prevent scuffing and seizing,
push tubes. control foaming and prevent air retention in the
oil.
Protection from oxidation and corrosion.
Oil Performance Classification System
Engine lubricating oil must be changed when it
can no longer perform its functions within an The American Petroleum Institute (API). The
engine. Oil does not wear out, but it becomes American Society of Testing and Materials
contaminated to the point that it can no longer (ASTM) and the Society of Automotive Engineers
satisfactorily protect the engine. Contamination (SAE) have jointly developed and maintained a
of the oil is a normal result of engine operation. system for classifying lubricating oil by
During engine operation wide variety of performance categories.
contaminants are introduce into the oil. Some Oil for Natural Gas Engine Model
of these are :
The engines using Natural Gas as fuel needs
By products of Engine Combustion - specific Engine Lubricating oil. CIL recommends
asphaltenes, soot and acids from partially the use of a SAE grade 15W40 tow ash content
burned fuel. engine lubricating oil for natural gas engines.
Acids, varnish and sludge which are formed Note the properties recommended for the lub oil.
as a result of the oxidation of the oil as it Use engine lubricating oil which meets these
breaks down or decomposes. specifications.
95
Oil Specifications Cummins service network and get oil analysed

in laboratories.
Sulfated Ash :
A sulfafed ash limit has been placed on lubricating Do not intermix different brands of oils as two
oil for use in CIL natural gas engines. The oil different brands of oils may not be compatible
must have sutphated ash less than 0.5 mass %. with each other. It is therefore recommended that
the brand which is used for initial fill, should only
The oils with a high ash contents will produce
be used for top up. Different brand of oil may be
deposits on valves that can progress to guttering
used after draining all the existing oil i.e., at the
and valve burning, piston damage, spark plug
oil drain interval and after flushing the lub oil
fouling and lead to excessive oil consumption
system with new brand of oil.
and degradation of the catalyst.
The viscosity of an oil is a measure of its A sulfated ash limit has been placed on
resistance of flow. SAE 15W40 Viscosity grade lubricating oil for use in Cummins engines. Past
oil is recommended for Gas engines. experience has shown that oils with a high ash
contents may produce deposits on. valves that
The sulphated ash and Viscosity
can progress to guttering and valve burning.
Recommendations are prime factors for this oil.
Other specifications meeting CIL recommended
For natural gas engines a sulfated ash range
15W-40 oil blends for natural gas engines are,
of 0.03 to 0.85 mass % is recommended
Cummins India Limited, Pune, does not
API Class CD Category
recommend the use of ashless oils for natural
SAE Grade 15W40 Viscosity
gas engines.
Suifated Ash Less than 0.5 mass %.
TBN (ASTM D2896) 5/5.5
When the ash content is below 15 mass % the
TAN (ASTM D664) 0.5/0.7
ash should represent organo-metallic anti-wear
Phosphorous 250/350 PPM
additives.
Zinc 250/350 PPM
Calcium 1200 PPM
Grease
Caution
Cummins India Limited, Pune recommends the
Beware of the spurious oils in the market. Bad use of grease meeting the specifications of MIL-
oil quality is detrimental to engine performance. G-3545, excluding those of sodium or soda soap
Hence oil should always be procured from the thickeners. Contact lubricant supplier for grease
original manufacturer or the authorised distributor. meeting these specifications.
Lubricating oil to be used in the engine must
meet all qualities as per manufacturer’s Caution: Do not mix brands of grease as
specifications. Cummins India recommends oil damage to bearings may result. Excessive
checks of fresh engine oil to ensure the quality lubrication is as harmful as inadequate
of oil. Facility to check suitability of oil for using lubrication. After lubricating fan hub, replace
in the engine is available with Cummins service both pipe plugs. Use of fittings will allow
network. If in doubt about the quality of lub oil, lubricant to be thrown out, due to rotative
contact lub oil manufacturing company / speed.
96
Par
artt Description Qty
Qty..
Coolant Specifications Number
Make Up Coolant Specifications 3167221 Premixed Coolant 5 lt.

It is recommended that a supply of make-up 3167222 Premixed Coolant 10 lt.
coolant be prepared to the following 3167223 Premixed Coolant 20 lt.
specifications, using soft water. Chromate
3167224 Premixed Coolant 205 lt.
treatment of coolant assures constant level of
concentration when coolent is added and
C. Test strip
requires no change in schedule of element
replacement.
Test strip is required to check coolant
2. Coolant Additive Concentrate (CAC) concentration. These are packed
A. Coolant Additive Concentrate individually in a foil pack.
Par
artt Number Description
3167225 Test strip
Fig. 4-1 D. Test Kit
This consists of 2 test strips, a clear plastic

beaker and a dropper to collect the
coolant. Test kits are supplied in cardboard
It is supplied in plastic red colour containors boxes.
having different part nos. for different volumes.
The colour of the coolant additive concentrate
Par
artt Number Description
is deep purple.
Par
artt Description Qty
Qty.. 3167226 Test Kit
Number
3167214 Coolant additive concentrate 0.5 lt.
3167215 Coolant additive concentrate 1 lt.
B. Premixed Coolant
Fig. 4-2
Fig. 4-3 Test Kit
IMPORTANT NO
IMPORT TE
NOTE
It is supplied in plastic white colour containers Shelf lif e ffor
life or Coolant Ad ditive
Additive
having different part nos. for different volumes. Concentrate & Premix
Premixeded Coolant is 5
The colour of the coolant is pink. years & that of test strip/kit is 18 months.
ears
97
Coolant Instructions ffor

or use a) Prepare coolant mixture by mixing 15 parts
of water with 1 part of Coolant Additive
The Coolant Additive Concentrate and premixed Concentrate supplied in kit and stir for
coolant is supplied with each engine as, thorough mixing.
• Required quantity of Coolant Addative b) Fill the system completely with this
Concentrate as per engine model. coolant. Measure and note down the
• Coolant test kit 3167226 system capacity for further reference
• Premixed coolant for top up. purpose.
1) First fill at the time of engine 2. Coolant Top Up

commissioning Genset Applications If system is topped up by water it leads to
a) Add Coolant Additive Concentrate dilution of the coolant i.e. coolant concentration
supplied in kit in radiator top tank / becomes lower. In order to maintain the coolant
expansion tank/LTA cooling system (Ref. concentration it is must to top up the system by
Picture 1). premixed coolant only and not by water.
To facilitate top up, premixed coolant is made
available. This premixed coolant is to be used
as supplied. Do not dilute.
If premixed coolant is not available, mix 15 parts
of water : 1 par t of Coolant Additive
Concentrate and use this coolant for top up.
Improper
Impr oper cooling system top-up is the
primar
primary y reason ffor
or low concentration le
low vels
levels
in the coolants whic whichh in term causes
corr osion and liner pitting.
corrosion
Salient Features of C CAAC
Fig. 4-4
- Safe / environmental & user friendly
- Easy operation, time saving at ‘B’ check.
b) Fill the remaining system by water till the
- To be filled in through Radiator / make up
system is completely filled. (Ref. Picture 2).
(auxiliary) tank Cap
- Cost benefit to the customer at ‘B’ check.
- Easy checking process.
CAC
CA CA Av
vailability fform Checking
orm and Chec king
CAC is available in two forms, a) Coolant
Additive Concentrate, which can be mixed with
water of 1:15 proportion and b) Pre-mixed
coolant, which can be directly added in cooling
system. To check the coolant concentration Test
Strip and a Test Kit are available.
3. Coolant Chec king
Checking
Fig. 4-5 In normal operating condition with system
maintained as per above, the coolant will be
Industrial Applications maintained to the required specifications and
The total coolant capacity varies for different no checking is required. However coolant
engine models and applications. Hence checking is suggested as audit check, at every
following procedure to be followed to maintain 1500 hrs./6 months during operation. Checking
concentration level of CAC. is also suggested in case of following :
98
— At the time of commissioning the engine, colour indicator has been added in the new CAC
— When coolant is totally replaced / excessive whose colour changes with pH. When colour
coolant loss occurs of the coolant is pink the pH is within limit. (8.5
— When concentration levels are unknown / to 10.0 pH)
doubtful.
If coolant becomes colourless, then it
Coolant checking is very easy with the use indicates ver y lo
very w le
low vel of concentration.
level
of Test Strip. Hence ad d CA
add CACC as
During coolant checking two coolant properties required to maintained the concentration
namely coolant concentration and pH value of le vel.
level.
coolant are to be checked as follows : Coolant Replacement
Concentration At 6000 hrs. of operation or after two years, it
is necessary to replace the coolant.
This can be checked by Test Kit, using following
method : Important Note :
i. Remove the top tank cap of radiator/ Use of good quality water alongwith CAC is
heat exchanger, use dropper or open impor tant for optimum cooling system
vent cocks in the cooling system & performance. Water used in cooling system
collect coolant sample in the beaker. must meet following specifications.
ii. Allow the coolant temperature to reach
Hardness (as CaCO3) - 170 ppm max
room temperature.
iii. Remove ‘Test Strip’ from the pack. Dip Chlorides (as Cl) - 40 ppm max
the strip in coolant for 3 seconds. Sulfate (as SO4) - 100 ppm max
iv. Remove strip and shake briskly to pH - 5 to 9
remove excess coolant. TDS - Less than 400 ppm.
v. Wait for 45 seconds. Compare the (Total Dissolved Solids)
colour of the strip with the colour chart
within next 30 seconds. It is suggested to get Water quality checked
vi. Take action as shown in the colour from authorised laboratories if water quality is
chart. doubtful.
Following action is required after checking CAC Con ver

Conver sion of field engines :
version
level. The engines working in field using Corrosion
Units/Lit. Action Required Resistor can be converted to use CAC with
following method. Cummins India Limited
Below 0.4 Add precharge quantity. encourages the field conversions to provide
i.e. quantity of Coolant customers benefit of the new improvement.
Additive Concentrate
liquid as required for 1. Drain coolant and remove Corrosion
initial commissioning. Resistor housing.
2. Disconnect and remove Corrosion Resistor
Between 0.4 to 0.6 Continue adding Coolant
connections. Plug the connections in block
Additive Concentrate as
/ water pump inlet. Use following plugs as
per service treatment
required :
chart at B check.
Above 0.6 OK, No action required. Description Part No.
1/4" NPTF S-910-B
pH of coolant 1/2" NPTF S-915-A
No special checking kit is required for this 3/4" NPTF S-995
property. This is only visual check. Special 1" NPTF S-962
99
3. Flush the coolant system with plain water Water maximum le

maximum vels
levels
twice to remove chromate from cooling
system. This is required as chromate has Calcium Magnesium 170 PPM as
yellow colour & new coolant has pink colour. (Hardness) (CaCO3 + MgCO3)
Chloride 40 PPM as (Cl)
4. Follow instructions 1 to 4 as given above
for first fill. Sulpher (Sulphates) 100 PPM as (SO4)
Coolant To ensure adequate corrosion protection check

engine coolant per procedure under Check
Water coolant is important for cooling system Engine Coolant in section 6.
performance. Excessive levels of calcium and
magnesium contributes to scaling problems Check magnesium plate for pitting or being
and excessive levels of chlorides and sulphates eaten away, change if more than 50% of area
cause cooling system corrosion. The quality is lost, where Corrosion Resistor is used.
of water must meet the requirements listed
below :
100
Capscrew Markings and Torque Values

Current Usage
Usag Much Used
Much Much Used
Much Used at Time Used at Time
Minimum Tensile To 1/2—69.000 (476) To 3/4—120,000 (827) To 5/8—140,000 (965) 150,000 (1034)
Strength PSI To 3/4—64,000 (421) To 1—115,000 (793 ) To 3/4—133,000(917)
MPa To 1-55,000 (379)
Quality of Material Indeterminate um Commer

Minimum
Minim cial
Commercial Medium Commercial
Commercial Best Commercial
Commercial
SAE Grade Number 1 or 2 5 6 or 7 8
Capscrew Head-Markings
Manufacturer’s marks
may vary
These are all SAE
Grade 5 (3 line)
Capscre
Capscreww Bod
Bodyy Siz
Sizee Torque
orque Torque
orque Torque
orque Torque
orque
(Inches)—(Thread)
(Inches)—(Thread) Ft-Lbs (N.M) Ft-Lbs (N.m) Ft-Lbs (N.m) Ft.Lbs (N.m)
1/4 — 20 5 (7) 8 (11) 10 (14) 12 (16)

— 28 6 (8) 10 (14) 14 (19)
5/16 — 18 11 (15) 17 (23) 19 (26) 24 (33)
— 24 13 (18) 19 (26) 27 (37)
3/8 — 16 18 (24) 31 (42) 34 (46) 44 (60)
— 24 20 (27) 35 (47) 49 (66)
7/16 — 14 28 (38) 49 (66) 55 (75) 70 (95)
— 20 30 (41) 55 (75) 78 (106)
1/2 — 13 39 (53) 75 (102) 85 (115) 105 (142)
— 20 41 (56) 85 (115) 120 (163)
9/16 — 12 51 (69) 110 (149) 120 (163) 155 (210)
— 18 55 (75) 120 (163) 170 (231)
5/8 — 11 83 (113) 150 (203) 167 (226) 210 (285)
— 18 95 (129) 170 (231) 240 (325)
3/4 — 10 105 (142) 270 (366) 280 (380) 375 (508)
— 16 115 (156) 295 (400) 420 (569)
7/8 — 9 160 (217) 395 (536) 440 (597) 605 (820)
— 14 175 (237) 435 (590) 675 (915)
1 — 8 235 (319) 590 (800) 660 (895) 910 (1234)
— 14 250 (339) 660 (895) 990 (1342)
Notes : Table 4-1

1. Always use the torque values listed above when specific torque values are not available.
2. Do not use above values in place of those specified in other sections of this manual; special attention should be
observed when using SAE Grade 6. 7 and 8 capscrews.
3. The above is based on use of clean. dry threads.
4. Reduce torque by 10 % when engine oil is used as a lubricant.
5. Reduce torque by 20 % if new plated capscrews are used.
6. Capscrews threaded into aluminium may require reductions in torque of 30% or more of Grade 5 capscrews torque and
must attain two times capscrew diameters of thread engagement.
Caution : If replacement capscrews are of a higher grade than originall

capscrews y supplied, adhere to tor
originally que specifications
torque
for that placement.
101
Capscrew Markings and Torque Values - Metric
Commercial Steel Class
Thread Diameter Torque Torque Torque

mm N•m (ft-lb) N•m (ft-lb) N•m (ft-lb)
5 6 (5) 8 (6) 8 (6)

6 9 (7) 14 (10) 15 (11)
8 24 (18) 34 (25) 38 (28)
10 43 (32) 64 (47) 77 (57)
12 77 (57) 112 (83) 137 (101)
14 127 (94) 180 (133) 216 (159)
16 195 (144) 266 (196) 319 (235)
Table 4-2
Notes :
1. Do not use these values when the torque values are specifid in another section of the
manual.
2. These values are based on clean, dry threads. Reduce the value by 10% when a lubricant
is used. Reduce the value by 20% if new plated capscrews are used.
Torque Specification
Always use caution to be sure that capscrews from the engine are put back in their proper
locations.
When replacing capscrews, always use a capscrew of the same measurement and strength as
the capscrew being replaced. Incorrect capscrews can result in engine damage.
Metric Capscrew Nomenclature
M8 X 1.25 – 25
Length in millimeters
Distance between threads in millimeters
Major thread diameter in millimeters
102
Wiring Diagrams 5-1
Section-5
Engine Wiring
Diagrams
Engine Lucas distributor System Altronic System
G 495 4055915 4072544
G 743 3875376 3874742
G 855 3875376 3874742
GTA 855 3874642
GTA 1150 4084998
G1710 3392714
GTA 1710 3167919
GTA 2300 3230490
GTA 3067 4073247
103
5-2
ITEM NUMBER
104
REVISIONS
4055915 REV. DESCRIPTION REV. DATE APPD
BY
00 REV. PER 007116-000 23.3.00
16 16 STARTING SWITCH
B R 3
6 5
BLOCK,TERMINAL
S
GAS SOLENOID VALVE 15
22 2
1 AMMETER
36 37 37 2
NO 2
NC 23 3
3
LOW LUB OIL PRESS. 4

SAFETY CONTROL 25 5
5 13
15
26 6
6
36
27 7 7
NC 7
35
NO
28 8
8
START PUSH BUTTON
OVER SPEED STOP 40 9
9
6. THIS DIAGRAM REFERS TO THE 12 VOLT H.T.
DISTRIBUTOR TYPE LUCAS IGNITION SYSTEM
10
USED ON GAS ENGINE.
NO INDICATION LAMP
35 11 5. TO STOP THE ENGINE:
NC TURN STARTING SWITCH TO OFF POSITION.
43 THEN TURN IGNITION SWITCH (TOGGLE
12
23 SWITCH TO OFF POSITION.
THIS IS ESSENTIAL FOR PREVENTING IGNITION
COIL DAMAGE
HIGH WATER TEMP.
SAFETY CONTROL 4. WATCH THE LUB OIL PRESSURE GAUGE &
SHIFT STARTING SWITCH KEY TO RUN
POSITION WHEN OIL PRESSURE GAUGE
25 INDICATES MORE THEN 1kg/cm 2
3. RELEASE THE PUSH BUTTON AFTER ENGINE

+ - 33 FIRES.
28
W 41 12 2. TO START ENGINE:
TURN THE STARTING SWITCH TO START
POSITION
ALTERNATOR KEEP THE IGNITION SWITCH "ON" TO GIVE
33 12 V SUPPLY TO
IGNITION SWITCH PRESS THE STARTER PUSH BUTTON.
TOGGLE SWITCH
1. 24 VOLT NEGATIVE GROUND SYSTEM.
SYSTEM-
26
S.O. NO. - G378200A
27 CUSTOMER- DESIGN STANDARD & VARIEAS
AMP.
CIRCUIT NO. CAPACITY WIRE GAUGE APPLICATION- GENSET
ENGINE MODEL - G-495-G
IGNITION COIL 12V 2,3,8,13,9
200
22,23,28 20 44/0.3MM REF. DWG. NO.- RD-01779
35,36,37
CLASSIFICATION OF CHARACTERISTICS
LUCAS STARTER 5,6,7,15,16,42 CRITICAL
30 65/0.3MM
25,26,27,33,34 MAJOR
KEY INSTRUCTION
41 PVC 95 SQ. MM MINOR (NONE)
150
39,40,41 200
DOUBLE LINE BELOW SYMBOLAPPLIES TO UPPER LIM
39 LINE ABOVE SYMBOLAPPLIES TO LOWER LIM
NO LINE WITH SYMBOL APPLIES TO BOTH LIM
+ +
41 40 DESIGN ENGINEER:-
R.Y.KAUSHIKKAR 20.3.00
41 99012
- - DRAWING PRACTICE:-
PRODUCT
GRAPHICS
FILE
NO ORIGINAL DRAWING EXISTS FOR THIS ITEM.
90 100
THE ENGINEERING GRAPHICS FOR THIS ITEM RESID
BATTERY 24 V.D.C.
80
THE PRODUCT GRAPHICS FILE AND IS CONTROLLE
REF. DRAWING
70
STANDARDS
60
ANSI Y 14.5m Registered Office: Kothrud, Pune 411029 (India)
DO NOT SCALE THIS DRAWING ISO R 1101 ITEM NAME
50
THIRD ANGLE PROJECTION This document (and the information shown
UNLESS OTHERWISE SPECIFIED
40
thereon) is CONFIDENTIAL AND PROPRIETARY
and DIAGRAM WIRING
shall not be disclosed to others in hard
DIMENSIONS ARE IN MILLIMETRES
30
copy or electronic form, reproduced by any
DWN DHANDE 20.3.00 SIZE CODE IDENT. NO.
ITEM NO.
20
means, or used for any purpose without
CHD JSS E
written consent of Cummins India Limited,
APPD
4055915
10
10 20 30 40 50 60 70 80 90 100 150 200
KND DRAWING
licensee of Cummins Engine Company, inc. SCALE- - OF
2
APPD RYK CONTROL KCL SHEET1
ITEM NUMBER REVISIONS
BY
00 REV. PER 007116-000 23.3.00
HIGH TENSION CABLE
BLOCK,TERMINAL
1 2 3 4
1
TO ENGINE
2
3 CAP, PROTECTION
8
4
9
10
11
43
12
3 2 + (BAT)
12
THIS DIAGRAM REFERS TO THE H.T. LUCAS
DISTRIBUTOR TYPE IGNITION SYSTEM ON
+ 43 4 CYLINDER GAS ENGINE
H.T. 41
ROTOR
TOGGLE SWITCH
12V SYSTEM-
Wiring Diagrams
S.O. NO. - G378200A

40 CUSTOMER- DESIGN STANDARD & VARIEAS
APPLICATION- GENSET
1
200
41
REF. DWG. NO.- RD-01779
39
DISTRIBUTOR COVER
CLASSIFICATION OF CHARACTERISTICS
+ + CRITICAL
41 41 40
MAJOR
- - KEY INSTRUCTION
MINOR (NONE)
150
FIRING ORDER 1-2-4-3 IGNITION COIL (12V)
LINE BELOW SYMBOLAPPLIES TO UPPER LIM
MOUNTED ON ENGINE LINE ABOVE SYMBOLAPPLIES TO LOWER LIM
(MOUNT IN INCLINED POSITION) NO LINE WITH SYMBOL APPLIES TO BOTH LIM
DESIGN ENGINEER:-
R.Y.KAUSHIKKAR 20.3.00
99012
DRAWING PRACTICE:-
PRODUCT
GRAPHICS
FILE
90 100
80
REF. DRAWING
70
STANDARDS
60
50
40
and DIAGRAM WIRING
12 VOLT -VE GROUND SYSTEM shall not be disclosed to others in hard
30
DWN DHANDE 20.3.00 SIZE CODE IDENT. NO.
ITEM NO.
20
CHD JSS E
written consent of Cummins India Limited, 4055915
APPD
10
10 20 30 40 50 60 70 80 90 100 150 200
KND DRAWING
2
APPD RYK CONTROL KCL SHEET2
5-3
105
DRAWING NUMBER
REVISIONS
5-4
3875376 REV. DESCRIPTION
REV.
DATE APPD
BY
106
00 ER NO.-927181-000 S.K.K. 24.4.92 V.V.C
22 16 16 STARTING SWITCH
B
6 5 R
S 3
40 L B 15
2
GAS SOLENOID VALVE AMMETER
36 37
NO
NC 22
1
37 2
LOW LUB. OIL PRESS 2
SAFETY CONTROL 3
3
36 23
NC 4
35 25 5 13
NO 5 15
26 6 6. THIS DIAGRAM REFERS TO THE 12 VOLT
6
OVER SPEED STOP 27 7 7 H.T. DISTRIBUTOR TYPE LUCAS
7 IGNITION SYSTEM USED ON GAS ENGINE .
28 8
8 START PUSH BUTTON
40 9 5. TO STOP THE ENGINE :-
9 8 13 - TURN STARTING SWITCH
NO
35 10 TO OFF POSITION.
NC -THEN TURN IGNITION SWITCH (TOGGLE
11 INDICATING LAMP SWITCH) TO OFF POSITION.
23
43 12 - THIS IS ESSENTIAL FOR PREVENTING
HIGH WATER TEMP. 12 IGNITION COIL DAMAGE.
SAFETY CONTROL
25 4. WATCH THE LUB OIL PRESSURE GAUGE
+ - 33 & SHIFT STARTING SWITCH KEY TO RUN
28 POSITION WHEN OIL PRESSURE GAUGE
W INDICATES MORE THEN 1kg/cm2
ALTERNATOR 3. RELEASE THE PUSH BUTTON

33
AFTER ENGINE FIRES
2. TO START ENGINE :-
-TURN THE STARTING SWITCH
43 IGNITION SWITCH TO START POSITION.
41 TOGGLE SWITCH -KEEP THE IGNITION SWITCH "ON" TO
- + GIVE 12 V SUPPLY TO IGNITION COIL.
26 -PRESS THE STARTER PUSH BUTTON.
12
27 IGN
34
COIL 1. 24 VOLT NEGATIVE GROUND SYSTEM
42 12V
40 41
MAGNETIC
SWITCH AMP.
P. G. F.
CIRCUIT NO. WIRE GAUGE NO ORIGINAL DRAWING EXISTS FOR TH
SM 130 PE CAPACITY ITEM. THE ENGINEERING GRAPHICS DA
STARTER FOR THIS ITEM RESIDES IN THE PRODU
2,3,8,13,9 GRAPHICS FILE AND IS CONTROLLED B
22,23,28 20 44/0.3MM THE AGENCY DESIGNATED AS HAVING
41 35,36,37 ITEM CONTROL.
39 UNLESS OTHERWISE SPECIFIED THE FOLLOWING GENERAL NOTES SHA
+ + 5,6,7,15,16,42 ALL PARTS MUST PERMANENTLY AND CLEARLY IDENTIFIED IN THE LOCA
NOTED, AS TO COUNTRY OF ORIGIN AND PART NUMBER PER MFG. 18,1
41 41 40 30 65/0.3MM
- - 25,26,27,33,34 BREAK SHARP CORNERS AND REMOVE BURRS, PER INSP. STD. 16,061
MADE FROM ROUGH CASTING/FORGING/BLANK NO.
39,40,41 200 PVC 95 SQ. MM FILLET RADII REF. DRAWING NO.

BATTERY 24 V.D.C. 3874642
DOUBLE EDGE RADII LAYOUT NO.
WALL THICKNESS FIRST USED ON
DRAFT ANGLES MATERIAL
SURFACE FINISHED A.A. MAX. PROCESS
FINISHED STOCK REL. PHASE
INSP. STD.
MFG. METHOD
ENGR. STD.
LAST SECTION REF. DRAWING

LTTERS USED STANDARDS
Kirloskar cummins Limited
INSI Y 14.5m
ISO R 1101 Kothrud Pune 411029 (INDIA)
ITEM NAME
WIRING DIAGRAM
IDENTIFIER
DIMENSIONS ARE IN MILLIMETERS
DO NOT SCALE THIS DRAWING
THIRD ANGLE PROJECTION
THIS DRAWING (AND THE DATA SHOWN THEREON) IS
CONFIDENTIAL AND PROPRIETARY AND SHALL NOT BE SIZE CODE IDENT. NO.
DRN 20.4.92 DRAWING NO.
USED, DISCLOSED TO OTHERS OR REPRODUCED FOR S.K.K.
ANY PURPOSE EXCEPT FOR QUOTATION TO OR ORDER
BY KIRLOSKAR CUMMINS LIMITED LINCESEES OF
CHD V.V.C. 24.4.92 A0 85 3875376
CUMMINS ENGINE COMPANY. INC. WITHOUT THEIR
WRITTEN CONSENT TO THE USE OF SUCH DRAWING AND/OR DATA
APPD
SCALE- CONTROL SHEET 1OF 2
APPD NTSDRAWING KCL
DRAWING NUMBER
REVISIONS
3875376 REV. DESCRIPTION
REV.
DATE APPD
BY
00 ER NO. 927181-000 S.K.K 24.4.92
HIGH TENSION CABLES
1
2 1 2 3 4 5 6
3
4 TO ENGINE
5 CAP, PROTECTION
6
7
8
9
10
11
43 12
12
- + (BAT)
41 12
- + 43
6 12V
TOGGLE SWITCH
1.- THIS DIAGRAM REFERS TO THE
40
H.T. LUCAS DISTRIBUTOR TYPE
IGNITION SYSTEM ON 6 CYLINDER
GAS ENGINE
IGNITION COIL (12V)
2 3
Wiring Diagrams
MOUNED ON ENGINE
(MOUNT IN INCLINED POSITION)
P. G. F.
NO ORIGINAL DRAWING EXISTS FOR T
ITEM. THE ENGINEERING GRAPHICS D
FOR THIS ITEM RESIDES IN THE PROD
GRAPHICS FILE AND IS CONTROLLED
THE AGENCY DESIGNATED AS HAVING
ITEM CONTROL.
H.T. UNLESS OTHERWISE SPECIFIED THE FOLLOWING GENERAL NOTES SHA
ROTOR 39 + 41 ALL PARTS MUST PERMANENTLY AND CLEARLY IDENTIFIED IN THE LOCA
NOTED, AS TO COUNTRY OF ORIGIN AND PART NUMBER PER MFG. 18,11
4 5 + + BREAK SHARP CORNERS AND REMOVE BURRS, PER INSP. STD. 16,061
12V 12V MADE FROM ROUGH CASTING/FORGING/BLANK NO.

40 FILLET RADII REF. DRAWING NO.3874642
- - EDGE RADII LAYOUT NO.
WALL THICKNESS FIRST USED ON
DRAFT ANGLES MATERIAL
SURFACE FINISHED A.A. MAX. PROCESS

1 FINISHED STOCK REL. PHASE
INSP. STD.
MFG. METHOD
DISTRIBUTOR COVER ENGR. STD.
LAST SECTION REF. DRAWING

LTTERS USED STANDARDS
Kirloskar cummins Limited
INSI Y 14.5m
ISO R 1101 Kothrud Pune 411029 (INDIA)
ITEM NAME
WIRING DIAGRAM
FIRING ORDER 1-5-3-6-2-4 12 VOLT -VE GROUND SYSTEM IDENTIFIER
DO NOT SCALE THIS DRAWINGDIMENSIONS ARE IN MILLIMETERS
THIRD ANGLE PROJECTION 3875376 THIS DRAWING (AND THE DATA SHOWN THEREON) IS
CONFIDENTIAL AND PROPRIETARY AND SHALL NOT BE SIZE CODE IDENT. NO.
DRN DRAWING NO.
USED, DISCLOSED TO OTHERS OR REPRODUCED FOR S.K.Kulkarni 20.4.92
ANY PURPOSE EXCEPT FOR QUOTATION TO OR ORDER
BY KIRLOSKAR CUMMINS LIMITED LINCESEES OF
CHD 24.4.92 A0 85 3875376
CUMMINS ENGINE COMPANY. INC. WITHOUT THEIR
V.V.C.
WRITTEN CONSENT TO THE USE OF SUCH DRAWING AND/OR DATA
APPD
DRAWING
SCALE- SHEET
SHEET 2 OF 2 APPD NTS CONTROL KCL 2 OF2
5-5
107
5-6
108
4072544 ALTRONIC UNIT REV. DESCRIPTION REV. DATE APPD
BY
00 REV. PER 017089-000 17.03.2001
BLOCK,TERMINAL
16 16 STARTING SWITCH
"G" LEAD
FROM ALTRONIC B R 3
IGNITION SWITCH 6 5
(TOGGLE SWITCH) S
GAS SOLENOID VALVE 15
22 2
1 AMMETER
36 37 37 2
NO 2
NC 23 3
3
LOW LUB OIL PRESS. 4

SAFETY CONTROL 25 5
5 13
15
26 6
6
36
27 7 7
NC 7
35
NO
28 8
8
START PUSH BUTTON
9
6. THIS DIAGRAM REFERS TO ALTRONIC
IGNITION SYSTEM USED ON G-495 GAS
10
ENGINE.
NO INDICATION LAMP
35 11 5. TO STOP THE ENGINE:
NC TURN STARTING SWITCH TO OFF POSITION.
12 THEN TURN IGNITION SWITCH (TOGGLE
23 SWITCH TO OFF POSITION.
HIGH WATER TEMP.

SAFETY CONTROL 4. WATCH THE LUB OIL PRESSURE GAUGE &
SHIFT STARTING SWITCH KEY TO RUN
POSITION WHEN OIL PRESSURE GAUGE
25 INDICATES MORE THEN 1kg/cm 2
3. RELEASE THE PUSH BUTTON AFTER ENGINE

+ - 33 FIRES.
28
W 2. TO START ENGINE:
TURN THE STARTING SWITCH TO START
POSITION
ALTERNATOR KEEP THE IGNITION SWITCH "ON"
33 PRESS THE STARTER PUSH BUTTON.
1. 24 VOLT NEGATIVE GROUND SYSTEM.
SYSTEM- ALTRONIC IGNITION SYSTEM.

26
S.O. NO. -
27 CUSTOMER- DESIGN STANDARD & VARIOUS
AMP.
CIRCUIT NO. CAPACITY WIRE GAUGE APPLICATION- GENSET
2,3,8,13,9
200
22,23,28 20 44/0.3MM REF. DWG. NO.- 4055915
35,36,37
CLASSIFICATION OF CHARACTERISTIC
LUCAS STARTER 5,6,7,15,16,42 30 CRITICAL
25,26,27,33,34 65/0.3MM
MAJOR
KEY INSTRUCTION
PVC 95 SQ. MM MINOR (NONE)
150
39,40,41 200
DOUBLE LINE BELOW SYMBOLAPPLIES TO UPPER LIM
39 LINE ABOVE SYMBOLAPPLIES TO LOWER LIM
NO LINE WITH SYMBOL APPLIES TO BOTH LIM
+ +
41 DESIGN ENGINEER:-
41 99012
- - DRAWING PRACTICE:-
PRODUCT
GRAPHICS
FILE
90 100
BATTERY 24 V.D.C.
80
REF. DRAWING
70
STANDARDS
60
50
40
and DIAGRAM WIRING
30
DWN R.N.P 21.02.2001 SIZE CODE IDENT. NO.
ITEM NO.
20
CHD E
APPD
4072544
10
10 20 30 40 50 60 70 80 90 100 150 200
V.V.C. DRAWING
1
APPD A.S.T. CONTROL KCL SHEET1
Wiring Diagrams 5-7
109
5-8
110
REV. DESCRIPTION REV. DATE APPD

BY
MAIN GAS SHUT OFF 22

VALVE
16 16 STARTING
35 37 1
NO B R 3 SWITCH
6 B L 5
4 TURN STARTING SWITCH TO ÒFF' POSITION
24 NC 21 S TO SHUTDOWN THE ENGINE, THEN TURN
13
START PUSH `TOGGLE SWITCH' TO ÒFF' POSITION TO
LOW LUB OIL 40 BUTTON EARTH ALTRONIC CONNECTION. THIS IS
SAFETY CONTROL AMMETER 7 ESSENTIAL FOR DISCHARGING ALTRONIC.
22
21 WATCH THE LUB OIL PRESSURE GAUGE
1 1 AND RELEASE THE PUSH BUTTON
37 WHEN OIL PRESSURE GAUGE
2
23 3 INDICATES MORE THAN 1Kg/cm2.
3
24 4
4 SHIFT THE STARTING KEY SWITCH TO
25 5
5 RUN POSITION WHEN ENGINE FIRES.
26 6
6
27 7 TURN THE STARTING KEY SWITCH TO START
7 POSITION TO CRANK THE ENGINE SIMULTAN-
28 8
8 EOUSLY PRESS THE STARTER PUSH BUTTON.
40 43 KEEP IGNITION TOGGLE SWITCH IN ÒN'
9
44 10 POSITION TO DISCONNECT ALTRONIC `G'
TERMINAL FROM ÈARTH' DURING STARTING
11 AND RUNNING OF ENGINE.
NO `G' LEAD 12
12 8 13
FROM 24 VOLT NEGATIVE SYSTEM.
35 ALTRONIC 43
NC SYSTEM- SYSTEM
INDICATING LAMP SYSTEM
23
HIGH WATER TEMP NO FRIST_USED_ON
44
SAFETY CONTROL S.O. NO. -
ALTRONIC CUSTOMER-
SWITCH TOGGLE
SWITCH APPLICATION-
OVERSPEED
25 ENGINE MODEL -
33
200
REF. DWG. NO.- REF.DWG. NO.
+ -
28 CRITICAL
W MAJOR
KEY INSTRUCTION
AMP MINOR (NONE)
150
ALTERNATOR CIRCUIT NO. CAPACITY WIRE GAUGE
APPLIES TO UPPER LIM
LINE BELOW SYMBOL
2,3,8,13,22,23 LINE ABOVE SYMBOLAPPLIES TO LOWER LIM
39E 20 44/0.3 MM NO LINE WITH SYMBOL APPLIES TO BOTH LI
38 28,35,37,24,1,4 DESIGN ENGINEER:- DATE
26 99012
DRAWING PRACTICE:-
5,6,7,15,16,25 65/0.3 MM
30 PRODUCT
GRAPHICS
FILE
STARTER 17 26,27,33,34,42
90 100
45 39E 17 THE ENGINEERING GRAPHICS FOR THIS ITEM RES
39,40,41 200 PVC 95 SQ. MM
80
EARTH WIRE DOUBLE THE PRODUCT GRAPHICS FILE AND IS CONTROLLE
REF. DRAWING
70
39E 27 Cummins India Limited
45 STANDARDS
60
+ Ve - Ve+ Ve -Ve 38 ANSI Y 14.5m Registered Office: Kothrud, Pune 411029 (India)
50
THIRD ANGLE PROJECTION MAGNETIC
This document (and the information shown
SWITCH UNLESS OTHERWISE SPECIFIED
40
and ITEM_NAME
30
BATTERY 24 V.D.C. copy or electronic form, reproduced by any SIZE CODE IDENT. NO.
ITEM NO.
DWN
20
means, or used for any purpose without CHD
D
APPD
10
10 20 30 40 50 60 70 80 90 100 150 200 licensee of Cummins Engine Company, inc. SCALE- DRAWING
APPD SHEET OF
CONTROL KCL
Wiring Diagrams 5-9
111
112
5-10
BY
00 REV. PER 977305-000 4.7.97 VVC
GAS SOLENOID 22 01 REV. PER 007167-000 SGC29.6.00

VALVE
16 16 STARTING
36 37
NO B R 3 SWITCH
6 B L 5
TURN STARTING SWITCH TO ÒFF' POSITION
NC S TO SHUTDOWN THE ENGINE, THEN TURN
`TOGGLE SWITCH' TO ÒFF' POSITION TO
LOW LUB OIL 40 EARTH ALTRONIC CONNECTION. THIS IS
15
SAFETY CONTROL AMMETER 2 ESSENTIAL FOR DISCHARGING ALTRONIC.
22
WATCH THE LUB OIL PRESSURE GAUGE
1 AND SHIFT STARTING SWITCH KEY TO RUN
37 2 POSITION WHEN OIL PRESSURE GAUGE
36 2
23 3 INDICATES MORE THAN 1Kg/cm2.
NC 3 13
4 15 RELEASE THE PUSH BUTTON AFTER ENGINE
25 5
NO 5 FIRES.
35 26 6
6
27 7 7 TURN THE STARTING KEY SWITCH TO START
7 POSITION TO CRANK THE ENGINE SIMULTAN-
8 EOUSLY PRESS THE STARTER PUSH BUTTON.
40 START PUSH KEEP IGNITION TOGGLE SWITCH IN ÒN'
9 BUTTON
10 POSITION TO DISCONNECT ALTRONIC `G'
TERMINAL FROM ÈARTH' DURING STARTING
11 AND RUNNING OF ENGINE.
NO `G' LEAD FROM 8 13
ALTRONIC 12
24 VOLT NEGATIVE SYSTEM.
35
NC SYSTEM-
INDICATING LAMP
23
HIGH WATER TEMP
SAFETY CONTROL S.O. NO. -
ALTRONIC CUSTOMER-
TOGGLE
SWITCH APPLICATION-
25 ENGINE MODEL - GV-1710-G/GTA-1710-G
26
33
200
REF. DWG. NO.- 3392714
+ -
28 42 CRITICAL
W MAJOR
39 34 27 KEY INSTRUCTION
34 AMP MINOR (NONE)
150
ALTERNATOR 42 CIRCUIT NO. CAPACITY WIRE GAUGE
APPLIES TO UPPER LIM
LINE BELOW SYMBOL
2,3,8,13,22,23 LINE ABOVE SYMBOLAPPLIES TO LOWER LIM
SM130 PE 40 20 44/0.3 MM NO LINE WITH SYMBOL APPLIES TO BOTH LI
28,35,36,37 DESIGN ENGINEER:-
STARTER MAGNETIC - -
99012
DRAWING PRACTICE:-
SWITCH 5,6,7,15,16,25
30 65/0.3 MM PRODUCT
GRAPHICS
FILE
26,27,33,34,42
90 100
PVC 95 SQ. MM THE ENGINEERING GRAPHICS FOR THIS ITEM RES
39,40,41 200
80
DOUBLE THE PRODUCT GRAPHICS FILE AND IS CONTROLLE
40 REF. DRAWING
70
STANDARDS
39 41
60
+ + DO NOT SCALE THIS DRAWING ISO R 1101 ITEM NAME
50
THIRD ANGLE PROJECTION - This document (and the information shown
40
41 - thereon) is CONFIDENTIAL AND PROPRIETARY
and DIAGRAM,WIRING
30
copy or electronic form, reproduced by any SIZE CODE IDENT. NO.
ITEM NO.
BATTERY 24 V.D.C DWN S.D.S. 4.7.97
20
means, or used for any purpose without CHD A.P.D. D 3167919
10
APPD V.V.C. DRAWING
10 20 30 40 50 60 70 80 90 100 150 200 licensee of Cummins Engine Company, inc. SCALE- -
APPD V.V.C. CONTROL 1
KCL SHEET1 OF
Wiring Diagrams 5-11
3230490
113
114
5-12
BY
00 REV. PER 017271-000 28.7.01
NO
17 17 16
37 3
NC 38 18
26 25 R
HIGH WTR. PUMP
GAS SOLENOID
SAFETY CONTROL 1 27 6. THIS DIAGRAM,WIRING TO BE USED WITH
AMMETER DUEL DELCO REMMY STARTER & LUCAS
37 40 2 STARTING SWITCH ALTERNATOR.
3 23
36 NC NO 3 5. BOTH THE STARTER EARTHING CABLES
24
4 24 18 SHOULD BE OF EQUAL LENGTH.
4
OVER SPEED STOP 5 5 25 4. SIZE & LENGTH OF CABLE NO. 76 & 56
SHOULD BE OF EQUAL LENGTH.
6 26 ASSLY LIGHT INDICATOR
6 AND DIODE 3875311 3. SIZE & LENGTH OF CABLE NO. 57 & 55
7 27 SHOULD BE OF EQUAL LENGTH.
9 7
36 38
NO
8 28
8 2. THIS DIAGRAM,WIRING IS USED WHEN SAFETY
8 29
9 CONTROLS FOR LOW LUB OIL PRESSURE
NC 9 28 HIGH WATER TEMPERATURE & OVERSPEED
40 10 STOP ARE CONNECTED.
LOW LUB OIL PRESSURE 29
11 31 1. FOR STARTING THE ENGINE PUSH BUTTON
SAFETY CONTROL 11
12 SHOULD BE PRESSED BEFORE CRANKING
12 32 & IT SHOULD BE RELEASED AFTER LUB OIL
START PUSH BUTTON
PRESSURE BUILDS UP.
5 35
+ - TOGGLE SWITCH
G LEAD FROM SYSTEM- ELECTRICAL
W 4 ALTRONIC
G TERMINAL
ALTERNATOR
S.O. NO. - VARIOUS
7 CUSTOMER- VARIOUS
73 ALTRONIC APPLICATION- GENSET
6 ENGINE MODEL - GTA-2300-G, GTA-3067-G
78
200
56 54
- - 55 REF. DWG. NO.- 3878916
56 54 MAGNETIC SWITCH 9. 24V -Ve GROUND ELECT SYSTEM WITH ALTERNATOR.
+ + CLASSIFICATION OF CHARACTERISTIC
79 8. KEEP IGNITION TOGGLE SWITCH IN ON POSITION CRITICAL
78 (i.e.OPEN) TO DISCONNECT ALTRONIC G TERMINAL MAJOR
FROM EARTH DURING STARTING & RUNNING OF ENGINE. KEY INSTRUCTION
+ + MINOR (NONE)
150
- - 55 73 APPLIES TO UPPER LIM
LINE BELOW SYMBOL
7. TURN STARTING SWITCH TO OFF POSITION (i. e. CLOSE)
STARTER LINE ABOVE SYMBOLAPPLIES TO LOWER LIM
TO SHUT DOWN THE ENGINE, THEN TURN TOGGLE SWITCH
76 57 NO LINE WITH SYMBOL APPLIES TO BOTH LI
75 74 TO OFF POSITION TO EARTH ALTRONIC CONNECTION DESIGN ENGINEER:-
N.C.DUBEY
BATTERIES THIS IS ESSENTIAL FOR DISCHARGING ALTRONIC. 99012
DRAWING PRACTICE:-
79 75 MAGNETIC SWITCH PRODUCT
GRAPHICS
FILE
90 100
76 CIRCUIT NO. AMP CAPACITY WIRE GUAGE THE ENGINEERING GRAPHICS FOR THIS ITEM RES
74
80
3,8,9,11,12,23
20 44/0.3 M.M. REF. DRAWING
70
27,28,29,31,32, Cummins India Limited
57 STANDARDS
35,36,37,77,79
60
STARTER DO NOT SCALE THIS DRAWING ISO R 1101 ITEM NAME
50
THIRD ANGLE PROJECTION 200 P.V.C.
55,56,57,76 This document (and the information shown
40
95 SQ M.M. DOUBLE thereon) is CONFIDENTIAL AND PROPRIETARY
and DIAGRAM,WIRING
30
4,5,6,7,24 copy or electronic form, reproduced by any SIZE CODE IDENT. NO.
ITEM NO.
DWN CHAUDHARI 12.7.01
20
25,26,54,73 30 65/0.3 M.M. means, or used for any purpose without CHD JSS D 4073247
10
10 20 30 40 50 60 70 80 90 100 150 200
74,75,78 APPD NCD DRAWING
licensee of Cummins Engine Company, inc. SCALE- - 1
APPD VMK CONTROL KCL SHEET1 OF
Troubleshooting 6-1
Section-6 Troub le shooting is an or

ouble ganiz
organiz ed stud
ganized y of
study
the problem and a planned method of
pr ocedure ffor
procedure or in vestigation and correction of
investigation
Trouble Shooting the difficulty
difficulty.. The c har
hartt at the end of this
char
section includes some of the problems that
an operator may encounter during the service
life of a Cummins Engine.
Cummins Gas Engines
The term “trouble shooting” means locating the loose throttle linkage or dirty fuel filters,
basic cause of the difficulty so that when repairs “excessive lube oil consumption” caused by
are made there will be no repetition of the failure. leaking gaskets or connections, etc.
Trouble shooting, in most cases, is very simple.
In the majority of problems, the only requirement Always check the easiest and obvious things
is a knowledge of construction of the unit and first; following this simplest rule will save time
the principles of its operation. Knowing these two and trouble.
factors, anyone-who is qualified to make repairs
on the unit can start at the beginning and follow
through each step in the functioning of each part Double-Check Before Beginning
until the cause of the trouble is found. Disassembly Operations
The source of most engine troubles can be traced

Think Before Acting not to one part alone put to the relationship of
one part with another. Too often, engines are
Study the problem thoroughly. Ask these completely disassembled in search of the cause
questions: of a certain complaint and all evidence is
destroyed during disassembly operations. Check
1. What were the warning signs preceding the again to be sure aneasy solution to the problem
trouble ? has not been overlooked.
2. What previous repair and maintenance
work has been done ?
Find And Correct Basic Cause Of Trouble
ouble
3. Has similar trouble occurred before ?
After a mechanical failure has been corrected,
4. If the engine still runs, is it safe to continue
be sure to locate and correct the cause of the
running it to make further checks?
trouble so the same failure will not be repeated.
Listed on the following pages are some of the

Do Easiest Things First
First
problems, causes and remedies used.
Most troubles are simple and easily corrected;
examples are “low power” complaints caused by
115
Symptoms Listing
Engine Will Not Crank ......................................................................................................................

Engine Cranks But Will Not Start .....................................................................................................
Hard To Start - Long Cranking Time ..................................................................................................
Engine Surge at Low Idle, Engine Shaking or Rough Idle .................................................................
Engine Runs Rough or Misfires ........................................................................................................
Engine Noise Excessive ..................................................................................................................
Engine Will Not Shut Off ..................................................................................................................
Lubricating Oil Pressure Low ............................................................................................................
Lubricating Oil Pressure Too High .....................................................................................................
Lubricating Oil Consumption Excessive ...........................................................................................
Coolant Loss ....................................................................................................................................
Coolant Temperature Above Normal .................................................................................................
Coolant Temperature Below Normal ..................................................................................................
Coolant Contaminated ......................................................................................................................
Engine Vibration Excessive ..............................................................................................................
Check Ignition System .....................................................................................................................
Check Fuel-Gas System ..................................................................................................................
Check Pressure Regulator ...............................................................................................................
Check Air Intake System .................................................................................................................
Check Individual Cylinders ...............................................................................................................
Governor Instability ..........................................................................................................................
116
Troubleshooting 6-3
Engine Will Not Crank
CAUSE CORRECTION
Bar the engine to check for rotational

Crankshaft rotation restricted.
resistance
OK
No voltage to starter solenoid. Check battery voltage to solenoid.
OK
Remove the starting motor and check for

Starting motor operating but not cranking
broken teeth on flywheel or broken starting
engine
motor spring.
OK
Starting circuit connections loose or Clean and tighten connection.

corroded.
OK
Check key switch line circuit for open

Key switch malfunction
circuits or loose connections.
OK
Solenoid or starting motor restriction. Replace starting motor.
OK
117
Engine Cranks But Will Not Start (Fuel System)
CAUSE CORRECTION
Check main line gas pressure.

No fuel pressure at fuel filter Contact local utility company. Confirm
proper flow rate and line pressure.
OK
Plugged gas filter. Replace with new element.
OK
No or low fuel-gas pressure. Check fuel supply shut-off valves.
OK
No gas pressure or low gas pressure at

Check gas regulator.
carburetor.
OK
FLEXBLE PIPE JOINT

OR 200 MM WC
7 PSIG 20 PSIG

MOUNTED ON
GAS ENGINE.
118
Troubleshooting 6-5
Engine Crank but will not Start (Ignition System)
CAUSE CORRECTION
Ignition firing circuit grounded. Check ignition switch. Check instrument

panel ground.
OK
Check for proper voltage. Check primary

Ignition generator. leads for voltage. Check wiring harness for
moisture.
OK
Check ignition timing marks alignment.
Inspect for cracks, moisture, broken

Ignition Coils (Transformers) connections. Check primary & secondary
resistence.
OK
Check for type, gap, damage, electrodes

Spark plug. & ceramic insulators. Check for water in
cylinder.
OK
Check spark plug adapter for water

Spark plug adapter. leakage at O-ring and for cracked
adapter.
OK
Ignition Timing. Check and correct Ignition Timing.
OK
119
Hard to Start - Long Cranking Time
CAUSE CORRECTION
Starting procedure incorrect. Refer to O & M Manual for correct

procedure.
OK
Cranking time approximately 2 to 3

No correction. Normal operation.
seconds.
OK
Cranking speed to slow (minimum Check battery voltage. Starting motor,

cranking speed is 100 RPM). and look for loose or corroded wiring
connection.
OK
Inspect or replace air cleaner element.

Intake air insufficient
Check for any obstructions to the air supply.
OK
No or low fuel pressure. Check fuel supply.
No or low pressure at carburetor. Perform gas flow troubleshooting.
OK
Bar the engine to check for internal

Crankshaft rotation is restricted.
rotational resistance.
OK
Intake or exhaust valves incorrectly Adjust valves. Refer to maintenance

adjusted. section for valve adjustment procedure.
OK
Contact a Cummins authorized repair

facility.
OK
120
Troubleshooting 6-7
Engine Surge at Low Idle, Engine Shaking or Rough Idle
CAUSE CORRECTION
Allow engine to warm up for 2 to 3 minutes.

Engine is cold. If still cold refer to troubleshooting for
coolant temp. below normal.
OK
Excessive load at idle RPM. Reduce excessive load.
OK
No or low fuel pressure in supply line. Check fuel supply.
OK
Fuel-Gas Leak. Check fuel lines, fittings and components

for leaks.
OK
Loose throttle butterfly plate. Check throttle butterfly plate.
OK
No or low pressure at carburetor. Perform gas flow troubleshooting.
OK
Ignition system failure. Perform ignition system troubleshooting.
OK 121
Engine Surge at Low Idle, Engine Shaking or Rough Idle
CAUSE CORRECTION
Intake manifold leaks. Check for a suction around intake

manifold and components.
OK
Verity conditions of mounts. Correct or

Engine mounts damaged or loose.
replace as necessary.
OK
Defective alternator. Temporarily disconnect alternator and

conduct engine test.
OK
Intake or exhaust valves not seating. Adjust valves. Refer to maintenance

section for correct procedure.
OK
Engine compression low. Perform compression check to identity

and malfunction. Correct as required.
OK
122
Troubleshooting 6-9
Engine Runs Rough or Misfires

CAUSE CORRECTION
Ignition System failure. Refer to Ignition System Trouble Shooting.
OK
Adjust valves. Refer to maintenance

Intake or exhaust valves adjusted wrong.
section for proper valve adjustment.
OK
Compression in one or more cylinders is Perform a compression check and repair

low. as needed.
OK
Camshaft out of time. Check/correct gear train timing alignment.
OK
Camshaft or tappets damaged. Inspect camshaft and tappets.
OK
Contact your local Cummins distributor or

authorized full-service dealer.
OK
123
Engine Noise Excessive

CAUSE CORRECTION
Drive belt squeal, insufficient tension or Check belt tension and inspect drive belts.
abnormal high loading. Make sure water pump, fan hub, and
alternator turn freely.
OK
Intake air or exhaust leaks. Check for intake or exhaust leaks.
OK
Adjust valves. Make sure push rods are

Valve lash excessive.
not bent or rocker levers worn.
OK
Check turbocharger impeller and turbine

Turbocharger noise.
wheel for housing contact.
OK
Visually inspect and measure gear

Gear train noise.
backlash. Replace gears as required.
OK
Pre-Ignition or detonation. Refer to “engine runs rough and or misfires”.
OK
Verify thatthere are no external voltage

External voltage supply
supply paths to the On-Off switch.
OK
Check oil specifications. Change to correct

Oil specifications incorrect.
specifications if required.

OK
124
Troubleshooting 6-11
Lubricating Oil Pressure Low

CAUSE CORRECTION
Incorrect oil level. Add or drain engine oil.
OK
Check for missing rain caps, oil fill caps,

Oil diluted with water.
dipstick, etc. Change oil.
OK
Oil filter plugged. Change oil and replace filter.
OK
Check oil specifications. Change oil to

correct specifications.
OK
Check for external leak at rear of cylinder

Loose or missing pipe plug. head, along fuel pump side of block, oil
cooler cover and gear hsg.
OK
Oil viscosity too low due to operating Refer to troubleshooting logic. “Coolant
aove normal coolant temperature. Temperature above Normal.”
OK
Oil pressure gauge malfunctioning. Check oil pressure gauge.
OK
Regulator valve stuck open or broken

Check and clean. Replace spring if broken.
spring.

OK
125
Lubricating Oil Pressure Too High
CAUSE CORRECTION
Oil pressure gauge malfunctioning. Check oil pressure gauge.
OK
Refer to troubleshooting logic for “Coolant

Engine Running Too Cold.
Temp. Below Normal.”
OK
Check oil specifications. Change oil to

correct specifications, if required.
OK
Pressure relief valve stuck closed. Check / replace valve.
OK

OK
126
Lubricating Oil Consumption Excessive
CAUSE CORRECTION
Increase engine load to a minimum of

Excessive light load.
60% of rated load.
OK
Shorten idle times or turn engine off when

Excessively Idling
not needed.
OK
Incorrect dipstick calibration and incared Verify the markings are correct and make
oil specifications. sure that correct oil is being used.
OK
Measure crankcase pressure and blow

Excessive Crankcase blowby. by and take corrective action.
OK
Inspect air crossover tube for evidence of

Oil leakage through turbocharger leakage
oil transfer. Inspect & repair the turbocharger
oil to the intake or exhaust.
governor.
OK

OK
127
Coolant Loss
CAUSE CORRECTION
Stop leakage visually inspect radiator,

Radiator or heat exchanger leaking. hoses and connections and check H.E.
for signs of external leakage.
OK
Visually inspect engine and components

External engine leaks. for seal or gasket leakage, and take
corrective action.
OK
Check for over heating.Refer to

overheating section as “Coolant
Coolant loss through top tank. Temperature Above Normal.” Check for
compression leakage and take corrective
action.
OK
Check and correct for cracked or porous

Cylinder head or head gasket leak.
cylinder head and head gasket leaks.
OK
Coolant in oil. Check / replace lube oil cooler.
OK

OK
128
Coolant Temperature Above Normal
CAUSE CORRECTION
Coolant level low. Add coolant.
OK
Radiator fins damaged or obstructed with Repair radiator fins and clean or repair if
debris. necessary.
OK
Radiator hose collasped. Inspect hoses. Replace if necessary.
OK
Provide for adequate air flow into engine

Excessive restriction for air flow. room or engine enclosure. Check and
remove excessive air restriction.
OK
Cooling fan shroud damaged or missing. Inspect shroud; repair, replace as required.
OK
Loose fan belts. Check and correct the belt tension.
OK
Check the radiator cap. Replace if

Incorrect or malfunctioning radiator cap.
necessary.
OK
129
Coolant Temperature Above Normal
CAUSE CORRECTION
Temperature gauge malfunction. Test the gauge and replace if necessary.
OK
Incorrect thermostat. Check / replace thermostat.
OK
Check for incorrect oil level and engine Check and correct engine oil level.
overload condition. Reduce engine load if required.
OK
Water pump malfunctioning. Check / replace water pump.
OK
Check hose clamps for leaks on suction

Air in cooling system. side of water pump and check for com-
pression leak at cylinder head gasket.
OK
Plugged cooling passages (in radiator,

FLUSH the cooling system and fill within
heat exchanger, cylinder head, head
new coolant.
gasket or cylinder block).
OK
130
Coolant Temperature Below Normal
CAUSE CORRECTION
Test the gauge - repair or replace if

Temperature gauge malfunction.
necessary.
OK
Check thermostats and replace as

Thermostats incorrect or malfunctioning.
necessary.
OK

OK
131
Coolant Contaminated
CAUSE CORRECTION
Rusty coolant, operation without correct Drain and flush the cooling system. Fill
mixture. with correct coolant.
OK
Oil leaks from oil cooler, head gasket, Refer to troubleshooting logic for
head and cylinder block. ‘Lubricating Oil Loss.”
OK

OK
OK
132
Engine Vibration Excessive

CAUSE CORRECTION
Engine not running smoothly. Refer to troubleshooting logic for “Rough

Running or Misfiring”.
OK
Engine low idle speed set too low. Re-adjust low idle speed.
OK
Engine mounts loose or broken. Check / replace engine mounts.
OK
Fan damaged or accessories

Check / replace the vibrating component.
malfunctioning
OK
Fan hub malfunctioning. Inspect / replace fan hub.
OK
Alternator bearing worn or damaged. Check / replace alternator.
OK
Vibration damper malfunctioning. Inspect / replace the vibration damper.
OK
Flywheel housing misaligned. Check / correct flywheel alignment.
OK
Drive line components worn unbalanced, Check / repair according to manufacturers

or out of alignment. procedures.

OK
133
Governor Instability / Speed Variation

Governor - Unstable - Engine Surges
CAUSE CORRECTION
i) Check Ignition System.

Engine Misfiring & vibrating
ii) Check fuel System.
OK
Check Ignition System.
Specifications as stated in the O & M

Timing is incorrect.
Manual. Refer Trouble Shooting logic.
OK
Check and correct as per recommended

in fuel system. Request that customer
Inadequate gas flow.
have pipeline size corrected as per
engine datasheet.
OK
Check Carburetion System.
Gas Pressure to Carburetor is too low or

Adjust gas pressure as per specifications.
too high.
OK
Carburetor moving parts are in bind. Check Carburetor moving parts and
insure free movement.
OK
Carburetor mounting gaskets or Check Carburetor gaskets and

connections are leaking. connections for leaks.
OK
(Contd....)
134
Governor Instability / Speed Variation

Governor
Governor - Unstable - Engine Surges
CAUSE CORRECTION
Check Fuel-Gas System.
Carburetor Power Valve inlet has foreign Check and correct Carburetor Power Valve
material. Inlet for foreign material andtake corrective
action.
OK
Check Intake Air System
Air Cleaner Restriction is excessive. Check Air Intake restriction and change air
cleaner element if required.
OK
Check Throttle Body, Linkages
Inadequate throttle valve travel. Adjust throttle valve travel.
OK
Check Throttle Shaft and Body for binding

Throttle Shaft and Body are in a Bind.
and correct.
OK
Throttle lever & Linkage ball Ends are

Check ball ends for binding and correct.
binding.
OK
135
NOTES
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136

O & M Manual Gas & Dual Fuel

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O & M Manual Gas & Dual Fuel

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Operation and Maintenance Manual

Gas and Dual Fuel Engines

BULLETIN NO. 3243676-04

While asking for assistance please

1. Your Name & Phone or Fax

2. Engine Serial Number.

3. Name of the Customer.

P.J.M. Khan ........................................... (020) 5434472 9822045502

Cummins India Limited

Repair operations should be performed by specially trained

Natural gas is the cleanest fossil fuel. To harness its enormous

Also their state-of-art technology provides high engine

Cummins India Limited

1 Keep dirt out of the engine

2 Maintain a lubricating film

3 Regulate the engine’s fuel

4 Control operating temperatures

5 Guard against corrosion

6 Let the engine breathe

8 Know your engine’s condition

9 Correct troubles while they are

10 Schedule and control

SECTION 1 OPERATING PRINCIPLES ............................................................................ 13

SECTON 2 ENGINE OPERATIONS ................................................................................. 53

SECTION 3 INSTALLATION AND SCHEDULE MAINTENANCE ........................................ 67

SECTION 4 SPECIFICATIONS AND TORQUE ................................................................. 89

SECTION 5 ENGINE WIRING DIAGRAMS ....................................................................... 99

SECTION 6 TROUBLE SHOOTING ................................................................................ 115

SECTION 7 CUMMINS DIESEL SALES & SERVICE NETWORK .................................. 139

A. Name and location of the Cummins dealer. Training Manager,

If you still have problems please write to :

Cummins India Limited

We do request that above steps be followed in order. Most

a) Engine Models and Specifications (G-Drive Applications)

b) Engine Models and Specifications (Industrial Applications)

c) Advantages of Gas Engines

d) General Operating Instructions

e) Difference between Gas and Diesel Engine

f) Derating guidelines with reference to gas composition (Natural gas engines)

h) 10 Maintenance Steps for Cummins Engines

Engine Bore Stroke Displacement Compression BHP rating

G-495-G 130 152 8.1 12:1 92

G-743-G 130 152 12.2 12:1 137

G-855-G 140 152 14 12:1 167

G-1710-G 140 152 28 12:1 333

GTA-855-G 140 152 14 10:1 242

GTA-1150-G 159 159 18.9 8.5:1 333

GTA-1710-G 140 152 28 10:1 480

GTA-2300-G 159 159 37.8 8.5:1 600

GTA-3067-G 159 159 50.3 8.5:1 800

ii) Engine Models and Specifications (Industrial Application)

Engine Bore Stroke Displacement Compression BHP rating

G-743-P 130 152 12.2 12:1 165

G-855-P 140 152 14 12:1 200

G-1710-P 140 152 28 12:1 400

b) Advantages of Gas Engines

2. Gas is abundantly available and also cheap as compared to diesel.

3. Gas induction through carburetor, requires low pressure.

6. Combustion is paniculate free and more complete.

7. Exhaust is smoke free, hence helps for environment protection.

12. Nationwide service network and easy spares availability.

c) GENERAL OPERATING PRINCIPLES